JP2887088B2 - Method for molding plastic honeycomb body and interior member having molded plastic honeycomb body - 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 plastic honeycomb body into a desired shape, and an interior member having the formed plastic honeycomb body.

[0002]

2. Description of the Related Art It has been well known that a plastic honeycomb body or a laminate obtained by laminating a fiber layer on the plastic honeycomb body is used as an interior member for a vehicle or a house. The plastic honeycomb body is a plate-like plastic molded body having a honeycomb shape or another appropriate shape having a large number of spaces therein.

For example, as shown in FIG. 7, a plastic honeycomb body composed of an embossed layer 1 having a plurality of concave portions 11 and a flat outer layer 2 adhered to the concave portion opening side of the embossed layer 1 is provided. As shown in FIG. 8, a plastic honeycomb body having a sandwich structure having a flat outer surface layer 3 adhered to the concave back surface 12 of the embossed layer 1 of the plastic honeycomb body shown in FIG. 7 is widely known. I have. Further, as shown in a cross section in FIG. 9, FIG.
In FIG. 9, the fiber layer 4 is bonded to the surface of the plastic honeycomb body shown in (1), that is, the outer surface layer on the front side when the plastic honeycomb body is actually used, in the example of FIG. The laminate 7 is also used, for example, as an interior member for a vehicle.

[0004] A plastic honeycomb body as described above, or a laminated body 7 in which a fiber layer 4 is bonded to the surface side thereof
Are formed in accordance with the form of a mounting portion such as a vehicle or a house in which these are mounted as interior members. At that time, conventionally, after heating and softening the plastic honeycomb body or the laminated body 7, as shown in FIG. 12, molding dies 5 and 6 provided with a cavity and a projection having a shape corresponding to the cavity are used. To form a desired shape. However, at the time of this molding, as shown in FIG. 13, one outer surface layer 2 and the other outer surface layer 3 are stretched along the molding surfaces of the molds 5 and 6 to become thinner. Side wall 13 buckles due to the pressure during molding, and the height of the side wall 13 decreases.
The thickness of the plastic honeycomb body is reduced. The portion of the side wall 13 is stretched at the time of processing the concave portion 11 of the embossed layer 1 and is already thin, so that it cannot be recovered once buckled, and the compressive strength of the plastic honeycomb body is reduced.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to eliminate the above-mentioned conventional disadvantages and to provide a molding method capable of molding a plastic honeycomb body in a desired form in a short time with a simple pressing die, and a molded plastic honeycomb. An object of the present invention is to provide an interior member having a body.

[0006]

According to the present invention, in order to achieve the above object, a plastic honeycomb body is placed on a receiving mold provided with a cavity having a desired shape such that the surface side thereof is in contact with the receiving mold. The present invention proposes a method for forming a plastic honeycomb body, which comprises pressing a plastic honeycomb body into a cavity while softening and melting the plastic honeycomb body by using a hot blade erected on a pressing die from the back side thereof.

In this case, the plastic honeycomb body may be constituted by an embossed layer having a plurality of recesses, and a flat outer surface layer adhered to the recess opening side of the embossed layer.

Further, the plastic honeycomb body has an embossed layer having a plurality of recesses, a flat outer surface layer adhered to the recess opening side of the embossed layer, and a flat shaped layer adhered to the back surface of the embossed layer. And an outer surface layer.

Further, in each of the above-mentioned configurations, it is also possible to provide a configuration in which a fiber layer is bonded to the surface side of the plastic honeycomb body.

In order to achieve the above object, the present invention provides an embossed layer having a plurality of recesses, a flat outer surface layer adhered to the recess opening side of the embossed layer, and a back surface of the embossed layer. The present invention proposes an interior member having a plastic honeycomb body composed of an adhered flat outer layer and a honeycomb body softened and melted by a hot blade pressed from the back side.

Further, in order to achieve the above object, the present invention provides an embossed layer having a plurality of concave portions, a flat outer layer adhered to the concave portion opening side of the embossed layer, and a concave back surface of the embossed layer. It has a plastic honeycomb body composed of an adhered flat outer layer and a laminate composed of a fiber layer bonded to the front side of the plastic honeycomb body, and the plastic honeycomb body is pressed from the back side. The present invention proposes an interior member that is softened and melted by a hot blade.

[0012]

The plastic honeycomb body forming method of the present invention is configured as described above. Therefore, when the plastic honeycomb body is pressed into the receiving mold cavity while the plastic honeycomb body is softened by the press-type hot blade. The portion of the plastic honeycomb body that has contacted the hot blade is melted to form a molten sidewall around the hot blade. Further, the plastic honeycomb body portion other than the honeycomb molded body portion in contact with the hot blade and a portion in the vicinity thereof is not compressed at the time of the extrusion molding and does not buckle. Therefore, by forming the molten side wall, the compressive strength of the plastic honeycomb body or the interior member having the honeycomb body is improved as compared with before the molding.

[0013]

Embodiments of the present invention will be described below in detail with reference to the drawings.

FIG. 3 shows an example of a vehicle interior member formed by the forming method according to the present invention. The shape of the interior member shown here is a plate-like body having a bulge along the longitudinal direction in the central region of FIG. The material before molding, that is, the plastic honeycomb body is a plastic honeycomb body in which flat outer layers 2 and 3 are adhered to each side of the embossed layer 1 shown in FIG. The embossed layer 1 is formed by forming a concave portion from a 0.35 mm polypropylene sheet by a vacuum forming method.
25 mm polypropylene sheet. Thus, the overall thickness of the plastic honeycomb body composed of a plurality of layers is about 5
mm, the recess is a hole having a diameter of about 5 mm. Then, on the surface side of the plastic honeycomb body, in this example, one outer surface layer 2 thereof
A fiber layer 4 made of a nonwoven fabric of 400 g per square meter is adhered to the surface of the laminate, and the whole constitutes a laminate 7 shown in FIG. In some cases, the other side of the outer surface layer 3 is the surface side of the plastic honeycomb body, and the fiber layer 4 is bonded to the surface side, and that side is the surface side of the laminate. In the following description, one outer layer 2 is referred to as a first outer layer and the other outer layer 3 is referred to as a second outer layer, as necessary.

FIG. 1 is a cross-sectional view for explaining the outline of a molding apparatus for carrying out the present invention. The receiving die 8 is provided with a cavity 81 having a shape corresponding to a desired shape to be molded on a molding surface 82, similarly to the conventional molding die 5 shown in FIG. In FIG. 1, the heating mechanism for softening and melting the material to be molded is omitted.

The base end of a plurality of plate-like hot blades 91 is fixed to the pressing die 9, and each of the hot blades 91 protrudes toward the receiving die 8. These hot blades 91 are maintained at a constant temperature of 100 to 250 ° C. by a heating device (not shown) provided in the press die 9. The tip of the hot blade 91 is rounded, and is subjected to an anti-adhesion treatment using a fluororesin or the like. Each hot blade 91 is formed on the molding surface 82 of the receiving die 8.
Of the cavity 81
Are formed longer than other heat blades. Thus, when the press die 9 is lowered, the tips of the hot blades 91 are located in a state of being arranged along the molding surface 82 of the receiving die 8. The interval between the hot blades 91 is, for example, 10 to 3
At about 0 mm, at least, upright ridges defining a cavity 81, i.e. a ridge line T ₁ defining the bottom surface of the cavity 81, the Netsuha 91 at a position corresponding to the ridge line T ₂ forming the outer shape of the cavity 81 It is preferable to keep it.

In molding, first, the laminate 7 is placed on the surface side, that is, the first outer surface layer 2 of the plastic honeycomb body.
Is placed so that the fiber layer 4 adhered to the receiving mold 8 is in contact with the receiving mold 8. In this way, the plastic honeycomb body is placed on the receiving die 8 provided with the cavity 18 of a desired form such that the surface side thereof is in contact with the receiving die 8. In the case of the laminate 7 in which the fiber layer 4 is bonded to the surface side of the plastic honeycomb body as in this example, the laminate 7 is placed on the receiving mold 8 so that the fiber layer 4 is in contact with the receiving mold 8. Place. Next, when the press die 9 is lowered, first, the most protruding hot blade 91 comes into contact with the back surface side of the laminated body 7, in this example, the second outer surface layer 3 of the plastic honeycomb body, and presses down that portion. As the descent further proceeds, another hot blade 9
1 contacts the second outer layer 3 and pushes it down. During this time, the softening and melting progresses from the portion of the second outer surface layer 3 with which the heat blade 91 is in contact, and the portion of the embossed layer 1 is softened by heat transfer. As described above, the plastic honeycomb body is pressed into the cavity 81 and molded while the plastic honeycomb body is softened and melted by the hot blade 91 erected from the back surface side of the plastic honeycomb body on the pressing die 9.

The final stage of the lowering of the pressing die 9 is when the tip of the hot blade 91 reaches the first outer surface layer 2 as shown in FIG. 2, and is further pressed by a stopper (not shown). 9 does not drop. At this stage, the fiber layer 4 of the laminate 7 is pressed against the molding surface of the receiving die 8,
The periphery of the portion of the embossed layer 1 that is in contact with the hot blade 91, as well as the portion of the second outer surface layer 3 that is in contact with the hot blade 91, is almost completely melted and fused. A molten side wall 18 is formed on the substrate.

Then, when the pressing die 9 is pulled up, an interior member made of the molded body shown in FIG. 3 is obtained. When the dimensional accuracy of the shape is particularly required, the molded body is furthermore shown in FIG.
As shown in the above, cooling is performed under pressure by upper and lower cooling dies having a mold surface corresponding to a desired shape.

The plastic honeycomb body portion of the laminate 7 thus formed is subjected to a molding pressure over the entire surface of the first outer layer 2 and the second outer layer 3 during the molding, as in the conventional molding method. Unlike the receiving blade, the molding pressure is directly received only around the hot blade 91, so that the side wall 13 of the concave portion 11 does not buckle. Further, since the plastic honeycomb body is locally softened by the heat of the hot blade 91, the force required for molding is small and the molding time is shortened.
In addition, since the molten side wall 18 is formed between the first outer surface layer 2 and the second outer surface layer 3, not only the compressive strength of the plastic honeycomb body before molding is maintained, but also it is more than doubled. There are cases. In addition, a concave groove 71 in the trace of the heat blade 91 remains on the rear surface side of the molded interior member, but when the interior member is mounted on a vehicle, the rear surface side is hidden. It does not appear outside, and there is no problem at all.

In this forming method, the interval between the hot blades 91 is appropriately determined depending on the structure of the plastic honeycomb body and the shape to be formed.
It is preferable that the diameter be about 1.5 to 5 times the diameter of 1 or the gap between adjacent concave portions. If the distance is too wide, the first outer layer 2
Cannot be formed into a desired smooth shape. Similarly, the descending speed of the pressing die 9 is also appropriately determined depending on the structure of the plastic honeycomb body and the shape to be molded. Further, the melting temperature of each sheet constituting the plastic honeycomb body, the temperature of the hot blade 91, and the like. Also need to be considered. If the temperature of the hot blade 91 is too high,
The outer surface layer 3 is quickly melted, the tip of the hot blade 91 melts the first outer surface layer 2 and reaches the fiber layer 4, and the fiber layer 4 is scorched or the portion pressed by the hot blade 91 becomes square. As a result, a molded product having a smooth outer surface may not be obtained. Conversely, hot blade 9
If the temperature of (1) is too low, the molding time is prolonged, and it is necessary to increase the pressing pressure of the pressing die 9, and when the pressing die 9 is pulled up, it returns elastically and cannot be formed into a predetermined shape. is there.

The arrangement of the hot blades is also determined by the shape of the molded product to be molded. FIG. 4 is a cross-sectional view of a pressing die 95 for forming a hemispherical convex portion, and FIG. 5 is a plan view of the pressing die 95 as viewed from the tip side of the hot blade. In this example, the hot blades 96 are circular and are arranged so as to be concentric. FIG. 6 is a plan view of a hot blade 98 of a press die 97 for forming a ridge roof-like convex portion as viewed from the front end side. In this case as well, it is preferable that the hot blade 98 be provided upright at least at a position corresponding to the ridgeline that defines the cavity of the receiving mold.

In the above embodiment, a case is shown in which the laminate shown in FIG. 9 in which the fiber layer is bonded to the plastic honeycomb body having the sandwich structure shown in FIG. 8 is used as the plastic honeycomb body. The single-plate plastic honeycomb body described above with reference to FIG. 8 or the plastic honeycomb body shown in FIG. 8 can also be used. That is,
The plastic honeycomb body that can be formed by the method according to the present invention includes, for example, an embossed layer 1 having a plurality of recesses 11, and a flat outer layer 2 attached to the recess opening side of the embossed layer 1, Alternatively, an embossed layer 1 having a plurality of recesses 11, a flat outer surface layer 2 adhered to the concave opening side of the embossed layer 1, and a flat outer surface layer adhered to the concave back surface 12 of the embossed layer 1 3). Alternatively, as described in the previous embodiment, the laminate 7 in which the fiber layer 4 is bonded to the surface side of each of the plastic honeycomb bodies, that is, the surface of the first outer layer 2 or the second outer layer 3 is used. , Can also be used as the material.

The embossing layer 1 having the plurality of recesses 11, the flat outer layer 2 adhered to the recess opening side of the embossing layer 1, and the embossing layer 2 are formed by the molding method as shown in the above-described embodiment. It has a plastic honeycomb body composed of a flat outer layer 3 adhered to the concave back surface 12 of the layer 1, and the honeycomb body is softened and melted by the hot blades 91, 96, 98 pressed from the rear surface side. Thus, an interior member formed by molding can be obtained. Similarly, an embossed layer 1 having a plurality of recesses 11, a flat outer surface layer 2 adhered to the recess opening side of the embossed layer 1, and a flat shaped layer adhered to the recessed back surface 12 of the embossed layer 1. It has a laminated body 7 composed of a plastic honeycomb body composed of an outer surface layer 3 and a fiber layer 4 bonded to the front surface side of the plastic honeycomb body, and the plastic honeycomb body has a hot blade pressed against the rear surface side thereof. According to 91, 96, 98, the interior member molded by softening and melting can be obtained.

A large number of side walls 15 are provided between outer layers 25 and 35 composed of two flat plates as shown in FIG.
A plastic honeycomb body having a continuous space formed therein, as shown in FIG. 11, an outer layer 26, 36 made of two so-called cardboard-shaped flat plates, and a corrugated emboss layer 16 therebetween. The plastic honeycomb body can be formed into a desired form by the method according to the present invention, and a predetermined interior member can be obtained. In any case, a fiber layer may be bonded to the surface.

As the plastic material of each layer constituting the plastic honeycomb body, various thermoplastic resins can be used, but general-purpose polyolefins, especially polypropylene-based or polyethylene-based materials are advantageous in terms of moldability and cost. is there.

The interior member molded according to the present invention can be widely used not only for vehicles, but also for interior members for houses and interior members of various other facilities.

[0028]

According to the method for forming a plastic honeycomb body according to any one of claims 1 to 4, when the plastic honeycomb body is pressed into the receiving mold cavity while the plastic honeycomb body is softened by the hot blade of the pressing die. Since the plastic honeycomb body portion in contact with the hot blade is melted to form a molten side wall around the hot blade, the plastic honeycomb body portion other than the portion of the plastic honeycomb body in contact with the hot blade and the vicinity thereof is It is not compressed at the time of the extrusion molding and does not buckle. Therefore, the interior member formed by this method, particularly, claim 5
In the interior member described in (1) and (6), the formation of the molten side wall improves the compressive strength of the plastic honeycomb body before molding, and the use of the molded interior member is expanded.

In the method according to any one of the first to fourth aspects, the plastic honeycomb body is molded while being softened or melted by the heat of the hot blade, so that the molding force required for molding is smaller than that of the conventional method. And the molding time can be shortened. Further, the press die including the hot blade has a simple structure, and can be manufactured in a short time by combining members.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of an apparatus for performing a molding method of the present invention.

FIG. 2 is a cross-sectional view of the device at the final stage of molding.

FIG. 3 is a cross-sectional view showing an example of a product formed by the forming method of the present invention.

FIG. 4 is a cross-sectional view showing another example of the arrangement of the press die and its hot blade.

FIG. 5 is a plan view of the push-type hot blade shown in FIG.

FIG. 6 is a plan view of another example of the pressing die as viewed from the tip of the hot blade.

FIG. 7 is a perspective view showing an example of a plastic honeycomb body.

FIG. 8 is a perspective view showing another example of the plastic honeycomb body.

9 is a cross-sectional view of a laminate in which a fiber layer is attached to an outer surface layer of the plastic honeycomb body shown in FIG.

FIG. 10 is a perspective view showing another plastic honeycomb body.

FIG. 11 is a perspective view showing still another plastic honeycomb body.

FIG. 12 is a cross-sectional view of a mold including a laminate for explaining a conventional molding method.

FIG. 13 is a partially enlarged cross-sectional view of a laminate formed by a conventional method.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 embossed layer 2 outer surface layer 3 outer surface layer 4 fiber layer 7 laminate 8 receiving die 11 concave portion 12 concave back surface 9 press die 81 cavity 91 hot blade 95 press die 96 hot blade 97 press die 98 hot blade

Claims (6)

(57) [Claims] 1. A plastic honeycomb body is placed on a receiving mold provided with a cavity of a desired shape such that the front surface side of the plastic honeycomb body is in contact with the receiving mold, and a hot blade is erected from a rear surface side of the pressing die. A method for forming a plastic honeycomb body, wherein the plastic honeycomb body is softened and melted and pressed into a cavity to be formed. 2. The plastic honeycomb body according to claim 1, wherein the plastic honeycomb body includes an embossed layer having a plurality of recesses, and a flat outer surface layer adhered to the recess opening side of the embossed layer. Method. 3. A plastic honeycomb body comprising an embossed layer having a plurality of recesses, a flat outer surface layer adhered to the recess opening side of the embossed layer, and a flat shape adhered to the back surface of the embossed layer. The method for forming a plastic honeycomb body according to claim 1, comprising an outer surface layer. 4. The method for forming a plastic honeycomb body according to claim 1, wherein a fiber layer is bonded to a surface side of the plastic honeycomb body. 5. An embossed layer having a plurality of concave portions, a flat outer surface layer adhered to the concave portion opening side of the embossed layer, and a flat outer surface layer adhered to the back surface of the concave portion of the embossed layer. An interior member having a plastic honeycomb body, wherein the honeycomb body is softened and melted by a hot blade pressed from the back side thereof. 6. An embossed layer having a plurality of recesses, a flat outer surface layer adhered to the recess opening side of the embossed layer, and a flat outer surface layer adhered to the back surface of the recessed portion of the embossed layer. Plastic honeycomb body, and a laminate comprising a fiber layer bonded to the front surface side of the plastic honeycomb body, the plastic honeycomb body is softened and melted by a hot blade pressed from the back surface side and molded. An interior member characterized in that: