JP5495439B2 - Multilayer foam substrate and method for producing the same - Google Patents

Description

  The present invention relates to a multilayer foam substrate and a method for producing the same. More specifically, the present invention relates to a multilayer foam substrate having sufficient rigidity and excellent in appearance, and a method for producing the same.

Conventionally, a low-pressure press has been used when shaping a substrate. For example, in patent document 1, the rib shape which protrudes in a back surface side is provided to the base material by the low pressure press. However, when ribs are formed on the base material using a low-pressure press, the base material is crushed on a general surface where the ribs are not formed, and the plate thickness is reduced. there were.
On the other hand, in a base material having a structure in which a foamed resin layer is sandwiched between two skin layers, a sufficient thickness of the base material is ensured by using a method of vacuuming from both sides of the base material. It is possible to prevent a decrease in heat insulation.

JP 2006-264207 A

However, when applying the above-described construction method to the manufacture of a design part having a curved part such as an interior part for a vehicle, as shown in FIG. 11 and FIG. 12, the convex part of the curved part R of the base material in the vacuum mold is shown. On the back side, when the vacuum is evacuated, the skin layer is left and wrinkles x are generated.
In particular, when evacuating the design surface side in order to reliably shape the substrate, the curved portion that is convex when viewed from the design surface side is evacuated to the design surface side. Is stretched once, the skin layer on the back surface side is more likely to be crumpled during the subsequent vacuuming from the back surface side.
When such a wrinkle is generated, not only the appearance is inferior, but the wrinkled portion becomes a starting point of bending, which may reduce the rigidity of the product.

  This invention is made | formed in view of the said situation, and it aims at providing the multilayer foaming base material which has sufficient rigidity, and is excellent in appearance, and its manufacturing method.

The present invention is as follows.
[1] A multilayer foam base material that is provided with a first skin layer, a resin foam layer, and a second skin layer in order, and that the resin foam layer is expanded by vacuuming in vacuum forming,
The multilayer foamed base material has a curved surface portion on which the first skin layer side is on the outside and the second skin layer side is on the inside,
A multilayer foamed base material, wherein the second skin layer in the curved surface portion is formed with a wavy shaped absorbing portion that absorbs the slack of the second skin layer generated by the vacuum forming.
[ 2 ] The multilayer foamed substrate according to [1] , wherein the first skin layer side is a design surface side.
[ 3 ] A substrate provided with a first skin layer, a resin foam layer, and a second skin layer in this order is paired with a first mold for shaping the first skin layer and the first mold, and the second skin. A method for producing a multilayer foam base material, wherein the resin foam layer is thickened by evacuating from both sides between molds comprising a second mold for shaping the layer,
The second mold is provided with a curved surface portion forming portion for forming a curved surface portion on the multilayer foamed base material, the first skin layer side being the outer side and the second skin layer side being the inner side,
The curved surface portion forming portion, the multilayer foam substrate, the absorbing portion forming portion of the undulating shape for forming the absorbing portion of the wavy shape to absorb the slack of the second skin layer caused by the vacuum molding is provided A method for producing a multilayer foamed substrate, comprising:

In the multilayer foamed base material of the present invention, a curved surface portion is formed in which the first skin layer side is the outside and the second skin layer side is the inside. The second skin layer in the curved surface portion is formed by vacuum forming. absorption portion is formed imbibed with slack of 2 skin layers. Therefore, it has sufficient rigidity and is excellent in appearance.
Moreover, the absorption part is wavy shape, it is possible to improve the rigidity, excellent appearance.
Furthermore, when the 1st skin layer side is made into the design surface side, since the 2nd skin layer side in which the absorption part was formed becomes a back surface side, it can be made more excellent in appearance.
According to the manufacturing method for a multilayer foam substrate of the present invention, since the suction Osamubu forming portion for forming a suction Osamubu you absorb the slack of the second skin layer is using a mold provided, sufficient rigidity It is possible to produce a multi-layer foam base material having excellent appearance.
Further, since absorbing portion forming portion is wavy shape, it is possible to improve the rigidity of the obtained multilayer foamed substrate can be made more excellent in appearance.

The present invention will be further described in the following detailed description with reference to the drawings referred to, with reference to non-limiting examples of exemplary embodiments according to the present invention. Similar parts are shown throughout the several figures.
1 is a schematic cross-sectional view of a multilayer foamed substrate according to Example 1. FIG. It is a principal part enlarged view of FIG. It is typical sectional drawing of the type | mold used for manufacture of a multilayer foaming base material. It is a principal part enlarged view of FIG. It is explanatory drawing for demonstrating the manufacturing method of the multilayer foaming base material which concerns on Example 1. FIG. It is explanatory drawing for demonstrating the manufacturing method of the multilayer foaming base material which concerns on Example 1. FIG. It is explanatory drawing for demonstrating the manufacturing method of the multilayer foaming base material which concerns on Example 1. FIG. It is a principal part enlarged view of FIG. It is a perspective view of the door trim upper obtained using the manufacturing method of the multilayer foaming base material concerning a present Example. FIG. 10 is a sectional view taken along line XX of the door trim upper of FIG. 9. It is explanatory drawing for demonstrating a prior art. It is explanatory drawing for demonstrating a prior art.

  The items shown here are for illustrative purposes and exemplary embodiments of the present invention, and are the most effective and easy-to-understand explanations of the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to illustrate the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention. It will be clear to those skilled in the art how it is actually implemented.

1. Multilayer foam base material Embodiment 1 The multilayer foam base material according to the present invention includes a first skin layer, a resin foam layer, and a second skin layer in this order, and the resin foam layer is expanded by vacuum drawing in vacuum molding, The base material is formed with a curved surface portion where the first skin layer side is the outer side and the second skin layer side is the inner side, and the second skin layer in the curved surface portion has a sagging of the second skin layer caused by vacuum forming. wherein the absorption portion is formed imbibed with.
The use of the multi-layer foam base material is not particularly limited. For example, it is used for interior parts for vehicles such as a door trim (door trim upper shown in FIG. 9), an instrument panel, a roof trim, a deck board, a package tray and the like. Can do.

As long as the “multilayer foamed base material” includes the first skin layer, the resin foam layer, and the second skin layer in this order, the structure, size, shape, material, and the like are not particularly limited.
Examples of the material of the “first skin layer” and the “second skin layer” include polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polyvinyl acetate (PVAc), Mention may be made of thermoplastic synthetic resins such as polytetrafluoroethylene (PTFE), acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate (PET).
As the material of the “resin foam layer”, for example, the same thermoplastic resin as that of the first skin layer and the second skin layer can be used. This resin foam layer is usually a foamed material obtained by adding a foaming agent to these thermoplastic resins. Furthermore, this resin foam layer can be expanded by vacuuming from both sides.

The "curved portion", first skin layer side becomes the outer, a curved second skin layer side becomes the inner has且one intake Osamubu. The curved surface portion may be formed only at one place, or may be formed at two or more places.

The “absorbing portion” is formed by absorbing the slack of the second skin layer generated by vacuum forming in the curved surface portion.
The shape of the absorption unit, Ru wavy shape der. When the absorbing portion has a wavy shape, sagging of the second skin layer caused by vacuum forming is sufficiently absorbed, and the rigidity can be further improved and the appearance is excellent.
This absorption part may be formed only in one place, and may be formed in two or more places. In particular, it is preferable that the absorption portion is formed in the vicinity of a portion where the curvature of the curved surface portion is maximum.

  In addition, the first embodiment. In the multilayer foam base material according to the present invention, the surface on the first skin layer side can be a design surface. In this case, since the 2nd skin layer side in which an absorption part is formed turns into a back surface side, the appearance of the obtained multilayer foaming base material can be improved more.

  In addition, although the method to manufacture the said multilayer foaming base material is not specifically limited, For example, it can obtain by the manufacturing method of the multilayer foaming base material of this invention mentioned later.

2. Manufacturing method of multilayer foam base material Embodiment 2 The manufacturing method of the multilayer foaming base material which concerns on the base material provided with the 1st skin layer, the resin foaming layer, and the 2nd skin layer in order, the 1st type | mold which shapes a 1st skin layer, and this 1st type | mold The resin foam layer is thickened by vacuuming from both sides between molds that are paired and have a second mold for shaping the second skin layer. The second mold includes a multilayer foam substrate. In addition, a curved surface portion forming portion is provided for forming a curved surface portion where the first skin layer side is the outer side and the second skin layer side is the inner side. wherein the suction Osamubu forming portion for forming the absorbent portion of the wavy shape to absorb the slack of the second skin layer caused by molding is provided.

As long as the “base material” includes the first skin layer, the resin foam layer, and the second skin layer in this order, the structure, size, shape, material, and the like are not particularly limited. As this base material, for example, it can be in the form of a sheet formed by laminating the above layers. In this base material, another layer may be interposed between one or both of the first skin layer and the resin foam layer and between the resin foam layer and the second skin layer.
Moreover, the multilayer foaming base material which consists of this base material can make the surface by the side of a 1st skin layer into a design surface. In this case, since the 2nd skin layer side in which an absorption part is formed turns into a back surface side, the appearance of the obtained multilayer foaming base material can be improved more.

Examples of the material of the “first skin layer” and the “second skin layer” include polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polyvinyl acetate (PVAc), Mention may be made of thermoplastic synthetic resins such as polytetrafluoroethylene (PTFE), acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate (PET). The first skin layer and the second skin layer are usually in the form of a sheet made of these thermoplastic resins.
As the material of the “resin foam layer”, for example, the same thermoplastic resin as that of the first skin layer and the second skin layer can be used. This resin foam layer is usually in the form of a sheet that is foamed by adding a foaming agent to these thermoplastic resins.

As long as the above-mentioned “mold” can expand (expand) the resin foam layer of the base material by evacuation and can form the wavy shaped absorption part, its structure, size, shape, material Etc. are not particularly limited.
Specifically, for example, as shown in FIG. 3, a first mold 51 that shapes the first skin layer, and a second mold 52 that forms a pair with the first mold 51 and shapes the second skin layer, The double-sided vacuum forming die in which the absorption part forming portion 53 for forming the absorption part is formed in the second mold 52 can be used.

The shape of the "absorbing portion forming site" Ru wavy shape der. When the absorbing portion forming portion has a corrugated shape, the slack of the second skin layer generated by vacuum forming can be sufficiently absorbed, the rigidity of the obtained multilayer foamed substrate can be further improved, and the appearance performance is also improved. Can be improved.
Moreover, this absorption part formation site | part should just be formed in the curved surface part formation site | part in 2nd type | mold, and it is preferable that it is formed in the site | part vicinity where the curvature in a curved surface part formation site | part is the maximum.

  Further, in the method for producing a multilayer foamed substrate of the present invention, the vacuuming conditions are not particularly limited, but the vacuuming is performed from the first skin layer side before the second skin layer side where the absorbing portion is formed. Preferably it is done.

  Hereinafter, the present invention will be specifically described with reference to the drawings.

<Example 1>
[1-1] Multilayer Foamed Substrate As shown in FIG. 1, the multilayer foamed substrate 1 according to Example 1 includes a first skin layer 11, a resin foam layer 12, and a second skin layer 13 in this order. The resin foam layer 12 is expanded by evacuation in vacuum forming.
Further, the multilayer foamed base material 1 is formed with a curved surface portion where the first skin layer 11 side is the outer side and the second skin layer 13 side is the inner side. A projecting absorbent portion 2 is formed that absorbs sagging of the second skin layer 13 caused by molding.
In addition, in this multilayer foaming base material 1, the 1st skin layer 11 side is a design surface side, and the 2nd skin layer 13 side in which the absorption part 2 was formed is a back surface side.

[1-2] Manufacturing Method of Multilayer Foamed Base Material A manufacturing method of the multilayer foamed base material 1 according to the first embodiment will be described with reference to FIGS.
(1) Mold Configuration The configuration of the double-sided vacuum mold used in the production of the multilayer foamed substrate of Example 1 is shown below.
As shown in FIG. 3, the mold 5 is paired with a first mold (design surface side mold) 51 for shaping the first skin layer of the substrate to be used, and the first mold 51. A second mold (back-side mold) 52 for shaping the two skin layers and a vacuuming means (not shown) capable of vacuuming from both sides are provided.
The first mold 51 is provided with a curved surface portion forming portion for forming a curved surface portion having a first skin layer side on the outer side and a second skin layer side on the inner side of the multilayer foam base material. The first mold 51 is configured to be evacuated from the first mold 51 side, and includes a plurality of vacuum holes (not shown).
The second mold 52 is provided with a curved surface portion forming portion for forming a curved surface portion in which the first skin layer side is the outside and the second skin layer side is the inside on the multilayer foamed base material. In the part, an undulating absorption part forming part 53 is provided. The second mold 52 is configured to be evacuated from the second mold 52 side, and includes a plurality of vacuum holes (not shown).

(2) Manufacturing method of multilayer foam base material First, as shown in FIG. 5, the base material 10 including the first skin layer 11, the resin foam layer 12, and the second skin layer 13 in this order is arranged on the first skin layer 11 side. Set on the mold 5 so as to be on the side of the first mold 51, and clamp the mold so that the end portion is crushed. In addition, in the base material 10, the 1st skin layer 11 side is a design surface side. Further, at the time of mold clamping, both ends of the base material 10 are sandwiched by support portions (not shown) outside the mold 5.
Next, as shown in FIG. 6, the substrate 10 set in the mold 5 is evacuated from the first skin layer 11 side (that is, the first mold 51 side) which is the design surface side.
Thereafter, in a state where evacuation from the first skin layer 11 side is continued, evacuation is performed from the second skin layer 13 side (that is, the second mold 52 side) as shown in FIGS. While expanding the foam layer 12, the absorption part 2 (refer FIG. 1) is formed.
Thus, the 1st skin layer 11, the resin foam layer 12, and the 2nd skin layer 13 are provided in order, and the curved surface part which the 1st skin layer 11 side became the outside and the 2nd skin layer 13 side became the inside is formed. In the second skin layer 13 in the curved surface portion, the multilayer foamed base material 1 in which the protruding portion (waved shape) absorbing portion 2 that absorbs the slack of the second skin layer generated by vacuum forming is formed. can get.

[1-3] Effects of Example 1 The multilayer foamed base material 1 according to Example 1 is the first produced by vacuum forming in the curved surface portion where the first skin layer 11 side is the outside and the second skin layer 13 side is the inside. The wavy shaped absorption part 2 which absorbed the slack of the two skin layers 13 is formed. Therefore, it is excellent in rigidity and has a good appearance.
Moreover, this multilayer foamed base material 1 has a first skin layer 11 side on the design surface side, and the second skin layer 13 side on which the absorbing portion 2 is formed is on the back surface side, so that it has a very good appearance. It has become.

  In addition, according to the method for producing a multilayer foamed base material of the present example, the first skin layer 11, the resin foam layer 12, and the second skin layer 13 as shown in FIGS. A curved surface portion is formed in which the first skin layer 11 side is the outer side and the second skin layer 13 side is the inner side. The curved surface portion absorbs the slack of the second skin layer 13 generated by vacuum forming. Interior parts for vehicles, such as the door trim upper 100 which consists of the multilayer foaming base material 1 in which the part 2 was formed, can be manufactured easily. The door trim upper 100 has a design surface side on the first skin layer 11 side, and is provided with an absorbing portion 2 that absorbs sagging of the second skin layer in the curved surface portion. It looks great.

  The foregoing examples are for illustrative purposes only and are not to be construed as limiting the invention. Although the invention has been described with reference to exemplary embodiments, it is to be understood that the language used in the description and illustration of the invention is illustrative and exemplary rather than limiting. As detailed herein, changes may be made in its form within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials and examples have been referred to in the detailed description of the invention herein, it is not intended to limit the invention to the disclosure herein, but rather, the invention is claimed. It covers all functionally equivalent structures, methods and uses within the scope of

  The present invention is not limited to the embodiments described in detail above, and various modifications or changes can be made within the scope of the claims of the present invention.

  The multilayer foamed base material and the method for producing the same according to the present invention are widely used as technologies related to the field of interior parts for vehicles such as trains, buses, trucks, railway vehicles such as trains and trains, construction vehicles, agricultural vehicles, and industrial vehicles. Used.

  DESCRIPTION OF SYMBOLS 1; Multilayer foam base material, 10; Base material, 100; Door trim upper, 11; First skin layer, 12; Resin foam layer, 13; Second skin layer, 2; Absorbing part, 5; Mold, 52; second type, 53; absorption part forming site, x; wrinkle, R; curved part.

Claims (3)

The first skin layer, the resin foam layer, and the second skin layer are provided in this order, and the resin foam layer is a multilayer foam base material that is expanded by vacuuming in vacuum forming,
The multilayer foamed base material has a curved surface portion on which the first skin layer side is on the outside and the second skin layer side is on the inside,
A multilayer foamed base material, wherein the second skin layer in the curved surface portion is formed with a wavy shaped absorbing portion that absorbs the slack of the second skin layer generated by the vacuum forming. The multilayer foamed base material according to claim 1 , wherein the first skin layer side is a design surface side. A substrate provided with a first skin layer, a resin foam layer, and a second skin layer in this order is paired with a first mold that shapes the first skin layer and the first mold, and the second skin layer is formed. A method for producing a multilayer foam base material, wherein the resin foam layer is thickened by evacuating from both sides between molds comprising a second mold to be formed,
The second mold is provided with a curved surface portion forming portion for forming a curved surface portion on the multilayer foamed base material, the first skin layer side being the outer side and the second skin layer side being the inner side,
The curved surface portion forming portion, the multilayer foam substrate, the absorbing portion forming portion of the undulating shape for forming the absorbing portion of the wavy shape to absorb the slack of the second skin layer caused by the vacuum molding is provided A method for producing a multilayer foamed substrate, comprising:

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