JP2020124783A - Laminated sheet cutting method - Google Patents

Abstract

To provide a laminated sheet cutting method which can suppress generation of fiber waste from a laminated sheet including a sheet with use of a textile material.SOLUTION: A method for cutting a laminated sheet S comprising: (a) a first layer 32 which comprises a knitted fabric formed into a sheet in such a manner that a textile material which can be melted by heat is knitted; and (b) a second layer 31 in which a material having a melting point, which is lower than a melting point of the textile material constituting the first layer 32 is formed into a sheet. According to this method, a cutting blade 40, which is heated to the melting point or higher of the textile material constituting the first layer 32, is inserted from the first layer 32 side, and cuts the laminated sheet S. Since cutting is performed while melting the first layer 32 by the heated cutting blade 40, generation of fiber waste is suppressed, and melting of the second layer 31 is suppressed, and thus, deterioration of appearance of a terminal of the laminated sheet S can be suppressed.SELECTED DRAWING: Figure 3B

Description

The present invention relates to a laminated sheet cutting method for cutting a laminated sheet in which two types of sheets having different materials are laminated.

Patent Document 1 below describes a vehicle interior material in which a surface sheet material is integrated by press molding on the surface of a base material (core sheet material). The vehicle interior material, during press molding, by trimming with a cutting blade while heating the skin sheet material to a softening point or more and less than the melting point, the end of the base material is covered with the skin sheet material. Has been done. Such a vehicle interior material has a structure in which a layer below the surface layer is formed of a material different from the surface layer, that is, a laminated sheet in which two kinds of sheets of different materials are laminated and integrated. May be adopted. As such a laminated sheet, there are, for example, those using a material formed by knitting a fibrous material in the lower layer (knitted fabric) or one in which fiber materials are entangled (nonwoven fabric).

JP 2012-240555 A

When a sheet using a knitted or non-woven fabric made of the above fibrous material is cut, the fibers are cut at the cut portions, which causes a large amount of fiber waste. For example, when a laminated sheet including such a sheet is used for the skin of a vehicle interior material, a large amount of a large amount is applied to the members around the vehicle interior material during the process of assembling the vehicle interior material. There is a risk that fiber waste will adhere.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a laminated sheet cutting method capable of suppressing generation of fiber waste from a laminated sheet including a sheet using a fibrous material.

In order to solve the above problems, the laminated sheet cutting method of the present invention,
A laminated sheet cutting method for cutting a laminated sheet in which two kinds of sheets having different materials are laminated,
The laminated sheet comprises a first layer made of a knitted fabric formed by knitting a heat-meltable fibrous material or a nonwoven fabric formed by intertwining the fibrous materials and a melting point of the fibrous material. A material having a melting point lower than that of the first layer, which is formed in a sheet shape, and is disposed on the upper layer side of the first layer;
It is characterized in that a cutting blade heated above the melting point of the fiber material is inserted from the first layer side to cut the laminated sheet.

In such a laminated sheet cutting method, when the laminated sheet is cut, the first layer made of the fibrous material is melted and cut by the heated cutting blade, so that the end of the first layer is not heated. Fibers that will be frayed or divided when cut with a blade can be welded to other fibers or the like. Therefore, according to the above laminated sheet cutting method, it is possible to suppress the generation of fiber scraps during cutting. Moreover, if the heated cutting blade is inserted from the side of the second layer having a low melting point, the heated cutting blade has to touch the second layer while cutting the first layer, and as a result, Since the cutting end portion of the second layer (the end of the portion torn by cutting) is touched for a long time, the melted second layer adheres to the cutting blade or the melted second layer expands. However, there arises a problem that the cutting terminal of the laminated sheet is deteriorated in appearance by solidifying in a state. However, according to the above laminated sheet cutting method, since the cutting blade is inserted from the first layer side, the time during which the heated cutting blade contacts the second layer is shortened, and the occurrence of the above problems can be suppressed. ..

In addition, the laminated sheet which is a target of the laminated sheet cutting method is not particularly limited as long as both the first layer and the second layer are formed of a material that can be melted by heat. As the material for forming the second layer, various materials such as a sheet made of synthetic resin (urethane resin, polyvinyl chloride, etc.), a non-woven fabric, etc. can be adopted. When the first layer is a knitted fabric, not only a knitted fabric but also a three-dimensional knitted fabric (three-dimensional knitted fabric) can be used.

In the above method, the first layer may be a three-dimensional knitted fabric having a structure in which two base fabrics are connected by connecting yarns.

The first layer in this structure is made of, for example, a knitted fabric called double russell. Since such a three-dimensional knitted fabric has innumerable connecting yarns between the base fabric and the base fabric, when ordinary cutting is performed, for example, there are two base fabrics or innumerable connecting yarns. Due to the fact that it is divided, more fiber waste is likely to be generated. Therefore, when the laminated sheet has the first layer made of a three-dimensional knit, the above laminated sheet cutting method is particularly effective.

Further, in the above method, the laminated sheet is placed on a flat base in a state where the second layer is located on the lower side, and the tip of the cutting blade is not lowered below the second layer. It can be cut into pieces.

For example, when the heated cutting blade is lowered to a position where it penetrates the second layer, when the cutting blade is lowered from the second layer or when the cutting blade is raised after cutting, the second layer is melted. Problems such as adhesion to the cutting blade and solidification of the molten second layer in the stretched state may deteriorate the appearance of the end of the laminated sheet. However, according to the above laminated sheet cutting method, the time when the heated cutting blade contacts the second layer can be shortened, so that the above situation can be avoided.

In the above method, a Thomson blade may be used as the cutting blade to cut the laminated sheet.

According to such a method, the laminated sheet can be punched out in a short time, so that the time when the heated cutting blade is in contact with the second layer is short, and the melted second layer adheres to the cutting blade or melts. The deterioration of the appearance of the terminal of the laminated sheet due to the second layer can be suppressed.

Further, in the above method, the first layer may be formed of a fiber material of an ester resin, and the second layer may be formed of a urethane resin.

In this case, for example, when the urethane resin is formed into a sheet, they are integrated by stacking sheets (knitted or non-woven fabric) formed from the fiber material of the ester resin before the urethane resin is completely solidified. Laminated sheet can be formed. Since the melting point of the ester resin is about 260° C., whereas the melting point of the urethane resin is about 180° C., the laminated sheet cutting method having the above configuration is suitable for the laminated sheet having this configuration.

ADVANTAGE OF THE INVENTION According to this invention, the laminated sheet cutting method which can suppress generation|occurrence|production of a fiber waste from the laminated sheet containing the sheet which used the fiber material can be provided.

It is a front view showing a door trim for vehicles using a laminated sheet cut by a laminated sheet cutting method which is an example of the present invention. It is sectional drawing which shows a laminated sheet typically. It is a figure which shows typically a mode that a fiber waste generate|occur|produces, when a laminated sheet is cut|disconnected by the cutting method of a comparative example. It is a figure which shows typically the cutting terminal of the laminated sheet at the time of cutting a laminated sheet by the laminated sheet cutting method of a present Example. It is the schematic which shows the laminated sheet cutting method of a present Example, and is a figure which shows the state before cutting. It is the schematic which shows the laminated sheet cutting method of a present Example, and is a figure which shows the state during cutting. It is the schematic which shows the laminated sheet cutting method of a present Example, and is a figure which shows the state after cutting.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings as modes for carrying out the present invention. The present invention is not limited to the following embodiments, and can be implemented in various modes with various modifications and improvements based on the knowledge of those skilled in the art.

The method for cutting a laminated sheet, which is an embodiment of the present invention, is used in the manufacturing process of the vehicle door trim 10 shown in FIG. First, the door trim 10 for the vehicle will be described. The door trim 10 constitutes a vehicle interior side portion of a side door for a vehicle, and is attached to the door inner panel from the vehicle interior side. The door trim 10 is mainly configured by a generally rectangular trim board 11, and in addition to the trim board 11, an inside handle 12, a switch base 13, an armrest 14, a door pocket 15, a speaker provided on the trim board 11. It is configured to include various functional parts such as the grill 16.

The trim board 11 is formed by assembling a plurality of board members with each other, and mainly includes an upper board 20, a lower board 21, an ornament board 22, and an armrest board 23. The inside handle 12 is provided on the ornament board 22. The armrest 14 is formed by fastening the armrest board 23 to the upper side of the lower board 21 and the lower side of the ornament board 22 (substantially the center of the trim board 11 ), and the switch base 13 is provided to the front side of the armrest 14. It is provided. The door pocket 15 and the speaker grill 16 are provided on the lower side of the lower board 21.

The upper board 20, the ornament board 22, and the armrest board 23 are configured by attaching a skin material 30 to a plate-shaped base material formed of a synthetic resin material such as polypropylene. The base material is not limited to the synthetic material, and for example, a material in which a wood-based material (kenaf, hemp, flux, sisal, etc.) and a synthetic resin are mixed may be used. The above-mentioned skin material 30 is a laminated sheet which is the target of the laminated sheet cutting method of the present invention.

The skin material 30 is composed of a laminated sheet in which two sheets of different materials shown in FIG. 2 are laminated. More specifically, the laminated sheet S is formed by laminating a surface layer 31, which is a design surface of the vehicle interior material such as the upper board 20, the ornament board 22, and the armrest board 23, and a cushion layer 32 on the lower side thereof. .. The cushion layer 32 is made of a knitted fabric in which a fibrous material is knitted to form a sheet. More specifically, the cushion layer 32 is a three-dimensional knitted fabric (three-dimensional knitted fabric) having a structure in which two base fabrics 32a and 32b are connected by a connecting yarn 32c, and is a knitted fabric called double raschel. That is, in this embodiment, the cushion layer 32 is the first layer and the surface layer 31 is the second layer.

Both the surface layer 31 and the cushion layer 32 are made of a thermoplastic resin. Specifically, the surface layer 31 is formed of a urethane resin (for example, polyurethane), and the cushion layer 32 is formed of an ester resin (for example, polyester). In the laminated sheet S, a urethane resin is spread in a sheet shape in the process of forming the surface layer 31, and a cushion layer 32 is overlaid before the urethane resin is completely solidified. And are integrally formed. Therefore, the skin material 30 produced by cutting the laminated sheet S only needs to be attached once to the base material, so that the cycle time at the time of producing the interior material for a vehicle can be shortened.

The melting point of the polyurethane forming the surface layer 31 is about 180°C. On the other hand, the polyester forming the cushion layer 32 has a melting point of about 260°C. That is, the surface layer 31 has a melting point lower than that of the cushion layer 32.

Since the cushion layer 32 is a three-dimensional knitted fabric as described above, the skin material 30 has excellent cushioning properties and a good tactile feel, and is suitable as a skin material for an interior material for a vehicle. However, since the cushion layer 32 is a knit, a problem occurs when the laminated sheet S is cut into the shape of the skin material 30. More specifically, when the knitted fabric is cut, as shown in FIG. 3A, the fibers are frayed at the cut portions, and a large amount of fiber waste 35 is generated. For example, if such a cut skin material is attached to the base material, even after the door trim 10 is assembled, fiber scraps may be generated and adhere to the design surface of the door trim 10. There is. The cushion layer 32, which is the first layer, is not limited to a three-dimensional knitted fabric and may be a knitted fabric. Furthermore, the cushioned layer 32 is not limited to these knitted fabrics, and is a non-woven fabric formed into a sheet by intertwining fiber materials. May be When a knitted fabric or a non-woven fabric is used for the first layer, the above problems similarly occur, so that the laminated sheet cutting method of this embodiment is effective.

Therefore, the method for cutting the laminated sheet of this embodiment is capable of suppressing the generation of the above-mentioned fiber waste. As shown in FIGS. 4A to 4C, the laminated sheet cutting method of the present embodiment uses a Thomson blade 40 as a cutting blade and lowers the Thomson blade 40 vertically downward to cut the laminated sheet S. .. However, the Thomson blade 40 is heated to a temperature of 260° C. (which may be higher than the melting point of polyester) which is approximately the same as the melting point of polyester forming the cushion layer 32. Further, in the laminated sheet cutting method of the present embodiment, as shown in FIGS. 4A to 4C, the laminated sheet S is placed on the horizontal base 41 in a state where the surface layer 31 is located below. Cut. By the way, the base 41 is at room temperature.

That is, in the laminated sheet cutting method of the present embodiment, the laminated sheet S is cut by inserting the Thomson blade 40 heated above the melting point of the cushion layer 32, which is the first layer, from the side of the cushion layer 32 having a high melting point. Is characterized by. In the laminated sheet cutting method of the present embodiment, as shown in FIG. 3B, when the laminated sheet S is cut, the cushion layer 32 is cut while being melted by the heated Thomson blade 40. The different fibers can be welded to each other at their cut ends, or to other fibers. Therefore, according to the laminated sheet cutting method of the present embodiment, it is possible to suppress the generation of fiber waste during cutting. Particularly, in the laminated sheet S which is the target of the cutting method of the present embodiment, since the first layer is a three-dimensional knit, more fiber scraps are likely to be generated. Can be effectively suppressed.

Further, if the heated Thomson blade 40 is inserted from the surface layer 31 side having a low melting point, the heated Thomson blade 40 comes into contact with the end portion of the surface layer 31 for a long time. There are problems such as adhesion to the Thomson blade 40 and solidification of the molten surface layer 31 in an expanded state to deteriorate the appearance of the end of the skin material. However, according to the laminated sheet cutting method of this embodiment, since the Thomson blade 40 is inserted from the cushion layer 32 side, the time during which the heated Thomson blade 40 touches the surface layer 31 is shortened, so that the end of the skin material 30 looks good. It is possible to suppress the deterioration of.

Further, in the laminated sheet cutting method of the present embodiment, the single laminated sheet S is placed on the base 41 so that the tip of the Thomson blade 40 does not fall below the surface layer 31 and is cut. Has become. For example, when the heated Thomson blade 40 is lowered to a position penetrating the surface layer 31, when the Thomson blade 40 is lowered from the surface layer 31 or when the Thomson blade 40 is lifted after cutting, what is melted in the surface layer 31 is There are problems such as adhesion to the Thomson blade 40 and solidification of the molten surface layer 31 in an expanded state to deteriorate the appearance of the end of the skin material. According to the laminated sheet cutting method of the present embodiment, the time when the heated Thomson blade 40 touches the surface layer 31 can be further shortened, so that deterioration of the appearance of the end of the skin material 30 can be suppressed more effectively. Wear.

The laminated sheet cutting method of the above-mentioned examples was adopted for cutting the skin material of the vehicle interior material, but is not limited thereto, and (a) a first heat-meltable fibrous material is formed into a sheet shape. It can be widely used for cutting a laminated sheet comprising a layer and (b) a second layer in which a material having a melting point lower than that of the fiber material is formed into a sheet shape. The materials used for the first layer and the second layer are not particularly limited as long as they can be melted by heat and have a melting point lower than that of the first layer. For example, not only resin but also synthetic leather or non-woven fabric can be used for the second layer.

10... Vehicle door trim, 20... Upper board (vehicle interior material), 30... Skin material, 31... Surface layer (second layer), 32... Cushion layer (1st layer, three-dimensional knit), 32a... Base cloth (upper layer) Side), 32b... base cloth (lower layer side), 32c... connecting yarn, 40... Thomson blade, 41... base, S... laminated sheet

Claims (5)

A laminated sheet cutting method for cutting a laminated sheet in which two kinds of sheets having different materials are laminated,
The laminated sheet comprises a first layer made of a knitted fabric formed by knitting a heat-meltable fibrous material or a nonwoven fabric formed by intertwining the fibrous materials and a melting point of the fibrous material. A material having a melting point lower than that of the first layer, which is formed in a sheet shape, and is disposed on the upper layer side of the first layer;
A method for cutting a laminated sheet, comprising cutting a laminated sheet by inserting a cutting blade heated above the melting point of the fiber material from the first layer side. The laminated sheet cutting method according to claim 1, wherein the first layer is a three-dimensional knitted fabric having a structure in which two base fabrics are connected by connecting yarns. The laminated sheet is placed on a flat base in a state where the second layer is located on the lower side, and is cut so that the tip of the cutting blade does not fall below the second layer. The method for cutting a laminated sheet according to claim 1 or claim 2. The laminated sheet cutting method according to any one of claims 1 to 3, wherein a Thomson blade is used as the cutting blade to cut the laminated sheet. The laminate according to any one of claims 1 to 4, wherein the first layer is formed of a fiber material of an ester resin, and the second layer is formed of a urethane resin. Sheet cutting method.

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