METHOD OF INJECTION MOLDING

- MORIROKU COMPANY, LTD.

An injection molded article with which a sheet material is integrated is manufactured without causing damage to the sheet material. A molten resin injected into a mold cavity, passes smoothly a peripheral edge of the mold cavity, and flows into a groove portion without accumulating in the vicinity of the peripheral edge. When cooling the molten resin, the temperature of the molten resin in the groove decreases more quickly than the temperature of the molten resin in the mold cavity, because the volume of the groove portion is small. The viscosity of the molten resin is increased rapidly, preventing further molten resin from flowing into the groove portion. The sheet material in the vicinity of the peripheral edge is covered and protected against exposure to heat and/or pressure of the molten resin.

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Description
FIELD OF THE INVENTION

The present invention relates to an apparatus and method of injection molding for molding an article of synthetic resin simultaneously with integrating a sheet-like material, such as a decorative sheet, onto a surface of the molded article in a cavity of an injection mold, and more particularly, to an apparatus and method of injection molding for molding an article of synthetic resign and simultaneously unifying a sheet-like material on a surface of the molded article in a cavity of an injection mold without causing damage to the sheet-like material during a molding process.

BACKGROUND OF THE INVENTION

As disclosed in Japanese Patent Public Disclosure No. 2004-017508, Japanese Patent Publication No. S50-19132 and Japanese Patent Publication No. S43-27488, it has been proposed to perform a method of injection molding in order to unify a sheet-like material, such as a decorative or ornamental sheet, on a surface of a molded article during a molding process and add new value or optional function to the molded article due to the properties of the sheet-like material, such as color, pattern, quality of material and the like. A conventional method of injection molding of this kind exemplifies the following steps of: installing a decorative sheet in an injection mold; injecting a molten resin to fill the mold cavity with the molten resin; and solidifying the resin in the cavity to form an injection molded body simultaneously with integrating the decorative sheet onto a surface of the injection molded body.

In this method, the sheet-like material such as a decorative sheet is pre-shaped, as required, by an appropriate forming process such as vacuum forming to be adapted to the shape of the mold cavity while installed in the mold or before installed in the mold. When installed in the mold, the sheet-like material such as a decorative sheet covers the whole or part of the mold cavity, and the area of the mold cavity that is covered with the sheet-like material corresponds to the surface of the injection molded body onto which the sheet-like material should be integrated. At this time, the remaining portion of the sheet-like material which protrudes outside the mold cavity is clamped between the parting surfaces or dividing surfaces or abutting surfaces of the first and second mold sections, for example, a cavity mold and a core mold forming opposite sides of the mold cavity, so that the sheet-like material should not be displaced by injection pressure.

To take a pair of a cavity mold and a core mold as an example, the sheet-like material installed on the cavity mold extends continuously from a mold cavity on to a parting surface of the cavity mold, via the peripheral edge of the mold cavity of the cavity mold. Then the core mold is closed against the cavity mold and the sheet-like material is clamped between the parting surfaces of the core mold and the cavity mold while the sheet-like material extends in the mold cavity. The sheet-like material extending in the mold cavity is defined by the peripheral edge of the mold cavity. When molten resign is injected into the mold cavity from an injection gate of the core mold, the molten resin flows along a surface of the sheet-like material to the peripheral edge of the mold cavity. Thereby, the mold cavity is filled with the molten resign and the sheet-like material defined by the peripheral edge of the mold cavity.

The sheet-like material installed in the mold cavity is affected by the temperature of the molten resin injected into the mold cavity and also affected by the injection pressure of the molten resin produced to fill the mold cavity up with the molten resin. The injected molted resin tends to apply a large pressure to the sheet-like material, in particular, in the vicinity of the peripheral edge of the mold cavity. Depending on conditions of injection molding, the sheet-like material may deform around the peripheral edge of the mold cavity. Especially when the sheet-like material extends along an elongated peripheral edge of the mold cavity, there is an increased risk of serious damage to the sheet-like material because of uneven dispersion of the molten resin. In the event that the sheet-like material is damaged, the molten resin leaks out of the mold cavity from the peripheral edge thereof and produce a flash between the parting surfaces of the mold sections. In addition, the molten resin may penetrate through the sheet-like material and damage the outer surface of an injection molded article to be produced. When the sheet-like material is made of an olefin-based thermoplastic elastomer (TPO) with soft texture or the like, the above-mentioned disadvantages may cause serious damage to an injection molded article.

SUMMARY OF THE INVENTION

An object of the present invention is to provide an apparatus of injection molding for molding an injection molded body and integrating a sheet-like material onto a surface of the injection molded body without causing damage to the sheet-like material.

Another object of the present invention is to provide an apparatus of injection molding for integrating a sheet-like material onto a surface of an injection molded body without causing damage to the sheet-like material.

Further object of the present invention is to provide an apparatus of injection molding for manufacturing an injection molded article integral with a sheet-like material.

Another object of the present invention is to provide a method of injection molding for integrating a sheet-like material onto a surface of an injection molded article during fabrication of the injection molded article.

Further object of the present invention is to provide a method of injection molding for manufacturing an injection molded article onto which a sheet-like material is integrated during fabrication of the injection molded article.

Another object of the present invention is to provide a method of injection molding for molding an injection molded article and integrating a sheet-like material with the injection molded article during fabrication of the injection molded article, without causing damage to the sheet-like material.

According to the first aspect of the present invention, there is provided an apparatus of injection molding comprising: at least a pair of mold sections that can be closed and opened, wherein a sheet-like material can be disposed between said mold sections; a fixing device for fixing said sheet-like material at a set place interposed between said mold sections; at least one mold cavity defined in said mold sections when said mold sections are closed; and

an injection gate for injecting a molten resin into said mold cavity; characterized in that a groove or recess portion is formed outside the peripheral edge of said mold cavity, and said groove or recess portion is adapted to receive a molten resin that is injected into said mold cavity and flows into said groove or a recess portion through the peripheral edge of said mold cavity.

According the second aspect of the present invention, there is provided a method of injection molding wherein a molten resin injected into a mold cavity and a sheet-like material supplied in mold sections are integrated in said mold sections, and said molten resin integrated with said sheet-like material is molded by said mold sections, characterized by the steps of: disposing said sheet-like material in said mold sections to expand from the interior of said mold cavity to the exterior of said mold cavity continuously; fixing said sheet-like material to said mold sections; injecting said molten resin into said mold cavity to mold an injection molded body made from the molten resin filled in said mold cavity and mold a protrusion made from the molten resin flowing out of the peripheral edge of said mold cavity, wherein said injection molded body is in close contact with said sheet-like material in the interior of said mold cavity, said protrusion is in close contact with said sheet-like material in the exterior of said mold cavity, and said protrusion has a predetermined thickness; cooling said mold sections and increasing a resin viscosity of said protrusion more rapidly than a resin viscosity of said injection molded body in said mold sections due to the difference of the volume capacities between said protrusion and said injection molded body; and applying a predetermined pressure to said molted resin injected into said mold cavity when the resin viscosity of said protrusion has increased to a predetermined value, and integrate said injection molded body and said protrusion with said sheet-like material in said mold sections.

According to the third aspect of the present invention, there is provided a method of injection molding for manufacturing an injection molded article with which a surface material is integrated, characterized by the steps of: disposing said sheet-like material in said mold sections to expand from the interior of said mold cavity to the exterior of said mold cavity continuously; fixing said sheet-like material to said mold sections; injecting said molten resin into said mold cavity to mold an injection molded body made from the molten resin filled in said mold cavity and mold a protrusion made from the molten resin flowing out of the peripheral edge of said mold cavity, wherein said injection molded body is in close contact with said sheet-like material in the interior of said mold cavity, said protrusion is in close contact with said sheet-like material in the exterior of said mold cavity, and said protrusion has a predetermined thickness; cooling said mold sections and increasing a resin viscosity of said protrusion more rapidly than a resin viscosity of said injection molded body in said mold sections due to the difference of the volume capacities between said protrusion and said injection molded body; applying a predetermined pressure to said molted resin injected into said mold cavity when the resin viscosity of said protrusion has increased to a predetermined value, and integrate said injection molded body and said protrusion with said sheet-like material in said mold sections; and taking said injection molded body out of said mold sections, wherein said injection molded body has been integrated with said sheet-like material and molded into a predetermined shape, and cutting out said protrusion together with the sheet-like material extending outside said mold cavity from said injection molded body.

According to the present invention, one or more groove portions or recess portions are formed on the whole or part of the peripheral edges of the mold cavity in such a manner as to protrude from the mold cavity along the surface of the sheet-like material in the direction in which the sheet-like material extends. Therefore, the molten material which flows into the groove or recess portions from the mold cavity flows smoothly along the sheet-like material at the peripheral edge of the mold cavity. Thereby, it is possible to eliminate a risk where an excessive pressure is applied to the sheet-like material lying at the peripheral edge of the mold cavity. Consequently, the temperature and/or pressure of the molten resin does not cause damage to the sheet-like material lying in the vicinity of the peripheral edge of the mold cavity during molding process.

Due to the difference of the volume capacities between the protrusion and the injection molded body according to the present invention, a resin viscosity of said protrusion increases more rapidly than a resin viscosity of said injection molded body when cooling the mold sections. In other wards, the fluidity of the resinous material in the vicinity of the peripheral edge of the mold cavity is diminished more quickly than the fluidity of the resinous material in the mold cavity by cooling the mold sections. Therefore, the sheet-like material lying in the vicinity of the peripheral edge of the cavity mold comes to be covered by the resinous material of diminished fluidity or increased viscosity so that the sheet-like material is protected against exposure to heat and/or pressure in the vicinity of the peripheral edge of said cavity mold.

In addition, the molten material flows smoothly in the vicinity of the edge portion of the mold cavity when the molten material is being injected, because the molten resin is received by the groove or recess portion at the peripheral edge of the mold cavity. Therefore, the sheet-like material can be prevented from being damaged by the heat and/or pressure of the molten resin accumulated in the vicinity of the peripheral edge of the mold cavity.

These and other objects and advantages of the present invention will be more fully and readily understood by referring to the following detailed description of the present invention and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows exemplarily an apparatus of injection molding according to the present invention, wherein FIG. 1A shows a state in which a mold is opened, and FIG. 1B shows a state in which the mold is closed.

FIG. 2A shows an enlarged sectional view of the area indicated by an arrow IIA in FIG. 1A, and FIG. 2B shows an enlarged sectional view of the area indicated by an arrow IIB in FIG. 1B.

FIG. 3 shows a perspective view of a meter cluster housing for vehicles with which a TPO sheet is integrated.

FIG. 4 shows a vertical sectional view of an apparatus of injection molding for manufacturing the interior component for vehicles shown in FIG. 3, with a cavity mold and a core mold separated from each other to open the cavity mold.

FIG. 5 shows a sectional view of a main part of the cavity mold and the core mold in FIG. 4, which are brought into mating engagement to close the mold cavity.

FIG. 6 shows as shown in FIG. 5.

FIG. 7 shows the vicinity of the peripheral edge of the mold cavity wherein a molten resin is injected into the mold cavity shown in FIG. 6.

FIG. 8 shows an enlarged sectional view of an edge portion of an injection molded article which is taken out of the mold sections shown in FIG. 6.

FIG. 9 shows an enlarged sectional view of an edge portion of an injection molded article after an unnecessary portion is trimmed off from the injection molded article shown in FIG. 8.

FIG. 10 shows an enlarged sectional view of the vicinity of a peripheral edge in a conventional mold cavity.

 DETAILED DESCRIPTION OF THE INVENTION The First Embodiment

For a preferred embodiment of the present invention, one or more shallow grooves are formed on a parting surface of a core mold. The grooves extend from an edge portion of a cavity in the core mold outwards of a mold cavity so that an injected molten material flows into the grooves smoothly and is cooled quickly in the vicinity of an edge portion of the mold cavity. When the injected molten material reached the edge portion of the cavity in the core mold, the molted material flows smoothly without staying on the edge portion of the cavity.

FIGS. 1 and 2 are drawings which show exemplarily an apparatus of injection molding according to the present invention, wherein the mold sections are open in FIG. 1A, while the mold sections are closed in FIG. 1B. An apparatus of injection molding 1 has a cavity mold 2 and a core mold 3 in those figures, and when the core mold 3 are closed against the cavity mold 2 as shown in FIG. 1B, a mold cavity 4 is formed between the cavity mold 2 and the core mold 3.

A sheet-like material 5 such as a decorative sheet for a molded article is formed of an olefin-based thermoplastic elastomer (TPO) or the like so as to provide a surface of the molded article with soft texture. The sheet-like material 5 may be pre-shaped by an apparatus of injection molding 1 using a suitable forming technique such as vacuum forming or the like so as to match a cavity configuration of the cavity mold or may be pre-shaped using any other vacuum forming system than the apparatus 1. As shown in FIG. 1A, the sheet-like material 5, which has been pre-shaped, is placed in the cavity mold 2. The pre-shaped sheet-like material 5 has a formed portion 5a which is closely secured to a cavity surface 2a of the cavity mold 2 and a holding portion 5b which extends along a parting surface 2b of the cavity mold 2.

As shown in FIG. 2A, a groove portion 3c is formed on an edge portion 3b of a cavity surface 3a of the core mold 3. The groove portion 3c is made of a single annular groove which is open in a parting surface 3d of the core mold 3. The groove portion 3c extends from the edge portion 3b of the cavity surface 3a outwards of the core mold 3 and exists along the edge portion 3b of the cavity surface 3a in the core mold 3.

As shown in FIG. 1B, the core mold 3 is closed against the cavity mold 2 and then a molten resin 7 is injected into the mold cavity 4 from an injection gate 6 in the core mold 3. The molten resin 7 injected into the mold cavity 4 flows along an upper surface of the sheet-like material 5 mounted in the cavity mold 2 and reaches the edge portion 3b of the cavity surface 3a. As shown in FIG. 2B, the groove portion 3c is made to open in the edge portion 3b. Thereby, the molten resin 7 flows along the upper surface of the sheet-like material 5 and smoothly into the groove portion 3c without staying on the edge portion 3b. When the mold cavity 4 and the groove portion 3c are filled with the molten resin 7, the molten resin 7 is held under pressure in the mold sections 2 and 3 for a certain period of time. Simultaneously, the mold sections 2 and 3 are cooled by a cooling apparatus (not shown). Due to the cooling process, the molten resin 7 is solidified to form a molded body (not shown) in the mold cavity 4, and the molded body is integrated onto the upper surface of the sheet-like material 5. During the cooling process, the molten resin 7 in the groove portion 3c is hardened sooner than the molten resin 7 in the mold cavity 4 becomes hardened, because the volume capacity of the groove portion 3c is far smaller than the volume capacity of the mold cavity 4. As the viscosity of the molten resin 7 is increased in the groove portion 3c, the fluidity of the molten resin 7 becomes diminished not only in the groove portion 3c but also in the vicinity of the edge portion 3c of the cavity surface 3a or a peripheral edge A of the mold cavity 4.

The diminished fluidity of the molten resin 7 prevents a further volume of the molten resin 7 from flowing into the groove portion 3c from the mold cavity 4 and also prevents the migration of the molten resin 7 in the vicinity of the peripheral edge A of the mold cavity 4. In the vicinity of the peripheral edge A of the mold cavity 4, the sheet-like material 5 comes to be covered by the molten resin 7 of increased viscosity and protected against exposure to heat and/or pressure. Thereby, the molten resin 7 does not leak out between the parting surface 3d and the upper surface of the sheet-like material 5 to form a flash, even in the process that the molten resin 7 is pressurized at a hold pressure in the mold sections 2 and 3. In addition, the sheet-like material lying in the vicinity of the peripheral edge A of the mold cavity 4 is prevented from being deformed or damaged by the pressure and/or heat of the molten resin 7, because of the protective resin coating over the peripheral edge A of the mold cavity 4.

When the cooling process is completed, the mold sections 2 and 3 are separated to open the mold cavity 4 and detach a semi-fabricated article consisting of the sheet-like material 5 and an injection molded body of the resin 7. The injection molded boy of the resin 7 is integrated onto the upper surface of the sheet-like material 5. The semi-fabricated article includes an extra part of the sheet-like material 5 which extended between the parting surfaces 2b and 3d of the mold sections 2 and 3 when molded. The semi-finished article also includes an extra part of the molded body in the form of an annular flange or the like, which was formed by the groove portion 3c when molded. Therefore, the extra parts of the sheet-like material 5 and the molded body are cut to be removed from the semi-fabricated article to obtain a finished product of the injection molded article.

The Second Embodiment

FIG. 3 illustrates a perspective view an automotive interior part, that is, a meter cluster housing 8. As a decorative sheet, a TPO sheet 9 having a soft texture is integrated onto a surface of the housing 8. Hereinafter, the present invention will be described further by taking as an example a manufacture of the meter cluster housing 8 with which the TPO sheet 9 is integrated. The flange-like protrusion that is made from the molten resin 7 filled in the groove portion 3c in FIG. 2B is formed along a front edge portion 8A of the meter cluster housing 8 and is positioned on a back side of the TPO sheet 9 extending toward the outside of the front edge portion 8A.

In FIG. 4, the TPO sheet 9 is heated by a heating device (not shown) so as to be softened and fixed to a parting surface of a cavity mold 11 of an apparatus of injection molding 10 by means of clampers 12, 12. In this example, the cavity mold 11 is a stationary mold held by a base member 13 and a plurality of suction ports 14, 15, 16 are formed in the cavity mold 11 and the base member 13. The TPO sheet 9 supplied on the cavity mold 11 is sucked by virtue of vacuum created in air suction ports 14, 15, 16 so as to be closely secured to a mold surface of the cavity mold 11 by means of vacuum forming. Thereby, the TPO sheet 9 is pre-shaped to conform with the mold surface of the cavity mold 11, which corresponds to a surface configuration of a meter cluster housing 8 to be molded.

A core mold 17 disposed above the cavity mold 11 is held by an upper flame 18 as a movable mold of the apparatus of injection molding 10. In the core mold 17, a pair of injection gates 20a, 20b and a pair of ejector rods or ejector pins 21, 22 are installed in order to remove a molded article from the mold sections 11, 17. When the pre-shaping of the TPO sheet 9 is completed, the core mold 17 is lowered together with the upper frame 18 and the core mold 17 is closed against the cavity mold 11 to define a mold cavities 19a, 19b between the core mold 17 and the cavity mold 11 as illustrated in FIG. 5. Then, a molten resin is injected into the mold cavity 19a from a injection gate 20a to form a visor portion 8a of the meter cluster housing 8 and simultaneously, a molten resin is injected into the mold cavity 19b from an injection gate 20b to form a shelf portions 8b, 8b of the meter cluster housing 8. Since the mold cavities 19a, 19b communicate with each other via one or more communicating paths (not shown) formed between the mold cavities 19a, 19b, the molted resin flowed into the communicating paths forms a mounting portion 8c on which various instruments such as meters are mounted. In those figures, reference numeral 23 denotes a seal member for sealing a gap between the TPO sheet 9 and the parting surface of the cavity mold 11 in cooperation with the dampers 12. Reference numeral 24 denotes a detachable piece which makes up part of the cavity mold 11 to be replaced when it gets worn.

As illustrated in FIG. 6, a groove portion 17b is formed on the parting surface of the core mold 17. The groove portion 17b is in the form of an elongated step extending along the end portion 17a of the cavity surface in the core mold 17. The end portion 17a corresponds to a peripheral edge A of the mold cavity 19a as shown in FIG. 6. The groove portion 17b is made up of a single groove that extends to curve along an outer side of the peripheral edge A of the mold cavity 19a as to form a thin protrusion 25a of a molded body 25 as illustrated in FIG. 8. The thin protrusion 25a is in the form of a flap that is made from a molten resin injected into the mold cavity 19a and integrated onto an upper surface of the TPO sheet 9 as shown in FIGS. 7 and 8. The thin protrusion 25a is made of resin flowing into the groove portion 17b from the mold cavity 19a as illustrated in FIG. 7.

FIG. 10 shows, on the contrary, a vertical section of the mold sections 17, 18 that has no groove 17b in the peripheral edge A of the mold cavity 19a. Comparing FIG. 10 to FIG. 7, it is apparent where the thin protrusion 25a is formed.

Now, the molted resin 25 is injected from the injection gates 20a, 20b into the mold cavities 19a, 19b after the core mold 17 is closed against the cavity mold 18. The molted resin injected into the mold cavity 19a flows along the upper surface of the TPO sheet 9 towards the peripheral edge A of the mold cavity 19a while filling the mold cavity 19a. As the molten resin reached the peripheral edge A of the mold cavity 19a, the molten resin passes smoothly the peripheral edge A of the mold cavity 19a and flows into the groove portion 17b without staying in the vicinity of the peripheral edge A of the mold cavity 19a or the end portion 17a of the cavity surface of the core mold 17. When the mold cavities 19a, 19b and the groove portion 17b as well as the communicating paths between the mold cavities 19a, 19b are filled with the molten resin, the injected molten resin is held under pressure in the mold sections 17, 18 for a certain period of time and is cooled down by a cooling device (not shown).

When cooling down the molten metal in the mold sections 17, 18, the temperature of the molten resin filled in the groove portion 17b decreases more quickly than the temperature of the molten resin within the mold cavities 19a, 19b because the volume capacity of the groove portion 17c is smaller than the volume capacity of the mold cavities 19a, 19b in the mold sections 17, 18. As a result that the viscosity of the molten resin is increased in the groove portion 17c, the fluidity of the molten resin becomes diminished not only in the groove portion 17c but also in the vicinity of the peripheral edge A of the mold cavity 19a. The diminished fluidity of the molten resin prevents a further volume of the molten resin from flowing into the groove portion 17b from the mold cavity 19a and also prevents the migration of the molten resin in the vicinity of the peripheral edge A of the mold cavity 19a. In the vicinity of the peripheral edge A of the mold cavity 19a, thereby, the TPO sheet 9 comes to be covered by the molten resin of increased viscosity and protected against exposure to heat and/or pressure of the molten resin in the mold cavity 19a. As a result, the TPO sheet 9 lying in the vicinity of the peripheral edge A of the mold cavity 19a is prevented from being deformed or damaged by the pressure and/or heat of the molten resin. Therefore, the molten resin injected into the mold cavities 19a, 19b does not leak out between the parting surface of the core mold 17 and the upper surface of the TOP sheet 9 to form a flash, even in the event that a molding pressure is applied further to the molten resin within the mold cavities 19a, 19b in the subsequent pressure holding step.

When the cooling down of the molten resin in the mold sections 17, 18 is completed, a molded body 25 is molded in the mold cavities 19a, 19b and the communicating paths (not shown) and integrated onto the upper surface of the TPO sheet 9 as illustrated in FIGS. 7 and 8. Simultaneously, the thin protrusion 25a of resin is molded in the groove portion 17b and integrated onto the upper surface of the TPO sheet 9. The thin protrusion 25a extends from the edge of the molded body 25 as shown in FIG. 8. Then, the core mold 17 is lifted from the cavity mold 18 to open the mold cavities 19a, 19b and the molded body 25 is removed from the mold sections 17, 18 together with the TPO sheet 9 by means of the ejector rods 21, 22. The molded article took out of the mold sections 17, 18 is a semi-fabricated article of a meter cluster housing 8, because it includes an extra part of the TPO sheet 9 extending from the molded body 25 and the thin protrusion 25a integrated onto the extra part of the TPO sheet 9 as shown in FIG. 8. Therefore, the semi-fabricated article is processed for a trimming operation by which the extra part of the TPO sheet 9 and the thin protrusion 25a is trimmed off, as shown in FIG. 9, to obtain a finished product of the meter cluster housing 8.

Claims

1-9. (canceled)

10. A method of injection molding wherein a molten resin injected into a mold cavity and a sheet material supplied in mold sections are integrated in said mold sections, and said molten resin integrated with said sheet material is molded by said mold sections, the method comprising:

disposing said sheet material in said mold sections to expand from the interior of said mold cavity to the exterior of said mold cavity continuously;
fixing said sheet material to said mold sections;
injecting said molten resin into said mold cavity to mold an injection molded body made from the molten resin filled in said mold cavity and mold a protrusion made from the molten resin flowing out of the peripheral edge of said mold cavity, wherein said injection molded body is in contact with said sheet material in the interior of said mold cavity, said protrusion is in contact with said sheet material in the exterior of said mold cavity, and said protrusion has a predetermined thickness;
cooling said mold sections and increasing a resin viscosity of said protrusion more rapidly than a resin viscosity of said injection molded body in said mold sections due to the difference of the volume capacities between said protrusion and said injection molded body; and
applying a predetermined pressure to said molted resin injected into said mold cavity when the resin viscosity of said protrusion has increased to a predetermined value, and integrate said injection molded body and said protrusion with said sheet material in said mold sections.

11. The method of injection molding as set forth in claim 10, including forming said resinous protrusion from the molten resin that has flowed into a groove or recess portion from said mold cavity, wherein said groove or recess portion is outside the peripheral edge of said mold cavity and extends along a surface of said sheet material in said mold sections.

12. The method of injection molding as set forth in claim 11, wherein said molten resin moves smoothly in the vicinity of the peripheral edge of said mold cavity and flows into said groove or recess portion from said mold cavity.

13. The method of injection molding as set forth in claim 11, wherein the fluidity of the resinous material of said protrusion is diminished by cooling said mold sections, and the diminished fluidity of the resinous material of said protrusion prevents a further volume of the molten resin from flowing into said groove or recess portion from the mold cavity.

14. The method of injection molding as set forth in claim 10, wherein said sheet material is a decorative sheet made of an olefin-based thermoplastic elastomer.

15. The method of injection molding as set forth in claim 10, wherein the fluidity of the resinous material in the vicinity of the peripheral edge of said mold cavity is diminished by cooling said mold sections, and the sheet material lying in the vicinity of the peripheral edge of said cavity mold comes to be covered by the resinous material of diminished fluidity or increased viscosity so that said sheet-like material is protected against exposure to heat and/or pressure in the vicinity of the peripheral edge of said cavity mold.

16. The method of injection molding as set forth in claim 11, wherein said mold cavity is defined between a cavity surface of said cavity mold and a cavity surface of said core mold, and said core mold reciprocates relative to said cavity mold to define said cavity mold when closed against said cavity mold.

17. The method of injection molding as set forth in claim 16, including supplying said sheet material to the parting surface of said cavity mold when said cavity mold and said core mold are separated, and then fixing said sheet material to the parting surface of said cavity mold by one or more clampers so said sheet material extends across the parting surface and the cavity surface of said cavity mold.

18. The method of injection molding as set forth in claim 17, including fixing said sheet material to the parting surface of said cavity mold to seal the cavity surface of said cavity mold from the atmosphere, and then pre-shaping said sheet material by the cavity surface of said cavity mold by vacuum molding.

19. The method of injection molding as set forth in claim 17, comprising:

closing said core mold against said cavity mold and disposing said sheet material within said mold cavity, and, simultaneously, defining said groove or recess portion between the parting surface of said core mold and said sheet material extending outside said mold cavity, wherein said groove or recess portion has an opening in the peripheral edge of said mold cavity;
injecting a molten resin into said mold cavity defined between the cavity surface of said core mold and said sheet material disposed within said mold cavity and forming an injection molded body, wherein said injection molded body is in contact with said sheet material in said mold cavity, and filling said groove or recess portion with said molten resin to form a resinous protrusion having a predetermined thickness, wherein said resinous protrusion is in contact with said sheet material outside said mold cavity;
cooling said core mold and said cavity mold and increasing a resin viscosity of said protrusion more rapidly than a resin viscosity of said injection molded body in said mold sections due to the difference of the volume capacities between said protrusion and said injection molded body; and
applying a predetermined pressure to said molted resin injected into said mold cavity when the resin viscosity of said protrusion has increased to a predetermined value, and integrate said injection molded body and said protrusion with said sheet material in said mold sections.

20. A method of injection molding for manufacturing an injection molded article with which a surface material is integrated, comprising:

disposing a sheet material in said mold sections to expand from the interior of said mold cavity to the exterior of said mold cavity continuously;
fixing said sheet material to said mold sections;
injecting said molten resin into said mold cavity to mold an injection molded body made from the molten resin filled in said mold cavity and mold a protrusion made from the molten resin flowing out of the peripheral edge of said mold cavity, wherein said injection molded body is in contact with said sheet material in the interior of said mold cavity, said protrusion is in contact with said sheet-like material in the exterior of said mold cavity, and said protrusion has a predetermined thickness;
cooling said mold sections and increasing a resin viscosity of said protrusion more rapidly than a resin viscosity of said injection molded body in said mold sections due to the difference of the volume capacities between said protrusion and said injection molded body;
applying a predetermined pressure to said molted resin injected into said mold cavity when the resin viscosity of said protrusion has increased to a predetermined value, and integrate said injection molded body and said protrusion with said sheet material in said mold sections; and
taking said injection molded body out of said mold sections, wherein said injection molded body has been integrated with said sheet material and molded into a predetermined shape, and cutting out said protrusion together with the sheet material extending outside said mold cavity from said injection molded body.

21. The method of injection molding as set forth in claim 20, wherein said resinous protrusion is formed from the molten resin that has flowed into a groove or recess portion from said mold cavity, and said groove or recess portion is located outside the peripheral edge of said mold cavity and extends along a surface of said material in said mold sections.

22. The method of injection molding as set forth in claim 21, wherein said molten resin moves smoothly in the vicinity of the peripheral edge of said mold cavity and flows into said groove or recess portion from said mold cavity.

23. The method of injection molding as set forth in claim 21, wherein the fluidity of the resinous material of said protrusion is diminished by cooling said mold sections, and the diminished fluidity of the resinous material of said protrusion prevents a further volume of the molten resin from flowing into said groove or recess portion from the mold cavity.

24. The method of injection molding as set forth in claim 20, wherein said sheet material is a decorative sheet made of an olefin-based thermoplastic elastomer.

25. The method of injection molding as set forth in claim 20, wherein the fluidity of the resinous material in the vicinity of the peripheral edge of said mold cavity is diminished by cooling said mold sections, and the sheet material lying in the vicinity of the peripheral edge of said cavity mold comes to be covered by the resinous material of diminished fluidity or increased viscosity so that said sheet material is protected against exposure to heat and/or pressure in the vicinity of the peripheral edge of said cavity mold.

26. The method of injection molding as set forth in claim 21, wherein said mold cavity is defined between a cavity surface of said cavity mold and a cavity surface of said core mold, and said core mold reciprocates relative to said cavity mold to define said cavity mold when closed against said cavity mold.

27. The method of injection molding as set forth in claim 26, including supplying said sheet material to the parting surface of said cavity mold when said cavity mold and said core mold are separated, and then fixing said sheet material to the parting surface of said cavity mold by one or more clampers so the sheet material extends across the parting surface and the cavity surface of said cavity mold.

28. The method of injection molding as set forth in claim 27, including fixing said sheet material to the parting surface of said cavity mold to seal the cavity surface of said cavity mold from the atmosphere, and then pre-shaping said sheet material by the cavity surface of said cavity mold by vacuum molding.

29. The method of injection molding as set forth in claim 27:

closing said core mold against said cavity mold and disposing said sheet material within said mold cavity, and, simultaneously, defining said groove or recess portion between the parting surface of said core mold and said sheet material extending outside said mold cavity, wherein said groove or recess portion has an opening in the peripheral edge of said mold cavity;
injecting a molten resin into said mold cavity defined between the cavity surface of said core mold and said sheet material disposed within said mold cavity and forming an injection molded body, wherein said injection molded body is in contact with said sheet material in said mold cavity, and filling said groove or recess portion with said molten resin to form a resinous protrusion having a predetermined thickness, wherein said resinous protrusion is in contact with said sheet material outside said mold cavity;
cooling said core mold and said cavity mold and increasing a resin viscosity of said protrusion more rapidly than a resin viscosity of said injection molded body in said mold sections due to the difference of the volume capacities between said protrusion and said injection molded body; and
applying a predetermined pressure to said molted resin injected into said mold cavity when the resin viscosity of said protrusion has increased to a predetermined value, and integrate said injection molded body and said protrusion with said sheet-like material in said mold sections; and
taking said injection molded body out of said mold sections, wherein said injection molded body has been integrated with said sheet material and molded into a predetermined shape, and cutting out said protrusion together with the sheet material extending outside said mold cavity from said injection molded body.

30. The method of injection molding as set forth in claim 29, wherein said injection molded article is an interior component for vehicles.

31. The method of injection molding as set forth in claim 14, wherein the fluidity of the resinous material in the vicinity of the peripheral edge of said mold cavity is diminished by cooling said mold sections, and the sheet-like material lying in the vicinity of the peripheral edge of said cavity mold comes to be covered by the resinous material of diminished fluidity or increased viscosity so that said sheet material is protected against exposure to heat and/or pressure in the vicinity of the peripheral edge of said cavity mold.

32. The method of injection molding as set forth in claim 18, comprising:

closing said core mold against said cavity mold and disposing said sheet material within said mold cavity, and, simultaneously, defining said groove or recess portion between the parting surface of said core mold and said sheet material extending outside said mold cavity, wherein said groove or recess portion has an opening in the peripheral edge of said mold cavity;
injecting a molten resin into said mold cavity defined between the cavity surface of said core mold and said sheet material disposed within said mold cavity and forming an injection molded body, wherein said injection molded body is in contact with said sheet material in said mold cavity, and filling said groove or recess portion with said molten resin to form a resinous protrusion having a predetermined thickness, wherein said resinous protrusion is in contact with said sheet material outside said mold cavity;
cooling said core mold and said cavity mold and increasing a resin viscosity of said protrusion more rapidly than a resin viscosity of said injection molded body in said mold sections due to the difference of the volume capacities between said protrusion and said injection molded body; and
applying a predetermined pressure to said molted resin injected into said mold cavity when the resin viscosity of said protrusion has increased to a predetermined value, and integrate said injection molded body and said protrusion with said sheet material in said mold sections.

33. The method of injection molding as set forth in claim 23, wherein the fluidity of the resinous material in the vicinity of the peripheral edge of said mold cavity is diminished by cooling said mold sections, and the sheet material lying in the vicinity of the peripheral edge of said cavity mold comes to be covered by the resinous material of diminished fluidity or increased viscosity so that said sheet material is protected against exposure to heat and/or pressure in the vicinity of the peripheral edge of said cavity mold.

34. The method of injection molding as set forth in claim 24, wherein the fluidity of the resinous material in the vicinity of the peripheral edge of said mold cavity is diminished by cooling said mold sections, and the sheet material lying in the vicinity of the peripheral edge of said cavity mold comes to be covered by the resinous material of diminished fluidity or increased viscosity so that said sheet material is protected against exposure to heat and/or pressure in the vicinity of the peripheral edge of said cavity mold.

35. The method of injection molding as set forth in claim 28,

closing said core mold against said cavity mold and disposing said sheet material within said mold cavity, and, simultaneously, defining said groove or recess portion between the parting surface of said core mold and said sheet-like material extending outside said mold cavity, wherein said groove or recess portion has an opening in the peripheral edge of said mold cavity;
injecting a molten resin into said mold cavity defined between the cavity surface of said core mold and said sheet material disposed within said mold cavity and forming an injection molded body, wherein said injection molded body is in close contact with said sheet-like material in said mold cavity, and filling said groove or recess portion with said molten resin to form a resinous protrusion having a predetermined thickness, wherein said resinous protrusion is in contact with said sheet material outside said mold cavity;
cooling said core mold and said cavity mold and increasing a resin viscosity of said protrusion more rapidly than a resin viscosity of said injection molded body in said mold sections due to the difference of the volume capacities between said protrusion and said injection molded body; and
applying a predetermined pressure to said molted resin injected into said mold cavity when the resin viscosity of said protrusion has increased to a predetermined value, and integrate said injection molded body and said protrusion with said sheet material in said mold sections; and
taking said injection molded body out of said mold sections, wherein said injection molded body has been integrated with said sheet material and molded into a predetermined shape, and cutting out said protrusion together with the sheet material extending outside said mold cavity from said injection molded body.
Patent History
Publication number: 20120043696
Type: Application
Filed: Oct 20, 2011
Publication Date: Feb 23, 2012
Applicant: MORIROKU COMPANY, LTD. (Tokyo)
Inventors: Hideki BABA (Moka-shi), Koji AKASAKA (Moka-shi), Daiju KAWAKAMI (Moka-shi)
Application Number: 13/277,296
Classifications
Current U.S. Class: Cavity Lining Type (264/269)
International Classification: B29C 45/14 (20060101);