JP3915206B2

JP3915206B2 - Manufacturing method of laminate

Info

Publication number: JP3915206B2
Application number: JP32358197A
Authority: JP
Inventors: 祐一宮下
Original assignee: Toyota Boshoku Corp
Current assignee: Toyota Boshoku Corp
Priority date: 1997-11-25
Filing date: 1997-11-25
Publication date: 2007-05-16
Anticipated expiration: 2017-11-25
Also published as: JPH11156875A

Description

【０００１】
【発明の属する技術分野】
本発明は、車両のドアトリム、車両の内装材、家屋の内装材、家具の外装材等に使用される積層体、特に基材を覆う表皮の表面に形成した木目込み溝を境としてその両側で表面の色または模様が異なっている積層体を製造する方法に関する。
【０００２】
【従来の技術】
例えば自動車のドアトリムのような、基材の表面を表皮により覆ってなる積層体において、装飾性を高めるために上半部と下半部とで表面の色を異なるものとする場合には、通常は上半部と下半部を別々に成形することにより表皮の色が異なるものを用意した後、これをかしめやねじ止めなどにより一体化している。また、一体成形した基材の表面に加熱軟化させた表皮材を負圧により吸引接着してこのような積層体を製造する場合は、色見切り線を境として上半部と下半部とで表面の色が異なる表皮材を使用することも考えられる。
【０００３】
【発明が解決しようとする課題】
しかしながら上記第１の従来技術では、成形工程が上半部と下半部とで別々に必要になり、また組付工程も必要であるので、製造コストが増大するという問題がある。また上記第２の従来技術では、製造コストは低下するが、表皮材は吸引接着の際に基材の表面に沿って多少ずれるので色見切り線形状が曲がりくねって外観が低下し、また平坦なドアトリムの表面が単に色分けまたは模様分けされているだけであるので豪華な感じを与えることができないという問題がある。この後者の問題を解決するためには、表皮材表面の色見切り線の位置に木目込み溝を設けてこの溝内に色見切り線が入るようにすることが考えられる。しかしこれでは前者の問題は解決されないので、曲がりくねった色見切り線が木目込み溝から部分的に露出してかえって見苦しくなることがある。また、感触を高めるために表皮の裏側に発泡層を設けると表皮の厚さが大きくなって木目込み溝の溝底の曲率半径、従って木目込み溝の幅が大きくなるので、溝底が見えて外観が低下するという問題も生じる。
【０００４】
本発明は、木目込み溝を境として表面の色が異なるこの種の積層体を一体的に成形する場合において、木目込み溝の幅を小さくし、しかも色見切り線が木目込み溝の中に隠れるようにして、このような各問題を解決することを目的とする。
【０００５】
【課題を解決するための手段】
本発明による積層体の製造方法は、色見切り線を境として異なる色または模様とした表面を有し表皮となる熱可塑性シートを加熱軟化させてその表面を第１成形型の表側成形面に接近させたのち、この表側成形面と対向する裏側成形面を有する第２成形型を第１成形型に接近させ、熱可塑性シートと第２成形型の間に介在され基材となる加熱軟化させた熱可塑性板材を熱可塑性シートの裏面と裏側成形面の間に充填することにより基材を表皮により覆ってなる積層体を製造する方法に関するものであり、熱可塑性シートは表面側となる薄い緻密な合成樹脂の表面層と裏面側となる発泡合成樹脂の裏面層よりなり、裏面層には表面層表面の色見切り線と対応する位置に沿ってその厚さのほゞ全部にわたる切れ目を形成し、第１成形型の表側成形面には色見切り線に沿って表面層の表面と当接する幅の狭い先端縁を有する突条を形成し、第２成形型の裏側成形面には突条に対応する位置に沿って凹条を形成したことを特徴とするものである。熱可塑性シートは第１成形型の表側成形面に密着される際に、色見切り線が突条の先端縁に当接され折り曲げられて木目込み溝が形成されるが、裏面層の色見切り線に対応する部分には切れ目が形成されているので折り曲げられるのは薄い表面層だけであってきわめて曲がりやすくそれ以外の部分で曲がることはなく、しかも突条は先端縁の幅が狭いので、木目込み溝の溝底の曲率半径はきわめて小さくなる。
【０００６】
前項の発明は、第２成形型を第１成形型に接近させる前に、熱可塑性シートの表面層の表面を第１成形型の表側成形面に吸引密着させることが好ましい。
【０００７】
前２項の発明は、第１成形型を下型とし、第２成形型を上型とし、加熱軟化させた熱可塑性板材は上型の裏側成形面よりも広い開口を有する基材ホルダに周囲部を保持させると共にこの基材ホルダは第２成形型よりも先に下型に対する最接近位置とするようにし、裏側成形面は開口を通って熱可塑性板材を熱可塑性シートの裏面との間に充填するようにすることが好ましい。
【０００８】
また前項の発明は、上型にその周辺部に固定されて下方に延びる複数のガイドバーを設け、基材ホルダはガイドバーにより昇降可能に案内支持されると共に上型に対する所定距離以上の下降は同ガイドバー下端部に形成した頭部に当接することにより阻止されるようにすることが好ましい。
【０００９】
【発明の実施の形態】
図１〜図６に示す実施の形態は、本発明による積層体の製造方法を自動車のドアトリムの製造に適用した場合の例を示す。
図６に示す半製品のように、本発明により成形されるドアトリムは、肉厚がほゞ一定で剛性のある基材３１の外表面を表皮３０により覆ったものであり、表皮３０は、図５に示すように、柔軟で緻密な薄い熱可塑性樹脂の表面層３０ａの裏面に弾性に富んだシート状の合成樹脂発泡体よりなる裏面層３０ｂをラミネート接着したものである。基材３１を覆う表皮３０の表面側には、取付状態でほゞ水平となる直線状あるいは多少屈曲した木目込み溝３２が横方向全幅にわたり形成され、その上側と下側では表面の色または模様が異なっている。例えば縦横の寸法が約６００mm×９００mmのドアトリムの場合、各部の肉厚は基材３５が２．５〜６．０mm、表皮３０が４．４５mm以下、従ってドアトリム全体で６．９５〜１０．４５mm以下である。
【００１０】
先ず図１〜図４により、この実施の形態に使用する成形装置の説明をする。この成形装置は、下部の固定側型支持部材（図示省略）に取り付けられる第１成形型（下型）１０と、上部の可動側型支持部材（図示省略）に取り付けられる第２成形型（上型）２０と、ガイドバー２３を介して第２成形型２０により支持される基材ホルダ２５を備えている。第１成形型１０の上側にはドアトリムの表皮３０の表面と対応する形状の表側成形面１１が形成され、その外側には外方に延びる外周面１１ａが形成されている。この表側成形面１１には、ドアトリムの木目込み溝３２と対応する位置に沿って、先端縁の幅が狭い一定断面形状の突条１２が真直状にあるいは多少屈曲して形成されている。第１成形型１０内には真空ポンプと真空タンクと開閉弁からなる真空源１４に接続された吸引管路１３が設けられ、この吸引管路１３から分岐された多数の細管路１３ａ（図では一部のみを示す）の他端は表側成形面１１のほゞ全面に分布して開口されている。突条１２は図示のように第１成形型１０と一体的に形成してもよいし、あるいは板状のものを植え込み固定してもよい。
【００１１】
第２成形型２０は第１成形型１０に対し上方から接近離隔可能であり、図２及び図３は離隔状態を示し、図４は最接近状態を示している。第２成形型２０の下面には第１成形型１０上側の表側成形面１１と対向する裏側成形面２１が形成され、裏側成形面２１と表側成形面１１との間の隙間は最接近状態においてドアトリムの厚さとなる。裏側成形面２１には、表側成形面１１に形成した突条１２と対応する位置に、凹条２２が形成されている。
【００１２】
図１、図３及び図４に示すように、第２成形型２０の四隅に固定されて下方に延びる４本のガイドバー２３には、基材ホルダ２５が昇降可能に案内支持されている。基材ホルダ２５は平面輪郭形状が第２成形型２０とほゞ同一の厚板状で裏側成形面２１よりもやや広い開口２６が形成され、四隅に設けたブッシュ２７が各ガイドバー２３に摺動可能に嵌合され、図３に示すように第２成形型２０が第１成形型１０から下方にある距離以上離隔した状態では、各ガイドバー２３の下端に形成した頭部２３ａにブッシュ２７が当接して、基材ホルダ２５が第２成形型２０に対しそれ以上下降することは阻止される。開口２６の三方となる基材ホルダ２５の上面には多数の係止針２８が起立して植設され、残る一方にはクランパ２９が設けられている。
【００１３】
基材３１の表面に接着されて表皮３０となる熱可塑性シート３０ｍは、柔軟な熱可塑性樹脂の緻密なソリッド層よりなる薄いシート状の表面層３０ａ（例えば厚さ０．３５mmのポリプロピレン樹脂シート等）の裏面に、弾性に富んだシート状の合成樹脂発泡体（例えば厚さ２〜３mmのポリプロピレン樹脂発泡体シート）よりなる裏面層３０ｂを予めラミネート接着してシート状としたものである。熱可塑性シート３０ｍの表面層３０ａの表面は、図２に示すように、表側成形面１１の突条１２の平面形状と一致する直線状あるいは多少屈曲した色見切り線Ｃを境として一側部（上半部）Ａと他側部（下半部）Ｂとで表面の色または模様が異なるものとし、また意匠的効果を高めるために、皮革模様などのしぼが形成されている。熱可塑性シート３０ｍの裏面層３０ｂには、図５に示すように、表面層３０ａ表面の色見切り線Ｃと対応する位置に沿ってその厚さのほゞ全部にわたる切れ目３０ｃが形成されている。この切れ目３０ｃは、熱可塑性シート３０ｍを所定形状に切断した後にナイフ状の切刃を有する型により形成すればよい。
【００１４】
基材３１となる熱可塑性板材３１ｍは、ポリプロピレンと木粉を混合し加熱圧縮して板状としたもの（混合比率は重量比で例えば５０：５０、厚さは例えば２．５ｍｍ）である。熱可塑性板材３１ｍは、基材ホルダ２５の開口２６よりも大きい長方形に予め切断し、３辺を基材ホルダ２５の係止針２８に刺し、１辺をクランパ２９により挟んで基材ホルダ２５に支持させる。
【００１５】
次に以上に述べた成形装置を用いた製造方法を、図２〜図５により説明する。先ず熱可塑性シート３０ｍを、色見切り線Ｃのある表面が下側となるように外周部を保持枠１９の間に挟むことにより保持し、遠赤外線ヒータ等により加熱（例えば１２０℃）して軟化させる。そして保持枠１９を下降させ、熱可塑性シート３０ｍの外周部を第１成形型１０の外周面１１ａ上に当接させて、表側成形面１１と熱可塑性シート３０ｍの間の空間を実質的に密閉する。この状態における熱可塑性シート３０ｍの水平方向位置は、図２及び図５(a) に示すように、熱可塑性シート３０ｍの表面層３０ａの色見切り線Ｃが表側成形面１１から突出する突条１２の真上となるようにされている。そして真空源１４からの負圧を吸引管路１３及び細管路１３ａを通して熱可塑性シート３０ｍの下側に与えれば、図２の二点鎖線３０Ａ及び図３の実線に示すように、熱可塑性シート３０ｍは表面層３０ａの表面が第１成形型１０の表側成形面１１に吸引密着され、突条１２の幅が狭い先端縁は色見切り線Ｃに沿って表面層３０ａの表面に当接される。
【００１６】
この吸引密着により、図５(b) に拡大して示すように、表面層３０ａはその表面の色見切り線Ｃが突条１２の先端縁に当接され折り曲げられて木目込み溝３２が形成されるが、裏面層３０ｂに切れ目３０ｃが形成された色見切り線Ｃの部分は、折り曲げられるのは薄い表面層３０ａだけであってきわめて曲がりやすいので幅が狭い突条１２の先端縁に密着して曲がり、木目込み溝３２の溝底の曲率半径はきわめて小さくなる。また、この色見切り線Ｃ以外の部分は裏面層３０ｂの分だけ厚さが大きくなって曲がりにくいので、突条１２の先端縁が色見切り線Ｃから多少ずれた位置に当接しても曲がるのは色見切り線Ｃに沿ってであり、その後の吸引密着により熱可塑性シート３０ｍは色見切り線Ｃが突条１２の先端縁と一致する向きに局部的にずれて位置が修正される。
【００１７】
次に熱可塑性板材３１ｍを、図３に示すように、３方の縁部を係止針２８に刺し残る１方の縁部をクランパ２９により挟んで基材ホルダ２５に支持させ、遠赤外線ヒータ等により加熱（例えば２２０℃）して軟化させてから、第２成形型２０を基材ホルダ２５と共に第１成形型１０に向けて下降させる。基材ホルダ２５は、その下面が第１成形型１０の外周面１１ａ上の熱可塑性シート３０ｍに当接して第１成形型１０に対する最接近位置に達した後は下降が停止され、第２成形型２０及びガイドバー２３だけが下降されて、図４に示すように第２成形型２０のガイドバー２３下端の頭部２３ａの先端が第１成形型１０に当接し、両成形面１１，２１の間の隙間がドアトリムの厚さとなる最接近状態になったところで停止させる。これにより、加熱軟化されて熱可塑性シート３０ｍと第２成形型２０の裏側成形面２１間に介在された熱可塑性板材３１ｍは、第２成形型２０の裏側成形面２１と熱可塑性シート３０ｍの裏面との間に隙間なく圧縮充填される。
【００１８】
両成形型１０，２０内部への熱伝達等により両成形面１１，２１の温度が低下し、熱可塑性シート３０ｍ及び熱可塑性板材３１ｍが硬化して、表皮３０及び基材３１となったところで、第２成形型２０及び基材ホルダ２５を上昇させれば、表面層３０ａ及び裏面層３０ｂからなる表皮３０と基材３１が一体化されたドアトリムの半製品は基材ホルダ２５と共に上昇される。この半製品は、クランパ２９を外して持ち上げることにより、基材ホルダ２５から取り外される。そして図６に示す切断線Ｄよりも外側の不要部分を切除すれば、突条１２により表皮３０の表面に形成された木目込み溝３２を境としてその両側で表面の色または模様が異なるドアトリムは完成する。基材３１には、第２成形型２０の裏側成形面２１の凹条２２により木目込み溝３２を囲むように突条が形成されるので、この部分の基材３１の肉厚が薄くなって強度が低下することがない。
【００１９】
上述した実施の形態によれば、表皮３０の色または模様が木目込み溝３２を境として異なるドアトリムを実質的に１つの工程により一体的に製造できる。しかも、幅が狭い突条１２の先端縁が当接されて折り曲げられる色見切り線Ｃに沿った表面層３０ａは裏面層３０ｂに切れ目３０ｃが形成されてきわめて曲がりやすいので、この折り曲げにより形成される木目込み溝３２は溝底の曲率半径がきわめて小さくなり、この溝底は外部から見えにくくなる。また、この色見切り線Ｃ以外の部分は裏面層３０ｂの分だけ厚さが大きくなって曲がりにくいので、突条１２の先端縁が色見切り線Ｃから多少ずれた位置に当接しても曲がるのは色見切り線Ｃに沿ってであり、この折れ曲がった部分が突条１２の先端縁と一致するようにずれは修正されて色見切り線Ｃは木目込み溝３２の溝底と一致するので、色見切り線Ｃが木目込み溝３２から外部に露出することもなくなる。従って外観に優れたドアトリムを容易に製造することができる。
【００２０】
上記実施の形態では、第２成形型２０を第１成形型１０に接近させる前に、熱可塑性シート３０ｍを第１成形型１０の表側成形面１１に吸引管路１３及び細管路１３ａと真空源１４により吸引密着させているので、突条１２の先端縁が色見切り線Ｃから多少ずれた場合におけるこのずれを修正する作用は比較的自由に行われる。このような吸引密着を行わない場合は、第１成形型１０の表側成形面１１に対する熱可塑性シート３０ｍの密着は第２成形型２０の裏側成形面２１との間に圧縮充填される加熱軟化された熱可塑性板材３１ｍにより行われることになり、前述したずれを修正する作用は、表皮３０の裏面層３０ｂに付着した熱可塑性板材３１ｍの粘性抵抗のため弱くはなるが失われることはない。
【００２１】
また上記実施の形態では、広い開口を有する基材ホルダ２５に熱可塑性板材３１ｍの周囲部を保持させて加熱軟化させており、このようにすれば加熱軟化させた熱可塑性板材３１ｍの取り扱いが簡単になるので積層体の製造が容易になる。しかし本発明は、押出しダイから板状に押し出した溶融樹脂よりなる熱可塑性板材３１ｍを、第１成形型１０の表側成形面１１に吸引密着させまたは接近させた熱可塑性シート３０ｍの上に供給することにより、熱可塑性シート３０ｍと第２成形型２０の裏側成形面２１間に介在させて実施することも可能であり、そのようにしても前記の各効果は得られる。
【００２２】
上記実施の形態では、上型である第２成形型２０の四隅に下方に延びるガイドバー２３を固定し、基材ホルダ２５はガイドバー２３により昇降可能に案内支持し、第２成形型２０に対する所定距離以上の下降はガイドバー２３下端部に形成した頭部２３ａに当接することにより阻止するようにしており、これによれば、基材ホルダ２５の作動のために特別な装置を設ける必要がなくなるのでドアトリムの成形に使用する装置の構造が簡略化される。しかし本発明は、基材ホルダ２５を支持して昇降させる装置を設けて実施しても差し支えない。
【００２３】
上記実施の形態では、第１成形型１０を下型とし第２成形型２０を上型としているが、本発明は、第１成形型１０を上型とし第２成形型２０を下型として実施することも可能である。
【００２４】
【発明の効果】
本発明によれば、表皮表面の色または模様が木目込み溝を境として異なるドアトリムを実質的に１つの工程により一体的に製造できる。しかも、表皮は裏面層に形成した切れ目により色見切り線の部分がきわめて曲がりやすくそれ以外の部分では曲がりにくいので表皮表面の色見切り線が木目込み溝の溝底からずれて木目込み溝の外側に露出するおそれはなくなり、また木目込み溝の溝底の曲率半径がきわめて小さくなることにより木目込み溝の幅が小さくなって溝底が見えることもなくなる。これにより、基材を覆う表皮の表面に形成した木目込み溝を境としてその両側で表面の色または模様が異なっている積層体の外観を向上させることができる。
【００２５】
第２成形型を第１成形型に接近させる前に熱可塑性シートを第１成形型の表側成形面に吸引密着させるようにしたものによれば、熱可塑性シートは吸引密着の際に熱可塑性板材に付着されていないので、突条の先端縁が色見切り線から多少ずれた位置に当接した場合でもその後の吸引密着により色見切り線は突条の先端縁と一致する向きに自由に修正され、従って色見切り線が木目込み溝の溝底からずれて木目込み溝の外側に露出するおそれは一層少なくなる。
【００２６】
また第１成形型を下型とし、広い開口を有する基材ホルダに加熱軟化させた熱可塑性板材の周囲部を保持させるようにした発明によれば、加熱軟化させた熱可塑性板材の取り扱いが簡単になるので積層体の製造が容易になる。
【００２７】
前項の発明において、上型の周辺部に下方に延びる複数のガイドバーを固定し、基材ホルダはガイドバーにより昇降可能に案内支持し、上型に対する所定距離以上の下降はガイドバー下端部に形成した頭部に当接することにより阻止するようにしたものによれば、基材ホルダの作動のために特別な装置を設ける必要がなくなるので本発明の実施に使用する装置の構造が簡略化される。
【図面の簡単な説明】
【図１】本発明による積層体の製造方法の一実施形態に使用する成形装置の第２成形型及び熱可塑性材料を除いた平面図である。
【図２】図１のＸ−Ｘ線に沿った断面図で、熱可塑性シートを第１成形型に接近させて表側成形面に吸引密着させる状態を示す図である。
【図３】図１のＸ−Ｘ線に沿った断面図で、第２成形型及び基材ホルダが第１成形型に接近する途中の状態を示す図である。
【図４】図１のＸ−Ｘ線に沿った断面図で、第２成形型及び基材ホルダが第１成形型に最も接近した状態を示す図である。
【図５】図１〜図４に示す装置の各段階における要部の部分拡大断面図である。
【図６】本発明による積層体の製造方法の一実施形態により製造されたドアトリムの半製品の断面図である。
【符号の説明】
１０…第１成形型、１１…表側成形面、１２…突条、２０…第２成形型、２１…裏側成形面、２２…凹条、２３…ガイドバー、２３ａ…頭部、２５…基材ホルダ、２６…開口、３０…表皮、３０ａ…表面層、３０ｂ…裏面層、３０ｃ…切れ目、３０ｍ…熱可塑性シート、３１…基材、３１ｍ…熱可塑性板材、Ｃ…色見切り線。[0001]
BACKGROUND OF THE INVENTION
The present invention is a laminated body used for vehicle door trims, vehicle interior materials, house interior materials, furniture exterior materials, etc., and particularly on both sides of a wood grain groove formed on the surface of the skin covering the base material. The present invention relates to a method of manufacturing a laminate having different colors or patterns.
[0002]
[Prior art]
For example, in a laminated body that covers the surface of a base material with a skin, such as an automobile door trim, when the surface color is different between the upper half and the lower half in order to enhance the decoration, Is prepared by molding the upper half and the lower half separately to prepare different colors of the skin and then integrating them by caulking or screwing. Also, when manufacturing such a laminate by adhering the heat-softened skin material to the surface of the integrally formed substrate with negative pressure, the upper half and the lower half are separated by a color parting line. It is also conceivable to use a skin material having a different surface color.
[0003]
[Problems to be solved by the invention]
However, in the first conventional technique, a molding process is separately required for the upper half and the lower half, and an assembling process is also required, resulting in an increase in manufacturing cost. In the second prior art, the manufacturing cost is reduced, but the skin material is slightly displaced along the surface of the base material during the suction bonding, so that the color parting line shape is twisted and the appearance is lowered, and the flat door trim There is a problem that it is not possible to give a luxurious feeling because the surface is simply color-coded or patterned. In order to solve this latter problem, it is conceivable to provide a grained groove at the position of the color parting line on the surface of the skin material so that the color parting line enters the groove. However, this does not solve the former problem, and the twisted color parting line may be partially exposed from the grained groove and may become unsightly. In addition, if a foam layer is provided on the back side of the skin to enhance the feel, the thickness of the skin increases and the curvature radius of the groove bottom of the grained groove, and hence the width of the grained groove, increases, so that the groove bottom is visible and the appearance is improved. There also arises a problem of lowering.
[0004]
In the present invention, in the case of integrally molding this type of laminate having different surface colors with the grained groove as a boundary, the width of the grained groove is reduced, and the color parting line is hidden in the grained groove. The purpose is to solve each such problem.
[0005]
[Means for Solving the Problems]
The method for producing a laminate according to the present invention comprises heat-softening a thermoplastic sheet having a surface having a different color or pattern with a color parting line as a boundary, and bringing the surface closer to the front molding surface of the first mold. After that, the second molding die having the back molding surface facing the front molding surface was brought close to the first molding die, and was softened by heating to be a base material interposed between the thermoplastic sheet and the second molding die. The present invention relates to a method for producing a laminate in which a base material is covered with a skin by filling a thermoplastic plate material between a back surface and a back side molding surface of a thermoplastic sheet, and the thermoplastic sheet is a thin and dense surface side. It consists of a surface layer of synthetic resin and a back surface layer of foamed synthetic resin on the back surface side, and in the back surface layer, a cut is formed over almost the entire thickness along the position corresponding to the color parting line on the surface layer surface, Front side molding of the first mold Forming a ridge having a narrow tip edge that abuts the surface of the surface layer along the color parting line, and forming a recess along the position corresponding to the ridge on the back side molding surface of the second mold. It is formed. When the thermoplastic sheet is in close contact with the front side molding surface of the first mold, the color parting line is brought into contact with the leading edge of the ridge and bent to form a grained groove. Since the corresponding part is cut, only the thin surface layer can be bent, it is very easy to bend, and it does not bend in other parts, and the ridge has a narrow width at the tip edge. The radius of curvature of the groove bottom is extremely small.
[0006]
In the invention of the preceding paragraph, it is preferable that the surface of the surface layer of the thermoplastic sheet is sucked and adhered to the front molding surface of the first mold before the second mold is brought close to the first mold.
[0007]
In the inventions of the preceding two paragraphs, the first mold is the lower mold, the second mold is the upper mold, and the heat-softened thermoplastic plate material is surrounded by a base material holder having an opening wider than the back side molding surface of the upper mold. The base holder is positioned at the closest position to the lower mold before the second mold, and the back-side molding surface passes through the opening between the thermoplastic plate material and the back surface of the thermoplastic sheet. Filling is preferred.
[0008]
In the invention of the preceding paragraph, the upper die is provided with a plurality of guide bars that are fixed to the periphery of the upper die and extend downward, and the base material holder is guided and supported by the guide bar so that it can be raised and lowered. It is preferable to be prevented by contacting a head formed at the lower end of the guide bar.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
The embodiment shown in FIGS. 1-6 shows the example at the time of applying the manufacturing method of the laminated body by this invention to manufacture of the door trim of a motor vehicle.
As in the semi-finished product shown in FIG. 6, the door trim molded according to the present invention is such that the outer surface of the base material 31 having a substantially constant thickness is covered with the outer skin 30, and the outer skin 30 is shown in FIG. As shown in FIG. 5, a back surface layer 30b made of a sheet-like synthetic resin foam rich in elasticity is laminated and bonded to the back surface of the surface layer 30a of a flexible and dense thin thermoplastic resin. On the surface side of the skin 30 that covers the base material 31, a straight or slightly bent wood grain groove 32 that is almost horizontal in the mounted state is formed over the entire width in the lateral direction, and the surface color or pattern is on the upper and lower sides. Is different. For example, in the case of a door trim having a vertical and horizontal dimension of about 600 mm × 900 mm, the thickness of each part is 2.5 to 6.0 mm for the base material 35 and the skin 30 is 4.45 mm or less, and therefore the entire door trim is 6.95 to 10.45 mm. It is as follows.
[0010]
First, the molding apparatus used in this embodiment will be described with reference to FIGS. This molding apparatus includes a first mold (lower mold) 10 attached to a lower fixed mold support member (not shown) and a second mold (upper mold) attached to an upper movable mold support member (not shown). Mold) 20 and a substrate holder 25 supported by the second mold 20 via a guide bar 23. A front molding surface 11 having a shape corresponding to the surface of the skin 30 of the door trim is formed on the upper side of the first mold 10, and an outer peripheral surface 11 a extending outward is formed on the outer side thereof. On the front side molding surface 11, along a position corresponding to the wood groove 32 of the door trim, a ridge 12 having a constant cross-sectional shape with a narrow end edge is formed in a straight shape or slightly bent. A suction line 13 connected to a vacuum source 14 including a vacuum pump, a vacuum tank, and an on-off valve is provided in the first mold 10, and a number of narrow pipes 13 a branched from the suction line 13 (in the drawing). The other end (only part of which is shown) is distributed and opened over almost the entire surface of the front molding surface 11. The ridges 12 may be formed integrally with the first mold 10 as shown, or a plate-like one may be implanted and fixed.
[0011]
The 2nd shaping | molding die 20 can approach / separate from the upper direction with respect to the 1st shaping | molding die 10, FIG.2 and FIG.3 shows the separation state, FIG. 4 has shown the closest approach state. A back side molding surface 21 is formed on the lower surface of the second molding die 20 so as to oppose the front side molding surface 11 on the upper side of the first molding die 10, and the gap between the back side molding surface 21 and the front side molding surface 11 is in the closest state. The thickness of the door trim. On the back side molding surface 21, recesses 22 are formed at positions corresponding to the ridges 12 formed on the front side molding surface 11.
[0012]
As shown in FIGS. 1, 3, and 4, a base material holder 25 is guided and supported by four guide bars 23 that are fixed to the four corners of the second mold 20 and extend downward. The base material holder 25 has a thick plate shape whose plane contour shape is substantially the same as that of the second mold 20 and has an opening 26 slightly wider than the back-side molding surface 21, and bushes 27 provided at the four corners slide on the guide bars 23. When the second mold 20 is separated from the first mold 10 by a distance below the first mold 10 as shown in FIG. 3, the bush 27 is attached to the head 23 a formed at the lower end of each guide bar 23. , And the base material holder 25 is prevented from further lowering with respect to the second mold 20. A number of locking needles 28 are erected and planted on the upper surface of the base material holder 25 in three directions of the opening 26, and a clamper 29 is provided on the remaining one.
[0013]
The thermoplastic sheet 30m bonded to the surface of the base material 31 to form the skin 30 is a thin sheet-like surface layer 30a made of a dense solid layer of a flexible thermoplastic resin (for example, a polypropylene resin sheet having a thickness of 0.35 mm). The back layer 30b made of a sheet-like synthetic resin foam rich in elasticity (for example, a polypropylene resin foam sheet having a thickness of 2 to 3 mm) is laminated in advance to form a sheet. As shown in FIG. 2, the surface of the surface layer 30 a of the thermoplastic sheet 30 m has one side portion with a straight line or a slightly bent color parting line C matching the planar shape of the protrusion 12 of the front molding surface 11 as a boundary ( The upper half part A and the other side part (lower half part) B are different in surface color or pattern, and a leather pattern or other crease is formed to enhance the design effect. In the back surface layer 30b of the thermoplastic sheet 30m, as shown in FIG. 5, a cut 30c is formed over almost the entire thickness along the position corresponding to the color parting line C on the surface of the surface layer 30a. The cut line 30c may be formed by a mold having a knife-like cutting edge after cutting the thermoplastic sheet 30m into a predetermined shape.
[0014]
The thermoplastic plate material 31m used as the base material 31 is a plate-like material obtained by mixing polypropylene and wood powder and heating and compressing them (mixing ratio is, for example, 50:50 by weight and thickness is, for example, 2.5 mm). The thermoplastic plate material 31m is cut in advance into a rectangle larger than the opening 26 of the base material holder 25, three sides are inserted into the locking needle 28 of the base material holder 25, and one side is sandwiched by the clamper 29 to the base material holder 25. Support.
[0015]
Next, a manufacturing method using the molding apparatus described above will be described with reference to FIGS. First, the thermoplastic sheet 30m is held by sandwiching the outer peripheral portion between the holding frames 19 so that the surface with the color parting line C is on the lower side, and heated by a far infrared heater or the like (for example, 120 ° C.) to be softened. Let Then, the holding frame 19 is lowered and the outer peripheral portion of the thermoplastic sheet 30m is brought into contact with the outer peripheral surface 11a of the first mold 10 so that the space between the front molding surface 11 and the thermoplastic sheet 30m is substantially sealed. To do. The horizontal position of the thermoplastic sheet 30m in this state is as shown in FIG. 2 and FIG. 5 (a). The ridge 12 on which the color parting line C of the surface layer 30a of the thermoplastic sheet 30m protrudes from the front molding surface 11 is shown. It is supposed to be directly above. If a negative pressure from the vacuum source 14 is applied to the lower side of the thermoplastic sheet 30m through the suction line 13 and the narrow line 13a, the thermoplastic sheet 30m as shown by a two-dot chain line 30A in FIG. 2 and a solid line in FIG. The surface of the surface layer 30a is brought into suction contact with the front molding surface 11 of the first mold 10, and the narrow edge of the protrusion 12 is brought into contact with the surface of the surface layer 30a along the color parting line C.
[0016]
As a result of this suction contact, as shown in an enlarged view in FIG. 5 (b), the surface layer 30a is bent by the color parting line C on the surface being brought into contact with the tip edge of the ridge 12 and bent. However, the part of the color parting line C in which the cut line 30c is formed in the back surface layer 30b is bent only by the thin surface layer 30a and is very easy to bend. The radius of curvature of the groove bottom of the grained groove 32 is extremely small. In addition, since the portion other than the color parting line C is thicker than the back layer 30b and is difficult to bend, even if the tip edge of the ridge 12 is in a position slightly shifted from the color parting line C, the part is bent. Is along the color parting line C, and the position of the thermoplastic sheet 30m is locally shifted in the direction in which the color parting line C coincides with the leading edge of the ridge 12 by the suction adhesion thereafter.
[0017]
Next, as shown in FIG. 3, the thermoplastic plate member 31m is supported by the base material holder 25 with the one edge portion that is left pierced by the locking needle 28 being sandwiched by the clamper 29, as shown in FIG. The second mold 20 is lowered toward the first mold 10 together with the substrate holder 25 after being softened by heating (for example, 220 ° C.) or the like. After the lower surface of the substrate holder 25 comes into contact with the thermoplastic sheet 30m on the outer peripheral surface 11a of the first mold 10 and reaches the closest position to the first mold 10, the lowering is stopped, and the second mold is stopped. Only the mold 20 and the guide bar 23 are lowered, and the tip of the head 23a at the lower end of the guide bar 23 of the second mold 20 abuts against the first mold 10 as shown in FIG. Stop when it reaches the closest state where the gap between the doors becomes the thickness of the door trim. Thereby, the thermoplastic sheet material 31m interposed between the thermoplastic sheet 30m and the back-side molding surface 21 of the second molding die 20 after being softened by heating is the back-side molding surface 21 of the second molding die 20 and the back surface of the thermoplastic sheet 30m. Compressed and filled with no gap between.
[0018]
When the temperatures of the molding surfaces 11 and 21 are lowered by heat transfer to the insides of the molding dies 10 and 20, the thermoplastic sheet 30m and the thermoplastic plate material 31m are cured, and the skin 30 and the base material 31 are obtained. When the second mold 20 and the base material holder 25 are raised, the semifinished product of the door trim in which the skin 30 and the base material 31 composed of the front surface layer 30 a and the back surface layer 30 b are integrated is raised together with the base material holder 25. This semi-finished product is removed from the substrate holder 25 by removing the clamper 29 and lifting it. Then, if unnecessary portions outside the cutting line D shown in FIG. 6 are cut off, door trims having different surface colors or patterns on both sides of the wood groove 32 formed on the surface of the skin 30 by the ridges 12 are completed. To do. Since the protrusion is formed on the base material 31 so as to surround the wood groove 32 by the concave line 22 of the back-side molding surface 21 of the second mold 20, the thickness of the base material 31 in this portion is reduced and the strength is increased. Will not drop.
[0019]
According to the above-described embodiment, door trims in which the color or pattern of the skin 30 is different at the grain groove 32 can be manufactured integrally in substantially one step. In addition, the surface layer 30a along the color parting line C that is bent when the leading edge of the narrow ridge 12 is brought into contact is formed by this bending because a cut 30c is formed in the back surface layer 30b and is very easy to bend. In the wood groove 32, the radius of curvature of the groove bottom becomes extremely small, and the groove bottom becomes difficult to see from the outside. In addition, since the portion other than the color parting line C is thicker than the back layer 30b and is difficult to bend, even if the tip edge of the ridge 12 is in a position slightly shifted from the color parting line C, the part is bent. Is along the color parting line C, and the misalignment is corrected so that the bent portion coincides with the tip edge of the ridge 12, and the color parting line C coincides with the groove bottom of the wood grain groove 32. The line C is not exposed to the outside from the wood groove 32. Therefore, a door trim having an excellent appearance can be easily manufactured.
[0020]
In the above embodiment, before bringing the second mold 20 close to the first mold 10, the thermoplastic sheet 30 m is placed on the front-side molding surface 11 of the first mold 10 with the suction duct 13, the narrow duct 13 a and the vacuum source. Accordingly, when the tip edge of the ridge 12 is slightly deviated from the color parting line C, the action of correcting this deviation can be performed relatively freely. When such suction adhesion is not performed, the adhesion of the thermoplastic sheet 30m to the front molding surface 11 of the first mold 10 is heat-softened by being compressed and filled with the back molding surface 21 of the second molding mold 20. The effect of correcting the above-described deviation is weakened due to the viscous resistance of the thermoplastic plate 31m attached to the back surface layer 30b of the skin 30, but is not lost.
[0021]
Moreover, in the said embodiment, the base-material holder 25 which has wide opening hold | maintains the surrounding part of the thermoplastic plate material 31m, and it heat-softens it, and handling of the thermoplastic plate material 31m heat-softened is made easy in this way. Therefore, the laminate can be easily manufactured. However, in the present invention, a thermoplastic plate material 31m made of a molten resin extruded in a plate shape from an extrusion die is supplied onto a thermoplastic sheet 30m that is brought into suction contact with or close to the front side molding surface 11 of the first mold 10. Thus, it is also possible to carry out by interposing between the thermoplastic sheet 30m and the back side molding surface 21 of the second molding die 20, and the above-described effects can be obtained even in such a case.
[0022]
In the above embodiment, the guide bars 23 extending downward are fixed to the four corners of the second mold 20 that is the upper mold, and the base material holder 25 is guided and supported by the guide bar 23 so as to be lifted and lowered. The lowering of the predetermined distance or more is prevented by contacting the head 23a formed at the lower end of the guide bar 23. According to this, it is necessary to provide a special device for the operation of the substrate holder 25. As a result, the structure of the apparatus used for molding the door trim is simplified. However, the present invention may be carried out by providing a device for supporting the substrate holder 25 and moving it up and down.
[0023]
In the above embodiment, the first mold 10 is the lower mold and the second mold 20 is the upper mold. However, the present invention is implemented with the first mold 10 as the upper mold and the second mold 20 as the lower mold. It is also possible to do.
[0024]
【The invention's effect】
According to the present invention, door trims having different colors or patterns on the surface of the skin with a grained groove as a boundary can be manufactured integrally in substantially one step. In addition, the color cut-off line part is very easy to bend due to the cut formed in the back layer of the skin, and the other part is difficult to bend. There is no fear, and since the radius of curvature of the groove bottom of the grained groove becomes extremely small, the width of the grained groove is reduced and the bottom of the groove is not seen. Thereby, the external appearance of the laminated body from which the surface color or pattern differs in the both sides on the grain groove formed in the surface of the skin which covers a base material can be improved.
[0025]
According to the first embodiment, the thermoplastic sheet is brought into suction contact with the front side molding surface of the first mold before the second mold is brought close to the first mold. Therefore, even if the tip edge of the ridge contacts a position slightly deviated from the color parting line, the color parting line is freely corrected in the direction that coincides with the tip edge of the ridge by subsequent suction contact. Therefore, the possibility that the color parting line is shifted from the groove bottom of the grained groove and exposed outside the grained groove is further reduced.
[0026]
Also, according to the invention in which the first mold is the lower mold and the periphery of the heat-softened thermoplastic plate is held by the base holder having a wide opening, the heat-softened thermoplastic plate is easy to handle. Therefore, the laminate can be easily manufactured.
[0027]
In the invention of the preceding paragraph, a plurality of guide bars extending downward are fixed to the periphery of the upper die, the base material holder is guided and supported by the guide bar so that it can be raised and lowered, and the lowering over a predetermined distance with respect to the upper die is at the lower end of the guide bar According to the structure which is prevented by contacting the formed head, it is not necessary to provide a special device for the operation of the base material holder, so the structure of the device used for carrying out the present invention is simplified. The
[Brief description of the drawings]
FIG. 1 is a plan view of a molding apparatus used in an embodiment of a method for producing a laminate according to the present invention, excluding a second mold and a thermoplastic material.
2 is a cross-sectional view taken along the line XX in FIG. 1 and shows a state in which a thermoplastic sheet is brought close to a first mold and sucked into close contact with a front molding surface.
FIG. 3 is a cross-sectional view taken along line XX in FIG. 1, showing a state in the middle of the second mold and the base material holder approaching the first mold.
4 is a cross-sectional view taken along line XX of FIG. 1, showing a state in which a second mold and a substrate holder are closest to the first mold. FIG.
5 is a partial enlarged cross-sectional view of a main part at each stage of the apparatus shown in FIGS. 1 to 4. FIG.
FIG. 6 is a sectional view of a semifinished door trim manufactured by an embodiment of the method for manufacturing a laminate according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... 1st shaping | molding die, 11 ... Front side shaping | molding surface, 12 ... Projection, 20 ... 2nd shaping | molding die, 21 ... Back side shaping | molding surface, 22 ... Concave, 23 ... Guide bar, 23a ... Head, 25 ... Base material Holder, 26 ... opening, 30 ... skin, 30a ... surface layer, 30b ... back layer, 30c ... cut, 30m ... thermoplastic sheet, 31 ... substrate, 31m ... thermoplastic plate, C ... color parting line.

Claims

The surface of the thermoplastic sheet, which has a different color or pattern with the color parting line as the boundary, is softened by heating, and the surface is brought close to the front molding surface of the first mold. A thermoplastic sheet material that is softened by heating and softening a base material interposed between the thermoplastic sheet and the second mold, and a second mold having a back-side molding surface to be brought close to the first mold In the method of manufacturing a laminate in which the base material is covered with a skin by filling between the back surface and the back side molding surface, the thermoplastic sheet is a thin dense synthetic resin surface layer on the front side and the back side The first molding die is formed of a back surface layer of a foamed synthetic resin to be formed, and the back surface layer is formed with a cut across the entire thickness along a position corresponding to the color parting line on the surface layer surface. On the front molding surface A ridge having a narrow tip edge that abuts the surface of the surface layer is formed along a color marking parting line, and a concave portion is formed along the position corresponding to the ridge on the back-side molding surface of the second mold. A method for producing a laminate, characterized in that a strip is formed.

2. The laminate according to claim 1, wherein the surface of the surface layer of the thermoplastic sheet is sucked and adhered to the front molding surface of the first mold before the second mold is brought close to the first mold. Manufacturing method.

The first mold is a lower mold, the second mold is an upper mold, and the heat-softened thermoplastic plate material holds a peripheral portion in a base material holder having an opening wider than the back-side molding surface of the upper mold. And the base holder is positioned closest to the lower mold before the second mold, and the back-side molding surface passes through the opening to place the thermoplastic plate material between the thermoplastic sheet and the back surface of the thermoplastic sheet. The manufacturing method of the laminated body of Claim 1 or Claim 2 formed by filling.

The upper mold is provided with a plurality of guide bars that are fixed to the periphery of the upper mold and extend downward, and the base holder is guided and supported by the guide bar so that it can be raised and lowered. The manufacturing method of the laminated body of Claim 3 blocked | prevented by contact | abutting to the head formed in the bar lower end part.