JP2000280388A - Laminated skin material, skin integrated molded article using the same and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminated skin material excellent in cushioning properties, an inexpensive skin integrated molded article using the same and a method for producing the molded article. SOLUTION: A laminated skin material is formed by integrally laminating a fibrous barrier layer 1c permitting the penetration of a molten plastic molding material but controlling the penetration thereof into an intermediate cushion layer 1b on the rear surface of a skin layer 1a through the intermediate cushion layer 1b comprising foamed plastic and a skin integrated molded article is constituted by integrally laminating the laminated skin material to a plastic molding base material at a required position by allowing the molten plastic molding material to equally penetrate into the fibrous barrier layer 1c without allowing the same into the intermediate cushion layer 1c and produced by setting the laminated skin material to a mold at a predetermined position and supplying the molten plastic molding material in a cavity from the rear side of the laminated skin material after the mold is closed to integrally bond the laminated skin material 1 to the plastic molding base material at a required position in the mold and molding the whole of them.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated skin material having a good cushioning property suitable for a vehicle interior material such as an automobile door interior material, an inexpensive integrally formed skin material using the same, and a method of manufacturing the same. Things.

[0002]

2. Description of the Related Art Conventionally, a method for producing a skin material having cushioning properties used for interior materials for automobiles and a molded article of skin using the same is disclosed in, for example, Japanese Patent Application Laid-Open No. 3-162.
914, JP-A-4-90313, JP-A-8
As shown in JP-A-183059, various types have been proposed and put to practical use.

However, Japanese Patent Laid-Open Publication No.
The technology described in Japanese Patent Application Laid-Open No. 4-90313 has a problem that it is necessary to change the protective film depending on the type of the base material and lacks versatility. There is a problem of peeling from the substrate due to the difference in thermal expansion due to the use of, and further, in the technology described in JP-A-8-183059,
There is a problem that diversification is difficult because the sheet member is arranged at the gate portion. In addition, any technology requires a molding machine equipped with a special mold clamping mechanism,
Since the molten resin is filled with the mold open, there is a problem that the mold structure must be special and complicated in order to prevent the generation of burrs.

[0004]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems in the prior art, can secure excellent cushioning property and design texture, and requires a special mold mechanism and construction method. The present invention has been completed for the purpose of providing a laminated skin material capable of efficiently and at low cost producing a skin integral molded product, a skin integral molded product using the same, and a method of manufacturing the same.

[0005]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems. The present invention provides an intermediate cushion layer made of a foamed synthetic resin on the back of a skin layer for forming a design surface.
A laminated skin material, wherein a fibrous barrier layer for controlling penetration of a molten synthetic resin molding material supplied from the back side evenly over the entire surface but controlling penetration into an intermediate cushion layer is integrated; The molding material of this synthetic resin molding base material penetrates into the intermediate cushion layer at the required position of the synthetic resin molding base material, and the skin material is evenly penetrated into the fibrous barrier layer without partially curing the intermediate cushion layer. A skin integral molded product characterized by being integrated with the adhesive;
After setting the laminated skin material according to claim 1 at a predetermined position of a molding die and clamping the mold, a molten synthetic resin material for molding a base material is supplied to the cavity from the back side of the laminated skin material, and the molten synthetic resin material is fed into the molding die. A method of manufacturing a skin integral molded product, comprising molding a skin integral molded product in which the laminated skin material is adhered and integrated at a required position of a synthetic resin molded base material. Incidentally, the fibrous barrier layer in each of the above-described inventions,
Those having an air permeability of 30 to ²⁰⁰ cm ³ / cm ² · s are particularly preferred.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, as a preferred embodiment of the present invention, a case where an automobile door trim is injection-molded will be described in detail with reference to the drawings. Reference numeral 1 denotes a laminated skin material, 2 denotes a synthetic resin molded base on which the laminated skin material 1 is adhered and integrated on the surface, and 10 denotes a molding die for molding a skin integral molded product using the laminated skin material 1. , Comprising a pair of mold cavities 10a and a core mold 10b which can be freely contacted and separated.

As shown in FIG. 1, the laminated skin material 1 includes a skin layer 1a for forming a design surface, an intermediate cushion layer 1b made of a foamed synthetic resin such as polyolefin or polyurethane, and an intermediate cushion layer 1b. The fibrous barrier layer having the property of controlling the amount of penetration into the intermediate cushion layer, although the molten synthetic resin molding material supplied from the back side attached to the back surface of the layer 1b evenly penetrates over the entire surface. 1c, these skin layers 1a
And the three layers of the intermediate cushion layer 1b and the fibrous barrier layer 1c are integrally laminated.

[0008] Such a laminated skin material 1 is set at a predetermined position in a mold in a state where a molding die 10 including a mold 10a and a core die 10b is opened, and after the mold is clamped, the laminated skin material 1 is formed. If a molten synthetic resin molding material for molding a base material is supplied to the cavity from the back side of the fibrous barrier layer 1c on the back surface of the mold 1, the molten synthetic resin molding material is molded into a synthetic resin molded base material in the cavity of the molding die 10. At the same time, the laminated skin material 1 is molded at a required position into an integrated skin-molded product in which the fibrous barrier layer 1c is supplied. And at the same time, the intermediate cushion layer 1
b has a property of controlling the amount of impregnation into the synthetic resin molding base material, so that the laminated skin material 1 is integrated without causing insufficient adhesion, and the intermediate cushion layer 1b is formed of a molten synthetic resin. Since it is not solidified by the infiltration of the molding material, a skin-integrated molded product having excellent cushioning properties and design texture can be obtained.

The above-mentioned skin layer 1a may be made of a fibrous skin material such as a woven fabric, a nonwoven fabric, a knitted fabric, a raised fiber fabric such as a carpet, or a soft vinyl chloride resin, an olefin resin, an olefin elastomer resin, or the like. Although a synthetic resin sheet or film may be used, it is necessary that the surface be designed or have a texture, so that the thickness is about 0.2 to 5.0 mm.

On the other hand, as the intermediate cushion layer 1b, a foamed sheet of olefin resin such as polyethylene resin or polypropylene resin (foaming rate: 10 to 40 times),
Foam sheet of soft vinyl chloride resin (foaming rate: 5 to 20)
Times), foamed sheet of polyurethane resin (density: 0.00
2 to 0.5 g / cm ³ )
Shall have elasticity.

The most important fibrous barrier layer 1c in the present invention may be a nonwoven fabric, a woven fabric, a knitted fabric, or the like made of a synthetic fiber such as polyester or polyamide in addition to natural fibers. 1b, the molten synthetic resin material supplied from the back side is not partially concentrated and permeates in the vicinity of the injection gate, but is dispersed and equalized over the entire surface, and at the same time, is transferred to the intermediate cushion layer 1b. Since it is used to control the amount of impregnation of JIS, it is particularly preferable that the air permeability by JIS-L1096A method is 30 to 200 cm ³ / cm ² · s. The reason is that if the air permeability is less than 30 cm ³ / cm ² · s, as described later, when the skin material 1 is set in a mold and the skin integral molded product is molded, the penetration of the molten synthetic resin material is prevented. In some cases, the adhesive strength may be reduced to cause a partial decrease in adhesion strength. On the other hand, when the adhesive strength is higher than 200 cm ³ / cm ² · s, the penetration of the molten synthetic resin material in the high flow resistance (pressure) portion increases, and The intermediate cushion layer 1b reaches the cushion layer 1b.
This is because the cushion feeling of is lost.

Next, a process of forming an integrally molded skin product using the laminated skin material 1 will be described. As shown in FIG. 2, the laminated skin material 1 is
After setting the fibrous barrier layer 1c at a predetermined position of 0b so as to face the supply gate 11 provided on the core mold 10b,
The mold 10a is closed and the mold is clamped. Next, a molten synthetic resin molding material for molding a base material is injected into the cavity from the supply gate 11 described above. At this time, cushion layer 1
b is compressed by the molten synthetic resin. Also,
The supply gate 11 is located directly behind the laminated skin material 1, and the laminated skin material 1 has the fibrous barrier layer 1 c set toward the supply gate 11 side.
The molten synthetic resin molding material filled in the cavity from the back side of the fibrous barrier layer 1c is molded into the synthetic resin molding base 2 and at the same time, has an air permeability of about 30 to ²⁰⁰ cm ³ / cm ^2. , The molten synthetic resin molding material is uniformly dispersed and permeated over the entire surface, and the laminated skin material 1 is bonded and integrated with the back surface of the synthetic resin molding base material 2. 1b is controlled so as not to penetrate at all even in a high pressure part such as the vicinity of the gate or to a degree that it penetrates only to a very low layer. Therefore, the molded synthetic resin molding base material 2 and the laminated skin are controlled. In addition to the entire surface being properly adhered to the material 1, the comfortable cushioning property is maintained without the intermediate cushion layer 1b being solidified due to a large amount of partial penetration of the molten synthetic resin molding material. When the molding process in the molding die 10 as described above is completed, if the mold is opened and the mold is released, the compressive force applied to the cushion layer 1b is released. The skin material 1 is stuck and integrated over the entire surface of a predetermined position of the synthetic resin molding base material 2,
There is no partial collapse or hardening of b, and it is restored to the cushion layer 1b side, so that a skin-integrated molded product having comfortable cushioning properties can be obtained. Although the case of injection molding has been described above, it goes without saying that the present invention can be applied to compression molding.

[Example] An intermediate cushion layer 1b made of slab urethane having a density of 0.028 g / cm ³ and having a back surface cut out of a 0.5 mm thick sharge cloth as a design surface forming skin layer 1a to a 1.3 mm thickness. 20-240 air permeability through
Changed every 10 cm ³ / cm ² · s within the range of cm ³ / cm ² · s.
A laminated skin material 1 in which a fibrous barrier layer 1c made of a 5 mm thick sharge cloth is laminated is prepared and set in a mold for an injection molding machine, and an injection molding machine (TOSHIBA IS-1600DF).
The resin temperature is 220 ° C as a molten synthetic resin molding material using
Polypropylene resin (IDEMI manufactured by Idemitsu Petrochemical Co., Ltd.)
TSU PP J-3056HP (MI: 30 g / 10
min) was injected from a core-type gate to form an interior material for an automobile with integrated skin. According to the experimental results, depending on the properties (viscosity and melting temperature, etc.) of the molten synthetic resin molding material to be used, when the air permeability is in the range of 30 to ²⁰⁰ cm ³ / cm ² · s, the molten synthetic resin molding material cannot be used. Fiber barrier layer 1c
In addition to having a sufficient adhesive strength to the synthetic resin molding base formed by uniformly dispersing and infiltrating the entire surface without concentrating near the gate, the intermediate cushion layer 1b is formed of molten synthetic resin even near the gate. Thus, there was obtained a door interior material for a car-integrated car door which did not collapse due to the penetration of the molding material and did not impair the cushioning property. In contrast, 200
When a fibrous barrier layer 1c exceeding cm ³ / cm ² s is used,
The molten synthetic resin molding material injected from the gate is not dispersed and equalized over the entire surface of the fibrous barrier layer 1c. The extra molten synthetic resin molding material that has penetrated partially penetrates into the intermediate cushion layer 1b through the fibrous barrier layer 1c, and the partial curing of the intermediate cushion layer 1b due to the penetration increases as the air permeability increases. This curing resulted in impaired cushioning properties. On the other hand, in the example using the fibrous barrier layer 1c having an air permeability of less than 30 cm ³ / cm ² · s, as the air permeability decreases, the penetration of the molten synthetic resin molding material into the intermediate cushion layer 1b disappears, and Although the curing of 1b disappeared, defective products having poor adhesion at the skin end or the like due to insufficient penetration of the molten synthetic resin molding material into the fibrous barrier layer 1c occurred frequently.

[0014]

As is clear from the above description, the present invention can ensure excellent cushioning properties and design texture, and is efficient and requires no special mold mechanism or construction method. It is possible to produce a skin integral molded product at low cost. Therefore, the present invention greatly contributes to the development of industry as a laminated skin material which has eliminated the conventional problems, a skin integrally molded product using the same, and a method for producing the same.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of a laminated skin material according to the present invention.

FIG. 2 is a cross-sectional view showing an embodiment of a skin integral molded product according to the present invention.

FIG. 3 is a cross-sectional view illustrating a method for manufacturing a skin integral molded product according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Laminated skin material 1a Skin layer 1b Intermediate cushion layer 1c Fibrous barrier layer 2 Synthetic resin molding base material 10 Mold 10a Mold type 10b Core type

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Takayoshi Tanaka Ichihara-shi, Chiba Pref. JK11 JK11B YY00C 4F206 AA11 AD15 AD16 AD20 AG03 AG20 AH26 JA07 JB13 JF05

Claims (4)

[Claims] 1. A molten synthetic resin molding material supplied from the back side uniformly penetrates the entire back surface of an outer skin layer (1a) for forming a design surface through an intermediate cushion layer (1b) made of a foamed synthetic resin. However, a laminated skin material characterized in that a fibrous barrier layer (1c) for controlling penetration into the intermediate cushion layer (1b) is integrally laminated. 2. The fibrous barrier layer (1c) has a thickness of 30 to 200 cm.
The laminated skin material according to claim 1, which has an air permeability of ³ / cm ² · s. 3. A molten synthetic resin molding material supplied from the back side uniformly penetrates the whole back surface of the skin layer (1a) for forming a design surface through an intermediate cushion layer (1b) made of a foamed synthetic resin. Laminate skin material with integrated fibrous barrier layer (1c), but controls penetration into intermediate cushion layer (1b)
(1), the molding material of the synthetic resin molding base material (2) penetrates into the intermediate cushion layer (1b) at a required position of the synthetic resin molding base material (2), and the intermediate cushion layer (1b) is partially formed. An integral skin-molded article characterized in that it is evenly penetrated into the fibrous barrier layer (1c) without being cured and is adhered and integrated. 4. The laminated skin material according to claim 1 is set at a predetermined position of a molding die, and after clamping, the molten synthetic resin molding material for molding a base material is supplied to the cavity from the back side of the laminated skin material. And forming a skin integral molded product in which the laminated skin material is adhered and integrated at a required position of a synthetic resin molding base in a molding die.