JP2023170843A - Method for manufacturing composite molded product and composite molded product - Google Patents

Abstract

To provide a method for manufacturing a composite molded product and a composite molded product, which can be stably manufactured without forming holes in a surface material, and can reduce the number of manufacturing steps, in the composite molded product in which two surface materials made of thermoplastic resin sheets have a separation part where they are separated from each other and a contact part where they are in contact with each other.SOLUTION: In a method for manufacturing a composite molded product 1, two softened sheets 2b softened by heating and an intermediate material 3 sandwiched between them are arranged between an upper mold 11 and a lower mold 12, with peripheral edges 11b and 12b in contact with the two softened sheets 2b, respectively, and the intermediate material 3 exposed to an outside from between them, air between molding surfaces 11a and 12a and the two softened sheets 2b is vacuumed to adhere the two softened sheets 2b to the molding surfaces 11a and 12a, thereafter, the upper mold 11 and the lower mold 12 are brought close to each other, and the two softened sheets 2b are welded together at the peripheral edges 11b and 12b.SELECTED DRAWING: Figure 2

Description

The present invention relates to a method for producing a composite molded article, in which two surface materials made of thermoplastic resin sheets have a separation part where they are separated from each other and a contact part where they are in contact with each other.

BACKGROUND ART As interior parts for automobiles and the like, there is a composite molded product in which both surfaces are formed into a predetermined shape using thermoplastic resin sheets, and the spaced apart portion between them is filled with an intermediate material. As a method for manufacturing this composite molded product, for example, a mold has a first mold and a second mold that open and close in the left-right direction, and a mold that moves forward and backward in the opening and closing direction and surrounds the outer periphery of the first mold. A manufacturing method using has been proposed (see Patent Document 1).

The technique disclosed in Patent Document 1 first opens the first mold and the second mold, and moves the mold between the mold and the second mold with the tip of the mold advanced toward the second mold rather than the first mold. In between, a first resin sheet and a second resin sheet, each of which has been softened by heating, are inserted. Next, the tip of the mold is brought into contact with the first resin sheet, and the air between the first mold and the first resin sheet is vacuum-sucked to place the first resin sheet on the molding surface of the first mold. Bring it into close contact. After that, an intermediate material is inserted on the side opposite to the molding surface of the first mold with the first resin sheet in between. This intermediate material is preliminarily provided with through holes penetrating from side to side. With the intermediate material inserted, the first mold and mold and the second mold are brought relatively close to each other, and the first resin sheet and the second resin sheet are sandwiched between the second mold and the mold, A blowing needle is inserted into the through hole of the intermediate material from the first mold side through the first resin sheet. In this state, while vacuum suctioning the air between the molding surface of the second mold and the second resin sheet, compressed air is blown between the second resin sheet and the intermediate material from the tip of the blowing needle. The second resin sheet is brought into close contact with the molding surface of the second mold. After that, the mold is retreated in the direction away from the second mold, and the first mold and the second mold are brought close to each other and clamped, so that the first resin sheet and the second resin sheet are separated at the peripheral edge of the molding surface. I'm trying to weld it.

However, by heating and softening the first resin sheet and the second resin sheet, each resin sheet becomes sticky, so the timing and circumstances of insertion between the first mold and the second mold, and the resin sheets Depending on the spacing between the resin sheets, the resin sheets may come into close contact with each other and adhere to each other before molding, resulting in a problem. Therefore, in the technique of Patent Document 1, the first resin sheet and the second resin sheet are molded in separate processes to prevent them from coming into close contact or adhering to each other, and an intermediate material is inserted between these processes. Since there are many steps, there is a problem that the number of steps is large and it takes time.

In addition, with the technology of Patent Document 1, it is necessary to pre-form the intermediate material into a size and shape corresponding to the space between the molding surface of the first mold and the molding surface of the second mold, which increases cost. There was a problem. Furthermore, when forming the second resin sheet, compressed air is blown between the second resin sheet and the intermediate material using a blowing needle, which deteriorates the adhesion between the second resin sheet and the intermediate material. There was a problem. Furthermore, there was a problem in that holes were formed in the first resin sheet by the blowing needles.

Japanese Patent Application Publication No. 2017-154430

Therefore, in view of the above-mentioned circumstances, the present invention forms holes in the surface material in a composite molded product in which two surface materials made of thermoplastic resin sheets have a separation part where they are separated from each other and a contact part where they are in contact with each other. It is an object of the present invention to provide a method for manufacturing a composite molded article and a composite molded article that can be stably manufactured without causing any damage and reduce the number of manufacturing steps.

In order to solve the above problems, the method for manufacturing a composite molded product according to the present invention includes:
``A method for manufacturing a composite molded article in which two surface materials made of thermoplastic resin sheets have a separation part where they are separated from each other and a contact part where they are in contact with each other,
Between a pair of molds each having a molding surface of a predetermined shape, two softened sheets obtained by heating and softening two of the resin sheets serving as the surface material are sandwiched between the two softened sheets. An intermediate material having air permeability and flexibility is disposed, and a peripheral edge portion outside the molding surface of each of the pair of molds is in contact with each of the two softening sheets. The intermediate material is exposed to the outside between the sheets, and the space between the two softened sheets is exposed to the atmosphere through the intermediate material,
Vacuuming air between the molding surface of at least one of the molds and the softening sheet on the side closer to the mold to bring the softening sheet into close contact with the molding surface;
Then, by bringing the pair of molds close together, the two softened sheets are welded together through the intermediate material at the peripheral edge or at a region inside the peripheral edge.
It is characterized by

Thermoplastic resin sheets include ``thermoplastic resin as a base resin, 10wt% to 50wt% of fibers, and 0wt% to 5wt% of additives''; Examples include "non-woven fabric of 15 gsm to 50 gsm having resistance" and "sheet made only of thermoplastic resin". Examples of the above-mentioned thermoplastic resins include polypropylene, polyethylene, polystyrene, polyamide, and the like. The fibers included include resin fibers such as polyethylene terephthalate, nylon, and polyester, and natural fibers such as cotton, linen, and kenaf. Examples of additives include talc and calcium carbonate. The two surface materials may be made of the same material or may be made of different materials.

Intermediate materials include ``fibrous mats or microfiber mats made of resin fibers such as polyethylene terephthalate, nylon, and polyester,'' and ``synthetic resins such as polypropylene, polyethylene, and polystyrene foamed so that the voids are connected.'' Examples include "porous foam material (sponge-like mat)" and "mat made of natural fibers such as cotton, linen, and kenaf."

According to this configuration, since the intermediate material is sandwiched between two softened sheets that have been softened by heating, there is no problem in which the two softened sheets come close to each other and stick together or adhere to each other at unintended timing or under unintended circumstances. This does not occur and stable production is possible. In addition, since the side opposite to the molding surface of the softened sheet to be evacuated is exposed to the atmosphere through a breathable intermediate material, there is no need to blow compressed air as in Patent Document 1, and the difference between vacuum and atmospheric pressure is eliminated. The pressure difference allows the softened sheet to be brought into sufficient contact with the molding surface. Thereby, it is possible to form a separation part in which the two surface materials are separated from each other. In addition, the softened sheet that becomes the surface material becomes sticky when heated, and the intermediate material has flexibility, so the softened sheet adheres to the molding surface by vacuuming and is vacuum-formed into a predetermined shape. During this process, the portion of the intermediate material that is in contact with and adhered to the softened sheet is pulled toward the molding surface due to the deformation of the softened sheet, and the intermediate material is deformed so as to expand.

Because of this, it is possible to form the intermediate material into the desired shape at the same time as the vacuum forming of the surface material using the softened sheet, so the size and shape correspond to the space between the molding surfaces of each pair of molds. There is no need to pre-shape the intermediate material. Moreover, there is no need to arrange an intermediate material after forming the surface material. Therefore, according to the manufacturing method of this configuration, the number of manufacturing steps can be reduced compared to the technique of Patent Document 1, and the manufacturing cost can be reduced.

In addition, when vacuuming, the side of the softened sheet opposite to the molding surface is exposed to the atmosphere through the intermediate material exposed to the outside, so as in Patent Document 1, the blowing needle It is not necessary to penetrate the hole through the hole, and it is possible to manufacture a composite molded article in which the surface material does not have a hole for a manufacturing blowing needle.

Furthermore, after forming the softened sheets into the shape of the surface material by vacuuming, the two softened sheets are welded together through an intermediate material at the outer peripheral edge of the molding surface or at a region inside the peripheral edge. Thereby, a contact portion where the two surface materials are in contact with each other can be formed. Due to this welded contact area, even if the intermediate material is flexible, the two surface materials will not move relative to each other, and the desired shape will be maintained in the composite molded product. can manufacture products.

The composite molded product according to the present invention is
"A composite molded product in which two surface materials made of thermoplastic resin sheets have a separation part where they are separated from each other and a contact part where they are in contact with each other,
An intermediate material having breathability and flexibility is sandwiched between the two surface materials,
In the separation part, a portion of the intermediate material that is in contact with the surface material is adhered to the surface material,
In the contact portion, the two surface materials are welded to each other through the intermediate material.
It is characterized by

According to this configuration, since the intermediate material having air permeability and flexibility is sandwiched between the separating part where the two surface materials are separated from each other, the separating part becomes a hollow molded product due to the presence of the intermediate material. In comparison, it is possible to improve the heat insulation and sound absorption properties. Furthermore, since no manufacturing holes are formed in the two surface materials, the appearance is good.

By the way, if the intermediate material is not adhered to the surface material, there is a risk that the intermediate material will move within the separation part, resulting in a decrease in heat insulation and sound absorption properties, and generation of vibrations and sounds. In contrast, in this configuration, since the intermediate material is bonded to the surface material, the intermediate material does not move relative to the surface material, resulting in a decrease in heat insulation and sound absorption, and the generation of vibrations and sounds. There is nothing to do.

As described above, as an effect of the present invention, holes are formed in the surface material in a composite molded product in which two surface materials made of thermoplastic resin sheets have a separation part where they are separated from each other and a contact part where they are in contact with each other. It is possible to provide a method for manufacturing a composite molded article and a composite molded article that can be stably manufactured without any problems and can reduce the number of manufacturing steps.

(a) schematically shows a state in which a pair of molds is opened and two resin sheets serving as surface materials and an intermediate material are placed outside the molds in a method for manufacturing a composite molded product, which is an embodiment of the present invention. (b) is an explanatory diagram showing a state in which two resin sheets are heated to form a softened sheet from the state in (a), and (c) is an explanatory diagram showing a state in which the two resin sheets are made into a softened sheet from the state in (b). It is an explanatory view showing a state in which two softened sheets and an intermediate material are moved between the molds. (a) is an explanatory diagram showing a state in which a pair of open molds are brought closer to each other from the state in FIG. FIG. 3C is an explanatory diagram showing the state of the first mold clamping position where the peripheral edges of the pair of molds are in contact with the two softened sheets and the intermediate material, and FIG. (d) is an explanatory diagram showing a state in which pulling has started, and (d) is an explanatory diagram showing a state in which two softened sheets are brought into close contact with the respective molding surfaces of a pair of molds by vacuuming from the state (c). e) is an explanatory view showing the state of the second mold clamping position where the pair of molds are brought closer together from the state of (d) and the two softened sheets are in contact with each other at the peripheral edges of the pair of molds; It is an explanatory view showing a state where a pair of metal molds are opened from the state of (e), and a composite molded product is manufactured therebetween. (a) is a method for manufacturing a composite molded product with a different form from that shown in FIG. 2(f), in which two softened sheets heated and softened are placed between a pair of open molds and an intermediate material is placed between them. FIG. 3B is an explanatory diagram showing a state in which a pair of molds are brought close to each other, and FIG. (c) is an explanatory diagram showing a state in which vacuuming is started in a pair of molds from the state in (b); d) is an explanatory diagram showing a state in which the two softened sheets are brought into close contact with the respective molding surfaces of a pair of molds by vacuuming from the state in (c), and (e) is an explanatory diagram showing a state in which the two softened sheets are brought into close contact with the respective molding surfaces of a pair of molds from the state in (d). It is an explanatory view showing the state of the second mold clamping position where the two softening sheets touch each other at the peripheral edge of the pair of molds by bringing them close to each other, and (f) is an explanatory diagram showing the state of the second mold clamping position where the two softening sheets are brought close to each other and are in contact with each other at the peripheral edge of the pair of molds, and (f) is an explanatory diagram showing a state in which the pair of molds is opened from the state of (e). It is an explanatory view showing the state where a composite molded article was manufactured in the meantime. (a) shows a different manufacturing method for the same composite molded product as in Fig. 3(f); in the first mold clamping position, only the lower side of the pair of molds is evacuated, and the lower side is It is an explanatory view showing a state in which the softened sheets are in close contact with the molding surface of the lower mold, and (b) is an explanatory diagram showing a state in which the upper mold is lowered from the state in (a) so that the two softened sheets are in contact with each other at the peripheral edge of the mold. (c) is an explanatory diagram showing a state in which a pair of molds are opened from the state in (b) and a composite molded product is manufactured therebetween.

1(a) to 1(c) and 2(a) to 2(a) to 1(c) and 2(a) to 1(c), respectively, regarding a composite molded product 1 and a method for manufacturing the composite molded product 1 (hereinafter simply referred to as a manufacturing method), which is an embodiment of the present invention. This will be explained in detail with reference to FIG. 2(f). The composite molded product 1 of this embodiment is used, for example, as an interior part of an automobile. This composite molded product 1 has two surface materials 2 made of thermoplastic resin sheets having a separation part 1a where they are separated from each other and a contact part 1b where they are in contact with each other (see FIG. 2(f)). . More specifically, in the composite molded product 1, an intermediate material 3 having air permeability and flexibility is sandwiched between two surface materials 2, and the intermediate material 3 is in contact with the surface material 2 in the separating part 1a. At the contact portion 1b, the two surface materials 2 are welded to each other through ventilation holes (gaps) in the intermediate material 3. In addition, the composite molded product 1 shown in FIG. 2(f) is vacuum formed so that both of the two surface materials 2 have unevenness.

In the composite molded product 1 of the present embodiment, the density of the intermediate material 3 at the separating portion 1a differs depending on the distance between the two surface materials 2. To be more specific, the intermediate material 3 has a low density in a region where the distance between the two surface materials 2 is wide, and a high density in a region where the distance between the two surface materials 2 is narrow. Due to the presence of the intermediate material 3, this composite molded product 1 has better heat insulation and sound absorption properties than a molded product in which the space between the two surface materials is hollow. Further, the composite molded product 1 has no manufacturing holes formed in either of the two surface materials 2, and has a better appearance than conventional molded products. Furthermore, in the composite molded product 1, since the intermediate material 3 is bonded to the surface material 2, the intermediate material 3 does not move relative to the surface material 2, resulting in a decrease in heat insulation and sound absorption, and vibration and vibration. It makes no sound or does anything.

The two surface materials 2 are made of the same material, and contain 10 wt% to 50 wt% (preferably 20 wt% to 30 wt%) of fibers using polypropylene, which is a thermoplastic resin, as a base resin, and contain fibers as an additive. It contains 1wt% to 3wt% of talc. The intermediate material 3 is a microfiber mat made of polyethylene terephthalate fibers.

Next, a method for manufacturing the composite molded product 1 will be explained. Here, a case will be described in which a mold 10 consisting of an upper mold 11 and a lower mold 12 that opens and closes in the vertical direction is used. As shown in FIG. 1(a), the upper die 11 has a molding surface 11a that is recessed upward from the lower surface, and a peripheral edge portion 11b provided outside of the molding surface 11a. . Further, the lower mold 12 has a molding surface 12a that is recessed downward from the upper surface, and a peripheral edge portion 12b that is provided outside of the molding surface 12a. The respective molding surfaces 11a and 12a are for molding the shell-shaped separation portion 1a. Each of the molding surfaces 11a and 12a is provided with irregularities that match the shape to be molded, and is also provided with a plurality of small holes for vacuuming.

First, with the mold 10 open, two thermoplastic resin sheets 2a that will become the surface material 2 are placed outside the mold 10, and one intermediate material is placed on the opposite side of the mold 10. Place 3. The two resin sheets 2a are arranged horizontally at a height between the upper mold 11 and the lower mold 12, separated from each other in the vertical direction. On the other hand, the intermediate material 3 is placed in a horizontal state at an intermediate height between the two resin sheets 2a.

Then, a plate-shaped heater (not shown) was inserted below each of the two resin sheets 2a, and each resin sheet 2a was heated and softened until its surface temperature reached 160° C. to 190° C. A softened sheet 2b is used (see FIG. 1(b)). Note that the surface temperature of the heater is 300° C. to 350° C., and the softened sheet 2b is obtained by heating for 2 to 3 minutes.

Next, the two softened sheets 2b are moved between the upper mold 11 and the lower mold 12, and the intermediate material 3 is moved between the upper mold 11 and the lower mold 12, and the intermediate material 3 is moved between the two softened sheets 2b. (see Figure 1(c)). In this state, the two softened sheets 2b have adhesive properties due to heating and softening, but since the intermediate material 3 is located between them, the two softened sheets 2b will stick and adhere to each other, causing a problem. Never.

Thereafter, the upper mold 11 is lowered and the lower mold 12 is raised (see FIG. 2(a)). Then, the upper softening sheet 2b contacts the peripheral edge 11b of the upper mold 11, and the peripheral edge 12b of the lower mold 12 contacts the lower softening sheet 2b, and then the upper softening sheet 2b and the lower softening sheet 2b contact each other. The sheets 2b are brought into contact with the intermediate material 3 (see FIG. 2(b)). When this state is reached, the lowering of the upper mold 11 is stopped, and the raising of the lower mold 12 is also stopped. This state is the state of the first mold clamping position in the mold 10.

In the state of the first mold clamping position, the softened sheet 2b has adhesive properties due to heating and softening, so that the portion in contact with the intermediate material 3 is adhered to the intermediate material 3. Further, in this state, the outer peripheral side surface of the intermediate material 3 is exposed to the outside of the mold 10. Thereby, the space between the two softened sheets 2b is exposed to the atmosphere through the breathable intermediate material 3.

In this state, the air between the molding surface 11a of the upper mold 11 and the softening sheet 2b and the air between the molding surface 12a of the lower mold 12 and the softening sheet 2b are evacuated at the same time (Fig. 2(c) ). Since the space between the two softened sheets 2b is exposed to the atmosphere through the intermediate material 3, the upper softened sheet 2b is plastically deformed due to the pressure difference between the vacuum and atmospheric pressure, and comes into close contact with the molding surface 11a of the upper mold 11. , the lower softened sheet 2b is plastically deformed and comes into close contact with the molding surface 12a of the lower mold 12 (see FIG. 2(d)). As a result, the two softened sheets 2b are vacuum formed into desired shapes. These vacuum-formed parts become separation parts 1a where the two surface materials 2 are separated from each other. Note that the white arrows in FIGS. 2(c) and 2(d) indicate the flow of air.

In addition, since the upper and lower surfaces of the intermediate material 3 are bonded to each other by the adhesive force of the softened sheet 2b, they are pulled toward the molding surfaces 11a and 12a as the softened sheet 2b is plastically deformed by vacuuming, and are pulled upward and downward. It deforms so that it expands in the direction. As a result, the density of the intermediate material 3 differs depending on the distance between the two surface materials 2.

Thereafter, the upper mold 11 is lowered, and when the two softened sheets 2b touch each other at a portion between the peripheral edge 11b of the upper mold 11 and the peripheral edge 12b of the lower mold 12, the lowering of the upper mold 11 is stopped ( (see Figure 2(e)). This state is the second mold clamping position of the mold 10. In this state, the intermediate material 3 is crushed at the portion sandwiched between the peripheral edges 11b and 12b, and the softened material of the two softened sheets 2b passes through the ventilation holes (here, between the fibers) of the intermediate material 3. , will be welded together. This welded portion becomes a contact portion 1b where the two surface materials 2 are in contact with each other. Further, when the mold 10 is in the second mold clamping position, an unillustrated cutting blade cuts off the excess portion of the outer periphery of the molded product so that it has the same size as the product.

After the softened sheet 2b is cooled and hardened, the upper mold 11 is raised, the lower mold 12 is lowered, and is taken out from between them, thereby producing the composite molded article 1 molded into a desired shape. (See FIG. 2(f)).

Next, a method for manufacturing a composite molded product 1 in which one of the two surface materials 2 is formed flat, as shown in FIG. 3F, will be described in FIGS. This will be explained with reference to (f). Note that here, the only difference is the upper die 11, and the other configurations are the same as above, so the same configurations are given the same reference numerals and detailed explanations are omitted. As shown in FIG. 3(a) etc., the upper mold 13 of the mold 10 is different from the upper mold 11 described above, and has a flat molding surface 13a and a peripheral edge provided outside the molding surface 13a. It has a portion 13b. The molding surface 13a and the peripheral edge portion 13b are formed in the same plane. The molding surface 13a is provided with a plurality of small holes for evacuation.

Similarly to the above, two softened sheets 2b softened by heating are placed between the vertically opened molds 10, and the intermediate material 3 is placed between them, and while the upper mold 13 is lowered, the lower mold 12 is raised. (See Figure 3(a)). Then, the upper softened sheet 2b comes into contact with the upper mold 13, and the peripheral edge 12b of the lower mold 12 comes into contact with the lower softened sheet 2b, and then the upper softened sheet 2b and the lower softened sheet 2b are brought into contact with each other. Each mold is placed in the first mold clamping position in contact with the intermediate material 3 (see FIG. 3(b)).

Subsequently, the air between the molding surface 13a of the upper mold 13 and the softening sheet 2b and the air between the molding surface 12a of the lower mold 12 and the softening sheet 2b are simultaneously evacuated (FIG. 3(c)). ). Since the space between the two softened sheets 2b is exposed to the atmosphere through the intermediate material 3, the pressure difference between the vacuum and atmospheric pressure causes the upper softened sheet 2b to come into close contact with the flat molding surface 13a of the upper mold 13, and the lower The side softened sheet 2b is plastically deformed and comes into close contact with the molding surface 12a of the lower mold 12 (see FIG. 3(d)).

At this time, the lower surface of the intermediate material 3 is deformed so as to be pulled downward and expanded with the plastic deformation of the lower softened sheet 2b. On the other hand, since the upper softened sheet 2b is in close contact with the flat upper mold 13 by vacuuming, it will not be deformed even if the intermediate material 3 is pulled downward.

Thereafter, the upper mold 13 is lowered to a second mold clamping position such that the two softened sheets 2b are in contact with each other in a region between the peripheral edge 13b of the upper mold 13 and the peripheral edge 12b of the lower mold 12. (See Figure 3(e)). As a result, the areas where the two softened sheets 2b are in contact with each other are welded together, and an unillustrated cutting blade cuts off the excess area on the outer periphery of the molded product so that it has the same size as the product.

Then, after the softened sheet 2b is cooled and hardened, the upper mold 13 is raised, the lower mold 12 is lowered, and the composite molded product 1 with one surface material 2 flat is manufactured by lowering the lower mold 12 and taking it out from between them. (See FIG. 3(f)).

Note that a core material may be placed in the intermediate material 3. In this case, the intermediate material 3 containing the core material is stacked between two resin sheets 2a (softened sheets 2b) and set in a mold 10 for molding. For example, even if the intermediate material 3 includes a core material with no air permeability, since the intermediate material 3 has air permeability, it can be exposed to the atmosphere through the intermediate material 3. Further, by surrounding the core material with the intermediate material 3, it is possible to hold and fix the core material in the composite molded product 1. By manufacturing in this way, the core material is adhered to the surface material 2 made of a thermoplastic resin sheet, and the intermediate material 3 is filled between the core material and the composite molding that is held in the desired shape. can manufacture products.

As described above, according to the manufacturing method of this embodiment, since the intermediate material 3 is sandwiched between the two softened sheets 2b that have been softened by heating, the two softened sheets 2b may come close to each other at unintended timing or under unintended circumstances. The composite molded product 1 can be stably manufactured without causing problems such as adhesion and adhesion.

In addition, since the side opposite to the forming surfaces 11a, 12a, and 13a of the softened sheet 2b to be evacuated is exposed to the atmosphere through the breathable intermediate material 3, the vacuum can be removed without blowing compressed air as in the past. The softened sheet 2b can be brought into sufficient close contact with the molding surfaces 11a, 12a, and 13a due to the pressure difference between the pressure and the atmospheric pressure. Thereby, it is possible to form a separation part 1a in which the two surface materials 2 are separated from each other. In this embodiment, the two softened sheets 2b are simultaneously evacuated (vacuum formed) to form each into the surface material 2.

Moreover, since the softened sheet 2b that becomes the surface material 2 has adhesive properties when heated, and the intermediate material 3 has flexibility, the softened sheet 2b is applied to the molding surfaces 11a, 12a, and 13a by vacuuming. When the intermediate material 3 is vacuum-formed into a predetermined shape in close contact with the softened sheet 2b, the portion of the intermediate material 3 that is in contact with and adhered to is pulled toward the molding surfaces 11a, 12a, and 13a due to plastic deformation of the softened sheet 2b, and the intermediate material 3 is 3 will be deformed so that it expands.

For this reason, since the intermediate material 3 can be molded into a desired shape at the same time as the two surface materials 2 are vacuum-formed using the softened sheet 2b, the spaces between the molding surfaces 11a, 12a, and 13a of the molds 10 are There is no need to pre-form the intermediate material 3 into a size and shape corresponding to the space. Moreover, it is not necessary to arrange the intermediate material 3 after forming the surface material 2. Therefore, according to the manufacturing method of this embodiment, the number of manufacturing steps can be reduced compared to conventional manufacturing methods, and manufacturing costs can be reduced.

In addition, when vacuuming, the side of the softened sheet 2b opposite to the forming surfaces 11a, 12a, and 13a is exposed to the atmosphere through the intermediate material 3 exposed to the outside, so that it becomes the surface material 2 as in the conventional case. There is no need to penetrate the softened sheet 2b with a blowing needle, and it is possible to manufacture a composite molded product 1 in which the surface material 2 does not have holes for blowing needles for production.

Furthermore, after forming the softened sheets 2b into the shape of the surface material 2 by vacuuming, the softened materials of the two softened sheets 2b form the intermediate material 3 at the outer peripheral edges 11b, 12b, 13b of the forming surfaces 11a, 12a. By passing through, the two softened sheets 2b are welded together. Thereby, a contact portion 1b where the two surface materials 2 are in contact with each other can be formed. Due to this welded contact portion 1b, in the composite molded product 1, even if the intermediate material 3 has flexibility, the two surface materials 2 do not move relative to each other, and are maintained in the desired shape. A composite molded article 1 can be manufactured.

In addition, since the outer periphery is cut to the same size as the product when the mold 10 is in the second mold clamping position, there is no need to cut the excess outer periphery after taking it out from the mold 10. , This also allows the number of manufacturing steps to be reduced.

Although the present invention has been described above with reference to preferred embodiments, the present invention is not limited to the above embodiments, and various improvements and design changes can be made without departing from the gist of the present invention. It is.

For example, in the above embodiment, the intermediate material 3 is overlapped between the two softened sheets 2b between the upper molds 11 and 13 and the lower mold 12, but the invention is not limited to this. The intermediate material 3 may be inserted between the two softened sheets 2b outside the mold 10, and then moved between the upper molds 11, 13 and the lower mold 12 after overlapping them. Alternatively, the intermediate material 3 is sandwiched between two resin sheets 2a in advance outside the mold 10, and the resin sheet 2a is heated and softened before being moved between the upper molds 11, 13 and the lower mold 12. You can do it like this.

Further, in the above embodiment, the two surface materials 2 are made of the same material, but the present invention is not limited to this, and the two surface materials 2 may be made of different materials.

Further, in the above embodiment, the surface material 2 is made of polypropylene as the base resin, but the present invention is not limited to this, and polyethylene, polystyrene, polyamide, etc. may be used as the base resin. Furthermore, the surface material 2 does not need to contain additives such as talc. Furthermore, the surface material 2 may be a single layer sheet or a multilayer sheet. Further, the intermediate material 3 may be a fibrous mat, a microfiber mat, a sponge mat, etc. made of resin fibers such as nylon or polyester.

Further, in the above embodiment, the mold 10 is shown to open and close in the vertical direction, but the mold is not limited to this, and may be a mold that opens and closes in the left and right directions. In this case, the surfaces of the resin sheet 2a serving as the surface material 2 and the intermediate material 3 are oriented in the left-right direction.

Further, in the above embodiment, the two softened sheets 2b are vacuumed, but the invention is not limited to this, and only one of the softened sheets 2b is vacuumed to form a shape along the molding surface. It may also be formed on the material 2. In other words, it may be a composite molded product in which only one of the two surface materials is vacuum formed. In this case, the surface material on the side to be evacuated is the same material as above, and the surface material on the side not to be evacuated is made of thermoplastic resin fibers such as polyethylene terephthalate and has an air flow resistance of 15 gsm to 50 gsm (preferably may be a non-woven fabric (20 gsm to 40 gsm). Alternatively, the material of the surface material that is not evacuated may be a sheet made only of thermoplastic resin.

A method for manufacturing a composite molded product in which only one surface material is vacuum formed as described above will be described with reference to FIGS. 4(a) to 4(c). Note that here, only the above-mentioned upper mold is different, and other configurations are the same as above, so the same configurations are given the same reference numerals and detailed explanations are omitted. As shown in FIG. 4A and the like, the upper mold 14 of the mold 10 has a flat molding surface 14a and a peripheral edge portion 14b provided outside the molding surface 14a. In this mold 10, a plurality of small holes for evacuation are not provided in the upper mold 14 but only in the lower mold 12.

Then, in the same way as above, between the upper mold 14 and the lower mold 12, with the intermediate material 3 sandwiched between the two softened sheets 2b1 and 2b2, the mold 10 is moved to the first mold clamping position. move it. After that, when vacuum is applied only from the lower mold 12 side, when the lower softened sheet 2b2 comes into close contact with the molding surface 12a of the lower mold 12, the intermediate material 3 is transferred together with the softened sheet 2b2 to the lower molding surface 12a side. However, the upper softened sheet 2b1 that is not evacuated does not deform (see FIG. 4(a)). Specifically, even if the upper softened sheet 2b1 that is not vacuumed is pulled toward the molding surface 12a (downward) via the intermediate material 3, this softened sheet 2b1 has non-air permeability or air flow resistance. Therefore, since no flow of evacuated air occurs between the softening sheet 2b1 and the upper mold 14, the softening sheet 2b1 does not move or deform.

Thereafter, the flat upper mold 14 is lowered to the second mold clamping position, and the flat softened sheet 2b1 and the molded softened sheet 2b2 are welded at the peripheral edges 14b and 12b (see FIG. 4(b)). After the softened sheets 2b1 and 2b2 have hardened, the mold 10 is opened and taken out, thereby producing a composite molded product 1 with one surface material 2 flat (see FIG. 4(c)). That is, even when vacuum forming only one surface material 2, a composite molded product similar to the composite molded product shown in FIG. 3(f) can be manufactured.

Further, in the above embodiment, the two softened sheets 2b are welded at the peripheral edge portions 11b and 12b of the upper mold 11 and the lower mold 12 at the second mold clamping position. However, the present invention is not limited to this, and the two softened sheets 2b may be welded at a portion inside the peripheral portions 11b and 12b (center portions of the molding surfaces 11a and 12a). In this case, at least one projection is provided that protrudes from one molding surface toward the facing molding surface, and the projection presses and welds one softened sheet to the other softened sheet.

Further, in the above embodiment, the excess portion of the outer periphery is cut off at the second mold clamping position, but the invention is not limited to this, and after taking out the molded product from the mold 10, You may cut off the excess portion on the outer periphery.

1 Composite molded product 1a Separating part 1b Contact part 2 Surface material 2a Resin sheet 2b Softening sheet 2b1 Softening sheet 2b2 Softening sheet 3 Intermediate material 10 Mold 11 Upper mold 11a Molding surface 11b Peripheral part 12 Lower mold 12a Molding surface 12b Peripheral part 13 Upper mold 13a Molding surface 13b Peripheral part 14 Upper mold 14a Molding surface 14b Peripheral part

Claims (2)

A method for manufacturing a composite molded article, in which two surface materials made of thermoplastic resin sheets have a separation part where they are separated from each other and a contact part where they are in contact with each other,
Between a pair of molds each having a molding surface of a predetermined shape, two softened sheets obtained by heating and softening two of the resin sheets serving as the surface material are sandwiched between the two softened sheets. An intermediate material having air permeability and flexibility is disposed, and a peripheral edge portion outside the molding surface of each of the pair of molds is in contact with each of the two softening sheets. The intermediate material is exposed to the outside between the sheets, and the space between the two softened sheets is exposed to the atmosphere through the intermediate material,
Vacuuming air between the molding surface of at least one of the molds and the softening sheet on the side closer to the mold to bring the softening sheet into close contact with the molding surface;
Thereafter, by bringing the pair of molds close together, the two softened sheets are welded to each other through the intermediate material at the periphery or at a portion inside the periphery. method of manufacturing the product. A composite molded product in which two surface materials made of thermoplastic resin sheets have a separation part where they are separated from each other and a contact part where they are in contact with each other,
An intermediate material having breathability and flexibility is sandwiched between the two surface materials,
In the separation part, a portion of the intermediate material that is in contact with the surface material is adhered to the surface material,
The composite molded article is characterized in that, in the contact portion, the two surface materials are welded to each other through the intermediate material.

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