JP4061706B2 - Method for producing multilayer molded product - Google Patents
Method for producing multilayer molded product Download PDFInfo
- Publication number
- JP4061706B2 JP4061706B2 JP12871098A JP12871098A JP4061706B2 JP 4061706 B2 JP4061706 B2 JP 4061706B2 JP 12871098 A JP12871098 A JP 12871098A JP 12871098 A JP12871098 A JP 12871098A JP 4061706 B2 JP4061706 B2 JP 4061706B2
- Authority
- JP
- Japan
- Prior art keywords
- mold
- skin material
- thermoplastic resin
- molten thermoplastic
- male
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
- B29C43/183—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
- B29C43/184—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould shaped by the compression of the material during moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3008—Instrument panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3014—Door linings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3041—Trim panels
Description
【０００１】
【発明の属する技術分野】
本発明は、熱可塑性樹脂からなる基材の表面に表皮材が貼合された多層成形品の製造方法に関する。
【０００２】
【従来の技術】
熱可塑性樹脂からなる基材の表面に表皮材が貼合された多層成形品は自動車内装部品（たとえばドアトリムやインストルメントパネル）、家電製品の内外装部品その他の広い分野で多く使用されている。
【０００３】
このような多層成形品の製造法としては、例えば、熱可塑性樹脂を射出成形等の種々の方法により予め所望の形状に成形した成形品（基材）の上に表皮材を接着剤等を使用して接着積層する方法や、雌雄一対の金型間に表皮材を供給したのち溶融熱可塑性樹脂を供給し、両金型を型締めして溶融熱可塑性樹脂を所望の形状に賦型すると同時にその表面に表皮材を貼合する射出プレス法による方法（特公平５−８３０５８号公報）などが知られている。
【０００４】
しかし、このような方法において、前者の方法は工程が複雑なうえに、接着剤に含まれる溶剤による人体や環境等への問題があり、また、後者の方法は、基材を形成すると同時にその表面に表皮材が貼合できるという利点はあるが、表皮材にも他の樹脂部分と全く同条件で成形圧が加えられるため、得られた成形品における表皮材の風合いが損なわれ、特に表皮材として起毛を有するファブリック表皮材を使用した場合には型締め時の圧力により毛倒れが生じて外観が著しく損なわれ、また、発泡層を裏打ちした表皮材を用いるような場合には型締め時の温度と成形圧により発泡層が潰れてクッション性が損なわれるという問題がある。
【０００５】
【発明が解決しようとする課題】
このようなことから、本発明者らは、基材を形成すると同時にその表面に表皮材が貼合できるという射出プレス法の利点を活かしつつ、起毛を有するファブリック表皮材や発泡層を裏打ちした表皮材を使用する場合であっても、毛倒れや発泡層の潰れにより外観が損なわれたりクッション性が損なわれることのない多層成形品の製造法について検討の結果、本発明に至った。
【０００６】
【課題を解決するための手段】
本発明は、雌雄一対からなる金型を使用して、熱可塑性樹脂からなる基材の表面に表皮材が貼合されてなる多層成形品を製造する方法において、
１．開放状態にある雌雄両金型間の所定の位置に表皮材を供給する工程、
２．表皮材と雌雄いずれか一方の金型の金型面との間に溶融熱可塑性樹脂を供給する工程、
３．溶融熱可塑性樹脂を供給後あるいは供給しながら型締めする工程、
４．金型内で溶融熱可塑性樹脂を一次冷却する工程、
５．両金型を（ｔ−ｔ 0 ）／２〜（ｔ−ｔ 0 ）の範囲で開き、表皮材表面と金型の成形面との間に隙間を形成させる工程（ここで、ｔは表皮材の成形前の原反厚みを示し、ｔ 0 は型締めにより圧縮された状態での表皮材厚みを示す）、
６．前記５．の状態で溶融熱可塑性樹脂を二次冷却する工程、
７．溶融熱可塑性樹脂が固化したのち両金型を開き、成形品を取り出す工程、
からなることを特徴とする多層成形品の製造方法を提供するものである。
【０００７】
【発明の実施の形態】
以下、図面に基づいて本発明を説明する。
尚、以下の説明は本発明の一例であり、本発明がこれに限定されるものでないことはいうまでもない。
【０００８】
【実施例】
本発明に使用される金型は、射出プレス成形等に通常使用されているものであって、型締め時に所望の製品形状となるキャビティを有する雄金型（１）および雌金型（２）の雌雄一対から構成され、そのいずれか一方はプレス機に連結されて上下もしくは左右に移動し、雌雄両金型が開閉可能となっている。
以下、上下に開閉する縦型の金型装置を用いた例を中心として説明する。
【０００９】
本発明の方法においては、先ず、かかる両金型を開いて開放状態とし、両金型間に表皮材（３）が供給される。（工程１．）（図１）
表皮材は、開閉が上下方向である縦型の金型装置である場合のようにそれが可能であれば、その下型（図１では雄金型に相当する）の金型面を覆うように載置してもよいし、雌雄両金型間に設けた表皮材固定枠等を用いて固定してもよく、或いは雌金型のパ−ティング面等にピン等の適宜の手段により固定してもよく、その供給、固定方法は任意である。
【００１０】
雌雄両金型間に表皮材が供給された後、表皮材と雌雄いずれか一方の金型の金型面との間に溶融熱可塑性樹脂（４）が供給される。（工程２．）（図２）
このとき、溶融熱可塑性樹脂は基材側となる成形面（図においては雄金型の成形面）と表皮材との間に供給される。
溶融熱可塑性樹脂（４）の供給は、金型外に設けた樹脂供給手段から金型面上に供給するような外部供給手段によってもよいが、図に示されるように基材樹脂側の成形面となる金型（図においては雄金型）の金型内に予め設けた溶融樹脂通路（５）を介して供給する方法が特に好ましい。
後者の場合、溶融樹脂通路（５）の一端は成形面に開口する樹脂供給口（６）と連結し、他端は金型外の可塑化装置（図示せず）と接続されている。
溶融樹脂通路（５）や樹脂供給口（６）の数は製品形状やその大きさ等により１つでもよいし２以上の複数であってもよく、その配置も適宜決定される。
また、このときの雌雄両金型間のキャビティクリアランスは、具体的には使用する表皮材の種類、厚みなどによって適宜決定される。
【００１１】
次いで、雌雄両金型を閉じて型締めを行う。（工程３．）（図３）
この型締めは、溶融熱可塑性樹脂の供給完了後に開始してもよいし、前記工程２．と同時に、すなわち溶融熱可塑性樹脂を供給しながら並行的に行ってもよい。
尚、溶融熱可塑性樹脂の供給完了後に型締めを行う際には、溶融熱可塑性樹脂の供給完了後速やかに型締めを開始することが好ましい。
型締めにより、表皮材（３）は雌金型（１）の成形面に接触すると同時に溶融熱可塑性樹脂層に一体的に貼合される。
【００１２】
型締めの後、型締め状態を保持しつつ一次冷却を行い（工程４．）、その後直ちに金型を僅かに開いて表皮材と接している金型成形面と表皮材表面との間に（ｔ−ｔ 0 ）／２〜（ｔ−ｔ 0 ）の範囲で隙間Ａを設け（工程５．）（図４）、この状態で二次冷却を行う。（工程６．）（ここで、ｔは表皮材の成形前の原反厚みを示し、ｔ 0 は型締めにより圧縮された状態での表皮材厚みを示す）。
【００１３】
ここで、一次冷却とは、型締め状態において溶融熱可塑性樹脂の表面部分が僅かに固化している状態にあればよく、熱可塑性樹脂層の厚み方向の中心部まで完全に固化している必要はない。
この一次冷却時間は、それが短すぎると製品の変形が大きく、長すぎる場合は表皮材へのダメ−ジが大きくなって毛倒れや発泡層のつぶれが生じるため、使用する表皮材の種類や製品厚み、成形時の樹脂温度、型締め圧力等によって最適の時間が選択される。
例えば、金型温度３０℃で、樹脂温度２００℃のポリプロピレン樹脂を使用し、２．５ｍｍ厚の基材に起毛のあるファブリック表皮材を貼合した多層成形品を製造する場合には、一次冷却時間はおよそ５秒から１０秒程度である。
【００１４】
また、金型を僅かに開いて表皮材と接している金型成形面と表皮材表面との間に設ける隙間Ａは金型の開き量に相当し、それがあまりに少なすぎると、例えば表皮材が発泡層を有している場合には圧縮された発泡層の回復量が少なく、また起毛のあるファブリック表皮材の場合には、圧縮により倒れた起毛部が十分に回復できず、成形後においても外観の悪いものとなり、一方、隙間Ａが広すぎると、冷却不足が顕著となって変形等の問題が生じるため、その隙間量Ａは、表皮材の成形前の原反厚みｔと型締めにより圧縮された状態での表皮材厚みｔ0との関係において、（ｔ−ｔ 0 ）／２〜（ｔ−ｔ 0 ）の範囲であり、表皮材の成形前の原反厚みと型締めにより圧縮された状態での厚みの差だけとするのが好ましい。
【００１５】
金型を僅かに開いて隙間Ａを設けた状態での二次冷却は、通常の成形方法と同様に、型締めされている溶融熱可塑性樹脂が完全に固化されるまで行われる。
前記工程３．の型締めによって圧縮された表皮材は、前記工程５．による隙間Ａによって圧縮状態が緩和され、この冷却期間中に発泡層付の表皮材であれば圧縮されていた発泡層が回復し、また起毛のある表皮材であれば倒れていた起毛部分が復元する。
【００１６】
溶融熱可塑性樹脂が固化した後、両金型を開き（工程７．）（図５）、基材表面に表皮材が貼合された多層成形品が取り出される。（図６）
【００１７】
かかる方法において、製品の大きさ、基材の厚み、製品形状、使用する表皮材等によっては冷却不足によって製品の変形が問題となることがあるが、このような場合には、基材の裏面側にリブ（７）等を設ける（図７）ことにより変形を抑制することができる。
【００１８】
以上の説明においては、金型の開閉方向が上下である雌雄両金型を用いた例について述べたが、金型の開閉方向は何ら本質ではなく、開閉方向が左右の横方向である雌雄両金型を用いても全く同様に実施することができる。
【００１９】
本発明の方法に適用される表皮材としてはファブリック表皮材が好んで用いられ、特に起毛のあるモケット、トリコット等の織物や編物、ニ−ドルパンチカ−ペット等の不織布などが好適に使用される。
このような表皮材はそれ単独で使用されるのみならず、２種以上を接着剤等で接着した複合表皮材として使用することもでき、特にポリプロピレン発泡シ−トなどのポリオレフィン系樹脂発泡シ−トやウレタン発泡シ−トなどを裏打ち材としたファブリック表皮材は好んで用いられる。
また、熱可塑性樹脂もしくは熱可塑性エラストマ−のシ−トまたはフィルム、紙、金属箔、ネット状物などに前記したような発泡シ−トを裏打ち材とした複合表皮材も好んで使用される。
尚、前記したポリプロピレン発泡シ−トなどのポリオレフィン系樹脂発泡シ−トは架橋タイプだけではなく非架橋タイプの発泡シ−トも用いることができ、その発泡倍率は特に限定されない。
また、これら表皮材の使用にあたっては、貼合すべき表皮材形状に応じて予備賦型を行っていてもよい。
【００２０】
また、本発明の方法に適用される熱可塑性樹脂としては、一般の射出成形、射出圧縮成形、押出成形、スタンピング成形などで通常使用されているものであれば特に制限なく使用することができ、例えば、ポリエチレンやポリプロピレンなどのポリオレフィン樹脂、ポリスチレン、アクリル樹脂、アクリロニトリル−スチレン−ブタジエンブロック共重合体、ナイロンなどのポリアミド、ポリ塩化ビニル、ポリカ−ボネ−ト、スチレン−ブタジエンブロック共重合体などの一般的な熱可塑性樹脂の他、ＥＰＭやＥＰＤＭなどの熱可塑性エラストマ−、これらの混合物、あるいはこれらを用いたポリマ−アロイなどが挙げられ、これらは発泡性であっても非発泡性であってもよい。
本発明でいう熱可塑性樹脂とはこれらのすべてを含むものである。
また、これらの熱可塑性樹脂には必要に応じてガラス繊維などの強化繊維、タルク、ワラストナイトなどの各種の無機もしくは有機フィラ−などの充填材を含有していてもよく、もちろん、通常使用される各種の顔料、滑材、帯電防止剤、酸化防止剤、紫外線防止剤などが適宜配合されていてもよい。
【００２１】
【発明の効果】
本発明の方法によれば、基材を形成すると同時にその表面に表皮材が貼合できるという射出プレス法の利点を活かしつつ、起毛を有するファブリック表皮材や発泡層を裏打ちした表皮材を使用する場合であっても、毛倒れや発泡層の潰れにより外観が損なわれたりクッション性が損なわれることがなく、しかも変形の少ない外観の良好な表皮材貼合の多層成形体を容易に製造することができる。
【図面の簡単な説明】
【図１】本発明の方法による製造工程を金型の概略断面図で示したものである。
【図２】本発明の方法による製造工程を金型の概略断面図で示したものである。
【図３】本発明の方法による製造工程を金型の概略断面図で示したものである。
【図４】本発明の方法による製造工程を金型の概略断面図で示したものである。
【図５】本発明の方法による製造工程を金型の概略断面図で示したものである。
【図６】本発明の方法により得られる多層成形品の例を断面図で示したものである。
【図７】本発明の方法による得られるリブ付の多層成形品の例を断面図で示したものである。
【符号の説明】
１：雄金型
２：雌金型
３：表皮材
４：溶融熱可塑性樹脂
５：溶融樹脂通路
６：樹脂供給口
７：リブ
Ａ：隙間[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a multilayer molded article in which a skin material is bonded to the surface of a base material made of a thermoplastic resin.
[0002]
[Prior art]
Multilayer molded products in which a skin material is bonded to the surface of a base material made of a thermoplastic resin are widely used in a wide range of fields such as automobile interior parts (for example, door trims and instrument panels), interior / exterior parts of home appliances, and the like.
[0003]
As a method for producing such a multilayer molded product, for example, an adhesive is used as a skin material on a molded product (base material) obtained by molding a thermoplastic resin into a desired shape in advance by various methods such as injection molding. The method of laminating and laminating and supplying the skin material between a pair of male and female molds, then supplying the molten thermoplastic resin, and clamping both molds to mold the molten thermoplastic resin into a desired shape at the same time A method using an injection press method (Japanese Patent Publication No. 5-83058) for bonding a skin material to the surface is known.
[0004]
However, in such a method, the former method is complicated in process and has a problem on the human body and environment due to the solvent contained in the adhesive, and the latter method simultaneously forms the base material. Although there is an advantage that the skin material can be bonded to the surface, molding pressure is applied to the skin material under exactly the same conditions as other resin parts, so the texture of the skin material in the obtained molded product is impaired, especially the skin When using a fabric skin material with brushed material as a material, the appearance of the skin is significantly impaired due to the pressure at the time of clamping, and when using a skin material lined with a foam layer, There is a problem that the foamed layer is crushed by the temperature and molding pressure, and the cushioning property is impaired.
[0005]
[Problems to be solved by the invention]
For this reason, the present inventors have used the advantage of the injection press method that the skin material can be bonded to the surface at the same time that the base material is formed, and the skin material lined with a fabric skin material or a foamed layer having a brushed surface. As a result of studying a method for producing a multilayer molded product in which the appearance is not impaired or the cushioning property is not impaired by the falling of the hair or the crushing of the foamed layer even when the material is used, the present invention has been achieved.
[0006]
[Means for Solving the Problems]
The present invention is a method for producing a multilayer molded article in which a skin material is bonded to the surface of a base material made of a thermoplastic resin using a mold consisting of a male and female pair,
1. Supplying the skin material to a predetermined position between the male and female molds in an open state;
2. Supplying molten thermoplastic resin between the skin material and the mold surface of either the male or female mold,
3. A process of clamping the mold after or while supplying the molten thermoplastic resin;
4). A step of primarily cooling the molten thermoplastic resin in the mold,
5. A step of opening both molds in the range of (t−t 0 ) / 2 to (t−t 0 ) to form a gap between the surface of the skin material and the molding surface of the mold (where t is the skin material) ) Indicates the thickness of the original fabric before molding, and t 0 indicates the thickness of the skin material in a state compressed by mold clamping) .
6). 5. above. Secondary cooling of the molten thermoplastic resin in the state of
7). The process of opening both molds after the molten thermoplastic resin has solidified and taking out the molded product,
The manufacturing method of the multilayer molded article characterized by consisting of these is provided.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described below with reference to the drawings.
In addition, the following description is an example of this invention and it cannot be overemphasized that this invention is not limited to this.
[0008]
【Example】
The mold used in the present invention is normally used for injection press molding or the like, and has a male mold (1) and a female mold (2) having a cavity that has a desired product shape when the mold is clamped. One of them is connected to a press machine and moves up and down or left and right, so that both male and female molds can be opened and closed.
Hereinafter, an example using a vertical mold apparatus that opens and closes vertically will be mainly described.
[0009]
In the method of the present invention, first, both the molds are opened and opened, and the skin material (3) is supplied between the both molds. (Step 1. ) (FIG. 1)
The skin material covers the mold surface of the lower mold (corresponding to the male mold in FIG. 1) if possible, as in the case of a vertical mold apparatus that opens and closes vertically. It may be placed on the surface, fixed using a skin material fixing frame provided between the male and female molds, or fixed to the parting surface of the female mold by an appropriate means such as a pin. The supply and fixing method may be arbitrary.
[0010]
After the skin material is supplied between the male and female molds, the molten thermoplastic resin (4) is supplied between the skin material and the mold surface of one of the male and female molds. (Step 2. ) (FIG. 2)
At this time, the molten thermoplastic resin is supplied between the molding surface on the base material side (the molding surface of the male mold in the figure) and the skin material.
The molten thermoplastic resin (4) may be supplied from an external supply means such as a resin supply means provided outside the mold onto the mold surface, but as shown in the figure, molding on the base resin side It is particularly preferable to supply the surface via a molten resin passage (5) provided in advance in a mold of a mold (male mold in the figure) to be a surface.
In the latter case, one end of the molten resin passage (5) is connected to a resin supply port (6) that opens to the molding surface, and the other end is connected to a plasticizing device (not shown) outside the mold.
The number of the molten resin passages (5) and the resin supply ports (6) may be one or a plurality of two or more depending on the product shape, the size thereof, and the like, and the arrangement thereof is also appropriately determined.
In addition, the cavity clearance between the male and female molds at this time is appropriately determined according to the type and thickness of the skin material used.
[0011]
Next, both the male and female molds are closed and clamping is performed. (Step 3. ) (FIG. 3)
This mold clamping may be started after the completion of the supply of the molten thermoplastic resin, or in the
In addition, when performing mold clamping after the completion of the supply of the molten thermoplastic resin, it is preferable to start the mold clamping immediately after the completion of the supply of the molten thermoplastic resin.
By the mold clamping, the skin material (3) comes into contact with the molding surface of the female mold (1) and at the same time is integrally bonded to the molten thermoplastic resin layer.
[0012]
After the mold clamping, primary cooling is performed while maintaining the mold clamping state (
[0013]
Here, the primary cooling means that the surface portion of the molten thermoplastic resin is only slightly solidified in the mold-clamping state, and needs to be completely solidified to the center in the thickness direction of the thermoplastic resin layer. There is no.
If this primary cooling time is too short, the deformation of the product will be large, and if it is too long, the damage to the skin material will become large and the hair will fall down and the foam layer will be crushed. The optimum time is selected according to the product thickness, the resin temperature during molding, the clamping pressure, and the like.
For example, when producing a multilayer molded product using a polypropylene resin with a mold temperature of 30 ° C. and a resin temperature of 200 ° C. and a raised fabric skin material bonded to a 2.5 mm thick base material, primary cooling is performed. The time is about 5 to 10 seconds.
[0014]
Further, the gap A provided between the mold molding surface that is in contact with the skin material by slightly opening the mold and the surface of the skin material corresponds to the amount of opening of the mold, and if it is too small, for example, the skin material If the fabric has a foam layer, the amount of recovery of the compressed foam layer is small, and in the case of a raised fabric skin material, the raised portion that has fallen due to compression cannot be recovered sufficiently, and after molding, On the other hand, if the gap A is too wide, cooling deficiency becomes prominent and problems such as deformation occur. Therefore, the gap amount A depends on the thickness t of the raw material before molding the skin material and the mold clamping. In relation to the thickness of the skin material t 0 in the state compressed by the above , it is in the range of (t−t 0 ) / 2 to (t−t 0 ). It is preferable that only the thickness difference in the compressed state is taken.
[0015]
Secondary cooling in a state where the mold is slightly opened and the gap A is provided is performed until the molten thermoplastic resin being clamped is completely solidified, as in a normal molding method.
[0016]
After the molten thermoplastic resin is solidified, both molds are opened (step 7. ) (FIG. 5), and a multilayer molded article having a skin material bonded to the substrate surface is taken out. (Fig. 6)
[0017]
In such a method, depending on the size of the product, the thickness of the base material, the product shape, the skin material used, etc., deformation of the product may become a problem due to insufficient cooling. By providing a rib (7) or the like on the side (FIG. 7), deformation can be suppressed.
[0018]
In the above description, an example using both male and female molds in which the opening and closing direction of the mold is up and down has been described. Even if a mold is used, it can be carried out in exactly the same way.
[0019]
As the skin material applied to the method of the present invention, a fabric skin material is preferably used, and in particular, a woven or knitted fabric such as a raised moquette or tricot, or a nonwoven fabric such as a needle punch carpet is preferably used.
Such a skin material is not only used alone, but can also be used as a composite skin material in which two or more kinds are bonded with an adhesive or the like, and in particular, a polyolefin resin foam sheet such as a polypropylene foam sheet. Fabric skin materials with a backing material such as sheet or urethane foam sheet are preferred.
Further, a composite skin material using a foam sheet as a backing material for a sheet of thermoplastic resin or thermoplastic elastomer or a film, paper, metal foil, net-like material or the like is also preferably used.
The polyolefin resin foam sheet such as the above-mentioned polypropylene foam sheet can be not only a crosslinked type but also a non-crosslinked type foamed sheet, and the expansion ratio is not particularly limited.
Moreover, in using these skin materials, pre-molding may be performed according to the skin material shape to be bonded.
[0020]
The thermoplastic resin applied to the method of the present invention can be used without particular limitation as long as it is normally used in general injection molding, injection compression molding, extrusion molding, stamping molding, etc. For example, polyolefin resin such as polyethylene and polypropylene, polystyrene, acrylic resin, acrylonitrile-styrene-butadiene block copolymer, polyamide such as nylon, polyvinyl chloride, polycarbonate, styrene-butadiene block copolymer, etc. In addition to typical thermoplastic resins, thermoplastic elastomers such as EPM and EPDM, mixtures thereof, polymer alloys using these, and the like may be mentioned. Good.
The thermoplastic resin referred to in the present invention includes all of these.
In addition, these thermoplastic resins may contain reinforcing fibers such as glass fibers, and fillers such as various inorganic or organic fillers such as talc and wollastonite. Various pigments, lubricants, antistatic agents, antioxidants, ultraviolet ray inhibitors and the like may be appropriately blended.
[0021]
【The invention's effect】
According to the method of the present invention, while utilizing the advantage of the injection press method that a skin material can be bonded to the surface at the same time as forming a base material, a fabric skin material having brushed or a skin material lined with a foam layer is used. Even if it is a case, the outer appearance is not impaired or the cushioning property is not impaired due to the fall of the hair or the foam layer, and a multilayer molded body with a good skin material bonded with an appearance with little deformation is easily manufactured. Can do.
[Brief description of the drawings]
FIG. 1 is a schematic sectional view of a mold showing a manufacturing process according to the method of the present invention.
FIG. 2 is a schematic sectional view of a mold showing a manufacturing process according to the method of the present invention.
FIG. 3 is a schematic sectional view of a mold showing a manufacturing process according to the method of the present invention.
FIG. 4 is a schematic sectional view of a mold showing a manufacturing process according to the method of the present invention.
FIG. 5 is a schematic sectional view of a mold showing a manufacturing process according to the method of the present invention.
FIG. 6 is a cross-sectional view showing an example of a multilayer molded product obtained by the method of the present invention.
FIG. 7 is a cross-sectional view showing an example of a multilayer molded product with ribs obtained by the method of the present invention.
[Explanation of symbols]
1: male mold 2: female mold 3: skin material 4: molten thermoplastic resin 5: molten resin passage 6: resin supply port 7: rib A: gap
Claims (2)
１．開放状態にある雌雄両金型間の所定の位置に表皮材を供給する工程、
２．表皮材と雌雄いずれか一方の金型の金型面との間に溶融熱可塑性樹脂を供給する工程、
３．溶融熱可塑性樹脂を供給後あるいは供給しながら型締めする工程、
４．金型内で溶融熱可塑性樹脂を一次冷却する工程、
５．両金型を（ｔ−ｔ 0 ）／２〜（ｔ−ｔ 0 ）の範囲で開き、表皮材表面と金型の成形面との間に隙間を形成させる工程（ここで、ｔは表皮材の成形前の原反厚みを示し、ｔ 0 は型締めにより圧縮された状態での表皮材厚みを示す）、
６．前記５．の状態で溶融熱可塑性樹脂を二次冷却する工程、
７．溶融熱可塑性樹脂が固化したのち両金型を開き、成形品を取り出す工程、
からなることを特徴とする多層成形品の製造方法。In a method for producing a multilayer molded article in which a skin material is bonded to the surface of a base material made of a thermoplastic resin, using a mold consisting of a male and female pair,
1. Supplying the skin material to a predetermined position between the male and female molds in an open state;
2. Supplying molten thermoplastic resin between the skin material and the mold surface of either the male or female mold,
3. A process of clamping the mold after or while supplying the molten thermoplastic resin;
4). A step of primarily cooling the molten thermoplastic resin in the mold,
5. A step of opening both molds in the range of (t−t 0 ) / 2 to (t−t 0 ) to form a gap between the surface of the skin material and the molding surface of the mold (where t is the skin material) ) Indicates the thickness of the original fabric before molding, and t 0 indicates the thickness of the skin material in a state compressed by mold clamping) .
6). 5. above . Secondary cooling of the molten thermoplastic resin in the state of
7). The process of opening both molds after the molten thermoplastic resin has solidified and taking out the molded product,
A method for producing a multilayer molded article comprising the steps of:
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP12871098A JP4061706B2 (en) | 1998-05-12 | 1998-05-12 | Method for producing multilayer molded product |
| US09/305,104 US6413461B1 (en) | 1998-05-08 | 1999-05-04 | Process for producing multilayer molded article |
| EP99108561A EP0955143A3 (en) | 1998-05-08 | 1999-05-05 | Process for producing multilayer molded article |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP12871098A JP4061706B2 (en) | 1998-05-12 | 1998-05-12 | Method for producing multilayer molded product |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH11320589A JPH11320589A (en) | 1999-11-24 |
| JP4061706B2 true JP4061706B2 (en) | 2008-03-19 |
Family
ID=14991524
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP12871098A Expired - Lifetime JP4061706B2 (en) | 1998-05-08 | 1998-05-12 | Method for producing multilayer molded product |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP4061706B2 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2001121561A (en) * | 1999-10-26 | 2001-05-08 | Sumitomo Chem Co Ltd | Thermoplastic resin molded article and method for making the same |
| US6835340B2 (en) | 2001-02-19 | 2004-12-28 | Sumitomo Chemical Company, Ltd. | Process for producing multilayer molded article |
| JP6514994B2 (en) * | 2015-08-31 | 2019-05-15 | 株式会社クラレ | Method of manufacturing in-mold molded body |
-
1998
- 1998-05-12 JP JP12871098A patent/JP4061706B2/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| JPH11320589A (en) | 1999-11-24 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US6413461B1 (en) | Process for producing multilayer molded article | |
| CA1334613C (en) | Process for producing a multilayer molded article | |
| US5759464A (en) | Methods for manufacturing multilayer moldings | |
| US5885515A (en) | Blow molding process | |
| US5558883A (en) | Mold design and process for producing a multilayer part by injection process molding | |
| EP0466181B1 (en) | Method for producing molded article of thermoplastic resin | |
| JP4186312B2 (en) | Method for producing multilayer molded product | |
| US6183680B1 (en) | Process for producing multilayer molded article | |
| JP4061706B2 (en) | Method for producing multilayer molded product | |
| US6579488B1 (en) | Process for producing a thermoplastic resin molded article | |
| JP4263269B2 (en) | Method for producing multilayer molded product | |
| JP3178956B2 (en) | Mold for stamping molding with integral skin and molding method | |
| EP0930142A2 (en) | Metal mold for producing a synthetic resin molded product in a compression-molding method | |
| CA2020117C (en) | Mold for producing a multilayer molded article | |
| JP2000313096A (en) | Multilayered molded article and production thereof | |
| JP2931236B2 (en) | Resin molding and method for producing the same | |
| JP3032328B2 (en) | Method and apparatus for manufacturing multilayer molded article | |
| JP2000313022A (en) | Production of multilayered molded product | |
| JP2611775B2 (en) | Molded body with skin and method for producing the same | |
| JP4453126B2 (en) | Mold for manufacturing thermoplastic resin molded body and method for manufacturing thermoplastic resin molded body | |
| JPS59136255A (en) | Manufacture of composite shape | |
| JP2000301645A (en) | Multilayer molded product and its manufacture | |
| JP3314979B2 (en) | Stamping molding die and stamping molding method | |
| JP2973565B2 (en) | Manufacturing method of multilayer molded products | |
| JP3363719B2 (en) | Manufacturing method of skin-integrated synthetic resin molded product |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| A621 | Written request for application examination |
Free format text: JAPANESE INTERMEDIATE CODE: A621 Effective date: 20050106 |
|
| A977 | Report on retrieval |
Free format text: JAPANESE INTERMEDIATE CODE: A971007 Effective date: 20060512 |
|
| A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20070123 |
|
| A521 | Written amendment |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20070323 |
|
| TRDD | Decision of grant or rejection written | ||
| A01 | Written decision to grant a patent or to grant a registration (utility model) |
Free format text: JAPANESE INTERMEDIATE CODE: A01 Effective date: 20071204 |
|
| A61 | First payment of annual fees (during grant procedure) |
Free format text: JAPANESE INTERMEDIATE CODE: A61 Effective date: 20071217 |
|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20110111 Year of fee payment: 3 |
|
| RD05 | Notification of revocation of power of attorney |
Free format text: JAPANESE INTERMEDIATE CODE: A7425 Effective date: 20080125 |
|
| RD05 | Notification of revocation of power of attorney |
Free format text: JAPANESE INTERMEDIATE CODE: R3D05 |
|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20110111 Year of fee payment: 3 |
|
| A072 | Dismissal of procedure |
Free format text: JAPANESE INTERMEDIATE CODE: A072 Effective date: 20080513 |
|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20110111 Year of fee payment: 3 |
|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20120111 Year of fee payment: 4 |
|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20130111 Year of fee payment: 5 |
|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20130111 Year of fee payment: 5 |
|
| EXPY | Cancellation because of completion of term |