Method for fabricating a laminated molded assembly

Details Method for fabricating a laminated molded assembly Method for fabricating a laminated molded assembly

1993-08-19

2001-01-16

Ortiz, Angela (Department: 1732)

Plastic and nonmetallic article shaping or treating: processes

Direct application of fluid pressure differential to...

Producing multilayer work or article

C264S265000, C264S266000

Reexamination Certificate

active

06174488

ABSTRACT:

TECHNICAL FIELD
The present invention relates to a device and a method for molding a laminated molded assembly suitable for use as automotive upholstery component parts such as door trims.
BACKGROUND OF THE INVENTION
The conventional structure of an automotive upholstery or interior component such as an automotive door trim, a rear corner trim or the like used on the interior of an automotive body panel is now described in the following with reference to
FIG. 21
by taking an example of automotive door trim. This automotive door trim
1
consists of a laminated molded assembly comprising a resin core member
2
molded into a desired contoured shape, and a surface skin member
3
integrally laminated on a front surface of the resin core member
2
and imparted with a suitable cushioning capability.
Because of the demand for ever increasingly complex three-dimensionally contoured shapes, the resin core member
2
is now typically molded by the process of mold press forming offering a favorably molding capability. To simplify the overall fabrication process, often, the surface skin member
3
is integrally joined with the resin core member
2
during the process of mold press forming the resin core member
2
.
More specifically, as illustrated in
FIG. 22
, the surface skin member
3
is mounted on the upper die
4
for mold press forming by using set pins
4
a
provided therein, and after lowering the upper die
4
for mold press forming until a prescribed clearance is defined between the upper and lower dies
4
and
5
, resin material
7
is supplied to the die surface of the lower die
5
for mold press forming from an injection molding device
6
via a hot runner
5
a
and a plurality of gates
5
b
branching off from the hot runner
5
a.
Then, the upper and lower dies
4
and
5
are closed upon each other, and are engaged with each other so that the surface skin member
3
is integrally joined with the front surface of the resin core member
2
at the same time as the resin material
7
is mold press formed into the resin core member
2
having a prescribed shape.
However, according to this conventional process of integrally joining the resin core member
2
and the surface skin member
3
and completing the laminated molded assembly by mold press forming, the surface skin member
3
may not be able to closely follow the highly complicated surface contour of the resin core member
2
during the process of mold press forming, and the surface skin member
3
may get damaged in some places. Such damages to the surface skin member
3
leads to the leaking of the resin material therefrom, and the assembly involving such damages to the surface skin member is obviously unacceptable as a finished product.
According to this method, since vacuum is created between the upper die
4
and the molded assembly when lifting the upper die
4
upon completion of the step of mold press forming, as a measure for preventing the molded assembly from being pulled by the upper die
4
, the lower die
5
is sometimes provided with vacuum suction holes
8
for retaining the molded assembly on the lower die
5
by vacuum suction after opening up the die assembly as illustrated in FIG.
23
.
Further, as a method for retaining the molded assembly on the lower die
5
when opening up the die assembly, the resin core member
2
may be provided with undercut portions
2
a
in the resin core member
2
as illustrated in
FIG. 24
so that the molded assembly may be retained by the lower die
5
after completion of the step of mold press forming by engaging the molded assembly with the lower die
5
by using the undercut portions
2
a
of the resin core member
2
. In such a situation, the undercut portions
2
a
, for instance serving as seat portions for clips and other fasteners, may get damaged in the process.
However, when a vacuum suction mechanism is used as illustrated in
FIG. 23
, due to the provision of a hot runner
5
a
and gates
5
b
for supplying molten resin from an injection molding device, there is a severe restriction on the layout of the vacuum suction holes
7
, and the work involved in providing the piping for the vacuum suction holes is substantial.
Further, the need for large additional equipment such as a vacuum pump will increase the cost, and the selection of the material to be molded will be limited.
According to the method of providing undercut portions
2
a
in the resin core member as illustrated in
FIG. 24
, these undercut portions
2
a
will create such problems as hindering the effort to remove the molded product from the lower die
2
a
, and increasing the possibility of deforming and damaging the molded product when removing the molded product from the lower die
5
. Further, the need for the undercut portions
2
a
leads to the increase in the weight of the resin core member
2
, and is detrimental to the desire to reduce the weight of the molded product.
In either of these conventional methods, since the force retaining the molded product to the lower die
5
is so small that the speed of opening the die assembly needs to be kept low, and the time required for the overall fabrication process tends to be increased.
BRIEF SUMMARY OF THE INVENTION
In view of such problems of the prior art, a primary object of the present invention is to provide a device for mold press forming a laminated molded assembly comprising a resin core member prepared by molding molten resin in a die assembly for mold press forming into a desired shape, and a surface skin member which is to be integrally joined with the resin core member during this step of mold press forming, which allows the structure of the die assembly to be simplified.
A second object of the present invention is to provide a device for mold press forming a laminated molded assembly comprising a resin core member and a surface skin member which can prevent the breakage of the surface skin member during the step of mold press forming, thereby avoiding the leaking of molten resin from such a breakage.
A third object of the present invention is to provide a device for mold press forming a laminated molded assembly comprising a resin core member and a surface skin member which allows the surface skin member to follow closely the complicated surface contour of resin core member.
A fourth object of the present invention is to provided a device for mold press forming a laminated molded assembly by using upper and lower dies which allows the molded assembly to be readily removed from the upper die so that the time required for each molding process may be minimized.
These and other objects of the present invention can be accomplished by providing a device for molding a laminated molded assembly including a resin core member and a surface skin member, comprising: a die assembly including a first die having a first die surface having a prescribed surface contour, and a second die having a second die surface adapted to cooperate with the first die surface to define a cavity for mold press forming; actuating means for opening and closing the die assembly by moving the second die relative to the first die; supply means for supplying molten resin to the first die surface of the first die, the molten resin being eventually molded into the resin core member by closure of the die assembly; mounting means provided in the second die for mounting the surface skin member thereon in such a manner that the surface skin member extends over the second die surface; and at least one air hole provided in the second die having one end opening out of the second die surface and another end communicated with air pressure control means.
When the surface skin member is provided with a thermoplastic property, and the air pressure control means may comprise means for supplying hot air to the air hole, the temperature of the hot air being selected so as to impart a desired elongation property to the surface skin member, the surface skin member is preheated and softened so that the surface skin member can easily follow the complex contoured shape of the die surf

Affiliated with

Also associated with

Rating

Method for fabricating a laminated molded assembly does not yet have a rating. At this time, there are no reviews or comments for this patent.

If you have personal experience with Method for fabricating a laminated molded assembly, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Method for fabricating a laminated molded assembly will most certainly appreciate the feedback.

Rate now

Comments { 0 }

Profile ID: LFUS-PAI-O-2445633