Stock material or miscellaneous articles – Structurally defined web or sheet – Fold at edge
Reexamination Certificate
1999-07-27
2002-12-10
Kuhns, Allan R. (Department: 1732)
Stock material or miscellaneous articles
Structurally defined web or sheet
Fold at edge
C156S227000, C264S045400, C264S046600, C264S046800, C264S296000, C428S304400, C428S318400, C428S318600
Reexamination Certificate
active
06492000
ABSTRACT:
TECHNICAL FIELD
This invention relates to a method for producing a cellular molded article having a surface skin in a mold pattern which is used, for example, as an automobile interior trim material or the like and an article thereof
BACKGROUND OF THE INVENTION
As for the conventional technique of this kind, for example, (a) so-called simultaneous molding with a surface skin in once (simultaneous one piece molding) is known as disclosed in TOKUKAI-SHO 62-108039. In this method, as illustrated in
FIG. 26
, a male-female coupled mold pattern
2
is used, and after a surface skin material
3
is preformed by vacuum-forming along a cavity surface
2
a
of female pattern
9
, an expansion molding is performed in a cavity (inside of the mold pattern)
4
which is shaped up by a male pattern
10
combining with a surface skin material
3
, at the same time, a cellular molded article (a cellular molded article in a mold pattern)
5
is united with the above-mentioned surface skin material
3
simultaneously. In this simultaneous molding, when the above-mentioned surface skin material
3
is vacuum formed, the outer edge part of said surface skin material
3
is fold-back formed as well from opening edge
2
b
toward an inside direction of the mold pattern along a folded back pattern (pattern for folding back)
6
which projects from opening edge
2
b
of the above-mentioned cavity face
2
a
toward the inside direction of the mold pattern in advance, and when the above-mentioned expansion molding is performed, a folded back part
7
of surface skin material
3
is united into one piece with back face
5
b
of the above-mentioned expanded molded article (the expanded molded article in the mold pattern)
5
.
In this method, at a time of the above-mentioned vacuum forming, the outer edge part of the surface skin material
3
is formed in advance as folded back from tip
7
c
of the folded back part
7
toward outside direction of the mold pattern in a manner of rolling up folding pattern (pattern for folding back)
6
, an expansion molding is performed with this state. And, after obtained a cellular molded article having a surface skin material (a cellular molded article having a surface skin in a mold pattern)
71
a
is removed from the pattern, unnecessary outer edge part of the surface skin material
3
is trimmed off at tip
7
c
of the above-mentioned folded back part
7
.
(b) On the other hand, it is known that, in a cellular molded article having a surface skin in a mold pattern with a surface skin in which an insert member is melt united with outer edge part of back face
5
b
of cellular molded article
5
, when the outer edge part of surface skin material
3
is folded back to back face
5
b
side of cellular molded article in a mold pattern
5
, a prescribed range of the outer edge part of surface skin material
3
is cut off so as to avert the above-mentioned insert member, thereafter, it is necessary a process of folded back part
7
to be adhered to back face
5
b
of cellular molded article in a mold pattern
5
.
(c) Furthermore, in a simultaneous one piece molding as in the above, a chamber connected with steam valve, decompression valve or the like is equipped in each of the 2 metal mold parts. And one metal mold part of them on which a surface skin material will be placed is formed to have a plural of decompressing holes and the other metal mold part is formed to have a plural of vapor holes connected with the above-mentioned chamber respectively. And when an expansion molding is performed, the filled expanded beads in this mold pattern are heat-expanded by feeding of a steam from the vapor holes of the above-mentioned the other metal pattern part to inside of the mold pattern.
In this case, for a purpose of effective expansion molding by preheating of the above-mentioned surface skin material to be preformed, it is common that the above-mentioned one metal pattern part is preheated by feeding of a steam into inside of the above-mentioned chamber before this surface skin material is placed on.
Nevertheless, in the above-mentioned (a) conventional example, since the outer edge part of the above-mentioned surface skin material
3
is at a state of standing from tip
7
c
of the above-mentioned folding back part
7
at a prescribed angle against back face
5
b
of cellular molded article (cellular molded article in a mold pattern)
5
, when the above-mentioned outer edge part is trimmed off at tip
7
c
of folding back part
7
, a prescribed length of projected edge part may remain. In such a case, when transportation, assembling process or the like of the cellular molded article having a surface skin material (cellular molded article having a surface skin in a mold pattern) is conducted, since the above-mentioned projected edge part may often hang up with the other member materials, there is a problem of easily peeled from tip
7
c
of the above-mentioned folded back part
7
.
And also, in the above-mentioned (b) conventional example, since the trim process and the adhesion process for a prescribed range of folded back part
7
, which is necessary when an insert member material is melt united to one piece, are needed all by hand works, there is a problem of requiring much labor.
Moreover, in the above-mentioned (c) conventional example, when the above-mentioned one metal pattern part is preheated, since the metal pattern part is totally heated by feeding a steam into the inside of its chamber, there is a problem of insufficient heating efficiency. In furthermore, when the above-mentioned surface skin material is place on by a vacuum forming, even though the above-mentioned one metal pattern part has been preheated by steam, at a time of decompression, since the heat is taken away by a vaporizing heat of condensed moisture within the chamber, there is a problem of lowering temperature of the metal pattern part, by which an efficient vacuum forming will not be successful. And furthermore, when the metal pattern part is preheated directly by steam, moisture or water drop will remain on the surface of metal pattern part, consequently, since this water drops or the like are stuck on surface of the skin material, there is a problem that surface appearance of the surface skin material is deteriorated, at the same time, when the surface skin material is placed on the one metal pattern part by a heat-molding such as vacuum forming, there is a problem of lowering its elongation property at a time of heat-molding.
This invention has been done for solving the above-mentioned problems,
(1) the folded back part, which is folded back to backside face of a cellular molded article in mold a pattern and melt united to one piece, is hardly peeled off,
(2) less hand working even when an insert member material is assembled,
(3) an expansion molding or a heat-molding of the surface skin material can be done effectively,
(4) improving the surface property of the surface skin material and/or the elongation property at a heat-molding,
(5) good heat efficiency of the metal pattern part at a time of preheating on which the surface skin material is placed,
it is objecting to provide a method for producing a cellular molded article having a surface skin in a mold pattern and a molded article thereof.
DISCLOSURE OF THE INVENTION
An essential feature residing in a method for producing a cellular molded article having a surface skin in a mold pattern of this invention which is claimed is that, in a method for producing a cellular molded article having a surface skin in a mold pattern in which the above-mentioned surface skin material is melt united to one piece with the surface of the cellular molded article in the mold pattern which is molded by an expansion molding within this mold pattern, after the surface skin material is heat-molded along a cavity face of the mold pattern, it is characterized in that when the above-mentioned heat-molding, after the outer edge part of the above-mentioned surface skin material is folded back toward the inside direction of the mold pattern and formed a folded back
Kakimoto Yoriki
Matsuki Kiyoshi
Kaneka Corporation
Kuhns Allan R.
Wolf Greenfield & Sacks PC
LandOfFree
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