JPH02145332A - Laminated sheet, method and apparatus for manufacture thereof - Google Patents

Abstract

PURPOSE:To manufacture a laminated sheet having a beautiful surface layer by sucking a surface layer material to a pattern mold manufactured by electroforming, and forming an embossing pattern on its surface. CONSTITUTION:A porous electroforming shell 80 is formed with an embossing pattern faithfully corresponding to the surface of a leather on its surface for forming a mold face 72, and wholly distributed with numerous fine continuous pores in a longitudinal direction. A decoration sheet 24 is positioned by a guide rib 82, and secured to the shell 80 for forming the face of a pattern mold 28 by the operation of a vacuum sucking mechanism 74. Then, a foamable material 14 made of polypropylene resin, etc. and a skin material 16 of vinyl chlorides, etc. are interposed between a pressing mold 26 and the mold 28, heated and pressed. Since a precise embossing pattern can be formed on the face 72 of the shell 80, an extremely precise leather pattern is formed on the material 16.

Description

Detailed Description of the Invention [Industrial Application Field] The present invention relates to a laminated sheet body, a method for manufacturing the same, and an apparatus. The present invention relates to a laminated sheet body formed with an uneven pattern, a decorative sheet pasted on one side of the surface layer material, and a base material injected and solidified on the other side, and a method and apparatus for manufacturing the same.

[Background of the Invention] For example, in door trims that are attached to the inner surface of vehicle doors, products that create a luxurious look by pasting decorative fabrics called ornaments on the armrest portion and/or the surface material around it have become popular. It is being done.

Therefore, as a method for manufacturing a laminated sheet body formed by laminating such a surface material and a decorative fabric, there is a method disclosed in, for example, Japanese Patent Application Laid-Open No. 63-41116. In this method, a locking part is provided at a predetermined part of a mold having a vacuum suction mechanism, and the surface material is adsorbed to the mold under the action of the vacuum suction mechanism while the decorative fabric is locked in the locking part. After this, the mold is clamped and the base material is injected to obtain the desired laminated sheet body.

In this case, in order to form a desired uneven pattern on the surface layer material, there is a method in which an engraved roll or an engraved plate is pressed against the heated surface of the surface layer material before molding. However, since an engraved roll or an engraved plate usually has an uneven pattern formed by etching, it is limited to a relatively simple continuous pattern. Therefore, the uneven pattern transferred and formed on the surface of the surface layer material becomes a simple pattern with little variation. In addition, positioning is performed by locking the circumferential part of the decorative fabric to a locking part provided in the mold.
It has been pointed out that the positioning work is extremely troublesome.

On the other hand, as another method for manufacturing a laminated sheet body,
There is one disclosed in Japanese Patent No.-172836. In this conventional technology, a composite sheet is laminated and placed in a mold with an uneven pattern through a decorative fabric, and then thermoformed to form an integrated laminated sheet body. be.

However, in this case, since the uneven pattern is formed on the mold by etching or the like, there is a drawback that only a simple uneven pattern can be formed, as in the case of the prior art described above. Further, it is difficult to accurately transfer the uneven pattern to the laminated sheet body by thermoforming alone.

Furthermore, since no means for holding the decorative fabric with respect to the mold is provided, there is a risk that misalignment may occur during thermoforming.

[Object of the Invention] The present invention has been made to overcome the above-mentioned disadvantages, and provides a laminated sheet body in which a fine uneven pattern is transferred by using a pattern mold manufactured by electroforming. The purpose is to

Furthermore, the present invention allows a fine uneven pattern to be created by adsorbing a surface layer material to a pattern mold produced by electroforming through a decorative sheet, and then injecting and solidifying the base material onto the surface layer material. It is an object of the present invention to provide a method and apparatus for manufacturing a laminated sheet body which has a wide variety of characteristics.

[Means for Achieving the Object] In order to achieve the above-mentioned object, the present invention provides a composite sheet in which a foam is laminated on a surface layer material having an uneven pattern formed on the surface using a pattern mold manufactured by electroforming. , comprising a base material laminated on the foam and a decorative sheet adhered to a predetermined portion of the surface material.

Further, the present invention provides a method of disposing a decorative sheet at a predetermined portion of a pattern having fine continuous pores manufactured by electroforming, and then applying a composite sheet in which a foam is laminated to the surface material through the decorative sheet. Transferring and forming an uneven pattern on the surface of the surface layer material by adsorbing it to the pattern pattern, and adhering the decorative sheet to a predetermined portion of the surface, and then injecting the base material onto the foam side of the composite sheet. In particular, the present invention is characterized by solidifying a pattern having fine continuous pores produced by electroforming, a sheet body, and a decorative sheet disposed at a predetermined portion of the sheet body. and a mold that has an injection port for injecting the base material to be laminated on the sheet body and performs the molding process in cooperation with the pattern mold. Features.

[Embodiments] Next, preferred embodiments of the laminated sheet body, its manufacturing method, and apparatus according to the present invention will be described in detail with reference to the accompanying drawings.

In FIG. 1, reference numeral 10 indicates a vehicle door trim made of a laminated sheet body according to this embodiment. As shown in FIGS. 2 and 3, this door trim 10 includes a base material 12 made of polypropylene resin containing talc as a filler, a foam 14 made of polypropylene resin, and a skin material made of vinyl chloride or the like. 16, and a decorative sheet 24 having an adhesive layer 20 such as a hot melt agent and disposed above the armrest portion 22 of the door trim 10. In this case, the skin material 1
As will be described later, a leather-like uneven pattern is formed on the surface of 6 by a pattern produced by electroforming.

Next, a method for manufacturing the door trim 10 configured as described above will be described.

4a to 4e schematically show a method for manufacturing the door trim 10 and a manufacturing apparatus to which the method is applied.

In this case, the manufacturing apparatus includes a pressing mold 26 and a pattern mold 28 that constitute a set of molds. The pressing mold 26 has a mold surface 30 corresponding to the outer shape of one side of the door trim 10, and a plurality of gates 34 connected to the runners 32 are opened at predetermined portions of the mold surface 300. In this case, each gate 34 faces a gate pin 36 that constitutes gate opening/closing means. Furthermore, an injection nozzle 38 that supplies polypropylene resin containing talc, which is a melted base material, to the gate 34 through the runner 32 is detachably attached to the end of the runner 32 .

Here, the gate opening/closing means having the gate pin 36 as a component is constructed as shown in FIG. That is, the press mold 26 includes a mold member 42 having a mold surface 30 and defining a cooling passage 40, a launch member 44 defining a runner 32, and a support member 46. A support ring 48 is attached to the mold member 42.
A nozzle member 50 is attached through the nozzle member 50, and a sleeve 52 fits into this nozzle member 50. A sheet 54 is attached to the lower end of the sleeve 52, and the hollow portion 56 of the sleeve 52 is connected to the mold surface 30 of the mold member 42 through the sheet 54.
It communicates with a gate 34 that opens to In addition, the sleeve 52
A guide member 58 is attached to the upper end portion, and the runner 32 and the hollow portion 56 of the sleeve 52 communicate with each other via the guide member 58.

A cylinder portion 60 constituting gate opening/closing means is attached to the support member 46. This cylinder part 60 is a cylinder chamber 6
It has a casing member 64 that defines parts 2a and 62b, and a piston member 66 that is housed in the casing member 64. In this case, the casing member 64 is formed with a port 68a communicating with the cylinder chamber 62a and a port 68b communicating with the cylinder chamber 62b. Further, one end portion of the gate pin 36 is fixed to the piston member 66 . The other end of the gate pin 36 is connected to a runner member 44 and a guide member 58.
and reaches the gate 34 via the sleeve 52.

On the other hand, the pattern mold 28 has a mold surface 72 that faces the mold surface 30 of the pressing mold 26 and is supported by a back-up body 70, and a vacuum suction mechanism 74 is connected to this mold surface 72 via the back-up body 70. Install consecutively. FIG. 6 is a detailed configuration diagram of the pattern 28. In this case, the back-up body 70 is housed in a casing 78 placed on a support member 76, and a porous electroformed shell 80 having a leather-like uneven pattern formed thereon and constituting the mold surface 72 is placed on the top of the casing 78. will be placed. A guide rib 82 for positioning the decorative sheet 24 is formed at a predetermined portion of the porous electroformed shell 80 so as to protrude toward the pressing die 26 .

Here, the porous electroformed shell 80 is formed so that an uneven pattern that faithfully corresponds to the surface of the leather is formed on the surface constituting the mold surface 72, and countless fine continuous pores are distributed throughout the thickness direction. has been done.

The production of this porous electroformed shell 80 is, for example,
As disclosed in Publication No. 1-104848, a step of creating a precision model from cowhide, a step of forming a conductive layer on the cowhide patterned surface of the precision model, and a step of forming a conductive layer on the surface of the conductive layer with a diameter Q, 2
The process of laminating 4 layers of polystyrene beads of 1.5 mm in diameter and installing a precision model in a liquid bath with a lifting prevention body with glass beads placed in a net on top of the layer, with the upper circumferential surface of the top layer of polystyrene beads exposed. This is carried out through an electroforming process in which a plating layer is formed to a certain thickness to fill the spaces between adjacent polystyrene beads with nickel, and a process in which the polystyrene beads are eluted from the nickel electroformed body. and,
Fine continuous pores are formed by elution of the polystyrene beads.

On the other hand, the back-up body 70 includes a first back-up body 84 made of a large number of corrosion-resistant steel balls such as stainless steel wire disposed on the porous electroformed shell 80 side, the first backup body 84, and a housing. A second back-up body 86 is disposed between the back-up body 78 and the second back-up body 86 is made of glass beads having a diameter of 500 to 600 μm. In this case, the first backup body 84 is a cooling pipe 8 disposed inside the backup body 70.
8, and is partially joined by a hardening synthetic resin coated on its outer periphery. Also,
Like the first backup body 84, the second backup body 86 is partially joined by a thermosetting synthetic resin coated on its outer periphery. Therefore, fine continuous pores are defined in the porous electroformed shell 80 through the gaps between the steel balls constituting the first backup body 84 and the gaps between the glass beads constituting the second backup body 86 and the conduit 90. is the vacuum suction mechanism 7
It connects to 4.

Next, a method of manufacturing the door (IJ) 10 using the above-mentioned manufacturing apparatus will be explained based on FIGS. 4a to 4e.

First, the adhesive layer 20 made of a hot melt agent or the like is oriented toward the pressing mold 26 side on the part surrounded by the guide ribs 82 of the porous electroformed shell 80 constituting the mold surface 72 of the pattern mold 28, and then a decorative layer is applied. Position the sheet 24. Then, the vacuum suction mechanism 74 is driven (see FIG. 4C). In this case, the mold surface 72 communicates with the vacuum suction mechanism 74 via the fine continuous pores defined in the porous electroformed shell 80 and the gaps between the first and second backup bodies 84 and 86 (see FIG. 6). ). Therefore, the decorative sheet 24 can be easily and accurately positioned by the guide ribs 82 provided on the porous electroformed shell 80, and is fixed to the porous electroformed shell 80 under the action of the vacuum suction mechanism 74. Therefore, there is no risk of misalignment occurring during the following manufacturing operations.

Next, a composite sheet 18 consisting of a foam 14 such as a polypropylene resin and a skin material 16 such as vinyl chloride is heated to around 180° C. between the pressing mold 26 and the pattern mold 28, so that the skin material 16 is shaped like the pattern. 28 (see Figure 4). Then, with the vacuum suction mechanism 74 being driven, the composite sheet material is made to follow the mold surface 70 of the pattern mold 28 and is sandwiched between it and the pressing mold 26 (see FIG. 4C). In this case, the surface of the composite sheet 18 is brought into close contact with the mold surface 72 of the porous electroformed shell 80 by the suction action by the vacuum suction mechanism 74 and the pressing action by the press mold 26, and a leather-like uneven pattern is transferred to the skin material 16. Ru. Here, since a highly precise uneven pattern can be formed on the mold surface 72 of the porous electroformed shell 80, an extremely precise leather pattern can be formed on the skin material 16. Note that the adhesive layer 20 of the decorative sheet 24
is melted by the heat of the composite sheet 18 and tightly adheres to a predetermined portion of the skin material 16.

Next, after the suppression mold 26 is separated from the pattern mold 28, the gate 34 is opened under the action of the gate opening/closing means. That is, in FIG. 5, the cylinder chamber 62b is
Air or the like is introduced into the cylinder chamber 62a through the port 68a, and thereby the gate pin 36 is displaced in the direction of the arrow via the piston 66 to open the gate 34. Next, an injection nozzle 38 is attached to the runner 32 of the press mold 26, and a base material made of polypropylene resin containing talc is injected into the runner 32 through the injection nozzle 38. This substrate material is directed out of the gate 34 via the runner 32 and the hollow 56 of the sleeve 52 towards the foam 14 of the composite sheet 18 (see FIG. 4d).

After a predetermined amount of the base material is injected through each gate 34, the gate 34 is closed under the action of the gate opening/closing means, and the press mold 26 is again displaced toward the pattern mold 28 to perform mold clamping and keep the base material constant. The molding is performed by applying low pressure (10 to 100 kg/cm2) (see Fig. 4e). In this case, the base material is cooled and assimilated by flowing cooling water through the cooling passage 40 disposed within the mold member 42 and the cooling pipe 88 disposed within the back-up body 70. Note that since the gate pin 36 constituting the gate opening/closing means opens and closes the gate 34 at the portion closest to the cavity, the amount of base material supplied to the cavity can be controlled with high precision. Finally, open the mold and take out the product.

In the embodiment described above, the molding is performed by lowering the pressing mold 26 from above with respect to the pattern mold 28 and injecting the base material from the pressing mold 26 side. On the other hand, the apparatus for manufacturing the door trim 10 may be configured as shown in FIG. 7.

The pressing mold 26 defining the runner 32 is fixed to the fixed mold 9.
2, and a pattern mold 28 is movably disposed above the fixed mold 92 so as to face the fixed mold 92. And fixed type 92
An injection nozzle 38 is always fixed to the 0 runner 32.

Therefore, first, with the decorative sheet 24 positioned at a predetermined portion of the pattern mold 28, the vacuum suction mechanism 74 is driven to adsorb the decorative sheet 24 to the pattern mold 28, and then the heated composite sheet 1
8 and then lower the pattern mold 28 toward the fixed mold 92 to sandwich the decorative sheet 24 and the composite sheet 18 between the fixed mold 92 and the pattern mold 28 (
(See Figure 7a).

In this case, the decorative sheet 24 is adhered to the composite sheet 18, and a precise leather pattern is formed on the surface of the composite sheet 180.

Next, the pattern mold 28 is temporarily attached to the fixed mold 9 together with the composite sheet 18.
2, and the base material is injected into the cavity from the injection nozzle 38 via the runner 32.

Next, after injecting a predetermined amount of the base material, the pattern mold 28 is again
Mold clamping is performed by displacing the fixed mold 92 toward the fixed mold 92 (see FIG. 7). Then, after maintaining a predetermined pressure for a predetermined time, the desired molded product is obtained by cooling.

Here, as described above, the pressing die 26 having the runner 32
When disposed as a fixed mold 92 below the pattern mold 28, various advantages can be obtained. For example, the base material injected into the cavity from the fixed mold 92 flows from the gate 34 under its own weight and is uniformly diffused into the cavity. As a result, extremely high quality molded products can be obtained. It should be noted that if the gate 34 is arranged at an upwardly convex portion of the fixed mold 92, an even better molded product can be obtained. Furthermore, since the injection nozzle 38 can be fixed to the fixed mold 92 at all times, there is no need to attach or detach the injection nozzle 38 during the molding process. This simplifies the control of the manufacturing equipment, and The advantage is that the transition from the injection process to the mold clamping process is smooth and the cycle time can be shortened.

Furthermore, maintenance and modification of the gate 34 and the like of the fixed mold 92 are facilitated.

[Effects of the Invention] As described above, according to the present invention, an uneven pattern is formed on the surface of a pattern mold manufactured by electroforming by adsorbing the surface layer material.

In this case, since a desired uneven pattern can be formed on the pattern, an extremely beautiful laminated sheet body is supplied. Further, by providing a rib at a predetermined portion of the pattern, positioning the decorative sheet on the rib, and adsorbing the surface material to the pattern through the decorative sheet, the decorative sheet can be attached to the desired surface material. It also becomes possible to easily and accurately attach the adhesive to the position of the adhesive.

Although the present invention has been described above with reference to preferred embodiments, the present invention is not limited to these embodiments.
Of course, various improvements and changes in design are possible without departing from the gist of the present invention.

[Brief explanation of the drawing]

FIG. 1 is a perspective explanatory view of a door trim as a laminated sheet body according to the present invention, FIG. 2 is a sectional view taken along line II-II of the door trim shown in FIG. 1, and FIG. 3 is a main part of FIG. 2. 4a to 4e are process explanatory diagrams of the method for manufacturing a laminated sheet body according to the present invention; FIGS. 5 and 6 are cross-sectional views of main parts of the manufacturing apparatus for a laminated sheet body according to the present invention; The configuration diagram and FIGS. 7a and 7b are explanatory diagrams of another embodiment of the method for manufacturing a laminated sheet body according to the present invention. 10...Door trim 12...Base material 14...
・Foam 16... Skin material 18... Composite sheet 20... Adhesive layer 24... Decorative sheet 26.
... Pressing mold 28 ... Pattern mold 32 ... Runner 36 ... Gate pin 38 ... Injection nozzle 50 ... Nozzle member 60 ... Cylinder part 74 ... Vacuum suction mechanism 92 ... Fixed Mold 80... Porous electroformed shell FIG, 5 1411: i 20 ゝ-)-1'

Claims (6)

[Claims] (1) A composite sheet in which a foam is laminated on a surface layer material with an uneven pattern formed on the surface using a pattern mold manufactured by electroforming, a base material laminated on the foam, and a predetermined portion of the surface layer material. A laminated sheet body comprising a decorative sheet affixed to. (2) After arranging a decorative sheet at a predetermined portion of a pattern having fine continuous pores manufactured by electroforming, a composite sheet in which a foam is laminated on the surface material is passed through the decorative sheet into the pattern. The uneven pattern is transferred and formed on the surface of the surface material by adsorption, and the decorative sheet is attached to a predetermined part of the surface, and then the base material is injected and solidified on the foam side of the composite sheet. A method for manufacturing a laminated sheet body, characterized by: (3) A pattern having fine continuous pores manufactured by electroforming, a sheet body, and a decorative sheet arranged at a predetermined portion of the sheet body are adsorbed to the pattern through the fine continuous pores. 1. An apparatus for manufacturing a laminated sheet body, comprising: a means for manufacturing a laminated sheet body; and a mold having an injection port for injecting a base material to be laminated on the sheet body and performing a molding process in cooperation with the pattern mold. (4) The apparatus for manufacturing a laminated sheet body according to claim 3, wherein the pattern pattern includes guide ribs for positioning the decorative sheet. (5) The apparatus for manufacturing a laminated sheet body according to claim 3, wherein the mold is provided with an opening/closing means that closes the injection port during press molding of the sheet body and opens it when injecting the base material. . (6) The apparatus for manufacturing a laminated sheet body according to any one of claims 3 to 5, wherein the mold is a fixed mold placed below the pattern mold.