JP3103724B2 - Laminate manufacturing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for manufacturing a laminate used for a vehicle door trim, a vehicle interior material, an indoor interior material, an exterior material of a vehicle seat, and the like.

[0002]

2. Description of the Related Art As one type of laminate used for the above-mentioned applications, a full-surface skin material made of resin is adhered to the entire surface of one side surface of a wooden molding base or a resin molding base formed in the shape of a door trim. A door trim in which a resin partial skin material made of another color or a material is applied to a part of the surface of the entire skin material in consideration of designability is known. As a method of applying the partial skin material, usually, a method of masking a part of the entire skin material, and then applying a resin to be a partial skin material by coating to an unmasked area, or a sheet-like method is used. In this method, the partial skin material formed on the entire surface is adhered to a predetermined portion of the entire skin material by sticking.

[0003]

However, when the partial skin material is applied by the above-mentioned conventional method, the entire skin material must be formed in a sheet shape in advance. Requires a separate apparatus and process. And in the method of applying the partial skin material by coating, since a masking step, a coating step, and a demasking step are performed, a series of many steps are necessary, and a member for masking is required, and the surface coating is performed. There is a problem that it can be applied only to the entire surface material of a possible material. On the other hand, in the method of applying the partial skin material by sticking, it is necessary to form the partial skin material in a sheet shape in advance, and in addition, the end of the partial skin material after sticking is grained. , And as a result, there is a problem that the number of manufacturing steps is large and complicated.

[0004]

SUMMARY OF THE INVENTION Accordingly, the present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a manufacturing apparatus for manufacturing a laminate in which a skin material made of a material different from one part to another is manufactured in a simple process. With the goal.

[0005]

Means for Solving the Problems The present invention according to claim 1, which has been made to achieve the above object, comprises a substrate and a plurality of sections which cover and partition the front surface of the substrate. An apparatus for manufacturing a laminate comprising a skin material and a skin material made of a resin material in which adjacent portions of the plurality of portions are different from each other, wherein the manufacturing apparatus has a shape of a back surface of a base material. A substrate-side molding die having a combined molding surface, and a molding surface adapted to the shape of the surface of the skin material, the base material being formed during polymerization of both molds along a boundary line that partitions a plurality of portions of the skin material. A skin material-side molding die having a molding surface composed of a plurality of partial molding surfaces partitioned by a boundary wall provided so as to abut, a substrate set on a molding surface of the substrate-side molding die, and Each part of the skin material is configured between the partial molding surface and A plurality of supply means for supplying a resinous material in a molten state, and curing the molten resinous material in a polymerization state of both molds to integrate the base material and the skin material to produce a laminate. It is characterized by being a manufacturing apparatus that can perform.

According to a second aspect of the present invention, in place of the skin material-side forming die according to the first aspect, a plurality of resin-based materials constituting a plurality of portions of the skin material are divided. A skin material side molding die comprising a partial molding die, wherein each of the partial molding dies is at least one of a plurality of partial molding surfaces partitioned along a boundary line that partitions a plurality of portions of the skin material. Surface mold, having a boundary wall so as to be in contact with the base material at the time of polymerization of the partial mold and the base mold along the outer periphery of the respective partial mold surfaces. Features.

[0007] The apparatus for producing a laminate according to claim 1 or 2 is supplied between the substrate-side molding die and the skin material-side molding die and the front surface of the substrate. An apparatus for manufacturing a laminate by pressing a molten resin-based material and curing the molten resin-based material, wherein the boundary wall is urged in the direction of the substrate-side molding die, and A movable boundary wall that is capable of moving back and forth with respect to the base and abutting the base material during polymerization of the two molds to prevent the supplied molten resin material from flowing beyond the boundary line. .

[0008]

When a laminate is manufactured by using the apparatus for manufacturing a laminate according to the present invention having the above-described structure, the mold for the substrate-side molding die is required. By setting the base material on the molding surface and curing the plurality of molten resin-based materials supplied to the front surface of the base material between the two molds, the base material surface is formed of different resin-based materials. Can be manufactured by coating with a skin material composed of

At this time, since the boundary wall is provided on the skin material side molding die, it is possible to prevent the resin-based material from flowing to an adjacent portion beyond the boundary wall. In particular, if the boundary wall is a movable boundary wall which can be urged in the direction of the substrate-side molding die and can advance and retreat with respect to the substrate-side molding die, as described in claim 3, both moldings are possible. When the mold is approached, first, the movable mold boundary wall comes into contact with the base material, so that the effect of preventing the molten resin-based material from flowing in the direction of the adjacent partial molding surface is sure.

[0010] In the laminate thus manufactured, since the resin-based material constituting each part of the skin material does not mix with the resin-based material constituting the adjacent part, the boundary line between the adjacent parts is reduced. It becomes a laminate of an excellent design with a clear and beautiful appearance. According to the apparatus for manufacturing a laminate of the present invention, there is no need to perform the step of forming the skin material, which is indispensable in the conventional manufacturing apparatus, and it is also advantageous in that the manufacturing steps can be shortened.

In the invention described in claim 2, since the molding die is divided into partial molding dies according to the types of resin-based materials constituting a plurality of portions of the skin material, for example, the substrate-side molding die is used. By using a turntable in which each partial mold is set at a predetermined position and shared, or by using a continuous molding process in which each partial mold is set in the process of transporting the substrate-side mold, different resin-based materials are used. The respective portions of the skin material composed of can be sequentially and efficiently formed.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As a preferred embodiment of an apparatus for manufacturing a laminate according to the present invention, an apparatus for manufacturing a door trim for a vehicle is employed, and the apparatus will be described below with reference to the drawings.

The door trim manufactured by the manufacturing apparatus of this embodiment is a door trim 10 for an automobile as shown in FIGS. 1 and 2, and a base material 11 formed in the shape of a door trim and a base material 11 A first skin material 12 covering a part of the front side surface of the base material 11 and a second skin material 13 covering another part of the same base material 11 (the first skin material 12 and the second skin material 13 are defined by the present invention). And a part of the skin material 12 is decorated with an ornament 14 as needed. The base material 11 is made of a wood-based molded body formed by maintaining the porosity of an aggregate obtained by adding and mixing a phenolic resin as a binder to a main material such as wood chips, fibers, and powder. (2) The skin material is a polypropylene resin to which different coloring agents are added in consideration of design properties (the polypropylene resins to which the different coloring agents are added correspond to different resin-based materials constituting adjacent portions of the present invention, respectively). ). The joint between the porous base material 11 and the first skin material 12 and the second skin material 13 is impregnated and filled in the pores inside the porous base material 11 with the polypropylene resin forming both the skin materials 12 and 13. The porous substrate 11 and the two skin materials 12, 13 are joined together by an anchor effect.

FIG. 3 shows a door trim 10 having such a structure.
1 shows a first embodiment of an apparatus for producing a lower mold 20 (a base-side molding die of the present invention) having a molding surface 20a formed in conformity with the shape of the rear surface of a door trim. And an upper mold 21 (corresponding to a skin material side molding die of the present invention) on which a molding surface 21a engraved with a grain for forming a design pattern on the surface of the skin material is formed. Lumber 1
A molten resin 12melt serving as the first skin material 12 is provided on the upper surface of the lower resin mold 1 with a molten resin supply passage 22 formed inside the lower mold 20 (the resin supply passage 22 has a
A heater 23 is provided to prevent the temperature of 2 melt from hardening. ), And a molten resin supply passage 25 formed inside the upper mold 21 with the molten resin 13melt to be the second skin material 13 (the resin supply passage 25 is filled with the molten resin 13melt during the supply). A heater 26 is provided to prevent the temperature from hardening). The molten resin supply passage 22, the heater 23 and the injection device 24, and the molten resin supply passage 25, the heater 26 and the injection device 27 correspond to a plurality of supply units of the present invention. The molding surface 21a of the upper mold 21 has both molds 2
When 0 and 21 are polymerized, the molten resin becomes 12 melt or 1
A boundary wall 21a1 is provided so that 3melt does not flow toward the skin material 13 or the skin material 12, respectively.

When manufacturing the door trim using the manufacturing apparatus of the first embodiment, the temperature must be set at 50.degree.
First, a porous substrate 11 made of a wood-based molded body in the shape of a door trim is set on the molding surface 20a of the lower mold 20 of the molding dies 20 and 21 adjusted to a temperature of ℃. 21 is polymerized. Subsequently, in a gap between the porous base material 11 and the molding surface 21a of the upper mold 21, a polypropylene resin 12melt serving as the first skin material 12 and a polypropylene resin 13melt serving as the second skin material 13 mixed with different coloring agents, respectively. In a molten state (180 ° C. to 200 ° C.) using the injection device 24 and the injection device 27 at a high pressure (100 to 300 ° C.).
kg / cm ² ). Injected molten resin 12mel
t, 13 melt spreads over the entire surface of the porous substrate 11.
At this time, the molten resin 12 melt and the molten resin 13 melt spread so as to cover the entire surface of the porous substrate 11.
On the boundary lines 2 and 13, the boundary wall 21a1 completely prevents the flow to the regions adjacent to each other. The molten resin 12 melt supplied to the entire surface of the porous substrate 11 in this manner
And 13melt are impregnated so as to fill at least the pores on the front side inside the porous base material 11, and the molten resins 12melt and 13melt are cured as they are, and the entire surface on the front side surface of the porous base material 11 has a different color tone. Skin material 12, consisting of
A door trim 10 covered with 13 is formed.

In the description of the manufacturing process of the door trim using the manufacturing apparatus of the first embodiment, both the molds 20 and 21 will be described.
The two molten resins 12melt and 13melt are supplied in a state in which both the molten resins 12melt and 13melt are polymerized.
lt), the two molds 20 and 21 are polymerized, the molten resin (12 melt) is spread and cured, and then the other molten resin (for example, molten resin 1) is polymerized in this polymerization state.
3melt) and the molten resin (13melt) may be cured to form the door trim 10.

In the manufacturing apparatus according to the first embodiment, as a means for supplying both molten resins 12melt and 13melt, the molten resin supply passages 22 and 21 formed inside the molds 20 and 21 by the injection devices 24 and 27, respectively. Although the means for injecting through 25 is adopted, instead of the supply means by this injection,
As a means for supplying at least one of the molten resin 12 melt and the molten resin 13 melt, the molten resin 1
A supply unit using a discharge device that discharges and supplies 2 melt or 13 melt may be adopted.

Further, in the manufacturing apparatus of the first embodiment, the molten resin supply passages 22 and 25, which are injection paths of the molten resins 12melt and 13melt, are formed inside the molding dies 20 and 21, respectively. Both of the molten resin injection paths may be formed inside either one of the molds.

Next, as a second embodiment of the apparatus for manufacturing a laminate according to the present invention, the door trim 1 shown in FIGS.
An apparatus for manufacturing the O. 0 will be described with reference to FIG.

The apparatus according to the second embodiment employs an upper die 31 (corresponding to a skin material side forming die of the present invention) as shown in FIG. 4 instead of the upper die 21 used in the manufacturing apparatus of the first embodiment. ), And is different from the manufacturing apparatus of the first embodiment only in that the door trim 10 is manufactured by pressing between both the molds 20 and 31. The upper mold 31 has a molten resin 13 melt inside.
Resin supply passage 32 for supplying the molten resin from the injection device 34 (note that the molten resin 1
A heater 33 is provided to prevent the temperature of 2 melt from hardening. ) Is formed, and both molds 2 are formed on the molding surface 31a.
A movable boundary wall 35 for preventing the molten resins 12melt and 13melt from flowing into the regions of the skin materials 13 and 12 at the time of polymerization of 0 and 31, respectively, is provided by being biased toward the lower mold 20 by a spring 36. It is characterized by having been done.

When the door trim 10 is manufactured using the manufacturing apparatus of the second embodiment, first, the door trim 10 is previously set to 50 ° C.
The porous substrate 11 made of a wood-based molded body is set on the molding surface 20a of the lower mold 20 adjusted to a temperature of about 80 ° C. Subsequently, the upper die 31 is lowered onto the lower die 20, and when the movable boundary wall 35 comes into contact with the porous substrate 11, the molten resins 12 melt and 13 melt are injected into the surfaces of the porous substrate 11 by the injection devices 24 and 34.
Supply using And this molten resin 12 melt, 13
After the injection of the melt is completed, the upper mold 31 is further lowered to terminate the press, and the molten resin 12melt and 13melt are cured in this state, whereby the desired door trim 10 is manufactured.

In the manufacturing apparatus of the second embodiment, the molten resin supply passages 22 and 32 formed inside the two molds 20 and 31 by the injection devices 24 and 34 are used as the supply means for the molten resins 12 melt and 13 melt. Although a means for injecting the molten resin is used, at least one of the molten resin 12melt and the molten resin 13melt is supplied on the porous substrate 11 instead of the supply means by the injection.
Supply means using a discharge device that discharges and supplies lt or 13 melt may be employed.

In the manufacturing apparatus of the second embodiment, the molten resin supply passages 22, 32, which are the injection paths for the molten resins 12melt, 13melt, are formed inside the molding dies 20, 31. Both of the molten resin injection paths may be formed inside either one of the molds.

Next, as a third embodiment of the apparatus for manufacturing a laminate according to the present invention, the door trim 1 shown in FIGS.
An apparatus for manufacturing the “0” will be described with reference to FIG.

The apparatus for manufacturing a door trim according to the third embodiment includes two lower dies 40, 40 'having the same shape and installed at symmetrical positions of a turntable 50 (each of which corresponds to a substrate side molding die of the present invention). ), And the first upper die 41 and the second upper die 42 attached to the position corresponding to the rotation stop position of the turntable 50 (the first upper die 41 and the second upper die 42 It corresponds to a plurality of partial molds of the present invention.)
On the upper surface of the porous base material 11, a molten resin 12 melt serving as the first skin material 12 is supplied to the molten resin supply passages 44, 44 ′ formed inside the lower molds 40, 40 ′ (the resin supply passages 44, 44 ′). 44 ′ are provided with heaters 45 and 45 ′ for preventing the temperature of the molten resin 12melt from hardening during the supply, and an injection device 46 for injecting the molten resin 12melt through the second skin material 13. The molten resin supply passages 47 and 47 ′ formed inside the lower molds 40 and 40 ′ with the 13 melt (the molten resin 1
Heaters 48,4 to prevent 3melt temperature from hardening
8 'is provided. Injector 4 for injecting through
9 is a main component. The molten resin supply passage 44 (44 '), the heater 45 (45') and the injection device 46, and the molten resin supply passage 47 (47 '), the heater 48 (48') and the injection device 49 are a plurality of the present invention. Of supply means.

The two lower molds 40, 40 'have molding surfaces 40a, 4 respectively corresponding to the shape of the rear surface of the door trim.
0′a is formed, and the first upper mold 41 and the second upper mold 42 are each engraved with a grain for forming a design pattern in a shape corresponding to the shape of the surface of the first skin material. Forming surface 41a and a forming surface 42a having a shape conforming to the shape of the surface of the second skin material and having a texture formed thereon to form a design pattern. And these upper dies 41, 4
The lower mold 40 (40 ') and the first upper mold 41 are superimposed on the molding surfaces 41a and 42a of the second mold 41 or the lower mold 40'.
When (40) and the second upper mold 42 are polymerized, the molten resin 12melt or the molten resin 13melt is
a, 40'a, a boundary wall 41a1, for preventing flow to the second skin material 13 side or the first skin material 12 side.
42a1 is provided.

When manufacturing the door trim 10 using the door trim manufacturing apparatus of the third embodiment, first,
The porous base material 11 made of a wood-based molded body is set on two lower molds 40 and 40 ′ which are previously adjusted to a temperature of 50 ° C. to 80 ° C., and the lower molds 40 and 40 ′ are set on the respective lower molds 40 and 40 ′. The first upper mold 41 and the second upper mold 4 adjusted to the temperature
2 is allowed to fall to polymerize. Subsequently, a gap between the porous substrate 11 and the molding surface 41a of the upper mold 41, and the porous substrate 11
In the gap between the upper mold 42 and the molding surface 42a, a polypropylene resin 12melt serving as the first skin material 12 and a polypropylene resin 13melt serving as the second skin material 13 mixed with different coloring agents are melted (at 180 ° C. (200 ° C.) at a high pressure (100 to
Inject at 300 kg / cm ² ). The injected molten resin 12melt and 13melt are the first of the porous substrate 11 respectively.
It extends to the formation surface of the skin material 12 and the formation surface of the second skin material 13. At this time, the molten resin 12melt and the molten resin 13melt
Boundary walls 41a1 and 42a1 provided on both upper dies 41 and 42 completely prevent flow to regions adjacent to each other. The molten resin 12melt and 13melt thus supplied to the surface of the porous substrate 11 are impregnated so as to fill at least the front-side holes inside the porous substrate 11,
As it is, the molten resin 12melt and 13melt harden,
The first skin material 12 is provided on the porous base material 11 set on the lower mold 40, and the porous base material 11 set on the lower mold 40 'is also provided.
Is coated with a second skin material 13.

Next, after the upper dies 41 and 42 are once raised, the turntable 50 is rotated 180 degrees to lower the lower dies 40 and 42.
And the lower mold 40 ′ are disposed at positions where they overlap the upper mold 42 and the upper mold 41, respectively. Subsequently, the molten resins 13melt and 12melt are supplied to the surfaces of the respective porous substrates 11 by the injection devices 49 and 46 in a state where the upper molds 42 and 41 are lowered to the lower molds 40 and 40 ', respectively. Let it cure. Also at this time, the molten resins 13melt and 12melt are applied to the boundary wall 42a.
The flow is blocked by 1, 41a1 and does not enter the regions adjacent to each other. Thus, the entire surface of the porous substrate 11 is covered with the skin material 1 made of a resin having a different color tone.
2 and 13 to form a door trim 10.

In the description of the manufacturing process of the door trim using the manufacturing apparatus of the third embodiment, the lower mold 40 (40 ')
In the state where the upper molds 41 and 42 are polymerized, both molten resins 12me
lt and 13melt are supplied. Before the lower mold 40 (40 ') and the upper molds 41 and 42 are polymerized, the molten resin 12melt and 13melt are supplied onto the porous substrate 11 and then the lower mold 40 is melted.
(40 ') and the upper molds 41 and 42 may be polymerized, and the molten resins 12melt and 13melt may be spread and then cured.

Further, in the manufacturing apparatus of the third embodiment, the molten resin supply passage 44 (formed in the lower mold 40 (40 ') by both the injection devices 46 and 49 as a supply means of the molten resins 12 melt and 13 melt. 44 '), 47 (47')
Is adopted, but instead of the supply means by this injection, the molten resin 12 melt and the molten resin 13 are used.
As at least one supply means of the melt, the porous substrate 1
A supply unit using a discharge device that discharges and supplies the molten resin 12melt or 13melt onto the unit 1 may be employed.

In the manufacturing apparatus of the third embodiment, the molten resin supply passages 44,
44 ′ and the molten resin supply passages 47 and 47 ′, which are the injection paths of the molten resin 13melt, are all formed in the lower molds 40 and 40 ′. Alternatively, the injection path of the molten resin 13melt may be formed inside the upper mold 42.

In the manufacturing apparatus of the third embodiment, the lower dies 40 and 40 'are set on the turntable 50 and
The upper and lower dies 40 and 40 'are arranged at positions corresponding to the stop positions of the lower dies 40 and 40'. May be configured in a manufacturing apparatus capable of sequentially and successively forming the respective portions of the skin material made of.

Next, as a fourth embodiment of the laminate manufacturing apparatus of the present invention, the door trim 1 shown in FIGS.
The apparatus for manufacturing the “0” will be described with reference to FIG.

The apparatus of the fourth embodiment differs from the apparatus of the third embodiment in that a first upper mold 41 and a second upper mold 42 are used instead of the first upper mold 41 and the second upper mold 42 shown in FIG. Using a mold 51 and a second upper mold 52 (both upper molds 51 and 52 correspond to a plurality of partial molds of the present invention), the door trim 10 is attached to the lower mold 40 (40 ') and the upper molds 51 and 52. Only the point of manufacturing by press is different from the manufacturing apparatus of the third embodiment.
The lower mold 40 (40 ') is provided on the molding surface 51a of the upper mold 51.
A movable boundary wall 53 for preventing the molten resin 12melt from flowing into an adjacent region of the skin material 13 at the time of the polymerization is provided by being urged in the direction of the lower mold 40 (40 ') by a spring 54. It is characterized by the following. Similarly, upper mold 5
The movable molding boundary wall 55 for preventing the molten resin 13 melt from flowing to the region of the adjacent skin material 12 during polymerization with the lower mold 40 ′ (40) is also provided on the molding surface 52 a of the second spring 52.
6 urged in the direction of the lower mold 40 ′ (40).

When the door trim 10 is manufactured by using the manufacturing apparatus of the fourth embodiment, first, 50 ° C.
Molding surface 4 of lower dies 40, 40 'adjusted to a temperature of ~ 80 ° C
0a, 40'a, a porous substrate 11 made of a wood-based molded body
Is set. Subsequently, the upper dies 51 and 52 are lowered onto the lower dies 40 and 40 ', respectively, so that the movable boundary walls 53 and 55 are formed.
When the substrate comes into contact with the porous substrate 11, molten resins 12 melt and 13 melt are supplied to the surface of the porous substrate 11 by using the injection devices 46 and 49. And this molten resin 12melt, 13melt
When the injection is completed and the upper dies 51 and 52 are further lowered to end the pressing, the molten resin 12 melt
And 13 melt. At this time, the flow of the molten resin 12melt and the molten resin 13melt is completely blocked by the movable boundary walls 53 and 55, and the surface on which the skin 13 is formed and the skin 1
2 does not flow to the formation surface.

Next, after the upper dies 51 and 52 are once raised, the turntable 50 is rotated by 180 degrees and the lower dies 40 are rotated.
And the lower mold 40 'are disposed at positions where they overlap the upper mold 52 and the upper mold 51, respectively. Subsequently, the upper molds 52 and 51 are lowered to the lower molds 40 and 40 ', respectively, and the movable mold boundary walls 55 and
When the 53 comes into contact with the porous substrate 11, the molten resin 13 melt and 12 melt are injected into the surface of the porous substrate 11 by the injection devices 49 and 46.
Supply using And this molten resin 13 melt, 12
After the injection of the melt is completed, the upper dies 52 and 51 are further lowered to terminate the pressing.
The melt and 12 melt harden. At this time, the molten resin 13
The melt and the 12 melt are prevented from flowing by the movable boundary walls 55 and 53 and do not enter the regions adjacent to each other. In this manner, the entire surface of the porous substrate 11 is covered with the skin materials 12 and 13 made of resins of different colors, and the desired door trim 10 is formed.

In the manufacturing apparatus of the fourth embodiment, the molten resin supply passage 44 (formed inside the lower mold 40 (40 ') by the two injection devices 46 and 49 as a supply means of both molten resins 12 melt and 13 melt. 44 '), 47 (47')
Is adopted, but instead of the supply means by this injection, the molten resin 12 melt and the molten resin 13 are used.
As at least one supply means of the melt, the porous substrate 1
A supply unit using a discharge device that discharges and supplies the molten resin 12melt or 13melt onto the unit 1 may be employed.

In the manufacturing apparatus of the fourth embodiment, the molten resin supply passages 44,
44 ′ and the molten resin supply passages 47 and 47 ′, which are injection paths for the molten resin 13melt, are all formed in the lower molds 40 and 40 ′. Alternatively, the injection path of the molten resin 13melt may be formed inside the upper mold 52.

In the manufacturing apparatus of the fourth embodiment, the lower dies 40, 40 'are set on the turntable 50, and the upper dies 5
1, 52 are arranged at positions corresponding to the stop positions of the lower dies 40, 40 '. May be configured in a manufacturing apparatus capable of sequentially and successively forming the respective portions of the skin material made of.

The front molding surfaces 21a, 31a, 41a, 42 used in the manufacturing apparatus of the first to fourth embodiments.
As shown in FIGS. 3 to 6, the first, second and third skin materials a, 51 a, and 52 a are provided with a grain for forming a design pattern on the first skin material 12 and the second skin material 13. At the same time, the first skin material 12 and the second skin material 13 are coated and formed on the surface 11, and at the same time, a design pattern can be formed on the surfaces of the two skin materials 12 and 13.

In the first to fourth embodiments, the lower dies 20, 40 (40 ') are used as the molding dies on which the porous substrate 11 can be set, and the upper dies 21, 31, 41, 42,
The molds 51 and 52 are formed as molds on the skin material side provided with the boundary walls 21a1, 41a1 and 42a1 or the movable mold boundary walls 35, 53 and 55.
Instead of (40 '), 21, 31, 41, 42, 51, 52, a molding die having a molding surface corresponding to the shape of the front side of the door trim and having a boundary wall or a movable boundary wall is used as a lower die. A manufacturing apparatus provided with a pair of forming dies by adopting a forming die on which a porous substrate is set as the upper die may be used.

In the above-described first to fourth embodiments, the apparatus for manufacturing the door trim 10 in which the skin material is made of a resin material of two colors is used. In order to manufacture the door trim covered with the skin material, a manufacturing apparatus using a skin material side forming die having more partial forming surfaces may be used.

As a description of the operation of the manufacturing apparatus of the second embodiment and the fourth embodiment, a method of manufacturing a door trim in which a molten resin is supplied to a base material surface, pressed, and then cured as it is, is adopted. Using a foamable resin as a resin constituting, the foamable resin in a molten state in the base material was once pressed between a pair of upper and lower molding dies of this example to spread the foamable resin on the surface of the base material. Subsequently, by separating the pair of upper and lower molds by a predetermined amount, the foamable resin on the base material side is foamed and cured to form a foamed layer, and the foamable resin on the foamed layer is not foamed. If the skin layer is cured, an elastic skin material made of a foam layer can be easily manufactured.

In the description of the manufacture of the door trim by the manufacturing apparatus of the above-described first to fourth embodiments, the porous substrate made of a woody molded body is used, but the porous resin system made of a hard urethane foam or the like is used. A molded article may be used. In addition,
A porous resin-based molded product mainly composed of a thermosetting material such as phenolic resin, epoxy resin, polyester resin, or a thermoplastic resin such as polypropylene resin or ABS resin, to which a reinforcing agent or a conductive agent for antistatic is appropriately added. Also, there can be used a porous molded product obtained by press-molding a metal fiber, a molded product made of a carbon material, a molded product in which a porous resin is supported or laminated on a support made of lath metal or nonwoven fabric, or the like.

If the wettability between the base material made of these materials and the resin constituting the skin material, or between the base part of the ornament and the resin constituting the skin material is poor, the surface modification of a modified olefin or the like is performed. By applying or impregnating the filler on the surface of the base material or the base of the ornament to improve the permeability of the molten resin into the pores of the porous base or the base of the ornament, the joining of the respective joints Strength can be increased. For example, when the base material is a polypropylene resin and the skin material is vinyl chloride, a primer based on chlorinated polyolefin is used as the surface modifier.

In the description of manufacturing the door trim using the manufacturing apparatus of the first to fourth embodiments, since the porous base material 11 is used as the base material, the base material 11 and the skin material 12 are used.
It is not necessary to apply an adhesive to the base material or the skin material side, but for example, when non-porous thermoplastic resin such as ABS resin is used as the base material, A process such as applying an adhesive to the base material set in the side mold in advance is required. On the other hand, if non-porous polypropylene resin, which is a thermoplastic resin, is used as the base material, it is possible to bond the base material to the polypropylene constituting the skin material by welding. At this time, a surface modifier for enhancing the wettability between the base material and the skin material and performing reliable welding can be applied as necessary.

In the description of manufacturing the door trim using the manufacturing apparatus of the first to fourth embodiments, polypropylene resin is used as the skin material, but other olefin resins such as vinyl chloride, polyethylene, and ethylene- Propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid polymer, polyamide resin, AS
A thermoplastic resin such as resin A may be used alone or in combination of two or more. In addition, a gloss imparting agent for imparting gloss to the skin material, a flame retardant, or the like can be appropriately added in consideration of appearance, performance, and the like of the finished product.

As described above, the door trim 10 manufactured by the manufacturing apparatus according to the first to fourth embodiments has the resin material constituting each part of the skin material, that is, the first skin material 12 and the second skin material. Since it does not mix with the resin-based material constituting the adjacent portion, the boundary between the adjacent portions is sharp, and the door trim of an excellent design is maintained with an aesthetic appearance. According to such a door trim manufacturing apparatus, there is no need to perform the step of forming the skin material, which is indispensable in the conventional manufacturing apparatus, and it is also advantageous in that the manufacturing step can be shortened.

[Brief description of the drawings]

FIG. 1 is a perspective view of a door trim manufactured by one embodiment of an apparatus for manufacturing a laminate according to the present invention.

FIG. 2 is a longitudinal sectional view taken along line 2-2 in FIG.

FIG. 3 is a diagram showing an apparatus for manufacturing a door trim which is a first embodiment of the apparatus for manufacturing a laminate according to the present invention.

FIG. 4 is a view showing a door trim manufacturing apparatus which is a second embodiment of the laminated body manufacturing apparatus according to the present invention.

FIG. 5 is a diagram showing an apparatus for manufacturing a door trim which is a third embodiment of the apparatus for manufacturing a laminate according to the present invention.

FIG. 6 is a view showing a door trim manufacturing apparatus which is a fourth embodiment of the stack manufacturing apparatus according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... Door trim, 11 ... Porous base material, 12 ... 1st skin material, 13 ... 2nd skin material, 12melt, 13melt ... Molten resin, 20, 40 (40 ') ... Lower mold, 21, 31, 41,
42, 51, 52 ... upper mold, 21a1, 41a1, 42a1 ... boundary wall, 35, 53, 55 ... movable boundary wall, 34, 54,
56 ... spring, 22, 25, 32, 44, 44 ',
47, 47 ': molten resin supply passage, 24, 27, 34,
46, 49: injection device, 50: turntable.

Continuation of the front page (51) Int.Cl. ⁷ Identification symbol FIB29L 31:58 (56) References JP-A-63-11212 (JP, A) JP-A-1-26414 (JP, A) JP-A-1 -168414 (JP, A) JP-A-2-167713 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 43/18-43/20 B29C 43/32-43/42 B29C 33 / 10,33 / 42

Claims (3)

(57) [Claims] 1. A base material comprising: a skin material composed of a plurality of sections covering and partitioning a front surface of the base material, wherein a plurality of adjacent portions of the plurality of parts are made of different resin-based materials; A manufacturing apparatus for a laminate, comprising: a base material side mold having a forming surface adapted to a shape of a back surface of the base material; and a shape of a surface of the skin material. It is a molding surface, comprising a plurality of partial molding surfaces divided by a boundary wall provided so as to abut on the base material at the time of polymerization of both molding dies along a boundary line dividing a plurality of portions of the skin material. A skin material-side molding die having a molding surface, and a resin-based material constituting each part of the skin material between the substrate set on the molding surface of the substrate-side molding die and the respective partial molding surfaces Supply means for supplying in a molten state, A laminate manufacturing apparatus for manufacturing a laminate by integrating the base material and the skin material by curing the molten resin-based material in a polymerization state of the two molds. 2. A base material comprising: a skin material comprising a plurality of sections which cover and partition the front side surface of the base material, wherein a plurality of adjacent portions of the plurality of parts are made of different resin-based materials; Wherein the manufacturing apparatus comprises a substrate-side molding die having a molding surface conforming to the shape of the back surface of the substrate, and a plurality of portions of the skin material. A skin material-side molding die composed of a plurality of partial molding dies divided according to types of resin-based materials, wherein each of the partial molding dies is partitioned along a boundary line that partitions a plurality of portions of the skin material. With at least one partial molding surface among the plurality of partial molding surfaces, so as to abut against the base material at the time of polymerization of the same partial molding die and the substrate-side molding die along the outer periphery of each partial molding surface. A skin material side forming mold having a boundary wall, A plurality of supply means for supplying, in a molten state, a resin-based material constituting each part of the skin material between the base material set on the molding surface of the substrate-side molding die and the respective partial molding surfaces; An apparatus for manufacturing a laminate, wherein the base material and the skin material are integrated by curing the molten resin-based material in a polymerization state of the both molds to produce a laminate. 3. The manufacturing apparatus for the laminate presses the base material and the molten resin-based material supplied to the front side surface of the base material between the base material side forming die and the skin material side forming die. An apparatus for manufacturing a laminated body by curing the molten resin-based material, wherein the boundary wall is urged in the direction of the substrate-side molding die and can advance and retreat with respect to the substrate-side molding die. 2. A movable boundary wall which abuts on the base material during polymerization of the two molds to prevent the supplied molten resin material from flowing beyond the boundary line. Item 3. An apparatus for producing a laminate according to any one of Items 2.