JP2609032B2 - Molding method for cardboard interior materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a corrugated board interior material comprising a corrugated board base material formed in a predetermined shape and a decorative skin material laminated on one surface of the corrugated board base material.

[0002]

2. Description of the Related Art This type of corrugated cardboard interior material is used, for example, as an interior material for automobile ceilings. Conventionally, a liner is attached to both sides of a corrugated core as shown in FIG. 1 via a thermoplastic resin film. The flat plate-shaped corrugated cardboard substrate is heated and press-formed by a predetermined hot press device, and then, using the same mold, the decorative skin material usually made of a resin sheet is applied to the formed corrugated cardboard substrate using a hot melt sheet or the like. They are stacked with a soluble adhesive interposed therebetween, and then heated and pressed again to melt the adhesive, so that the skin material and the corrugated board base material are bonded together.

[0003]

As described above, according to the conventional method, the molding material for the hot press formed by heating and pressurizing the corrugated board base material is used as it is, and the skin material for the corrugated board base material after molding is used. Since the corrugated board is bonded, the corrugated board is held in a heated state until the bonding between the skin material and the corrugated board is completed, and the resin film for adhering the liner and the core is also in a molten state. Since it does not completely solidify immediately after finishing and demolding, springback occurs,
Often causes deformation of the molded article. In addition, productivity cannot be improved because the next molding cycle cannot be started until the skin material is completely bonded and the molding die becomes empty. The present invention has been made in view of the above problems of the prior art, and has as its object to prevent deformation due to springback after molding to improve quality, and to improve productivity and manufacture. Another object of the present invention is to reduce costs.

[0004]

According to the present invention, there is provided a method for forming a corrugated cardboard interior material, comprising the steps of: forming a flat corrugated cardboard on both sides of a corrugated core through a thermoplastic resin film; First, the material is heated by a hot press at a temperature high enough to leave a residual heat sufficient to melt the heat-soluble adhesive on the surface of the corrugated cardboard after the molding is completed and demolded, and the corrugated cardboard is formed at the time of molding. The paper is heated and pressed at such a temperature that the paper does not burn, and the molded cardboard base material is removed from the mold and transferred to a mold of a cold press machine, and a decorative skin material is applied to the surface via a heat-soluble adhesive. By stacking and cold pressing, the residual heat of the corrugated board base material is used to melt the adhesive agent to bond the corrugated board base material and the skin material.

[0005]

In the method of molding the interior material made of corrugated board constructed as described above, after the hot pressing of the corrugated board base material, adhesion of the decorative skin material to the formed corrugated board base material is performed by the residual heat of the corrugated board base material. Therefore, the thermoplastic resin interposed between the core and the liner of the corrugated cardboard substrate and melted in the molding process of the corrugated cardboard substrate is cooled and solidified in the process of bonding the skin material to be removed. During molding, the molded shape is securely held. In addition, the hot press device used in the corrugated board base material forming process is in a state in which it can be used for the next molding when the skin material adhering process is performed, and the cold press device for performing the skin material adhering process is When the molding process is performed, it is ready for the next use.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. A is a corrugated cardboard substrate constituting an interior material made of corrugated cardboard. The corrugated cardboard substrate A is provided with a corrugated core 1 and thermoplastic resin films 2, 3 such as polyethylene films on both sides of the corrugated core, respectively. And one of the liners 4 is completely adhered to the core 1, while the other liner 5 is formed of the liner 5 and the core 1 during press molding. Are temporarily stopped at only both sides to allow relative slippage.

In the method of the present invention, first, the corrugated cardboard substrate A is heated and pressed by a hot press device B to form a predetermined shape. The hot press apparatus B has a conventionally well-known structure and form comprising a fixed lower mold B1 and a movable upper mold B2, and although not shown, the molding surfaces of these two molds B1 and B2 are formed by a suitable heating means. It is heated to the molding temperature.

The corrugated cardboard substrate A is placed on a fixed lower die B1 of a hot press apparatus B with the liner 5 temporarily fixed to the core 1 facing upward, and the movable upper die B2 is lowered to form the two die B.
Molded by pressurizing and heating between 1 and B2.

[0009] In this hot pressing step, after the molding is completed and the mold is removed, the molding is performed at a high temperature to the extent that residual heat sufficient to melt the heat-soluble adhesive 6 to be described later remains on the surface of the molded corrugated board substrate A '. Sometimes the paper of the corrugated board base material A is heated at a temperature at which it does not burn. For example, heat-soluble adhesive
For hot melt films that melt at 130 ° C, the heating temperature should be 220 ° C.

In general, in cardboard molding, hot press molding is used to melt thermoplastic resin films 2, 3 such as polyethylene films interposed between the core 1 and the liners 4, 5, so that the heating temperature is set to this value. Although the temperature is set to about 130 ° C. which is sufficient to melt the thermoplastic resin films 2 and 3, the melting of the films 2 and 3 is accelerated by molding at a heating temperature much higher than the above, and the pressing time is reduced. It can be shortened.

After completion of the molding, the movable upper mold B2 is lifted, and the molded cardboard substrate A 'is released from the fixed lower mold B1. In this state, the resin films 2 and 3 interposed between the core 1 and the liners 4 and 5 are in a molten state and not yet solidified, so that the molded corrugated board base material A ′ undergoes springback. Is in a state of gaining. The corrugated cardboard substrate A ′, which has been removed from the mold after the molding, is immediately transferred to a cold press device C, and the surface thereof is coated with a heat-soluble adhesive 6.
The decorative skin material 7 is overlaid via the above and pressurized. During this period, more specifically, the corrugated board base material A'with the cold press device C.
While hot pressing the decorative skin material 7, the hot press device B after demolding the molded corrugated board substrate A ′,
The cardboard substrate A for the next molding cycle is charged.

The decorative skin material 7 is usually made of a resin sheet, and the heat-soluble adhesive 6 is made of, for example, a polyolefin-based or polyamide-based hot melt film. 7 may be preliminarily laminated on the back surface, or may be formed into a film sheet by using a cold press device C.
You may make it mount on the molded corrugated-cardboard base material A'which was moved to.

On the other hand, the cold press device C comprises a fixed lower die C1 and a movable upper die C2 like the hot press device B, but differs from the hot press device in that it does not have a heating device. In some cases, a cooling device for cooling the molding surface may be provided. The forming parts of the upper and lower molds C1 and C2 of the cold press device C are hot press devices except that the clearance is formed larger than that of the upper and lower molds B1 and B2 of the hot press device B by an amount corresponding to the thickness of the decorative skin material 7. The upper and lower molds B1 and B2 are formed in exactly the same shape.

In this cold press step, there is still sufficient residual heat of about 130 ° C. to melt the hot melt film 6 in the corrugated cardboard base material A'which has been demolded from the hot press machine B and put therein. The melted film 6 is melted by the residual heat of the molded cardboard substrate A ′, and the cardboard substrate A ′ and the decorative skin material 7 are adhered by pressurization.

Then, after the adhesion of the decorative skin material 7, the molds C1 and C2 are opened and demolded to obtain a corrugated board interior material D, which is a product. In the process of this step, the corrugated board base material A is used. The temperature of the thermoplastic resins 2 and 3 between the center core 1 and the liners 4 and 5 is lowered. Therefore, at the time of demolding, the solidification of the thermoplastic resins 2 and 3 proceeds, and the shape of the product D is reliably maintained.

Incidentally, the molded corrugated board base material A'and the skin material 7 for the demolding and the next molding cycle of the cold press machine C.
Can be added during the heating and pressurizing time in the hot pressing step.

[Effect] Since the present invention is configured as described above, the following effects can be obtained. (1). After hot-pressing the corrugated board base material, the decorative skin material of the formed corrugated board base material is bonded by cold pressing using the residual heat of the corrugated board base material, so that the space between the core of the corrugated board base material and the liner is increased. The thermoplastic resin interposed and melted in the molding step of the corrugated cardboard substrate is cooled in the course of the step of bonding the skin material, and is solidified at the time of demolding, so that there is no fear of springback. Therefore, the product can surely retain the molded shape and the quality is improved, so that the commercial value can be increased. (2). Excellent as above without fear of springback
Hot and cold press machines
Molding by only one pressing process
Therefore, the production efficiency is reduced compared to the conventional method.
In addition, the above hot press equipment
Ready for use in the next molding when the bonding process of the skin material due to less equipment is performed, one of the cold press
Since device is in a state to be subjected to subsequent use when the forming process of the cardboard substrate by hot pressing apparatus is performed, it is possible to efficiently rather good use of the device by operating this alternately Moreover, Hot introduction of demolding and cardboard substrate for the next molding cycle of the press device during pressurization time of the cold pressing process, introduction of demolding and molding cardboard substrate and a skin material for the next molding cycle of cold pressing device Can be performed during the heating and pressurizing time in the hot press process, so that the work efficiency can be improved by eliminating the waiting time of the operator. Therefore, productivity is improved and production cost is reduced.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a cardboard substrate.

FIG. 2 is an explanatory view showing a hot press molding step of a corrugated cardboard substrate.

FIG. 3 is an explanatory view showing a step of transferring a molded cardboard substrate to a cold press device.

FIG. 4 is an explanatory diagram showing a step of bonding a molded corrugated board base material and a decorative skin material by cold pressing.

FIG. 5 is an explanatory diagram showing a product demolding process.

FIG. 6 is a cross-sectional view of a product corrugated cardboard interior material.

[Explanation of symbols]

A Corrugated substrate A 'Molded corrugated substrate B Hot press device C Cold press device D Product corrugated cardboard interior material 1 Core 2, 3 Thermoplastic resin film 4, 5 Liner 6 Heat soluble adhesive 7 Cosmetic skin material ( Hot melt film)

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yutaka Sato 1-2-3 Kita-Aoyama, Minato-ku, Tokyo Aoyama Building Ding 1306 Triwall Co., Ltd. (56) Reference JP-A-58-36442 (JP, A)

Claims (1)

(57) [Claims] 1. A flat corrugated cardboard substrate having a liner bonded to both sides of a corrugated core via a thermoplastic resin film, after completion of molding by a hot press device and demolding, is heat-soluble on the corrugated cardboard substrate surface. Heating and pressure molding at a temperature high enough to leave residual heat enough to melt the adhesive, and at a temperature that does not cause the paper constituting the corrugated cardboard substrate to burn during molding; removing the molded corrugated cardboard substrate The mold is transferred to a molding die of a cold press machine, and a step of laminating a decorative skin material on the surface thereof through a heat-soluble adhesive is performed. A method for forming a corrugated cardboard interior material, comprising a step of bonding the two using the residual heat of the corrugated cardboard.