JP3205671B2 - Manufacturing method of laminate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The invention laminate BACKGROUND OF THE, particularly, between the core and the synthetic resin skin, manufacturing method of a laminated body in which is interposed a synthetic resin foam layer for bonding them core and the skin .

[0002] This kind of laminate is applied to instrument panels, door linings, console boxes and the like in automobiles.

[0003]

2. Description of the Related Art Heretofore, it has been known that a skin is made of vinyl chloride resin and a foam layer is made of urethane resin.

[0004] However, the epidermis changes color over time.
There is a problem that. An example of the discoloration mechanism is as follows. That is, since the tertiary amine (R ₃ N), which is the catalyst of the urethane resin foam layer, sublimates by heat and moves into the epidermis, the N of the tertiary amine and the vinyl chloride group (—CH—CHCl—) To form a hydrochloride (R ₃ HN ⁺ Cl ⁻ ). Since this reaction occurs sequentially, the dehydrochlorination reaction is promoted in the vinyl chloride resin, and as a result, the polyene structure (-C = C-) increases in the vinyl chloride resin, and the polyene structure reaches 7,8. Then the discoloration of the epidermis starts.

[0005] In order to avoid such inconveniences, conventionally, the thickness of the skin is increased, or between the skin and the foam layer,
Means such as interposing a vinyl chloride resin foam layer of the same material as the skin are employed (Japanese Patent Publication No. 5-112).
No. 3).

[0006]

However, in the conventional laminate, the material cost is increased due to the increase in the thickness of the vinyl chloride resin skin or the addition of the vinyl chloride resin foam layer. This leads to increased production costs.

[0007] The present invention has been made in view of the above, aims to provide an extremely by adopting simple means it is possible to suppress the discoloration of the skin made of vinyl chloride resin, manufacturing method of cheap production cost the laminate And

[0008]

According to the present invention, there is provided a method for manufacturing a laminate according to the present invention .
For the construction method , the heartwood and the vinyl chloride resin skin are made of urethane
Bonded through a fat made foam layer, then the urethane tree
After the vinyl chloride resin skin occurring in fat made foam layer
In order to discharge the gases that cause time discoloration, the core and
One end opens to the outer surface of the core material in the urethane resin foam layer
And the other end bites into the urethane resin foam layer
A plurality of gas vent holes of 1.5 to 4.0 mm, longitudinal and lateral directions
It is characterized by being drilled at a pitch of 15 to 40 mm .

[0009]

[Function] In the above-mentioned laminated body, the urethane resin foam layer is generated and causes the temporal discoloration of the vinyl chloride resin skin.
Harmful gas as a cause is discharged to the outside through the plurality of gas vent holes, thereby Since migration of harmful gases to the epidermis is greatly reduced over time varying <br/> vinyl chloride tree epidermis Color is suppressed.

When the above method is employed in manufacturing a laminated body, the laminated body can be easily mass-produced. In addition, since the venting operation is performed at the final stage, for example, when an unfoamed undiluted solution is injected between the skin and the core material, it may get wet through the venting hole, or foam may be added to the venting hole during the foaming process. There is no problem that a part of the gas enters and breaks.

[0011]

1 and 2, an instrument panel (laminate) 1 for an automobile includes a core material 2 made of ABS and a skin 3 made of vinyl chloride resin (synthetic resin) formed of a foam layer 4 made of urethane resin (synthetic resin). Are joined together.

A plurality of gas vent holes 5 are formed in the core material 2, one end of each gas vent hole 5 is opened on the outer surface of the core material 2, and the other end is cut into the foam layer 4. The inner diameter of each gas vent hole 5 is 1.5 to 4.0 mm, 2.0 mm in the embodiment, and is arranged at a pitch of 15 to 40 mm in the front, rear, left and right directions, and 15 mm in the embodiment.

With this configuration, most of the tertiary amine (gas) sublimated in the foam layer 4 is discharged to the outside through the plurality of vent holes 5 of the core material 2, whereby the skin 3 is removed.
The amount of tertiary amines transferred to
Is suppressed.

In manufacturing the instrument panel 1, the following method was employed. (A) As shown in FIG. 3, a number of intake holes (not shown)
The surface skin 3 was formed by applying a vacuum forming process to a 0.6 mm thick vinyl chloride resin sheet using the concave mold 6 having (B) The convex mold 7 to which the ABS core 2 having a thickness of 3 mm was attached was fitted to the concave mold 6 to form a gap between the skin 3 and the core 2. (C) The urethane stock solution was injected into the gap from the injection device 8 and foamed to form a urethane resin foam layer 4 having a thickness of 17 mm, and the skin 3 and the core material 2 were joined via the layer 4. (D) In the instrument panel 1 after release,
A plurality of vent holes 5 having an inner diameter of 2.0 mm were drilled in the core material 2 at a pitch of 15 mm in the front, rear, left and right directions.

Further, two types of instrument panel panels 1 were manufactured in the same manner as described above, using 0.8 mm and 1.0 mm thick vinyl chloride resin sheets for skin. In addition, three types of instrument panels 1 having the same configuration as above were manufactured except that no vent hole 5 was formed in the core material 2.

Next, test pieces were taken from each instrument panel 1 and subjected to a heat aging test in which the test pieces were kept at a high temperature of 110 ° C. for 500 hours, after which the color difference ΔE of the skin 3 was measured.

FIG. 4 shows the relationship between the thickness of the skin 3 and the color difference ΔE. As is clear from FIG.
Is provided, the color difference Δ
If E is improved by 19 to 53% and the color difference ΔE = 2.0 is set as the allowable upper limit value, the thickness of the skin 3 is increased from the conventional 1.0 mm to 0.1 mm.
It can be reduced to 8 mm. This is extremely effective in reducing the production cost of the instrument panel 1.

[0018]

According to the first aspect of the present invention, the heartwood and the urethane are provided.
One end is opened to the outer surface of the core,
In addition, the other end is cut into the urethane resin foam layer at the other end.
A plurality of vent holes of 5 to 4.0 mm
Drill at a pitch of 5 to 40 mm and pass through these vent holes.
Harmful gas was discharged to the outside,
Occurs in the foam layer made of tongue resin,
The amount of harmful gas that causes discoloration over time to the epidermis
Dramatically reduced, and the discoloration of vinyl chloride bark over time was suppressed.
It is. On a plurality of gas vent holes Moreover heartwood and the foam layer
By a very simple means of drilling in serial inside diameter pitch, it is possible to suppress the temporal discoloration of the vinyl chloride resin skin, Ru can be easily mass-produced the laminate at a low production cost.

[Brief description of the drawings]

FIG. 1 is a perspective view of an instrument panel.

FIG. 2 is a sectional view taken along line 2-2 of FIG.

FIG. 3 is an explanatory view of a method of manufacturing an instrument panel.

FIG. 4 is a graph showing the relationship between skin thickness and color difference ΔE.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Instrument panel (laminated body) 2 Core material 3 Skin 4 Foam 5 Gas vent hole

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ identification code FI B29K 75:00 105: 04 B29L 9:00 31:30 31:58 (58) Investigated field (Int.Cl. ⁷ , DB name ) B32B 1/00-35/00 B29C 39/00-39/44 B29C 45/00-45/84

Claims (1)

(57) [Claims] 1. A bonded through the core (2) and the vinyl chloride resin skin (3) and a urethane resin foam layer (4), then generated by the urethane resin foam layer (4) hand
The core material (2) and the urethane tree are used to discharge a gas which causes the temporal discoloration of the vinyl chloride resin skin (3).
One end opens to the outer surface of the core material (2) on the foam layer (4) made of fat.
And the other end is inserted into the urethane resin foam layer (4).
A plurality of gas vent holes with an inner diameter of 1.5 to 4.0 mm (5)
Characterized by the fact that holes are pierced at a pitch of 15 to 40 mm in the front, rear, left and right directions .