JP2016175270A - Molding method and molding device of resin laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molding method and a molding device of a resin laminate capable of simultaneously performing formation and sealing of a terminal of a laminate.SOLUTION: A molding device 30 comprises a cutting edge die 31 and a receiving die 32 capable of sandwiching and pressurizing a substrate W formed of a laminate in which resin sheet layers 13a, 13b are arranged on front and rear both sides of a foam resin layer 11. The cutting edge die 31 has a cutting edge part 35 which comprises a cutting edge 35a for cutting the substrate W, a pressurization surface 35b disposed adjacently to the cutting edge 35a and pressurizing the substrate W, and which can be heated. The receiving die 32 comprises a receiving part 39 which comprises a cutting edge receiving surface 39a for receiving the cutting edge 35a, and a pressurization receiving surface 39b which faces the pressurization surface at an interval capable of pressurizing a portion between the resin sheet layers 13a, 13b along the pressurization surface 35b. In the molding device 30, the substrate W is cut by pressurizing the substrate W by the heated cutting edge 35a and the pressurization surface 35b, and the portion between the resin sheet layers 13a, 13b on a terminal 17 is planarly welded.SELECTED DRAWING: Figure 2C

Description

  The present invention relates to a molding method and a molding apparatus for a resin laminate in which a terminal portion of a laminate in which resin sheet layers are arranged on both front and back sides of a foamed resin layer is formed and sealed.

  Conventionally, a laminate using a gas-containing material for various purposes such as weight reduction, heat insulation, and sound absorption has been used. For example, Patent Document 1 proposes a molded ceiling for a vehicle in which a laminate in which a surface material is laminated on a base material via a nonwoven fabric is used. When manufacturing this molded ceiling for vehicles, in order to cover the terminal, the skin material is wound around and bonded to the back side of the base material at the terminal.

  Patent Document 2 proposes a top plate in which a surface material and a back material are laminated on a plurality of plate-like panels made of foamed resin. When manufacturing this top plate, the end portion of the laminate is covered with urethane resin or the like in order to enhance the waterproof performance of the edge.

JP 2009-132294 A JP 2012-65684 A

  However, the conventional laminate requires time and labor for forming and sealing terminals. For example, in Patent Document 1, a cut is made in the base material on the terminal side, a part of the base material is cut off leaving the skin material on the terminal side, an adhesive is applied to the back surface of the skin material, and the skin material is wound on the back side. And covered the terminal of the substrate. Moreover, in patent document 2, after forming the terminal of a laminated body, the terminal of the laminated body was set in the metal mold | die, and the terminal was coat | covered by the predetermined shape by inject | pouring and shape | molding resin.

  Therefore, an object of the present invention is to provide a method and an apparatus for molding a resin laminate capable of simultaneously cutting the laminate and forming and sealing the terminal portion.

The method for molding a resin laminate according to the present invention that achieves the above object is to pressurize a laminate in which resin sheet layers are disposed on both front and back sides of a foamed resin layer with a heated blade edge and a pressing surface. Thereby, while cutting a laminated body with a blade edge | tip, the some resin sheet interlayer of a terminal part is welded in planar shape by a press surface.
In this method for molding a resin laminate, it is preferable that the heated portion of one resin sheet layer is stretched by the blade edge and the pressing surface and welded to the other resin sheet layer.

The apparatus for molding a resin laminate according to the present invention that achieves the above object includes a blade mold and a receiving mold that pressurize the laminate in which the resin sheet layers are arranged on both front and back sides of the foamed resin layer. The blade has a blade edge that cuts the laminated body, a pressing surface that is provided adjacent to the blade edge and pressurizes the laminated body, and can be heated, and the receiving die has a blade edge receiving surface that receives the blade edge, and a resin. A receiving portion having a pressing receiving surface facing the pressing surface at intervals between which the sheet layers can be pressed.
In this device, the receiving die preferably has a relief portion that is wider than the pressing receiving surface at a position adjacent to the pressing receiving surface.

  According to the method for molding a resin laminate of the present invention, the laminate in which the resin sheet layers are arranged on both the front and back sides of the foamed resin layer is pressed by the heated blade edge and the pressing surface. The laminated body in the vicinity of the surface can be heated, the laminated body can be easily cut into a predetermined shape by the blade edge, and the plurality of resin sheet layers can be welded and sealed in a planar shape by the pressing surface. Furthermore, since it is not necessary to heat another part excessively, a deformation | transformation of a laminated body can be prevented and a terminal part can be formed in a desired shape by this. Therefore, it is possible to provide a method for forming a resin laminate that can simultaneously perform cutting of the laminate and formation and sealing of the terminal portion by applying pressure with the heated blade edge and the pressing surface.

  According to the apparatus for molding a resin laminate of the present invention, the blade mold has a cutting edge that cuts the laminate, and a pressing surface that is provided adjacent to the blade edge and presses the laminate between the receiving portion. Since the possible blade part is provided, the part according to the blade part of a laminated body can be heated when a blade part is heated and a laminated body is pressurized between a blade type | mold and a receiving die. Therefore, the laminate can be easily cut into a predetermined shape between the blade edge and the blade receiving surface, and the terminal portion is pressed between the pressing surface and the pressure receiving surface to weld a plurality of resin sheet layers into a planar shape. Can be sealed. Furthermore, since it is not necessary to heat another part excessively, a deformation | transformation of a laminated body can be prevented and a terminal part can be formed in a desired shape. Therefore, it is possible to provide a resin laminate molding apparatus capable of simultaneously cutting the laminate and forming and sealing the terminal portion.

It is the fragmentary perspective view which showed a part of resin molded product which concerns on embodiment of this invention in the cross section. It is sectional drawing for demonstrating the manufacturing method of the resin molded product which concerns on embodiment of this invention, and shows the state which has arrange | positioned the laminated body. It is sectional drawing for demonstrating the manufacturing method of the resin molded product which concerns on embodiment of this invention, and shows the state in the middle of the pressurization of a laminated body between a blade type | mold and a receiving die. It is sectional drawing for demonstrating the manufacturing method of the resin molded product which concerns on embodiment of this invention, and shows the state which pressurized the laminated body between the blade type | mold and the receiving die.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
In this embodiment, the resin molded product obtained by the molding method and the molding apparatus will be described using an example of a resin molded product used as a roof panel of a vehicle body. However, in the present invention, the use, shape, and size of the resin molded product are described. There is no limitation at all.

First, the resin molded product 10 molded in the present embodiment will be described.
As shown in FIG. 1, the resin molded product 10 is formed of a laminate in which first and second resin sheet layers 13 a and 13 b are laminated on the front and back both sides of the foamed resin layer 11. The first and second resin sheet layers 13 a and 13 b include a film, a film, a plate, and the like attached to the foamed resin layer 11.

  As the material constituting the foamed resin layer 11 and the material constituting the first and second resin sheet layers 13a and 13b arranged on the front and back sides of the foamed resin layer 11, the first and second resin sheet layers 13a are used. , 13b may be any material that can be welded between the resin sheet layers 13a, 13b by locally applying heat and pressurization from the outside.

  The material that can be welded between the resin sheet layers 13a and 13b is that the heated foamed resin layer 11 is pressed and moved to directly weld the first resin sheet layer 13a and the second resin sheet layer 13b. The heated foamed resin layer 11 is compressed and compressed, so that the first resin sheet layer 13a and the foamed resin layer 11 are welded together, and the foamed resin layer 11 and the second resin sheet layer 13b The gap may be welded.

  In this embodiment, the foamed resin layer 11 and the first and second resin sheet layers 13a and 13b are rigid enough to prevent deformation due to stress applied during use while supporting the periphery of the laminate. The thermoplastic resin which has is used.

  The resin molded product 10 includes a main body portion 15 and a terminal portion 17 provided along the outer periphery of the main body portion 15. In this embodiment, the resin molded product 10 is provided between the terminal portion 17 and the main body portion 15. A reinforcing portion 19 is provided. The main body 15 is formed into an appropriate shape according to the application and use position. In the present embodiment, the main body 15 is formed into a plate shape suitable for the roof of the vehicle body to be mounted. The front surface and the back surface of the main body 15 are formed by joining the first and second resin sheet layers 13a and 13b in a state where the foamed resin layer 11 is not compressed. The side surface of the main body portion 15 is configured by covering the side surface of the foamed resin layer 11 with a first resin sheet layer 13 a continuous from the surface of the main body portion 15.

  The terminal portion 17 protrudes from the second resin sheet layer 13b on the back surface of the main body portion 15 toward the back side and is formed into a predetermined shape. By forming the terminal portion 17 along the outer periphery of the main body portion 15, an inner space surrounded by the terminal portion 17 is provided on the back surface side of the main body portion 15.

  In the terminal portion 17, the first and second resin sheet layers 13 a and 13 b continuous from the front surface side and the back surface side of the main body portion 15 are welded in a planar shape to form a welded portion 17 a. In the terminal portion 17, the first and second resin sheet layers 13 a and 13 b are continuous from the main body portion 15 together with the foamed resin layer 11, and are heated while the foamed resin layer 11 is interposed as will be described later. And it is welded by pressurizing.

  The thickness of the welded portion 17a may be about the sum of the thicknesses of the first and second resin sheet layers 13a and 13b in the main body 15 or less. In the welding part 17a, the opposing direction of the welded first resin sheet layer 13a and the second resin sheet layer 13b intersects the opposing direction of the first resin sheet layer 13a and the second resin sheet layer 13b in the main body portion 15. The direction to do. Thereby, the welding site | part 17a is made hard to peel with respect to the force loaded between the 1st and 2nd resin sheet layers 13a and 13b in the main-body part 15. FIG.

  Between the welding part 17a and the main body part 15 in the terminal part 17, the reinforcement part 19 formed thicker than the welding part 17a is provided. The reinforcing portion 19 is provided so as to protrude into the inner space surrounded by the terminal portion 17, and the second resin sheet layer 13 b protrudes inward from the main body portion in a stepped manner, and the gap with the first resin sheet layer 13 a. The resin of the foamed resin layer 11 is accommodated in the container. The resin of the foamed resin layer 11 accommodated in the reinforcing part 19 may be in the same physical state as the resin of the main body part 15. However, when forming the welded portion 17a, the foamed resin layer 11 is heated and compressed to move and move. It may be a resin in a state where is changed.

Next, a method for molding such a resin molded product according to this embodiment will be described.
The resin molded product 10 is obtained by preparing a base material W in advance and molding the base material W by the molding device 30. As shown in FIG. 2A, the base material W of this embodiment includes a foamed resin layer 11 and first and second resin sheet layers 13a and 13b arranged on both the front and back surfaces of the foamed resin layer 11. It is a plate-like body made of a laminate having a substantially constant thickness.

  As shown in FIG. 2A, the molding apparatus 30 of this embodiment includes a blade mold 31 such as a Thomson mold that can pressurize the substrate W and a receiving mold 32. The blade mold 31 and the receiving mold 32 are configured to be detachable from each other by being relatively driven in one axial direction.

  The blade mold 31 includes a blade mold base 31a and a blade section 35 provided so as to protrude from the surface of the blade mold base 31a in a shape corresponding to the contour shape of the terminal portion 17 in the target resin molded product 10. doing. The blade part 35 is configured to be capable of heating and temperature adjustment. The blade portion 35 includes a blade edge 35a for cutting the substrate W and a pressing surface 35b that is provided adjacent to the blade edge 35a and pressurizes the substrate W. Here, the pressing surface 35b utilizes one side surface continuous from the blade edge 35a in the blade portion 35. The pressing surface 35b is formed in a taper shape in the vertical direction or in a substantially lower bud.

The receiving mold 32 includes a receiving base 37 and a receiving portion 39 provided in a shape corresponding to the contour shape of the terminal portion 17 in the target resin molded product 10 and protruding from the surface of the receiving base 37. Have.
The receiving portion 39 includes a blade receiving surface 39a that receives the blade edge 35a, and a pressure receiving surface 39b that can pressurize between the first resin sheet layer 13a and the second resin sheet layer 13b between the pressing surface 35b. I have.

  When the blade mold 31 and the receiving mold 32 are closest to each other, the pressure receiving surface 39b is formed between the first resin sheet layer 13a and the second resin sheet layer 13b due to an interval between the pressure surface 35b of the blade portion 35 that faces the pressure receiving surface 39b. It is formed in a shape along the pressing surface 35b of the blade portion 35 so that the space can be pressed into a plane, and is formed in a taper shape in the vertical direction or substantially downward. In the present embodiment, an escape portion 39c is provided at a position adjacent to the pressure receiving surface 39b of the receiving die 32 so that the distance from the blade portion 35 is wider than the pressure receiving surface 39b.

In order to manufacture the resin molded product 10 using such a molding apparatus 30, it is performed as follows.
First, a base material W made of a plate-like laminate is prepared in advance. As shown in FIG. 2A, the substrate W is disposed between the receiving mold 32 and the blade mold 31, and the blade portion 35 of the blade mold 31 is heated to a set temperature in accordance with the resin constituting the substrate W. Then, the molding device 30 is driven to relatively move the receiving mold 32 and the blade mold 31 in the approaching direction.
As the heated blade portion 35 of the blade mold 31 approaches the substrate W, the portion corresponding to the blade portion 35 of the substrate W, that is, the vicinity of the cutting position is heated.

  As shown in FIG. 2B, after the blade mold 31 and the receiving mold 32 are brought close to each other and the blade portion 35 comes into contact with the substrate W, when the blade mold 31 and the receiving mold 32 are moved closer to each other, the substrate W becomes While being supported by the receiving portion 39 of the receiving mold 32, the blade portion 35 of the blade mold 31 moves in contact with the first resin sheet layer 13a on the surface side. Thereby, the heated part in the 1st resin sheet layer 13a is extended and deform | transformed to the 2nd resin sheet layer 13b side.

  Thereafter, when the blade mold 31 and the receiving mold 32 are further moved relative to each other and moved closer to each other, as shown in FIG. 2C, the first and second resin sheet layers 13a and 13b and the foamed resin layer 11 on both the front and back surfaces are cut and In a state heated to a temperature suitable for welding, the blade edge 35a of the blade portion 35 and the blade edge receiving surface 39a of the receiving portion 39 approach to a position where the substrate W is cut. Thereby, the base material W is cut at a position between the blade edge 35a and the blade edge receiving surface 39a. At the same time, the terminal portion 17 adjacent to the cutting edge 17e of the substrate W is pressed into a planar shape between the pressing surface 35b adjacent to the cutting edge 35a of the blade portion 35 and the pressing receiving surface 39b of the receiving portion 39. .

  At the same time, in the escape portion 39c adjacent to the pressure receiving surface 39b of the receiving portion 39, the softened foamed resin or the like is accommodated in the escape portion 39c, and the second resin sheet layer 13b is deformed into the shape of the escape portion 39c. Further, since the relief portion 39c is provided adjacent to the press receiving surface 39b, only the facing portion between the pressing surface 35b of the blade portion 35 and the press receiving surface 39b of the receiving portion 39 is strongly pressed.

  In the present embodiment, the pressurized state is maintained for a predetermined period and then released. The period to be maintained is appropriately set according to the resin of each layer, the heating temperature, and the like. Thereby, the base material W is cut at a predetermined position, and the first resin sheet layer 13a and the second resin sheet layer 13b are welded in a planar shape at the terminal portion 17 adjacent to the cut edge 17e.

  According to the molding method of the present embodiment as described above, the base material W made of a laminate in which the first resin sheet layer 13a and the second resin sheet layer 13b are arranged on both front and back sides of the foamed resin layer is heated. Since the pressure is applied by the blade edge 35a and the pressing surface 35b, the substrate W in the vicinity of the blade edge 35a and the pressing surface 35b can be heated at the time of pressing. Therefore, the base material W can be easily cut into a predetermined shape, and the first resin sheet layer 13a and the second resin sheet layer 13b can be welded in a planar shape and sealed. Furthermore, since it is not necessary to heat the other site | part W excessively, a deformation | transformation of the resin molded product 10 can be prevented and, thereby, the terminal part 17 can be formed in a desired shape. Therefore, the substrate W can be cut and the terminal portion can be formed and sealed at the same time by applying pressure by the heated blade edge 35a and the pressing surface 35b.

  Further, since the terminal portion 17 can weld the first resin sheet layer 13a and the second resin sheet layer 13b in a planar shape, sufficient welding strength is obtained, and the first resin sheet layer 13a and the second resin sheet layer 13b are obtained. Even if the repulsive force of the foamed resin layer 11 is applied between the two, the separation of the cut edge 17e immediately after welding or during use can be prevented, and the sealed state can be reliably maintained. Moreover, in the welded portion 17a, the facing direction of the welded first resin sheet layer 13a and the second resin sheet layer 13b is the facing direction of the first resin sheet layer 13a and the second resin sheet layer 13b in the main body portion 15. It is the direction that intersects. As a result, even if a force in the direction of separating from the foamed resin layer 11 or the like is applied between the first and second resin sheet layers 13a and 13b of the main body portion 15, the first and second resin sheet layers 13a of the welded portion 17a. , 13b is different from the direction in which they are separated from each other, and therefore, the peeling of the welded portion 17a can be further prevented.

  In this molding method, the pressure state is maintained between the first and second resin sheet layers 13a and 13b by the pressing surface 35b, and then the pressurized state is maintained for a predetermined period. The first and second resin sheet layers 13a and 13b can be welded in a planar shape, and the first and second resin sheet layers 13a and 13b of the terminal portion 17 are immediately after welding or at the time of use due to the repulsive force of the foamed resin layer 11. It is possible to prevent the gaps from separating.

  In this molding method, the heated portion of the first resin sheet layer 13a is stretched by the cutting edge 35a and the pressing surface 35b, and the first and second resin sheet layers 13a and 13b are welded. It can be formed on the resin sheet layer 13b side. At that time, since the first resin sheet layer 13a is longer than the second resin sheet layer 13b, the foamed resin layer 11 is excessive in the vicinity of the terminal portion 17 by the first resin sheet layer 13a even if welding is performed on the second resin sheet 13b side. Can be prevented from being compressed. As a result, it is possible to improve moldability and improve the quality of the resin molded product 10 to be obtained such as appearance and touch.

  According to the molding apparatus 30 for the resin molded product 10 of the present invention, the base material between the blade edge 35a for cutting the base material W, the blade mold 31 of which is a laminate, and the receiving portion 39 provided adjacent to the blade edge 35a. A pressing surface 35b that pressurizes W, and includes a heatable blade portion 35. Therefore, when the blade portion 35 is heated to pressurize the substrate W between the blade mold 31 and the receiving die 32, the blade edge 35a and the blade edge receiving member are heated in a state where the portion corresponding to the blade portion 35 of the substrate W is heated. The substrate W can be easily cut into a predetermined shape between the surface 39a. Further, by pressing the terminal portion 17 adjacent to the cutting edge 17e between the pressing surface 35b and the pressing receiving surface 39b along the pressing surface 35b, the first resin sheet layer 13a and the second resin sheet layer 13b are pressed. The space can be welded in a planar shape. Furthermore, since it is not necessary to heat the other site | part W excessively, the deformation | transformation of the resin molded product 10 can be prevented and the terminal part 17 can be formed in a desired shape.

  In this molding apparatus 30, since it has the escape part 39c which expanded the space | interval with the blade part 35 from the press receiving surface 39b in the position adjacent to the press receiving surface 39b of the receiving mold 32, it softens at the time of pressurization, or The molten and moved resin can be accommodated in the escape portion 39c. Further, by adjusting the arrangement of the second resin sheet layer 13b arranged on the receiving mold 32 side, the difference in length and the like from the first resin sheet layer 13a arranged on the blade mold 31 side is absorbed, and It is possible to prevent the occurrence of molding defects such as.

The above-described embodiment can be appropriately changed within the scope of the present invention.
For example, in the above-described embodiment, the example in which the terminal unit 17 is continuously provided on the entire circumference of the outer peripheral edge of the main body unit 15 has been described. However, the terminal unit 17 is provided on a part of the peripheral edge of the main body unit 15. There may be. Further, the present invention can be applied even if a terminal portion is provided on the inner peripheral edge such as an opening provided in the main body portion 15.

  In the above embodiment, the first resin sheet layer 13a constituting the front surface, the second resin sheet layer 13b constituting the back surface, and the foamed resin layer 11 disposed between the two resin sheet layers 13a and 13b. Although the laminated body of the layer structure has been described, it is not particularly limited. For example, other layers may be laminated between the resin sheet layers 13a and 13b or on the outer side to form a laminate of four or more layers.

  In the said embodiment, although the blade part 35 of the blade type | mold 31 was heated, you may heat the receiving part 32 of the receiving die 32 with the blade part 35. FIG.

  In the above-described embodiment, an example in which a plate-like body made of a laminated body is used as the base material W before molding has been described, but a laminated body molded into various shapes can be used as the base material W.

W: base material 10: resin molded article 11: foamed resin layer 13a: first resin sheet layer 13b: second resin sheet layer 15: body part 17: terminal part 17a: welded part 17e: edge 19: reinforcing part 30: Molding device 31: blade mold 32: receiving mold 33: blade mold base 35: blade portion 35a: blade edge 35b: pressing surface 37: receiving base 39: receiving portion 39a: blade edge receiving surface 39b: pressure receiving surface 39c: relief Part

Claims (4)

  The laminated body in which the resin sheet layers are arranged on both the front and back sides of the foamed resin layer is pressed with a blade edge and a pressing surface heated adjacent to each other, thereby cutting the laminate with the blade edge and the pressing surface. A method of molding a resin laminate, in which the plurality of resin sheet layers of the terminal portion are welded in a planar shape.   The method for forming a resin laminate according to claim 1, wherein a heated portion in one of the resin sheet layers is stretched by the blade edge and the pressing surface and welded to the other resin sheet layer. A blade mold and a receiving mold that pressurize a laminate in which resin sheet layers are arranged on both front and back sides of the foamed resin layer,
The blade mold includes a blade portion that has a blade edge that cuts the laminate, and a pressing surface that is provided adjacent to the blade edge and pressurizes the laminate, and is heatable,
The receiving mold includes a receiving part having a cutting edge receiving surface that receives the cutting edge, and a pressing receiving surface that is opposed to the resin sheet layer along the pressing surface at a pressurizable interval. Molding equipment.   The said receiving mold is a shaping | molding apparatus of the resin laminated body of Claim 3 which has the escape part which expanded the space | interval with the said blade part from the said pressure receiving surface in the position adjacent to the said pressure receiving surface.

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