JP2009234037A - Resin laminate and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin laminate having flexibility at a desired position and to provide its manufacturing method. <P>SOLUTION: The resin laminate comprises a base material 11 and a resin foamed body 7. The first foamed layer 12 is formed on the surface of the base material 11. An opening 13 is mounted on the base material 11, and the second foamed layer 14 formed by further foaming the resin foamed body 7 is mounted in the opening 13. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a resin laminate such as an automobile interior material and a method for producing the same.

For example, a resin laminate having a soft feel surface may be used for an interior material such as a self-propelled vehicle. In manufacturing this laminated body, a base material made of a synthetic resin formed into a sheet shape and formed into a shape that is in close contact with the molding surface of the skin side mold, and a base material that can be separated from the skin side mold Some manufacture a laminate by filling a molten synthetic resin serving as a base material between the molding surfaces of a side mold. Here, a foaming agent is mixed in the synthetic resin in the molten state in advance, and the synthetic resin in the molten state is mixed with the molding surface of the base-side molding die and the skin-side molding die in a state where both molds are brought close to each other. Compressive filling is performed between the skin materials that are in close contact with the molding surface, and immediately after the compression filling, both molding dies are separated from each other by a certain distance (see Patent Document 1).
Japanese Patent Application Laid-Open No. 09-300375

  However, in the above prior art, since the base material mixed with the foam material is laminated on the lower side of the skin material, a soft feel can be obtained, but this flexible portion is formed over the entire skin material. Therefore, there is a problem that it cannot be applied when it is desired to manufacture a part that is flexible.

  Then, this invention aims at providing the resin laminated body which can give a softness | flexibility to a desired site | part, and its manufacturing method.

  In order to achieve the above object, the invention described in claim 1 is a resin laminate including a base material (for example, the base material 11 in the embodiment) and a resin foam (for example, the resin foam 7 in the embodiment). The resin foam includes a first foam layer (for example, the first foam layer 12 in the embodiment) formed on the surface side of the base material, and an opening (for example, the base material). The second foam layer (for example, the second foam layer 14 in the embodiment) formed in the opening portion 13) in the embodiment, and the second foam layer has the first foam layer in the opening portion. Further, it is characterized by being formed by foaming.

  The invention described in claim 2 is characterized in that the base material has a flat surface portion (for example, the flat surface portion 8 in the embodiment), and the opening portion is provided in a central portion of the flat surface portion.

  The invention described in claim 3 is characterized in that the planar portion is an armrest portion (for example, the armrest portion 10 in the embodiment).

  The invention described in claim 4 has a front surface side mold (for example, the front surface side mold 50 in the embodiment) and a back surface side mold (for example, the back surface side mold 60 in the embodiment), and the back surface side. The molding die is provided with a slide hole (for example, the slide hole 62 in the embodiment) through which the slide die (for example, the slide die 61 in the embodiment) is inserted, and the surface side molding die and the slide die are used as the slide holes. After forming the first foam layer by filling the resin foam on the surface side of the base material placed between the inserted back surface side mold and moving the slide mold from the slide hole to the back surface side In this case, a second foamed layer obtained by further foaming the first foamed layer is formed.

  According to a fifth aspect of the present invention, in the stage before forming the first foamed layer, the front surface side mold and the back surface side mold in a state where the slide mold is inserted into the slide hole, the slide The substrate is molded by filling a resin in a state where the mold is in contact with the surface-side mold.

  In the invention described in claim 6, the surface-side mold includes a substrate mold portion for forming the substrate (for example, the substrate mold portion 51 in the embodiment), and the first foam layer. And a foam layer mold portion (for example, a foam layer mold portion 53 in the embodiment).

According to the first aspect of the present invention, since the second foamed layer obtained by further foaming the resin foam that forms the first foamed layer is provided in the opening of the base material, the flexibility of the desired portion is provided. There is an effect that can be increased.
According to the second aspect of the present invention, since the base material is present around the opening in the flat portion, the foam layer provided in the opening is the back surface even when a force is applied from the front surface side. There is an effect of ensuring a flexible support rigidity without sinking to the side.
According to the invention described in claim 3, by using the armrest portion with increased flexibility as described above, there is an effect that the merchantability can be improved.
According to the invention described in claim 4, there is an effect that it is possible to manufacture a resin laminate in which flexibility of a desired portion is increased.
According to the invention described in claim 5, there is an effect that the substrate can be formed in the same process.
According to the invention described in claim 6, since it is not necessary to prepare separate molds for the base material and the foam layer, there is an effect that the mold cost can be reduced.

Next, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows an armrest 1 for a door lining of a vehicle door according to an embodiment of the present invention. The armrest 1 is for a right door, and has a U-shaped main cross section that is open to the outside of the passenger compartment. The opened portion is attached to a door inner panel (not shown) with a clip (not shown), and constitutes an interior material of the door together with the door lining.
On the upper wall 2 of the armrest 1, a grip portion 3 extends obliquely upward on the front side, and a concave portion 4 is formed in the center portion in the front-rear direction. Between the recessed part 4 and the grip part 3, the raising / lowering switch 5 of a power window is arrange | positioned.

  The upper wall 2 has a flat portion 8 formed behind the concave portion 4 and is configured as an armrest portion 10 that supports the elbow portion. Here, a first foam layer 12 is provided on the upper wall 2 of the armrest portion 10 so as to cover the base material 11. An opening 13 is provided at the center of the flat surface portion 8 of the substrate 11, and a second foam layer 14 is provided in the opening 13. Therefore, the first foamed layer 12 and the second foamed layer 14 are adjacent to each other because the opening 13 is provided, and the portion of the armrest portion 10 corresponding to the opening 13 of the base material 11 is flexible. It is possible to form the resin foam 7 which is a simple part. A surface layer is provided around the grip portion 3 and the inner wall portion of the recess 4.

FIG. 2 schematically shows a process for manufacturing the armrest 1.
As shown in FIG. 2A, the first mold surface 21 of the mold 20 and the core mold 30 are clamped, and the resin serving as the substrate 11 is injected into the substrate cavity 40 from the runner 22 of the mold 20. (Primary molding process).
Next, as shown in FIG. 2B, after the mold is opened, the mold 20 is slid as indicated by an arrow so that the second mold surface 23 of the mold 20 is opposed to the core mold 30 (mold slide process). . At this time, the molded base material 11 is left in the core mold 30.

Then, as shown in FIG. 2C, the second mold surface 23 of the mold 20 and the core mold 30 are clamped. Since the second mold surface 23 of the mold 20 is deeper than the first mold 21, the first foam cavity 41 is formed between the base 11 of the core mold 30 and the second mold 23 of the mold 20. Is done. A foamable resin is injected into the first foam material cavity 41 from the runner 24 of the mold 20. Thereby, the 1st foaming layer 12 is formed between the base material 11 hold | maintained at the core type | mold 30, and the 2nd type | mold surface 23 of the cavity type | mold 20 (secondary shaping | molding process).
Next, as shown in FIG. 2 (d), the core mold 30 is slightly separated from the cavity mold 20 as indicated by the arrow, and the core back is left on the substrate 11 and the cavity mold 20 held by the core mold 30. A second foam material cavity 42 is formed between the first foam layer 12 and the first foam layer 12. In this state, the core mold 30 and the mold mold 20 are heated to foam the first foam layer 12 in the second foam material cavity 42 to form the second foam layer 14 (foaming step).

  Next, the case where the flexible armrest part 10 is actually shape | molded in the rear part of the upper wall 2 of the armrest 1 is demonstrated. FIG. 3 is a partially enlarged view of the main part of FIG. 1 viewed from the back side. In FIG. 3, the rear portion of the armrest 1 includes an upper wall 2 for placing an elbow portion and a vertical wall portion 6 extending obliquely downward from the upper wall 2 as described above. An opening 13 is formed in the flat portion 8 of the upper wall 2, and the upper wall 2 and the vertical wall 6 around the opening 13 are formed of a base material 11 that is a resin material. The surface of the upper wall 2 is covered with a resin foam 7 so as to surround the periphery of the opening 13 from the outside, and the resin foam 7 reaches a portion of the opening 13 and a position below the opening 13. It is arranged over the range.

FIG. 4 shows a process of manufacturing the armrest 1 by paying attention to the armrest portion 10 where the resin foam 7 is formed.
As shown to Fig.4 (a), the base material 11 of the armrest 1 is shape | molded with the surface side shaping | molding die 50 and back side shaping | molding die 60 which are mold types. The base material cavity 70 for forming the upper wall 2 and the vertical wall portion 6 of the base material 11 is formed of the base portion mold portion 51 of the front surface side mold 50 and the back surface side mold 60. The portion that is formed and forms the vertical wall portion 6 is mainly formed by the rear surface side mold 60. Here, the back surface side mold 60 is configured to be divided so that the vertical wall portion 6 and the like can be punched.

A slide hole 62 through which the slide mold 61 is inserted from the lower side is provided in the back side mold 60, and the slide mold 61 is inserted through the opening 13 of the base material 11 and protrudes from the upper surface of the back side mold 60. The side mold 50 is in contact with the back surface of the base mold 51. In this state, the substrate cavity 70 is filled with resin to mold the substrate 11 (primary molding step).
Next, the rear surface side mold 60 is used as it is, the front surface side mold 50 is slid (corresponding to FIG. 3), and the foam layer mold portion 53 is replaced with the base material mold portion 51 of the front surface side mold 50. It corresponds to the back side mold 60 (cavity slide process).

As shown in FIG. 4B, the foam layer mold portion 53 and the back surface side mold 60 of the front surface side mold 50 are clamped in a state where the already molded base material 11 is still present. In this state, the upper part of the slide mold 61 is inserted into the opening 13 of the base material 11 and is flush with the upper wall 2 of the base material 11.
The foam layer mold portion 53 of the surface side mold 50 forms a first foam material cavity 71 filled with a resin foam between the upper wall 2 of the substrate 11 and the upper surface 63 of the slide mold 61. Here, the first foam material cavity 71 is formed so as to cover the periphery of the opening 13. The foam layer mold portion 53 is a mold surface formed on the surface side mold 50 as in the case of the substrate mold portion 51 shown in FIG. 4A. However, since the molding surface is different, the direction of hatching is different. I changed and drawn.

In this state, as shown in FIG. 4C, the first foam layer 12 is formed by filling the first foam material cavity 71 with a foamable resin from a runner (not shown) (secondary molding step). ).
Next, as shown in FIG. 4 (d), the slide mold 61 is lowered to the lower side, which is the back surface side, along the slide hole 62, and the upper surface 63 of the slide mold 61 is substantially the same as the back surface of the opening 13 of the base material 11. The second foam material cavity 72 for further foaming the first foamed layer 12 is formed by moving to a flush position as indicated by the arrow (core back). When heated in this state, the first foam layer 12 is further foamed into the second foam material cavity 72 to form the second foam layer 14 (foaming step). Here, the second foam layer 14 spreads outward around the opening 13 of the base material 11, reaches between the upper wall 2, the vertical wall portion 6 of the base material 11, and the first foam layer 12. A resin foam 7 is formed which is integral with the one foamed layer 12 and has no boundary.

  Therefore, as shown in FIG. 4D, the surface of the upper wall 2 of the base material 11 of the armrest portion 10 is covered with the first foam layer 12 to form a flexible outer surface, and the opening of the base material 11 13 and the opening 13 are formed as a resin laminate in which the second foam layer 14 is integrated, so that the upper wall 2 of the armrest portion 10 can receive the base material 11 and the elbow portion flexibly. It can be molded into a flexible part made of foam 7.

  According to the embodiment, in addition to the first foam layer 12 provided on the surface of the base material 11 constituting the armrest 1, the first foam layer 12 is further foamed in the opening 13 of the base material 11. The foamed layer 14 is provided, and the first foamed layer 12 and the second foamed layer form the flexible resin foam 7, so that the armrest portion 10 can have desired flexibility. Therefore, since the elbow is supported flexibly, the merchantability of the armrest 1 can be improved. In particular, the portion where the elbow is supported is the flat surface portion 8 of the base material 11, and in this flat surface portion 8, since the base material 11 exists around the opening portion 13, a force acts from the surface side. Even if it is a case, the 2nd foaming layer 14 provided in the opening part 13 does not sink in a back surface side, but flexible support rigidity can be ensured.

Moreover, when manufacturing the armrest part 10 having such a feature, the first foamed layer 12 and the second foamed layer 14 are locally laminated on the part supporting the elbow part so as to be integrated. Since the flexible resin foam 7 can be formed, the degree of freedom in design is high, and the mold side for the base 51 and the foam layer mold are used for the mold side of the front side mold 50 while leaving the back side mold 60 as it is. Therefore, the manufacturing process can be reduced and the manufacturing cost can be reduced.
That is, since the base material 11 can be manufactured using a mold for molding the resin foam 7 in the previous stage of the process of manufacturing the resin foam 7, the base material 11 and the resin foam 7 are prepared by preparing separate molds. Compared to the case, the mold cost can be reduced and the manufacturing cost can be greatly suppressed.

  The present invention is not limited to the above-described embodiment. For example, the resin laminate is not limited to the armrest, and supports a part of the occupant's body such as a headrest provided on the vehicle interior side of the rear pillar inner. Applicable to parts.

It is a perspective view of the armrest of this invention. It is sectional explanatory drawing which modeled the manufacturing process of the armrest of this invention, (a) is a secondary molding process, (b) is a cabinet slide process, (c) is a secondary molding process, (d) is a foaming process. FIG. It is the enlarged view which looked at the principal part of FIG. 1 from the back side. FIGS. 4A and 4B show a manufacturing process using a cross-sectional view of a molding die along a line A-A in FIG. 3, where (a) is a secondary molding process, (b) is a cavity slide process, and (c) is two. (D) is a cross-sectional view showing a foaming process.

Explanation of symbols

7 Resin Foam 8 Plane Part 10 Armrest Part 11 Base Material 12 First Foam Layer 13 Opening Part 14 Second Foam Layer 50 Surface Side Mold 51 Base Material Mold 53 Foam Layer Mold 61 Slide Mold 62 Slide Hole

Claims (6)

  A resin laminate including a base material and a resin foam, wherein the resin foam is formed in a first foam layer formed on a surface side of the base material and an opening provided in the base material A resin laminate comprising a second foam layer, wherein the second foam layer is formed by further foaming the first foam layer in the opening.   The resin laminate according to claim 1, wherein the substrate has a flat portion, and the opening is provided in a central portion of the flat portion.   The resin laminate according to claim 2, wherein the flat portion is an armrest portion. It has a front surface side mold and a back surface side mold, and the back surface side mold is provided with a slide hole through which a slide mold is inserted,
A first foam layer is formed by filling a resin foam on the surface side of a base placed between the front side mold and the back side mold in a state where the slide mold is inserted into the slide hole. After
A method for producing a resin laminate, wherein the second foam layer obtained by further foaming the first foam layer is formed by moving the slide mold from the slide hole to the back surface side.   In the previous step of forming the first foam layer, the slide mold is brought into contact with the surface-side mold by the front-side mold and the back-side mold with the slide mold inserted into the slide hole. The method for producing a resin laminate according to claim 4, wherein the base material is molded by filling a resin in a contact state.   The said surface side shaping | molding die is equipped with the base-material type | mold part for shape | molding the said base material, and the foaming layer type | mold part for shape | molding a said 1st foaming layer, It is characterized by the above-mentioned. Item 6. A method for producing a resin laminate according to Item 5.

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