JP2003334916A - Method for manufacturing laminated molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a laminated molded product whose friction with the other member is reduced by using a preformed skin material by a reduced number of processes. <P>SOLUTION: This method for manufacturing the laminated molded product with a base and the skin material comprises a process for arranging the skin material 22 between the paired molds 32 and 34 by bringing a marring part 45 into contact with the surface 22a of the skin material corresponding to the contact region with the other member of the laminated molded product to be manufactured and a process for moving the skin material brought into contact under pressure with the marring part 45 by the movement of the skin material 22 along the molding surface 34a at the time of the integral molding of a base material 20a and the skin material 22 by the mold 30 to roughen the surface thereof. In this method, the marring part 45 is brought into contact with the predetermined of the skin material 22 during the period from the arrangement of the skin material 22 between the molds 32 and 34 to the integral molding process to impart unevenness to the contact region without increasing the number of production processes to manufacture the laminated molded product reduced in friction. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a laminated molded body, which is provided with a portion that comes into contact with another member under vibration.

[0002]

BACKGROUND OF THE INVENTION Vehicle interiors, such as pockets, armrests,
The interior wall and the like are formed by attaching interior materials having a three-dimensional shape such as pockets and armrests to a panel material that constitutes the vehicle body with a clip or the like. The interior material is
Generally, a resin board or a wood board, which is molded into a predetermined shape, is used as a substrate, and a surface material such as synthetic leather, woven cloth, or flocked sheet is provided on the surface thereof. These interior materials may squeak when attached to the vehicle, because the interior materials are in direct contact with each other or the panel and the interior material are in direct contact with each other and may come into contact with each other due to vibration or the like when the vehicle is running.

In order to suppress this squeak, friction has been conventionally reduced by various methods. For example, as disclosed in JP-A-4-188989,
A paraffin lubricant is applied to a contact portion with another member of the interior material (panel or other interior material), or a non-woven fabric having a softness like felt is attached to the contact portion.
With these configurations, the frictional resistance between the members can be reduced,
It absorbs vibrations to reduce friction. However, such laminated moldings require additional materials such as lubricants and nonwoven fabrics. Also, with a lubricant, the period during which the effect is obtained is short.

On the other hand, as a method for reducing friction without using other additional materials, a contact portion between the molded interior material and another member is rubbed with a file or disclosed in JP-A-1-53357. As described above, there is a method of applying a squeeze to the skin material portion corresponding to the contact portion. In all of these methods, the contact surface is made uneven to reduce the friction area, and vibration is appropriately absorbed by the fluffy portions to reduce the friction.

[0005]

However, in the method using the file, the number of steps of rubbing the interior material after molding with the file is increased. Further, when a diaphragm is provided, in order to suppress squeezing satisfactorily, it is necessary to use a diaphragm having fine irregularities provided with sharp convex portions. The skin material is molded at the same time as molding. Therefore, the preformed skin material cannot be used, and the design and material of the skin material are limited.

[0006] Therefore, it is an object of the present invention to provide a method for producing a laminated molded body in which the friction with other members is reduced by using a preformed skin material in a smaller number of steps.

[0007]

DISCLOSURE OF THE INVENTION The present invention for solving the above-mentioned problems is a method for producing a laminated molded article comprising a substrate and a skin material, and a contact portion of another laminated molded article to be produced. The step of pressing the scratched portion on the surface of the skin material corresponding to the step of placing the skin material between the pair of molding dies, and the step of integrally forming the base material and the skin material with the pair of molding dies The step of moving the material in the direction along the molding die surface to move the surface material pressed against the scratched portion to roughen the surface. In this method, when the skin material is arranged between a pair of molding dies, the scratched portion is pressed against the surface of the skin material, which is a contact portion that comes into contact with another member when formed into a laminated molding. Then, when the base material and the skin material are integrally molded by the pair of molding dies, the skin material is moved along the mold surface of the molding die to move the skin material to the scratched portion to roughen the surface. By this, unevenness is formed on the surface of the skin material, which is the contact site of the laminated molded body,
Friction can be reduced by reducing the contact area with other members. Alternatively, it is also possible to form a convex portion that elastically deforms like a fluff on the surface of the skin material and form it at a contact portion that can absorb vibration and reduce friction. Therefore, according to the present manufacturing method, the contact portion is contacted without increasing the number of manufacturing steps by pressing the scratched portion to a predetermined portion of the skin material from the disposition of the skin material between the molding dies and the step of molding integration. It is possible to manufacture a laminated molded body with reduced friction by giving irregularities as if scratches were created with a file.

Further, in the above manufacturing method according to the present invention, the scratched portion is integrally formed on a portion of the skin material sandwiching portion for holding the skin material between the pair of molding dies, which is in contact with the surface of the skin material. If so, an extra member is not required as compared with the conventional one. In the present invention, in any one of the above manufacturing methods, in the step of roughening the surface of the skin material,
In the cavity formed by the pair of molds,
A method of injecting the softened base material and performing injection press molding may be used. In this manufacturing method, the base material does not contact the skin material when the mold is clamped,
The movement of the skin material is less likely to be regulated, and the movement of the skin material surface with respect to the scratched portion is smoothly performed. Further, the skin material can be moved along the molding die surface by the pressure applied to the cavity of the softened base material and the spreading in the cavity, and the surface of the skin material is surely secured against the scratched portion. It can be moved to roughen the surface.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 shows a laminated molded body 1 for a vehicle interior, which is an embodiment of a laminated molded body that can be molded by the manufacturing method of the present invention. The laminated molded body 1 shown in FIG. 1 is formed in a board shape to be attached along a door panel. The laminated molded body 1 is appropriately provided with an armrest, a convex portion as a pocket, a concave portion (including a through hole) for installing other members such as a concave portion and a lighting fixture, and a concave and convex portion as a design.

FIG. 2 is an enlarged sectional view of the lower left corner of FIG. This portion is formed in a fan shape, and an edge extending along the circumference is formed in the attachment portion 3 for attachment to another member such as a vehicle body panel. Then, a fan-shaped flat surface protruding from the mounting portion 3 by a predetermined height is formed to form the interior surface 5
Is formed in. Further, near the center of the interior surface 5, a wall portion 7a to which another member is attached to form the pocket 7 and another member fixing portion 7b are formed in a concave shape with respect to the interior surface 5.

As shown in FIG. 2, the laminated molded body 1 has a base 2
0 and the skin material 22 are laminated and formed integrally.
The skin material 22 covers the surface of the base body 20.
It is folded to the back with an edge of 0. With this configuration, the part that can be seen when the laminated molded body 1 is attached is covered with the skin material 22.

The substrate 20 is made of a material that can be pressure-molded, and contains a thermoplastic resin material. Also, the base 2
0 may contain a wood material, that is, a lignocellulosic material. The wood-based material may be a fibrous material or a material that is subdivided into a state larger than fibers. Further, the base 20 may be a foam.

The skin material 22 is formed of a known skin material that can withstand the pressure molding temperature of the base body 20. Skin material 22
Can be formed of a sheet-shaped member such as a film, a non-woven fabric, or a woven fabric containing various thermoplastic resin materials such as polyester, urethane, polypropylene, polyethylene terephthalate, and polyvinylene.
Also, a thermoplastic elastomer material having excellent elasticity can be used. The skin material 22 is not limited to a single layer,
It may be a laminated body. In the present embodiment shown in FIG. 2, the skin material 22 has a design material 24 made of polyene vinyl or thermoplastic olefin (TPO) or the like on the front surface and a foam material made of polyene vinyl foam or polypropylene foam on the back surface. The material 25 is provided.

As shown in FIG. 2, the mounting portion 3 is provided at the end edge of the laminated molded body 1, and the back surface of the mounting portion 3 is formed at the contact portion 10 which is an uneven surface. Specifically, the contact portion 10 is a surface having a roughened surface of the skin material, and is configured to be roughly rubbed with a file.

The contact portion 10 has an original flat surface portion of the skin material 22 and a recessed portion which is hollowed out. In addition, the surface portion of the skin material 22 is appropriately provided with a flaky portion or a raised portion, which is formed by being left uncut. The contact portion 10 has a contact area smaller than that of the contact portion 10 when the contact portion 10 is formed on a smooth surface because the concave portion does not contact another member. Further, when the convex portion having elastic deformability is formed, it is possible to absorb the vibration generated between the convex portion and another member. With these configurations, friction between the other member and the laminated molded body 1 is reduced, and generation of squeaking due to vibration or friction is suppressed.

Next, one embodiment of the method for manufacturing a laminated molded body according to the present invention will be described by taking the case of manufacturing the laminated molded body 1 as an example. In the manufacturing method of the present invention, the scratched portion is pressed against the surface of the skin material corresponding to the contact portion with the other member to be manufactured, and the skin material is arranged between the pair of molding dies. The step, and by moving the base material and the skin material in a direction along the surface of the molding die when integrally forming the base material and the skin material by a pair of molding dies, the skin material pressed against the scratched portion is moved to A second step of roughening the surface.

In the method for producing a laminated molding of the present invention, a pair of molding dies for pressure molding is used. A predetermined three-dimensional shape is given by a pair of forming dies, and laminated members are integrated. As the molding die, a known molding die used in general press molding can be used. Further, it is possible to use a molding die for injection press molding in which the molding material is injected into the cavity. In this embodiment, as shown in FIGS. 3 to 5, a molding die 30 for injection press molding including a convex molding die 32 having a sprue 36 and a concave molding die 34 is used.

(First Step) The skin material 22 is preliminarily formed into a sheet and supplied. Preferably, the skin material 22
Is used for the entire molding including the three-dimensional design. Further, when the skin material 22 is a laminated body as in the present embodiment, it is preferable that the respective layers are supplied in a laminated and integrated state as shown in FIG. Design material sheet 24
The a and the foam material sheet 25a are welded by the thermoplastic resin of the design material sheet 24a.

The skin material 22 is a pair of molding dies 32, 34.
Placed between. In FIG. 2, it is provided in a stretched state along the abutting surface of the concave mold 34. Skin material 22
May be placed between any of the pair of molds 32, 34, preferably in the expanded state, but may be in the natural state.

In the first step, the contact portion 1 of the skin material 22
The scratched portion 45 formed in an uneven shape is pressed against the surface corresponding to 0. The scratched portion 45 is a portion that can roughen the surface of the skin material 22 by moving the skin material 22 while being pressed against the scratched portion 45. The scratched portion 45 can typically be a surface formed in an uneven shape. The concavo-convex shape of the scratched portion 45 may be a surface that has been subjected to various file processing or knurling processing in accordance with the concavo-convex shape desired to be applied to the contact portion 10 of the skin material 22. Alternatively,
The file itself may be used as the scratched portion 45.

The scratched portion 45 may be provided as a single member, but is preferably integrated with the concave molding die 34 or a skin material holding member for holding the skin material 22. More preferably, the sandwiching surface of the skin material sandwiching portion 50 that has been conventionally used for sandwiching and holding the skin material 22 is provided with an uneven shape to be integrated. The skin material sandwiching portion 50 is, specifically, a clamp, an abutting surface of the concave mold 34 that cooperates with the clamp, or the like.

If the scratched portion 45 is formed on the sandwiching surface of the skin material holding member, that is, the portion (surface) in contact with the surface of the skin material 22, the sandwiching pressure of the skin material 22 presses the scratched portion 45 against the skin material 22. can do. The scratched portion 45
May be formed on the extension of the sandwiching surface in the same plane as the sandwiching surface of the skin material 22 of the skin material sandwiching portion 50. With such a configuration, even if the scratched portion is integrated with the skin material holding member, the scratched portion can be arranged at various portions.

In this embodiment, as shown in FIG. 3, the scratched portion 45 is provided on the abutting surface of the concave molding die 34 which is in contact with the surface of the skin material 22. Then, in the first step, the skin material 22 is sandwiched between the portion of the concave molding die 34 provided with the scratched portion 45 and the known clamp member 52 attached to the convex molding die 32 to form the concave molding die 34. It was placed in a stretched state along the line. The clamp member 52 is attached to the convex mold 32 through the elastic member 54 and is urged toward the concave mold 34. The skin member 22 was placed in pressure contact with the scratched portion 45 by the biasing force of the elastic member 54.

(Second Step) Base Material 20a and Skin Material 2
2 is integrated with the molding die 30 forming a pair at the same time when the base body is molded. The molding method can be selected from various molding methods in which pressure is applied, as described for the molding die. The base material may be supplied in a state having a predetermined shape or may be supplied in a molten state. Further, the base material and the skin material are integrated by providing a fixing layer such as an adhesive between the base material and the skin material, or by melting and melting the thermoplastic resin material of the base material and / or the skin material. It can be performed by a known method.

In the second step, the mold 30 is clamped. When the base material is supplied in a state of holding a predetermined shape such as a plate, the mold clamping of the molding die 30 is performed after the base material is supplied. Further, as shown in FIG. 5, when supplying the base material 20a in the softened state by injection into the cavity 40, it is performed before the supply of the base material 20a.

In the embodiment shown in FIG. 4, when the convex molding die 32 is fitted in the concave molding die 34 when the molding die 30 is clamped, the molding material of the molding die 32 having the convex skin material 22 is formed. It is pressed by the surface 32a. By this pressing, the skin material 22 moves along the molding die surface 34 a of the concave molding die 34, and the skin material surface 22 a pressed against the scratched portion 45.
Move to the scratched portion 45. By this movement, the skin material surface 22a is rubbed by the convex portion of the scratched portion 45 so that the skin material surface 22a is sanded by the scratched portion 45, and is scratched and roughened. Therefore, the surface material surface 22a is formed into a surface having an uneven shape.

The degree of roughening of the surface of the skin material 22 is such that the friction is reduced, that is, the contact area with other members is reduced or the elastic deformation is imparted. However, it is not particularly limited. Therefore, only the surface portion of the skin material 22 may be scratched or the entire thickness may be scratched. In addition, as in the present embodiment, the foam material 25 is attached to the base 20.
In the surface material 22 provided on the side, at least the surface of the design material 24 may be roughened.

Next, in the present embodiment, as shown in FIG. 5, the sprue 3 of the convex forming die 32 is applied to the molten base material 20a after the completion of mold clamping or immediately before the completion of mold clamping.
6 is injected into the cavity 40. Base material 20a
Depends on the injection pressure of the sprue 36.
The skin material 22 is spread throughout the cavity 40 while pressing the skin material 22 toward the molding die surface 34a of the concave molding die 34 facing the.

The skin material 22 is further moved along the molding die surface 34a of the concave molding die 34 by being pressed by the base material 20a. As a result, when the base material 20a is ejected, the surface portion of the skin material 22 pressed against the scratched portion 45 moves with respect to the scratched portion 45 and is rubbed and damaged. The skin material 2 is formed by injecting and spreading the base material 20a.
Even when 2 moves, it is formed on a surface having an uneven shape formed by roughening the surface, as in the case of clamping the molding die 30.

The base material 20a is molded into a predetermined three-dimensional shape by the pressure injected into the cavity 40 of the molding die 30 and the pressure due to the clamping of the molding die 30. At this time,
Since the skin material 22 is in direct contact with the molten base material 20a, it is integrated by thermal welding of the base material 20a with a thermoplastic resin.

After that, the base 20 is solidified by cooling, the molding die 30 is opened, and the laminated molding 1 is taken out. And FIG.
As shown in FIG. 5, the portion of the skin material 22 corresponding to the contact portion 10 is fixed by various fixing methods such as adhesion and welding so as to cover the edge of the base body 20. As a result, the uneven portion of the skin material 22 is formed on the surface of the contact portion 10.

In this manufacturing method, the molding die 3 similar to the conventional one is used.
The skin material 22 is obtained by clamping the die 0 and injecting the base material 20a.
By pulling along the molding die surface 34a, it is possible to relatively move the scratched portion 45 and the skin material 22 that have been pressed in advance. By this movement, the surface of the skin material 22 can be scratched and roughened by the scratched portion 45 to form a surface having an uneven shape without providing a step of rubbing with a file. Therefore, without increasing the number of steps in particular, it is possible to manufacture a molded body having a contact portion having the same shape as that when the contact portion is rubbed with a file after the laminated molded body is manufactured.

Further, in order to determine the portion to be roughened when the skin material 22 is placed between the convex molding die 32 and the concave molding die 34, the skin material portion corresponding to a predetermined portion of the laminated molded body is formed before molding. It can be predicted more reliably. For this reason, the surface of a predetermined part can be roughened, and an uneven shape can be surely given to the surface of the skin material 22 that constitutes the contact part 10 of the laminated molded body (laminated molded body 1). In particular, by providing the scratched portion 45 on the skin material sandwiching portion 50, the scratched portion 45 can be pressed against the skin material 22 in the same process as the conventional process of sandwiching the skin material 22 by the skin material sandwiching portion 50. It is preferable because the number does not increase.

The method for producing a laminated molded article according to the present invention is not limited to the above embodiment. When the scratched portion 45 is provided separately from the skin material holding member, the scratched portion 45 is pressed against the surface of the skin material 22 by various methods with a pressure that can damage and roughen the surface of the skin material 22. For example,
It is pressed against the surface of the skin material 22 arranged in a stretched state, or another member is arranged at a position facing the scratched portion 45 with the skin material 22 sandwiched between the skin material 22 and the skin material 22 sandwiched. You may be taken. Further, by providing a scratched portion on a skin material holding member that is separate from the molding die, by replacing the skin material holding member to be used, for example, a clamp member,
You can easily change the part that roughens the surface.

The step of roughening the surface of the skin material, that is, the formation of scratches may be carried out at any time of the molding integration step, and both the timing of clamping the molding die and the injection and spreading of the base material. It is not limited to the form performed in. For example, in the case of the elastic skin material 22, the portion pressed against the scratched portion 45 does not move when the molding die 30 is clamped, but moves by injection and spreading of the molten base material 20a. It may be. Alternatively, it is possible that the portion pressed against the scratched portion 45 moves due to the movement of the molding die 30 during the mold clamping, and does not particularly move during the injection and spreading of the base material 20a.

Further, in the molding-integrating step, the order of clamping the molding die and injecting the base material is not particularly limited. Clamping of the mold and injection of the base material may proceed simultaneously, or the mold may be clamped after the base material is injected. Further, it goes without saying that the present invention is not limited to the production of a laminated molded body in which all of the contact portions have an uneven shape, and can also be used in the production of a laminated molded article in which the contact portions partially have an uneven shape. The scratched portion may be provided at a plurality of locations or may be provided continuously.

[0037]

EFFECTS OF THE INVENTION The present invention provides a method for producing a laminated molded article in which friction with other members is reduced by using a preformed skin material in a smaller number of steps, thereby reducing the occurrence of squeaking. The laminated molded body can be easily manufactured.

[Brief description of drawings]

FIG. 1 is a perspective view of an interior member that is an embodiment of a laminated molded body manufactured by a method for manufacturing a laminated molded body of the present invention.

FIG. 2 is a partially enlarged cross-sectional view of a part of the laminated molded body of FIG.

FIG. 3 is a cross-sectional view when a skin material is arranged between a pair of molding dies in an embodiment of the method for manufacturing a laminated molding of the present invention.

FIG. 4 is a cross-sectional view when a pair of molding dies are clamped in one embodiment of the method for manufacturing a laminated molding of the present invention.

FIG. 5 is a cross-sectional view when a molten base material is supplied into a mold that has been clamped in an embodiment of the method for manufacturing a laminated molded body of the present invention.

FIG. 6 is a cross-sectional view when an uneven skin material is arranged at a contact portion of a laminated body in the embodiment of the method for manufacturing a laminated body of the present invention.

[Explanation of symbols]

1 Laminated body 3 Attachment 5 Interior surface 7 pockets 7a wall 7b Other member fixing part 10 contact area 20 base 20a Base material 22 Skin material 22a Surface of skin material 24 Design materials 24a Design material sheet 25 foam material 25a foam sheet 30 Mold 32 convex mold 34 concave mold 32a, 34a Mold surface 36 sprue 38 Discharge port 40 cavities 45 scratched area 50 Skin material sandwiching part 52 Clamping member 54 Elastic member

Continued front page    F-term (reference) 4F100 AS00B AT00A BA02 BA07                       DD07B EH362 EJ202 GB33                       JL02                 4F202 AD08 AG03 AG23 AG25 CA11                       CB13 CK83                 4F206 AD08 AG03 AG05 AG23 JA07                       JB13 JM04 JQ81

Claims (3)

[Claims] 1. A method for manufacturing a laminated molded body comprising a substrate and a skin material, wherein a scratched portion is pressed onto the surface of the skin material corresponding to a contact portion with another member of the laminated molded body to be manufactured, and the skin is By the step of arranging the material between the forming dies forming a pair, and the movement of the skin material in the direction along the forming die surface when the base material and the skin material are integrally formed by the forming die forming a pair,
And a step of moving the skin material pressed against the scratched portion to roughen the surface thereof, the method for producing a laminated molded body. 2. The scratched portion is integrally molded with a portion of the skin material sandwiching portion for holding the skin material between the pair of molding dies, which is in contact with the surface of the skin material. Laminated molded article manufacturing method. 3. The method according to claim 1, wherein in the step of roughening the surface of the skin material, the softened base material is injected into a cavity formed by the pair of molds to perform injection press molding. A method for producing the laminated molded article described.