JP4854416B2 - Method and apparatus for manufacturing synthetic resin laminate - Google Patents

Description

  The present invention relates to a method and apparatus for manufacturing a synthetic resin laminate composed of a surface material and a substrate, for example, a method and apparatus for manufacturing a synthetic resin laminate used as an interior part for a vehicle, and a synthetic resin laminate. It is about goods.

  2. Description of the Related Art Conventionally, in order to improve the value of automobile interiors, interior parts for vehicles are used in which a surface material excellent in design, touch, etc. is integrated with a base material having necessary rigidity. As one of the interior parts for vehicles, there are a dashboard panel and an instrument panel on which various devices are mounted. In general, these panels are formed with so-called meter visors protruding above the devices so as to improve the visibility of the devices by blocking sunlight or the like from outside the vehicle. Meter visors typically have relatively large ridges on the surface of these panels. For this reason, when the surface material is molded with a female mold in which a concave portion corresponding to the raised portion of the panel is formed, the surface material may be excessively stretched and thinned in the female concave portion, and the quality of the panel may be lowered.

  Japanese Patent Application Laid-Open No. 10-146861 discloses a method in which a sheet-like surface material is gradually stretched in two stages, a first preforming step and a second preforming step, without preheating the sheet-like surface material. Disclosed is a method for manufacturing an integrally molded article of a skin material and a base material and a manufacturing apparatus therefor, which can prevent breakage of a sheet-like surface material even when there is an angular ridge line portion in the concave portion of the mold.

  JP-A-2003-326576 discloses a method in which a surface material is closed by preheating a sheet-like surface material and then closing the female die and the male die while holding the end of the sheet-like surface material movably. Disclosed is a sheet-clad injection compression molding method and molding apparatus for preventing thinning at a female recess.

  Japanese Patent Laid-Open No. 06-1115011 forms a sheet for lamination by laminating a surface layer mainly composed of a thermoplastic resin and elastic beads or a porous inorganic filler, and a thermoplastic elastomer layer. Disclosed is a laminated molded article having a soft touch feeling (suede feeling) by laminating a lamination sheet on the surface of the molded article main body. Furthermore, a laminated molded product is disclosed in which a foamed layer made of a synthetic resin is laminated on the thermoplastic elastomer layer side of the laminating sheet, thereby increasing the soft touch feeling (suede feeling).

Japanese Patent Application Laid-Open No. 07-047630 discloses an adhesive layer made of a low-melting polyolefin interposed between a skin material layer formed as a cushion layer from a polyolefin resin foam and a core resin layer made of a polyolefin resin. Thus, a multilayer molded article having excellent adhesiveness is disclosed.
Japanese Patent Laid-Open No. 10-146861 JP 2003-326576 A Japanese Patent Laid-Open No. 06-115011 Japanese Patent Application Laid-Open No. 07-047630

  However, as disclosed in JP-A-10-146861, when the sheet-like surface material is extended without preheating, the sheet-like surface material is cold-worked. Compared to the case of preheating, the closing speed of male and female molds must be reduced. Furthermore, since the sheet-like surface material is gradually extended in two stages of the first pre-forming step and the second pre-forming step, it is difficult to shorten the time required for forming.

  Further, as disclosed in Japanese Patent Application Laid-Open No. 2003-326576, when the preheating of the sheet surface material is performed at a stage before the sheet surface material is disposed between the male mold and the female mold, the preheating is performed. When the placed sheet-like surface material is placed between the male mold and the female mold, not only the sheet-like surface material may be bent or deformed, but the temperature of the sheet-like surface material is determined when the preheating is finished. Therefore, it is necessary to consider the temperature decrease of the sheet-like surface material when setting the mold closing speed of the male mold and the female mold. Further, since the vacuum suction is performed before the mold closing is completed, the sheet-like surface material is gradually in contact with the vacuum forming suction port on the bottom surface from the upper edge of the inner surface of the female recess. Will be extended. The amount of extension of the sheet-like surface material in the portion in contact with the inner surface of the female recess is less than the amount of extension of the sheet-like surface material in the portion not in contact with the inner surface of the female recess. Accordingly, the thickness of the sheet-like surface material near the bottom of the female recess is smaller than the thickness of the sheet-like surface material near the opening of the female recess. For this reason, when a pattern such as a squeeze or a pattern is arranged on the sheet-like surface material, there is a risk of appearance defects such as pattern elongation on the sheet-like surface material near the bottom of the female recess. There is.

  Moreover, since the lamination sheet disclosed in Japanese Patent Laid-Open Nos. 06-1115011 and 07-047630 itself is composed of a plurality of layers, it requires many steps for its production. Therefore, there exists a malfunction that the manufacturing cost of the laminated molded product coat | covered with this lamination sheet | seat rises. Furthermore, when it is composed of many layers including the molded product body, such as a laminated molded product using the laminated sheet disclosed in these publications, the laminated molded product is hot or cold. Occasionally, the laminated molded product may be deformed due to the difference in the linear expansion coefficient of each layer, or internal stress may accumulate in the laminated molded product, causing problems in the laminated molded product. Furthermore, since the laminated molded product disclosed in Japanese Patent Application Laid-Open No. 06-111501 is covered with a plurality of layers made of different materials, the recyclability may be reduced.

An object of the present invention is to provide a method for producing a synthetic resin laminate having a raised portion on the surface, which has high productivity, can be easily changed according to the material, and has a low incidence of defective products.
Another object of the present invention is to provide a method for producing a synthetic resin laminate, which has high production efficiency, can be easily changed according to the material, has a low incidence of defective products, and has a simple structure. is there.
Still another object of the present invention is to provide a method and apparatus for producing a synthetic resin laminate having a sheet-like surface material having a single-layer structure and sufficient impact resistance.

According to a first aspect of the present invention, in the method for manufacturing a synthetic resin laminate having a raised portion on the surface, a female molding surface having a recess corresponding to the surface shape of the raised portion, and a back surface shape of the raised portion. Arranging and fixing a sheet-like surface material made of a thermoplastic synthetic resin between a male molding surface having a corresponding convex part, and the sheet-like surface fixed between the molding surfaces Applying a heating fluid such as heated air to the material, heating the sheet-like surface material, and passing the heating fluid on the sheet-like surface material through the male guide, while applying the heating fluid nozzle fixed to the male, or, after applying the heated fluid to the sheet surface material, have mold line closed in the male and the female, the Before the projection is heated by contacting the sheet-like surface material Heat transfer from the sheet-like surface material to the male mold is generated, the sheet-like surface material is extended along the molding surface of the female mold at the convex portion, and the sheet-shaped surface material The temperature of the abutting portion of the sheet-like surface material is set around the abutting portion so that the thinning or breakage that constitutes the malfunction of the sheet-like surface material does not occur at the abutting portion with the convex portion. Maintaining the temperature lower than the temperature of the sheet-like surface material extending to the sheet, and after completion of the mold closing, the sheet-like surface material is vacuum-formed with respect to the molding surface of the female die, and the sheet-like Injecting molten resin into the cavity defined between the sheet-shaped surface material and the male molding surface by the vacuum forming and the step of closely attaching the surface material to the molding surface of the female mold, and the melting Forming a base material layer laminated on the sheet-like surface material with resin That is characterized in that a step is a method for producing a synthetic resin laminate.

According to a second aspect of the present invention, in the method for producing a synthetic resin laminate having a raised portion on the surface, a female molding surface having a recess corresponding to the surface shape of the raised portion, and a back surface shape of the raised portion. A step of placing and fixing a sheet-like surface material made of a thermoplastic synthetic resin between a male molding surface having a corresponding convex part, and after fixing the sheet-like surface material, After the female mold is closed and the convex portion comes into contact with the sheet-like surface material, a heating fluid such as air is applied to the sheet-like surface material to heat the sheet-like surface material. The male mold and the female mold are closed during the application of the heating fluid to the sheet-shaped surface material or after the heating fluid is applied to the sheet-shaped surface material. The sheet-like surface material is extended along the molding surface of the female mold by a convex portion. Together, by allowing abutment of the convex portion on the sheet surface material, causing thermal conduction thermal energy is transferred to the male from the heated the sheet surface material, the convex of the sheet-shaped surface material Maintaining the temperature of the contact part with the part at a temperature lower than the temperature of the sheet-like surface material extending around the contact part, and after completing the mold closing, the sheet-like surface material Vacuum forming the molding surface of the female mold and closely attaching the sheet-like surface material to the molding surface of the female mold; and between the sheet-like surface material and the male molding surface by the vacuum molding And a step of injecting a molten resin into the cavity defined by the step of forming a base material layer laminated on the sheet-like surface material with the molten resin. It is.

According to a third invention of the present application, the male mold having a convex molding surface as a whole, the female mold having a concave molding surface as a whole, and the both moldings when the male mold and the female mold are closed. A cavity defined between surfaces, at least one injection molding resin passage opening in the convex molding surface, a plurality of vacuum molding suction holes opening in the concave molding surface, and both moldings Heating the sheet-like surface material in a synthetic resin laminate manufacturing apparatus having a clamp device for fixing a sheet-like surface material made of a thermoplastic synthetic resin between surfaces and a device for heating the sheet-like surface material A heating fluid nozzle fixed to the female mold and supplying a heated fluid such as heated air between the molding surfaces, and a fluid guide surface formed on the male mold. The fluid guide surface includes the male mold and the When the mold closes, the male mold comes into contact with the sheet-like surface material fixed by the clamping device, and then extends the sheet-like surface material along the concave molding surface. The fluid ejected from the heating fluid nozzle is configured to be applied to a desired portion of the sheet-like surface material , and the male mold is in contact with the sheet-like surface material fixed by the clamp device. Until the sheet-shaped surface material is stretched along the concave molding surface, the convex portion formed on the molding surface of the male mold is brought into contact with the sheet-shaped surface material to be heated. In addition , the synthetic resin laminate manufacturing apparatus is configured to generate heat conduction in which heat energy is transferred from the sheet-shaped surface material to the male mold .

4th invention of this application is comprised with the sheet-like surface material which consists of a thermoplastic elastomer single | mono layer structure, and the material which has compatibility with the said surface material, and is integrated with the back surface of the said surface material by a hot-melt state. It is related with the manufacturing method or manufacturing apparatus of a synthetic resin laminated product characterized by consisting of a resin-made base material layer.

  According to the first invention of the present application, the male convex portion is in contact with the sheet-shaped surface material while the male convex portion extends the sheet-shaped surface material. In between, heat conduction based on the thermal gradient between the sheet-like surface material and the male mold occurs. That is, thermal energy is transferred from the heated sheet-shaped surface material to the male mold, and the temperature of the sheet-shaped surface material at the contact portion between the sheet-shaped surface material and the male convex portion is around the contact portion. The temperature is lower than the temperature of the extending sheet-like surface material.

  Further, when the male convex portion is brought into contact with the sheet-like surface material while the heating of the sheet-like surface material is continued, both the sheet-like surface material and the male convex portion are heated. Since the heat capacity of the mold is much larger than that of the sheet-like surface material, the temperature of the male mold is maintained at a temperature lower than that of the sheet-like surface material. Therefore, even when the male convex portion abuts during heating of the sheet surface material, the thermal gradient between the sheet surface material and the male die is maintained, and the sheet surface material and the male convex portion The temperature of the sheet-like surface material at the contact portion is lower than the temperature of the sheet-like surface material extending around the contact portion.

  Further, in the state where the male convex portion is brought into contact with the sheet-like surface material, the heating fluid is not applied to the contact portion between the sheet-like surface material and the male convex portion. The temperature rise rate of the sheet-like surface material at the contact portion between the material and the male convex portion can be suppressed to a value lower than the temperature rise rate of the sheet-like surface material extending around the contact portion. .

  For this reason, when the sheet-like surface material is heated by the heating fluid, the tensile strength of the sheet-like surface material at the contact portion between the sheet-like surface material and the male convex portion extends around the contact portion. The tensile strength of the sheet-like surface material is maintained higher than the tensile strength of the sheet-like surface material, and the contact portion with the convex portion of the sheet-like surface material is in a state that “is less likely to stretch” than the remaining portion of the sheet-like surface material.

  Therefore, according to the first invention of the present application, in order to extend the sheet-like surface material along the female molding surface, the male convex portion is brought into contact with the sheet-like surface material, and this male convex portion Even when the sheet-like surface material is pressed at the contact portion between the male convex portion and the sheet-like surface material, problems such as thinning or breaking of the sheet-like surface material are unlikely to occur. Therefore, a high-quality synthetic resin laminate can be provided.

  Further, the sheet-like surface material is stretched along the female molding surface, and then is brought into close contact with the female molding surface by the negative pressure supplied to the female suction hole and vacuum-formed. In order to improve the accuracy of this vacuum forming and obtain a high-quality synthetic resin laminate, the bottom of the concave portion formed by sucking the sheet-shaped surface material and forming the corresponding portion of the sheet-shaped surface material on the molding surface of the female mold Or it is necessary to fill the deepest part. However, when a sheet-like surface material that has been uniformly heated as a whole is vacuum-sucked into a female mold having suction holes at the bottom or deepest part of the recess, the sheet-like surface is generally directed toward the bottom or deepest part of the recess. The thickness of the material gradually decreases, and the thickness of the sheet-like surface material does not become uniform. In some cases, the sheet-like surface material is broken or perforated. This is because the sheet-like surface material is stretched while sequentially contacting from the shallow wall surface of the female molding surface toward the bottom of the recess or the deepest suction hole. According to 1st invention of this application, the part of the sheet-like surface material pushed into the bottom part or deepest part of a female recessed part with the front-end | tip part of a male convex part is the low temperature which the male convex part contact | abutted. Since it is a portion that is difficult to stretch with high tensile strength, the thickness of the sheet-like surface material is maintained substantially uniformly over the bottom or deepest portion of the recess. Therefore, even when a pattern such as a drawing or a handle is attached to the surface of the sheet-like surface material, it is possible to prevent these patterns from being deformed at the bottom or deepest part of the recess of the female molding surface. it can.

  Moreover, according to 1st invention of this application, it is possible to set arbitrarily the heating start time and heating end time of a sheet-like surface material. If necessary, the heating can be resumed after the heating. Therefore, the sheet-like surface material can be molded at an optimum temperature according to the material of the sheet-like surface material and the shape of the molding surface. Furthermore, by adjusting the heating timing and heating temperature of the sheet-shaped surface material, the temperature of the sheet-shaped surface material is set to a temperature suitable for vacuum forming when the male and female molds are closed. If possible, the vacuum forming process can be performed immediately after the male and female molds are closed. Thereby, the productivity of the synthetic resin laminate can be further increased. Also, due to factors such as the material and thickness of the sheet-like surface material, when the temperature of the sheet-like surface material at the time when the mold closing is completed must be lower than the temperature suitable for vacuum forming, Equivalent productivity can be obtained by heating the female mold in advance with a conventional mold heating apparatus.

  A feature of the second invention of the present application resides in that the male convex portion is brought into contact with the sheet-like surface material before heating the sheet-like surface material. That is, when the male convex part abuts on the sheet-like surface material, the sheet-like surface material is in a cold state, and the heating of the sheet-like surface material is performed after the male convex part abuts. The process is started in a state where the projections of the abutment. Since the contact portion between the sheet-like surface material and the male convex portion is not exposed to the heating fluid, the contact portion between the sheet-like surface material and the male convex portion is gradually heated from the cold state. Is done. Therefore, the portion of the sheet-like surface material pushed into the bottom or deepest portion of the female concave portion by the tip of the male convex portion is held at a lower temperature than in the case of the first invention of the present application. Therefore, according to the second invention of the present application, since the protruding amount of the convex portion formed on the male molding surface is large, when deformation of the pattern such as breakage of the sheet-like surface material and pattern elongation is likely to occur, The effect that these malfunctions can be eliminated is produced. In addition to this effect, the second invention of the present application produces the effect of the first invention of the present application described above.

  3rd invention of this application provides the manufacturing apparatus of a synthetic resin laminated product which can heat a sheet-like surface material in various aspects during mold closing operation | movement of a male type | mold and a female type | mold. Since this apparatus reliably applies the heating fluid ejected from the heating nozzle to the sheet-like surface material by the fluid guide surface during the male and female mold closing operations, the sheet-like surface material is heated and stretched simultaneously. be able to. For this reason, the productivity of the synthetic resin laminate can be remarkably improved.

  Also, during the mold closing operation, the fluid guide surface is displaced relative to the heating nozzle, so by selecting the form of the fluid guide surface, the heated portions of the sheet-like surface material are continuously connected as the mold closing operation proceeds. Can be changed. For example, the heated fluid that has been ejected toward the center of the sheet-like surface material at the beginning of the mold closing operation can be moved to the peripheral edge of the sheet-like surface material as the mold closing operation proceeds. If the peripheral part of the sheet-like surface material is heated intensively at the end of the mold closing operation and the peripheral part is easily stretched, problems such as thinning and breaking of the central part of the sheet-like surface material can be prevented. Can do. Further, in the portion where the heating of the peripheral portion is concentrated, the degree of adhesion with the base material layer is increased, and problems such as peeling of the surface material after molding do not occur.

  According to the fourth invention of the present application, the sheet-like surface material has a single-layer structure, and is directly integrated with the base material layer by thermal welding without using the foamed layer. By not having a foamed layer that causes peeling or material destruction when is applied, a synthetic resin laminate having high impact resistance can be obtained. In addition, since the sheet-like surface material is composed of a highly elastic thermoplastic elastomer, the sheet-like surface material is also broken when the synthetic resin laminate is impacted or the like and the base material layer is damaged. There is little fear. Therefore, it is possible to prevent the damaged portion of the base material layer from protruding on the surface of the synthetic resin laminate by covering the base material layer with the damaged sheet-like surface material. Furthermore, since the synthetic resin laminate of the present invention is composed only of the surface material and the base material layer, the influence of the expansion and contraction of each layer accompanying a temperature change compared to a synthetic resin laminate having a laminate structure of three or more layers. Can be minimized. In other words, since the synthetic resin laminate of the present invention has a two-layer structure, it is possible to easily prevent deformation such as warpage that occurs in the synthetic resin laminate due to the difference in linear expansion coefficient of each layer. And according to the synthetic resin laminate of the present invention, the sheet-like surface material itself made of thermoplastic elastomer can not only give an appropriate soft feeling to the synthetic resin laminate, but also the sheet. The resin base material layer on which the surface material is laminated is composed of the same material that is compatible with the sheet surface material. It is possible to use.

  Other features of the present invention will become apparent from the following description of this specification.

  The production method and production apparatus of the present invention are suitable for mass production of a synthetic resin laminate such as a meter visor for a vehicle comprising a sheet-like surface material such as a decorative sheet and a synthetic resin base material having a required rigidity. When manufacturing such mass-produced products, various mold closing operations are performed under various heating conditions in order to find the optimum processing conditions for the sheet-like surface material to be used. The temperature change of the contact portion between the male convex portion and the sheet-like surface material is detected by a temperature sensor or the like built in the convex portion of the male molding surface. Based on the data thus obtained, the heater for supplying the heating fluid and the actuator for driving the mold are controlled so that the sheet-like surface material is appropriately formed to process the sheet-like surface material. Once the processing conditions of the synthetic resin base material that is injection-molded on the back side of the vacuum-formed sheet-like laminated material are determined, the synthetic resin laminated product molded into the same shape using the same material is the same Can be manufactured under the following processing conditions. In addition, when the thickness of the synthetic resin laminate of the present invention is 3.5 mm including the thickness of the sheet-like surface material, the sheet-like surface material is used to impart impact strength to the synthetic resin laminate. It is desirable to make the wall thickness of 0.35 mm or more.

  Fig.1 (a) is the perspective view which looked at the meter visor 1 for vehicles from the surface side. The meter visor 1 includes an inclined portion 3 formed with an opening 2 for attaching meters, a raised portion 4 extending so as to cover the upper portion of the inclined portion 3, and a lower edge of the inclined portion 3 toward the driver side. It has an extended deck portion 5. The raised portion 4 has an upper edge portion 6 extending along the inclined portion 3 and a lower edge portion 7 extending along a windshield (not shown) of the vehicle. It is formed by a convex curved surface that inclines toward the lower edge portion 7. An extra portion 8 formed when the meter visor 1 is molded extends to the outer edge portion of the lower edge portion 7.

  As shown in FIG. 1B, the meter visor 1 is a laminate of a surface layer 9 made of a decorative sheet or the like and a base layer 10 made of synthetic resin. The surface layer 9 is formed of a material having a soft feel such as an olefin-based thermoplastic elastomer (TPO). Moreover, the base material layer 10 can be injection-molded, can give the necessary rigidity to the injection-molded product, and is molded from polypropylene (PP) or the like having compatibility with the surface layer. The surplus portion 8 is cut out by a technique such as trimming together with the surface layer 9 covering the opening 2 after the molding of the meter visor 1 is completed.

  In the synthetic resin laminate such as the meter visor 1 shown in FIG. 1B, the synthetic resin laminate is made compatible with the surface layer 9 having a single layer structure of a thermoplastic elastomer and the surface layer 9. The synthetic resin base material layer 10 is made of a material having a thickness of the synthetic resin laminate including the thickness of the surface layer 9 is 3.5 mm, and the thickness of the surface layer 9 is 0.35 mm. Table 1 shows the results of the DuPont impact test when 0.75 mm and 1.2 mm. Table 1 also shows the test results for a sample in which the thickness of the base layer 10 made of synthetic resin is 3.5 mm and the surface layer 9 is not laminated as a sheet thickness of 0.0 mm. . This DuPont impact test was performed in an environment of −30 ° C.

  As a result of the above test, as shown in Table 1, the impact strength of the synthetic resin laminate without the surface layer 9 was the lowest, and the impact strength increased as the thickness of the surface layer 9 increased. As can be seen from Table 1, when the thickness of the surface layer 9 is in the range of 0.75 mm to 1.2 mm, the impact strength is almost the same. The strength cannot be expected to increase significantly. Therefore, from the economical viewpoint, it is preferable to set the upper limit value of the thickness of the surface layer 9 to 1.2 mm. On the other hand, when the thickness of the surface layer 9 is less than 0.35 mm, the surface feel of the synthetic resin laminate is similar to the case where the surface layer 9 is not laminated. The lower limit value of the thickness of the layer 9 is preferably 0.35 mm. As a result of the impact test, even when a crack occurs in the base material layer 10 when the thickness of the surface layer 9 is in the range of 0.35 mm to 1.2 mm, the surface layer 9 is not damaged such as a crack or a crack. No breakage of the base material layer 10 broke the surface layer 9 and was not exposed on the surface of the synthetic resin laminate.

  2 to 7 show an embodiment of the manufacturing method and manufacturing apparatus of the present invention. Hereinafter, the manufacturing method and the manufacturing apparatus of the present invention will be described with reference to these drawings, taking the manufacture of the meter visor 1 as an example.

  As shown in FIG. 2, the synthetic resin laminate manufacturing apparatus 11 of the present invention includes an upper base 13 on which a male mold 12 is mounted and a lower base 15 on which a female mold 14 is mounted. The male mold 12 and the female mold 14 are arranged to face each other, and the male mold 12 can reciprocate with respect to the female mold 14 together with an upper base 13 driven by an actuator (not shown). On the molding surface 12 a of the male mold 12, a convex portion 12 b having a shape corresponding to the back surface shape of the protruding portion 4 of the meter visor 1 is formed, and on the molding surface 14 a of the female mold 14, the protrusion of the meter visor 1 is formed. A recess 14 b having a shape corresponding to the surface shape of the portion 4 is formed. When the male mold 12 and the female mold 14 are closed, a cavity is defined between the molding surfaces 12a and 14a. At this time, the convex portion 12b of the male mold 12 enters the concave portion 14b of the female mold 14, and the raised portion 4 of the meter visor 1 is formed between the curved surface 12c of the convex portion 12b and the curved surface 14c of the concave portion 14b. A curved air gap is defined.

  In the male mold 12, resin passages 16 and 17 for injection molding extending from the upper base 13 to the molding surface 12a of the male mold 12 are formed. One resin passage 16 opens to the curved surface 12c of the convex portion 12b, and the other resin passage 17 opens to the flat portion of the molding surface 12a. The reason why the two resin passages 16 and 17 for injection molding are provided is that the molten resin does not flow into the location corresponding to the opening 2 of the inclined portion 3 of the meter visor 1, so that it melts into the gaps on both sides of the inclined portion 3. This is for reliably filling the resin. A pair of ejector rods 18, 19 extending from the upper base 13 to the molding surface 12 a of the male mold 12 are attached to the male mold 12. The tip portions of the ejector rods 18 and 19 are respectively exposed to the molding surface 12a of the male mold 12 to form a part of the molding surface 12a, and project from the molding surface 12a when the molded meter visor 1 is demolded. To do.

  The female die 14 has a piece 20 that constitutes a part of the molding surface 14a of the female die 14, and the side wall 20a of the piece 20 forms a part of the recess 14b. When the male mold 12 and the female mold 14 are closed, a sheet-like surface material 21 constituting the surface layer 10 of the meter visor 1 is sandwiched between the side wall 20a of the piece 20 and the side wall 12d of the male mold 12. Since the opening 2 of the meter visor 1 is formed at a portion corresponding to the side wall 20a of the piece 20, the molten resin injected from the resin passages 16 and 17 is formed between the side wall 20a of the piece 20 and the side wall 12d of the male mold 12. It is desirable not to flow into the gap. Therefore, the piece 20 is detachably attached to the female die 14 so that the piece 20 can be immediately replaced when worn.

  The female mold 14 is formed with a vacuum forming suction hole 22 that opens at the lower edge of the side wall 20a of the piece 20. Since the lower edge of the side wall 20a of the piece 20 is located at the bottom of the recess 14b of the molding surface 14a of the female die 14, that is, the deepest part of the molding surface 14a, the vacuum forming suction hole 22 is the deepest part of the molding surface 14a. Will be open. The female mold 14 is also formed with vacuum forming suction holes 23 and 24. The vacuum forming suction hole 23 opens in the upper edge of the recess 14 b of the female die 14, that is, near the shallowest portion, and the vacuum forming suction hole 24 is the edge of the deck portion 5 of the meter visor 1. Open in the part corresponding to. Reference numeral 25 is an air suction passage for venting air from these vacuum forming suction holes 22, 23, 24.

  Clamp devices 26 and 27 are attached to the parting surface PL of the female die 14 on both sides of the molding surface 14a of the female die 14 therebetween. The clamp devices 26 and 27 are used for fixing the sheet-like surface material 21 to the parting surface PL of the female die 14. Heating fluid nozzles 28 and 29 are respectively fixed to the clamping devices 26 and 27, and the heating fluid nozzles 28 and 29 are heated between the molding surface 12 a of the male mold 12 and the molding surface 14 a of the female mold 14. Or the like.

  On the side surface of the male mold 12, fluid guide surfaces 30, 31 are formed. As the male mold 12 moves in the direction of the female mold 14, the fluid guide surfaces 30, 31 enter the flow of fluid ejected from the heating fluid nozzles 28, 29, and the fluid guide surfaces 30, 31 The heating fluid B ejected from the nozzles 28 and 29 is guided in the direction of the sheet-like surface material 21 fixed to the female mold 14 by the clamping devices 26 and 27. As shown in FIGS. 2 and 3, the shape of the fluid guide surfaces 30 and 31 can be configured by an inclined surface extending from a midway portion of the side surface of the male mold 12 to the molding surface 12 a of the male mold 12.

  The form of the fluid guide surfaces 30 and 31 is not limited to an inclined plane as shown in FIGS. For example, the fluid guide surfaces 30 and 31 may be curved surfaces protruding in the direction of the heating fluid nozzles 28 and 29, and may be concave curved surfaces curved in the direction of the ejector rods 18 and 19. You can also. By changing the forms of the fluid guide surfaces 30 and 31 in various ways, the heating position of the sheet-like surface material 21 by the heating fluid is continuously changed as the mold closing operation of the male mold 12 and the female mold 14 proceeds. Can do. For example, as the mold closing operation of the male mold 12 and the female mold 14 proceeds, the tip of the convex portion 12b of the male mold 12 is moved away from the center of the sheet-like surface material 21 by the heating position by the heating fluid. It is possible to prevent the viscosity of the portion D that C abuts against the sheet-like surface material 21 from decreasing, and to prevent the contact portion D from being thinned or broken. Further, by making the fluid guide surfaces 30 and 31 into grooves having a certain depth, the heating position of the sheet-like surface material 21 by the heating fluid is specified as the mold closing operation of the male mold 12 and the female mold 14 proceeds. It can also be limited to the range.

  Next, with reference to FIG. 2 thru | or 7, the manufacturing method of the meter visor 1 for vehicles is demonstrated. Among the reference numbers used in FIGS. 2 to 7, the same reference numbers indicate the same components.

  FIG. 2 shows a state in which a sheet-like surface material 21 such as a TPO sheet constituting the surface layer 9 of the vehicle meter visor 1 is fixed to the parting surface PL of the female die 14 by the clamping devices 26 and 27. For example, the sheet-like surface material 21 is automatically sent out from a roll around which the sheet-like surface material 21 is wound by a conveying device (not shown), and between the male mold 12 and the female mold 14, Carry in from E direction. In this embodiment, before starting the closing of the male mold 12 and the female mold 14, the heated fluid B such as heated air is ejected from the heated fluid nozzles 28 and 29, and the parting surface PL of the female mold 14 is ejected. The heating of the sheet-like surface material 21 fixed to is started. Thereby, the whole extending part (processed part) of the sheet-like surface material 21 is heated at a predetermined temperature for a predetermined time by the heating fluid B.

  When the heating of the sheet-like surface material 21 is completed in the process of FIG. 2, as shown in FIG. 3, the male mold 12 is lowered, and the tip C of the convex part 12b formed on the molding surface 12a of the male mold 12 is The contact portion D of the sheet-like surface material 21 is pressed. When the tip C of the convex portion 12b of the male mold 12 is pressed against the contact portion D of the sheet-like surface material 21, the thermal gradient between the convex portion 12b of the male mold 12 and the contact portion D of the sheet-like surface material 21 is caused. Since the temperature of the contact portion D of the sheet-like surface material 21 gradually decreases and the heating fluid B ejected from the heating fluid nozzles 28 and 29 is blocked by the convex portion 12b of the male mold 12, the sheet-like surface The contact portion D of the material 21 is not directly heated by the heating fluid B. During this time, the ejection direction of the heating fluid B is changed from the center portion of the sheet-like surface material 21 to the outer edge portion (region near the clamp devices 26 and 27) by the fluid guide surfaces 30 and 31 formed on the side surface of the male mold 12. Therefore, while the temperature of the contact part D of the sheet-like surface material 21 decreases, the temperature of the outer edge portion of the sheet-like surface material 21 continues to increase. In this state, when the temperature of the contact portion D of the sheet-like surface material 21 is lowered to a predetermined temperature and the tensile strength of the contact portion D of the sheet-like surface material 21 is increased to a predetermined value, the male die 12 is The mold is lowered to the female mold 14 and closed.

  When the male mold 12 is lowered in the direction of the female mold 14 from the state of FIG. 3, the sheet-like surface material 21 is pushed down by the tip C of the convex portion 12 b of the male mold 12, and finally the female mold The molding surface 14 moves to the vicinity of the bottom of the recess 14b formed on the molding surface 14a of the molding surface 14, that is, to the vicinity of the deepest portion of the molding surface 14a. During this time, the contact portion D of the sheet-like surface material 21 receives a continuous compressive force by the tip portion C of the convex portion 12b of the male mold 12, but the temperature of the contact portion D of the sheet-like surface material 21 is around it. It is maintained at a temperature lower than the temperature of the sheet-like surface material 21 extending to the surface. During this time, the outer edge portion of the sheet-like surface material 21 is continuously heated by the heating fluid B. Therefore, the tensile strength of the contact portion D of the sheet-shaped surface material 21 is higher than the tensile strength of the portion of the sheet-shaped surface material 21 extending around the periphery, and it is difficult to extend. Even if the mold is closed, the contact portion D of the sheet-like surface material 21 is not thinned or broken. Further, when a pattern is applied to the surface of the sheet-like surface material 21, the pattern in the vicinity of the contact portion D of the sheet-like surface material 21 is not deformed. When the male mold 12 and the female mold 14 are closed, the outer edge portion having a lower tensile strength than the abutting portion D of the sheet-like surface material 21 is elongated, but the outer edge portion of the sheet-like surface material 21 is a vehicle meter. Since the surplus portion is not used in the product of the visor 1, the quality of the vehicle meter visor 1 does not deteriorate even if the thickness of the portion is reduced.

  As shown in FIG. 4, when the closing of the male mold 12 and the female mold 14 is completed, the ejection of the heating fluid from the heating fluid nozzles 28 and 29 stops, and the sheet-like surface material 21 is formed by molding the female mold 14. In a state of being stretched along the surface 14 a, it is located in a space defined by the molding surface 12 a of the male mold 12 and the molding surface 14 a of the female mold 14. At this time, since the sheet-like surface material 21 is sandwiched between the side wall 20a of the piece 20 and the side wall 12d of the male mold 12, there is no gap between the side wall 20a of the piece 20 and the side wall 12d of the male mold 12 ( (See FIG. 2). In addition, since the sheet-like surface material 21 is sandwiched between the male mold 12 and the female mold 14 at the outer portion of the molding surface 12a of the male mold 12 and the outer portion of the molding surface 14a of the female mold 14, There is no void in the part (see FIG. 4). In this state, air is evacuated from the vacuum forming suction holes 22, 23, and 24, and the sheet-like surface material 21 located in the space defined by the molding surface 12 a of the male mold 12 and the molding surface 14 a of the female mold 14 is removed. Then, vacuum forming is performed on the molding surface 14a of the female die 14. At this time, the contact portion D of the sheet-like surface material 21 pushed into the bottom or deepest portion of the concave portion 14b of the female die 14 by the tip portion C of the convex portion 12b of the male die 12 has a low tensile strength and is difficult to stretch. Therefore, the sheet-like surface material 21 sequentially contacts from the wall surface of the shallow portion of the molding surface 14a of the female mold 14 toward the vacuum forming suction hole 22 located at the bottom or deepest portion of the recess 14b. However, even when the sheet-like surface material 21 is stretched, the thickness of the sheet-like surface material 21 is maintained substantially uniform. When performing this vacuum forming, if necessary, the sheet-like surface material 21 can be heated to a predetermined temperature using a heating device (not shown) attached to the female die 14. .

  When the vacuum forming of the sheet-shaped surface material 21 is completed, the sheet-shaped surface material 21 comes into close contact with the molding surface 14b of the female mold 14, so that a cavity is formed between the back surface of the sheet-shaped surface material 21 and the molding surface 12a of the male mold 12. It is formed. As shown in FIG. 5, molten resin is injected into the cavity from the two injection molding resin passages 16 and 17, and the cavity is filled with the molten resin F. The injected molten resin F forms the base material layer 10 laminated on the vacuum-formed sheet-like surface material 21 (surface layer 9) (see FIG. 1b). Next, the base material layer 10 integrated with the sheet-like surface material 21 is cooled while the male mold 12 and the female mold 14 are closed. When this cooling is completed, the ejector rods 18 and 19 are actuated as necessary to raise the male mold 12 to the product removal position and take out the meter visor 1 from the female mold 14 as shown in FIG. The taken-out meter visor 1 is cut off unnecessary portions by trimming or the like, and further subjected to necessary processing such as cutting. Thus, the vehicle meter visor 1 is completed.

  In FIG. 7, the conceptual diagram of the control system of the manufacturing apparatus 11 of this invention is shown. In carrying out the manufacturing method of the present invention, it is necessary to find out in advance the optimum processing conditions for the sheet-like surface material 21 to be used. The optimum processing conditions vary depending on the material of the sheet-like surface material 21 used, the shape of the manufactured product, and the like. Therefore, for example, various mold closing operations are performed under various heating conditions for a specific product such as the vehicle meter visor 1, and the convex portion of the molding surface 12 a of the male mold 12 is performed during these mold closing operations. The temperature change of the contact part D of the convex part 12b of the male mold | type 12 and the sheet-like surface material 21 is detected by the temperature sensor 32 etc. which were incorporated in 12b. Based on the data thus obtained, the heater 33 that supplies the heating fluid and the actuator 34 that drives the male mold 12 are controlled so that the sheet-like surface material 21 is properly formed, and the sheet-like surface material 21 is processed. Do. For example, the temperature of the contact portion D of the sheet-like surface material 21 is determined by the degree of adhesion between the convex portion 12b of the male mold 12 and the sheet-like surface material 21 and the degree of failure appearing in the contact portion D of the sheet-like surface material 21. Can be set by comparing and considering. The temperature of the contact portion D of the sheet-like surface material 21 can be set by adjusting the mold closing speed of the male mold 12 and the female mold 14. Furthermore, the material of the synthetic resin base material to be injection-molded on the back surface of the vacuum-formed sheet-like laminated material 21 and the injection conditions are set, and the manufacturing apparatus 11 of the present invention is controlled by the CPU 35 or the like based on these data. Thus, synthetic resin laminates molded into the same shape using the same material can be manufactured under the same processing conditions.

  8 and 9 show another embodiment of the manufacturing method and manufacturing apparatus of the present invention. Among the reference numerals used in FIGS. 8 and 9, the same reference numerals as those in FIGS. 1 to 7 indicate the same components. As shown in FIG. 8, the feature of this embodiment is that the sheet-like surface material 21 is in a cold state after the sheet-like surface material 21 is fixed to the parting surface PL of the female die 14 by the clamping devices 26 and 27. In the meantime, the tip C of the convex portion 12b of the male mold 12 is pressed against the abutting portion D of the sheet-like surface material 21, and then the heating fluid (hot air) is heated from the heating fluid nozzles 28 and 29 as shown in FIG. ) B is injected to start heating the sheet-like surface material 21. According to this embodiment, the mold closing operation is started, and the heating fluid (hot air) B is supplied in a state where the tip portion C of the convex portion 12b of the male die 12 is in pressure contact with the contact portion D of the sheet-like surface material 21. Therefore, the heating fluid B is not directly applied to the contact portion D of the sheet-like surface material 21. Therefore, it is easy to suppress the temperature rise of the contact portion D of the sheet-like surface material 21 lower than in the case of the first embodiment described above. Therefore, when the protruding amount of the raised portion of the product to be manufactured is large and there is a high possibility that the contact portion D of the sheet-like surface material 21 is likely to have problems such as breakage and pattern elongation, the manufacturing method of this embodiment is Sometimes useful. Other configurations of the present embodiment are the same as those of the first embodiment described above.

  The production method and production apparatus of the present invention typically includes a surface layer made of a material having a flexible feel, such as an olefinic thermoplastic elastomer (TPO), and a synthetic resin base material having the necessary rigidity. It can be used for the production of vehicle interior parts in which layers are laminated. However, the production method and production apparatus of the present invention are not limited to the production of interior parts for vehicles, and can be widely used for the production of synthetic resin laminates having relatively large irregularities. In addition, the synthetic resin laminate of the present invention can be typically used for interior parts for vehicles such as a meter visor, but has high impact resistance and safety when the base material layer is destroyed. Because of its low effect of temperature change by the two-layer structure composed of the same resin material and high recyclability, its use is not limited to interior parts for vehicles, and is extremely versatile.

Fig.1 (a) is a perspective view of the meter visor for vehicles which is an example of the synthetic resin laminated product manufactured by the manufacturing method or manufacturing apparatus of this invention. FIG.1 (b) is sectional drawing which follows the AA line of Fig.1 (a). It is a longitudinal cross-sectional view of the manufacturing apparatus in the state which has heated the sheet-like surface material, after fixing a sheet-like surface material to the manufacturing apparatus of this invention, but before the start of mold closing. The manufacturing apparatus of the present invention in a state in which the closing of the male and female dies is started following the process of FIG. 2 and the male convex portion comes into contact with the sheet-like surface material and the stretching of the sheet-like surface material is started. FIG. The process of FIG. 3 is continued to complete the closing of the male and female molds, and the sheet-like surface material stretched along the molding surface of the female mold is vacuum-formed on the molding surface of the female mold. It is a longitudinal cross-sectional view of the manufacturing apparatus of this invention. The sheet-shaped surface material is obtained by injecting molten resin into a cavity formed between the sheet-shaped surface material that is in close contact with the molding surface of the female mold and the molding surface of the male mold by vacuum forming performed in the process of FIG. It is a longitudinal cross-sectional view of the manufacturing apparatus of this invention when the base material layer laminated | stacked on is formed. FIG. 6 is a longitudinal cross-sectional view of the manufacturing apparatus of the present invention in a state in which the male mold is raised to a position where the meter visor is taken out from the mold after completion of the injection molding of FIG. 5 through a predetermined cooling step. It is a conceptual diagram of the control system of the manufacturing apparatus of this invention. After fixing the sheet-like surface material to the production apparatus of the present invention, before starting the heating of the sheet-like surface material, the vertical section of the production apparatus in a state where the male convex portion is in contact with the sheet-like surface material FIG. FIG. 9 is a longitudinal sectional view of the manufacturing apparatus of the present invention when heating of the sheet-like surface material is started after the male convex portion is brought into contact with the sheet-like surface material in FIG. 8.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Vehicle meter visor 2 Opening for meter attachment 3 Inclined part 4 Raised part 5 Deck part 6 Upper edge part of raised part 7 Lower edge part of raised part 8 Surplus part 9 Surface layer 10 Base material layer 11 Synthetic resin laminate 12 male mold 12a male molding surface 12b convex portion formed on male molding surface 12c curved surface of male convex portion 14 female mold 14a male molding surface 14b formed on male molding surface Concave portion 14c Curved surface 26 of female concave portion 26, 27 Clamp device 28, 29 Nozzle for heating fluid 30, 31 Fluid guide surface B Heating fluid (hot air)
C The tip part of the male convex part D The part (contact part) where the front part of the male convex part contacts the sheet-like surface material
E Loading direction of sheet surface material F Molten resin

Claims (5)

In the method for producing a synthetic resin laminate having a raised portion on the surface,
It consists of a thermoplastic synthetic resin between the female molding surface provided with the recessed part corresponding to the surface shape of the said protruding part, and the male molding surface provided with the convex part corresponding to the back surface shape of the said protruding part. Arranging and fixing the sheet-like surface material; and
For the heating fluid fixed to the male mold through a fluid guide surface formed in the male mold with heating fluid such as heated air on the sheet-like surface material fixed between the molding surfaces Applying from the nozzle and heating the sheet-like surface material;
During the application of the heating fluid to the sheet-like surface material, or after the heating fluid is applied to the sheet-like surface material, the male mold and the female mold are closed, and the convex portions are formed. By abutting on the sheet-like surface material, heat conduction in which thermal energy is transferred from the heated sheet-like surface material to the male mold is generated, and the sheet-like surface material is The sheet-like surface material is stretched along the molding surface, and the sheet-like surface material is prevented from being thinned or broken at the contact portion with the convex portion of the sheet-like surface material. Maintaining the temperature of the contact portion at a temperature lower than the temperature of the sheet-like surface material extending around the contact portion;
After completion of the mold closing, vacuum forming the sheet-like surface material with respect to the molding surface of the female mold, and closely contacting the sheet-like surface material to the molding surface of the female mold;
A molten resin is injected into a cavity defined between the sheet-shaped surface material and the male molding surface by the vacuum forming, and a base material layer laminated on the sheet-shaped surface material with the molten resin is formed. Forming, and
A method for producing a synthetic resin laminate, comprising: In the method for producing a synthetic resin laminate having a raised portion on the surface,
It consists of a thermoplastic synthetic resin between the female molding surface provided with the recessed part corresponding to the surface shape of the said protruding part, and the male molding surface provided with the convex part corresponding to the back surface shape of the said protruding part. Arranging and fixing the sheet-like surface material; and
After fixing the sheet-like surface material, the mold closing of the male mold and the female mold is started, and after the convex portion comes into contact with the sheet-like surface material, air heated by the sheet-like surface material, etc. While the heating fluid is applied to heat the sheet-like surface material and the heating fluid is applied to the sheet-like surface material, or after the heating fluid is applied to the sheet-like surface material, the male The sheet-like surface material is stretched along the molding surface of the female die by the convex portion by closing the die between the female die and the female die, and the convex portion is brought into contact with the sheet-like surface material. To cause heat conduction in which thermal energy is transferred from the heated sheet-like surface material to the male mold, and the temperature of the contact portion with the convex portion of the sheet-like surface material is changed around the contact portion. To a temperature lower than the temperature of the sheet-like surface material extending to A step of lifting,
After completion of the mold closing, vacuum forming the sheet-like surface material with respect to the molding surface of the female mold, and closely contacting the sheet-like surface material to the molding surface of the female mold;
A molten resin is injected into a cavity defined between the sheet-shaped surface material and the male molding surface by the vacuum forming, and a base material layer laminated on the sheet-shaped surface material with the molten resin is formed. Forming, and
A method for producing a synthetic resin laminate, comprising: A male mold having a generally convex molding surface, a female mold having a concave molding surface as a whole, and the male mold and the female mold are defined between the molding surfaces when the male mold and the female mold are closed. A cavity, at least one injection molding resin passage opening in the convex molding surface, a plurality of vacuum molding suction holes opening in the concave molding surface, and a thermoplastic synthetic resin between the molding surfaces In a manufacturing apparatus for a synthetic resin laminate product, comprising: a clamp device for fixing a sheet-like surface material comprising: and a device for heating the sheet-like surface material.
The apparatus for heating the sheet-like surface material is formed on the male mold, which is fixed with respect to the female mold and supplies a heating fluid such as heated air between the molding surfaces. The fluid guide surface is configured such that when the male mold and the female mold are closed, the male mold contacts the sheet-like surface material fixed by the clamp device. From the time until the sheet-like surface material is stretched along the concave molding surface, the fluid ejected from the heating fluid nozzle is applied to a desired portion of the sheet-like surface material,
Furthermore, after the male mold abuts on the sheet-like surface material fixed by the clamp device, the sheet-shaped surface material is stretched along the concave molding surface, and the male mold By causing the convex portion formed on the molding surface to abut against the sheet-like surface material, heat conduction in which heat energy is transferred from the heated sheet-like surface material to the male mold is generated. An apparatus for producing a synthetic resin laminate product. Oite the manufacture how synthetic resin laminate according to claim 1 or 2, wherein the synthetic resin laminate, and the sheet-shaped surface material made of a thermoplastic elastomer single-layer structure, compatibility with the surface material is formed of a material having and integrated by heat melt the back surface of said surface material, characterized in that comprising a resin substrate layer, producing how the synthetic resin laminate. The synthetic resin laminate product manufacturing apparatus according to claim 3, wherein the synthetic resin laminate product is composed of a sheet-like surface material having a single layer structure of a thermoplastic elastomer and a material having compatibility with the surface material. And the manufacturing apparatus of the said synthetic resin laminated product which consists of a resin-made base material layer integrated with the back surface of the said surface material by the heat-melting state .

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