JP2002210850A - Laminated molded article and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate setting in a foaming mold and to prevent erosion of a cushion layer with heat in forming a foamed layer and also depression of the foamed layer, in a manufacturing process of a laminated molded article. SOLUTION: A core 11 is molded. A skin 15 and a reinforcing layer 13 are laminated in the shape of a sheet so that they hold the cushion layer 14 between, and then they are vacuum-formed to obtain a surface-side laminate 16. The reinforcing layer 13 is harder than the skin 15. Next, the core 11 is set on a molding tool 21 of a foam molding apparatus 20, while the surface-side laminate 16 is set on a molding tool 22. The reinforcing layer 13 is directed to the core 11. Then, foamed beads (not shown in Fig.) are filled in a space A between the core 11 and the surface-side laminate 16. These beads are steam- heated to be welded mutually and also to be welded to the core 11 and the reinforcing layer 13. Thereby the foamed layer is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle interior (instrument panel, door trim, pillar,
Laminated molded products used as console boxes, etc.)
And its manufacturing method.

[0002]

2. Description of the Related Art For example, Japanese Patent Application Laid-Open No. 7-32523 discloses a laminated molded product having a four-layer structure in which a core material, a foam layer, a cushion layer, and a skin are sequentially laminated. When manufacturing this laminated molded product, the core material is first molded,
The cushion layer and the skin are integrally formed. After that, foamed beads are filled between the cushion layer and the core material,
The beads are heat-welded to form a foamed layer.

[0003]

In the above-mentioned conventional products, the skin and the cushion layer are soft and lack shape retention. for that reason,
If these two layers are set in a foaming mold after vacuum forming, the setting operation is difficult. Further, the cushion layer is eroded by heat at the time of welding the beads, and the thickness tends to vary. Furthermore, when used as a product in an environment where the temperature is high (for example, 80 ° C. or higher), if the skin is strongly pressed with a finger or the like, the foamed layer may also be dented and may not be able to return to its original state.

[0004]

Means for Solving the Problems In order to solve the above problems, a laminated molded article according to the present invention comprises a core material, a foamed layer made of foamed beads, a reinforcing layer, a cushion layer, and a skin. The reinforcing layer is laminated, and is characterized in that it is harder than the skin. Here, the reinforcing layer, the cushion layer, and the skin are laminated and formed into a sheet, and then integrally vacuum-formed, and the reinforcing layer is formed of a mixed resin of polypropylene and polystyrene. desirable.

[0005] A method of manufacturing a laminated molded article according to the present invention comprises a core material forming step of forming a core material, a skin and a reinforcing layer harder than the skin sandwiched by a cushion layer, and then integrally formed. Vacuum forming, a laminate forming step to obtain a front side laminate, and setting the core material in one of a pair of forming dies,
On the other hand, the front side laminate, a setting step of setting the reinforcing layer to face the core material, a filling step of filling the expanded beads between the set core material and the front side laminate, The method further comprises the steps of: heating the already-expanded beads to be welded to each other, and also welding the core material and the reinforcing layer to obtain a foamed layer.

[0006]

An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 shows an instrument panel 10 (laminated product) of an automobile. The instrument panel 10 includes a core 11 and a foam layer 12.
, A reinforcing layer 13, a cushion layer 14, and a skin 15 are sequentially laminated to form a five-layer structure. The reinforcing layer 13, the cushion layer 14, and the skin 15 constitute a front-side laminate 16.

[0007] The core material 11 is formed of polypropylene or a polypropylene filler to a thickness of 1 mm to 3 mm. The foam layer 12 is formed by foaming foam beads made of polypropylene 15 to 60 times, and has a thickness of about 3 mm at a thin portion and about 25 mm at a thick portion.

The cushion layer 14 of the front side laminate 16 is formed of polypropylene foam having an expansion ratio of 10 to 30 times and a thickness of 1 to 4 mm. Epidermis 15
Is a polyolefin-based thermoplastic elastomer,
It is formed to a thickness of 0.3 mm to 1.5 mm.

The reinforcing layer 13 is made of a resin obtained by mixing polypropylene and polystyrene with a compatibilizer, and is made of a resin having a thickness of 0.2 mm.
It is formed to a thickness of 1.5 mm. The content of each component is as follows: polypropylene is 30 to 40% by weight, polystyrene is 55 to 65% by weight, and the compatibilizer is about 3 to 5% by weight.
% By weight. This reinforcing layer 13 is harder than the skin 15.

A method for manufacturing the instrument panel 10 will be described. First, the core material 11 is injection-molded (core material forming step). As shown in FIG. 2, the core material 11 has holes 1 for beads.
1a and steam holes 11b and 11c are formed.

Further, after the reinforcing layer 13, the cushion layer 14, and the skin 15 are formed into a sheet by extrusion lamination, they are vacuum-formed to obtain a front-side laminate 16 (laminate forming step). Since the reinforcing layer 13 is made of a mixed resin of polypropylene and polystyrene, the reinforcing layer 13 is more easily extended during vacuum forming than the case of only polypropylene,
Moreover, it can be hardly broken, and the vacuum formability is good.

The completed core material 11 and the front side laminate 16
Is sent to the foam molding apparatus 20 shown in FIG. 2 to execute the setting step. That is, after the pair of molding dies 21 and 22 of the foam molding apparatus 20 are separated from each other, the core material side molding dies 21
The core material 11 is set on the mold surface 21x of the
The front-side laminate 16 is set on the second mold surface 22 x so that the reinforcing layer 13 faces the core material 11. At this time, since the shape of the front-side laminate 16 can be maintained by the hard reinforcing layer 13, the setting operation of the front-side laminate 16 can be easily performed.

By setting the core material 11 in the molding die 21, the bead hole 11a of the core material 11 is connected to the opening end of the bead supply passage 23 of the device 20 to the mold surface 21x. Further, the steam hole 11b is connected to the opening end of the steam supply passage 24 of the device 20 to the mold surface 21x. Further, the steam hole 11c
Are connected to a through hole 21b extending from the mold surface 21x to the chamber 21a of the mold 21.

Next, the molds 21 and 22 are closed (mold clamping step). Thereby, between the core material 11 and the reinforcing layer 13,
A closed space A is created. This space A is filled with foamed beads (see FIG. 1) via the bead supply passage 23 and the bead hole 11a (filling step).

Next, in the space A filled with the beads,
The high-temperature steam is supplied through the steam supply passage 24 and the steam hole 11b. By the heat of this steam, the beads are welded to each other and also to the core material 11 and the reinforcing layer 13 (welding step). When the beads are welded to the reinforcing layer 13, the cushion layer 14 is protected from the heat of the steam by the reinforcing layer 13 and can be prevented from erosion. Therefore,
The thickness of the cushion layer 14 does not vary.

The steam used for welding the beads is discharged through the holes 11c and 21b, the chamber 21a, and the exhaust passage 25 in this order.

The foaming layer 12 (FIG. 1) is formed by the above-described welding step, and the instrument panel 1
0 is completed. Thereafter, the molds 21 and 22 are separated from each other, and the instrument panel 10 is released (demolding step). And it is attached to the car.

When the vehicle is exposed to direct sunlight and the instrument panel 10 is heated to a high temperature of, for example, 80 ° C. or more, and the skin 15 is pressed with a finger or the like to apply a stress to one place, the stress is increased. Dispersed by the harder reinforcement layer 13. Therefore, there is no possibility that the foamed layer 12 does not dent and return to its original state.

Each layer 11 to 11 of the instrument panel 10
No. 15 is easy to recycle because it is formed of a polyolefin resin. Although not shown, the core 11 may be provided with mounting bosses and positioning ribs for accessories such as instruments, ventilation grills, and car audio. The core material 11 is
Rigidity capable of supporting these equipment can be provided. The foam layer 12 can bear rigidity similarly to the core material 11,
Moreover, since the core material 11 is lighter than the core material 11, the thickness of the core material 11 can be reduced, and the weight of the entire instrument panel 10 can be reduced. In addition, a portion that is difficult to be injection-molded due to undercut is omitted from the core material 11, and the omitted portion is filled with the foam layer 12, so that the core material 1 is removed.
1 and the front-side laminate 16 can be combined.

The present invention is not limited to the above embodiment, and various modifications are possible. For example, the core material 11 may be made of a polypropylene filler as a raw material, or may be manufactured by a molding method in which the raw material resin is injected and pressurized together with the resin, or a vacuum molding. The present invention is not limited to instrument panels, door trims,
It is also applied to other automobile interiors such as pillars and console boxes.

[0021]

As described above, according to the present invention,
By laminating a reinforcement layer on the skin and cushion layer,
Shape retention can be improved. Thus, when the three layers are set in a foaming mold after vacuum forming, the setting operation can be easily performed. Also,
The cushion layer can be protected from heat when the foam layer is formed by the reinforcing layer. Furthermore, even when the laminated molded product is used as a product in a high-temperature environment, even if stress is applied to one place by strongly pressing the skin with a finger or the like, the stress can be dispersed by the reinforcing layer, and the foam layer is dented and traced. Can be prevented from remaining. By forming the reinforcing layer with a mixed resin of polypropylene and polystyrene, vacuum forming can be performed favorably.

[Brief description of the drawings]

FIG. 1 is an enlarged sectional view showing a part of an instrument panel according to an embodiment of the present invention.

FIG. 2 is a schematic configuration diagram of a foam molding apparatus showing a state in which a core material and a front-side laminate are set in a molding die, clamped, and before filling of beads.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Instrument panel (laminated molded product) 11 Core material 12 Foam layer 13 Reinforcement layer 14 Cushion layer 15 Skin 16 Front side laminated body 21,22 Mold

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Claims (3)

[Claims] 1. A core material, a foamed layer comprising foamed beads,
A laminated molded product, wherein a reinforcing layer, a cushion layer, and a skin are sequentially laminated, and the reinforcing layer is harder than the skin. 2. The reinforcing layer, the cushion layer and the skin,
The laminated molded article according to claim 1, wherein the laminated layer is formed into a sheet, and then vacuum molded integrally, and the reinforcing layer is formed of a mixed resin of polypropylene and polystyrene. 3. A core material forming step of forming a core material, and after laminating a skin and a reinforcing layer harder than the skin with a cushion layer interposed therebetween in a sheet shape, integrally vacuum forming to obtain a front side laminate. A body forming step, a setting step of setting the core material in one of a pair of molds, and a setting step of setting the front laminate to the other so that the reinforcing layer faces the core material; A filling step of filling the foamed beads between the material and the front side laminate, and a heating step of heating the foamed beads and welding them together, and also welding the core material and the reinforcing layer to obtain a foamed layer And a method for producing a laminated molded product.