JPH0314335Y2 - - Google Patents
Info
- Publication number
- JPH0314335Y2 JPH0314335Y2 JP17230086U JP17230086U JPH0314335Y2 JP H0314335 Y2 JPH0314335 Y2 JP H0314335Y2 JP 17230086 U JP17230086 U JP 17230086U JP 17230086 U JP17230086 U JP 17230086U JP H0314335 Y2 JPH0314335 Y2 JP H0314335Y2
- Authority
- JP
- Japan
- Prior art keywords
- cloth
- mold
- molded product
- resin
- urethane foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 239000004744 fabric Substances 0.000 claims description 37
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 25
- 239000006260 foam Substances 0.000 claims description 25
- 239000000463 material Substances 0.000 claims description 23
- 229920005989 resin Polymers 0.000 claims description 22
- 239000011347 resin Substances 0.000 claims description 22
- 230000035699 permeability Effects 0.000 claims description 9
- 229920005992 thermoplastic resin Polymers 0.000 claims description 5
- 238000002347 injection Methods 0.000 description 8
- 239000007924 injection Substances 0.000 description 8
- 238000001746 injection moulding Methods 0.000 description 7
- 239000002984 plastic foam Substances 0.000 description 7
- 229920005830 Polyurethane Foam Polymers 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000011496 polyurethane foam Substances 0.000 description 5
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 4
- 230000000704 physical effect Effects 0.000 description 4
- 230000007547 defect Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 230000037303 wrinkles Effects 0.000 description 3
- 238000000034 method Methods 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000011162 core material Substances 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000000088 plastic resin Substances 0.000 description 1
- 229920013716 polyethylene resin Polymers 0.000 description 1
- -1 polypropylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
Description
《考案の分野》
この考案は、自動車用内装部品に好適な積層成
形品に係り、特に、表面外観の優れた積層成形品
に関する。
《従来技術とその問題点》
最近、表面にソフト感を持たせるために、表皮
材としてクロスを用いた自動車用内装部品が多
く、一般に、射出成形を利用して、クロスを射出
成形用金型のキヤビテイ内にセツトし、次に熱可
塑性樹脂を金型のキヤビテイ内に射出，充填して
前記クロスと一体化させ、その後、冷却して樹脂
成形体と上記クロスとの積層成形品を製造してい
る。
しかしながら、この従来の製造方法（俗に、イ
ンサートインジエクシヨン工法という）では、溶
融樹脂の射出時、樹脂圧によりクロスが金型の型
面に強く押圧されて、折れ曲がつたり、また溶融
樹脂の熱によりクロスの起毛部分が湾曲，傾斜す
るいわゆる毛倒れが生じ、表面外観の良好な積層
成形品を得ることが困難であつた。
これらの対策として、例えば樹脂成形体とクロ
スとの間にプラスチツクフオームを介在させて、
このプラスチツクフオームの緩衝性を利用して、
クロス表面の不具合を解消することが従来から提
案されている（特開昭60−212343号公報参照）。
しかしながら、プラスチツクフオームをクロスと
樹脂成形体との間に配置したとしても、必ずしも
クロス表面の不具合が有効に解決されるものでは
なく、プラスチツクフオームの密度，厚み等の物
性によりかなりの開きがあり、実際には、プラス
チツクフオームの裏面側に布，紙等のバツクアツ
プ材をさらにラミネートしてクロス表面の外観を
良好に保つか、あるいはクロス当接側の金型の型
面に多数の針を植設して、クロス表面の毛倒れを
防止するか、型面にクツシヨン用フオームをセツ
トするようにしているのが実状である。
以上のことから、考案者らは、プラスチツクフ
オームの物性を考慮して、プラスチツクフオーム
の密度や通気度等の物性値を適切な範囲に設定す
ることにより、クロスの表面状態が良好に保てる
かどうかについて試作実験を行なつた。
《考案の目的》
本考案は、以上の着眼点に基づきなされたもの
で、本考案の目的とするところは、クロスを表皮
材として用い、射出成形により、樹脂成形体と上
記クロスとを積層一体化して積層成形品におい
て、簡易な構成で、かつ優れた表面外観を備えた
積層成形品を提供することにある。
《考案の構成と効果》
上記目的を達成するために、本考案は、クロス
の裏面にクツシヨン材を接着あるいは融着してな
る表皮材を金型内にセツトするとともに、金型の
キヤビテイ内に熱可塑性樹脂を射出，充填し，表
皮材と樹脂成形体とを一体化して構成された積層
成形品において、
前記表皮材は、ウレタンフオームを圧縮加工し
て，密度0.05〜0.30g／cm3、通気度５〜30c.c.／
cm2・secに設定された圧縮ウレタンフオームであ
ることを特徴とする。
すなわち、本考案によれば、クロスの裏面側に
接着、あるいは融着される圧縮ウレタンフオーム
は、通常のウレタンフオームを圧縮加工して得ら
れたもので、密度0.05〜0.30g／cm3、通気度５〜
30c.c.／cm2・secにそれぞれ設定されているもので
あるから、射出成形時、この圧縮ウレタンフオー
ムにより、クロスに過剰の熱，圧力が加わること
がないので、クロス表面の毛倒れならびに溶融樹
脂のしみだしやまた、フローマーク，ウエルド等
の表面不良が確実に防止できる。
しかも、クロスに対して過剰の射出圧が加わる
ことはないが、適度の射出圧が作用しているの
で、クロスが射出成形用金型の型面に馴染み、ク
ロス表面にシワ等の発生が生じることはない。
このように圧縮ウレタンフオームを有効な緩衝
材として作用させるため、従来のようにポリウレ
タンフオームの裏面側に布，紙等のバツクアツプ
材をラミネートするか、あるいは金型のクロス側
型面に多数の針を植設するか、もしくはクツシヨ
ン用のフオームをセツトする等の複雑な構成を不
要とし、簡単かつ廉価にこれら積層成形品を製造
できる利点があり、成形された製品の表面はその
表面外観ならびに表面感触とも極めて良好な状態
であり、その商品価値を著しく高める等の効果が
ある。
《実施例の説明》
以下、この考案に係る積層成形品の実施例につ
いて添付図面を参照しながら詳細に説明する。
第１図はこの積層成形品を示す要部断面図であ
り、第２図はその製造工程を説明する断面図であ
る。
第１図に示すように、この実施例の積層成形品
１は芯材としての樹脂成形体２と、この樹脂成形
体２表面に貼着一体化された表皮材３とから大略
構成され、表皮材３はクロス４と、このクロス４
の裏面にラミネートされたエーテル系、もしくは
エステル系のポリウレタンフオームを圧縮加工し
た圧縮ポリウレタンフオーム５とからなる。
さらに詳しくは、上記クロス４は、トリコツ
ト，ジヤージ，平織等から適宜選択されて良い
が、その破断点における伸び率は100〜150％に設
定されている。クロス４の破断点における伸び率
が上記範囲内であると、後述する射出成形用金型
の型面形状がかなり複雑な形状であつても、型面
に容易に追従することができ、クロス４表面にシ
ワが発生したり、溶融樹脂がクロス４の繊維間か
ら染みでる等の不良が発生することはなく、また
射出成形時の圧力が過剰に加わることによるクロ
ス表面のフローマーク，ウエルド等の外観不良も
確実に防止できる。
次に圧縮ウレタンフオーム５としては、本実施
例ではエーテル系ポリウレタンフオームを圧縮加
工したものを使用しており、通常のスラブウレタ
ンフオームと本願に係る圧縮ウレタンフオームと
の物性比較を表１にて示す。
<<Field of the invention>> This invention relates to a laminate molded product suitable for automobile interior parts, and particularly relates to a laminate molded product with an excellent surface appearance. [Prior art and its problems] Recently, many automobile interior parts use cloth as a skin material to give a soft feel to the surface.Generally, injection molding is used to insert cloth into an injection mold. Next, thermoplastic resin is injected and filled into the cavity of the mold to integrate it with the cloth, and then cooled to produce a laminated molded product of the resin molding and the cloth. ing. However, in this conventional manufacturing method (commonly referred to as the insert injection method), when the molten resin is injected, the resin pressure presses the cloth strongly against the mold surface of the mold, causing it to bend and cause the cloth to melt. The heat of the resin causes the raised portion of the cloth to curve and slope, so-called hair fall, making it difficult to obtain a laminated molded product with a good surface appearance. As a countermeasure against these problems, for example, by interposing a plastic foam between the resin molded body and the cloth,
Utilizing the cushioning properties of this plastic foam,
It has been proposed in the past to solve the problem of the cloth surface (see Japanese Patent Application Laid-Open No. 60-212343).
However, even if the plastic foam is placed between the cloth and the resin molded body, problems with the cloth surface cannot necessarily be effectively solved, and there are considerable differences depending on the physical properties such as the density and thickness of the plastic foam. In practice, a back-up material such as cloth or paper is further laminated on the back side of the plastic foam to maintain a good appearance of the cloth surface, or a large number of needles are implanted on the surface of the mold on the side that contacts the cloth. The current situation is to prevent the hair from falling on the surface of the cloth, or to set a cushioning foam on the mold surface. Based on the above, the inventors considered whether the surface condition of the cloth could be maintained in good condition by taking into account the physical properties of the plastic foam and setting the physical properties such as the density and air permeability of the plastic foam within an appropriate range. We conducted a prototype experiment on this. 《Purpose of the invention》 The present invention was made based on the above points of view.The purpose of the present invention is to use cloth as a skin material and to laminate and integrate the resin molded body and the cloth by injection molding. The object of the present invention is to provide a laminate molded product having a simple structure and an excellent surface appearance. 《Structure and Effects of the Invention》 In order to achieve the above object, the present invention includes setting a skin material in a mold, which is made by adhering or fusing a cushion material to the back side of a cloth, and setting the skin material in the cavity of the mold. In a laminate molded product constructed by injecting and filling a thermoplastic resin and integrating a skin material and a resin molded body, the skin material is made by compressing urethane foam and has a density of 0.05 to 0.30 g/cm 3 , Air permeability 5-30c.c./
It is characterized by being a compressed urethane foam set at cm 2 sec. That is, according to the present invention, the compressed urethane foam that is adhered or fused to the back side of the cloth is obtained by compressing ordinary urethane foam, has a density of 0.05 to 0.30 g/cm 3 , and is air-permeable. degree 5~
30 c.c./cm 2 sec, the compressed urethane foam prevents excess heat and pressure from being applied to the cloth during injection molding, preventing hair from falling on the surface of the cloth. Seepage of molten resin and surface defects such as flow marks and welds can be reliably prevented. Moreover, although excessive injection pressure is not applied to the cloth, since a moderate injection pressure is applied, the cloth conforms to the mold surface of the injection mold, causing wrinkles etc. to occur on the cloth surface. Never. In order to make the compressed urethane foam act as an effective cushioning material, either a back-up material such as cloth or paper is laminated on the back side of the polyurethane foam as in the past, or a large number of needles are placed on the cross-side mold surface of the mold. The advantage is that these laminated molded products can be easily and inexpensively manufactured without the need for complex configurations such as planting foam or setting foam for cushioning, and the surface of the molded product has a good surface appearance and It has an extremely good feel and has the effect of significantly increasing its commercial value. <<Description of Examples>> Examples of the laminate molded product according to this invention will be described in detail below with reference to the accompanying drawings. FIG. 1 is a sectional view of the main parts of this laminated molded product, and FIG. 2 is a sectional view illustrating its manufacturing process. As shown in FIG. 1, the laminate molded product 1 of this embodiment is roughly composed of a resin molded body 2 as a core material, and a skin material 3 that is integrally attached to the surface of this resin molded body 2. Material 3 is cross 4 and this cross 4
A compressed polyurethane foam 5 is formed by compressing an ether-based or ester-based polyurethane foam laminated on the back side of the . More specifically, the cloth 4 may be appropriately selected from tricot, jersey, plain weave, etc., and its elongation at the breaking point is set to 100 to 150%. When the elongation rate at the breaking point of the cross 4 is within the above range, even if the mold surface shape of the injection mold, which will be described later, is quite complex, the cross 4 can easily follow the mold surface. There will be no defects such as wrinkles on the surface or molten resin seeping out between the fibers of the cloth 4, and there will be no flow marks, welds, etc. on the surface of the cloth due to excessive pressure during injection molding. Appearance defects can also be reliably prevented. Next, as the compressed urethane foam 5, in this example, a compressed ether-based polyurethane foam is used, and Table 1 shows a comparison of the physical properties of the ordinary slab urethane foam and the compressed urethane foam according to the present application. .
【表】
なお表１において、通気度（c.c.／cm2・sec）は、
ASTM Ｄ−737−46試験による。
ここで、圧縮ウレタンフオーム５の密度および
通気度の上限ならびに下限について説明すると、
まず圧縮ウレタンフオーム５の密度0.05ｇ／cm3未
満か通気度が30c.c.／cm2・secを越える場合には、
クロス４に過剰の射出成形圧が加わり、溶融樹脂
がクロス表面からしみだす等の不具合が生じる。
逆に、圧縮ウレタンフオーム５の密度が0.3
ｇ／cm3を越えるかもしくは通気度が５c.c.／cm2・
sec未満の場合には、圧縮ウレタンフオーム５の
緩衝性が過剰となり、射出成形圧がクロス４に充
分に伝わらないため、クロス４は射出成形金型の
型面に馴染まず、表面にシワ等が発生する不具合
が生じてしまう。
次に、通常のウレタンフオーム（スラブウレタ
ン）とこのスラブウレタンをほぼ５倍に圧縮加工
した圧縮ウレタンフオームとをそれぞれ使用して
積層成形品を製造した場合、両者の製品外観を表
２に比較する。[Table] In Table 1, the air permeability (cc/cm 2 sec) is
According to ASTM D-737-46 test. Here, the upper and lower limits of the density and air permeability of the compressed urethane foam 5 will be explained.
First, if the density of the compressed urethane foam 5 is less than 0.05 g/cm 3 or the air permeability exceeds 30 c.c./cm 2 sec,
Excessive injection molding pressure is applied to the cloth 4, causing problems such as molten resin seeping out from the surface of the cloth. Conversely, the density of compressed urethane foam 5 is 0.3
g/cm 3 or the air permeability is 5 c.c./cm 2 .
If it is less than sec, the cushioning properties of the compressed urethane foam 5 will be excessive and the injection molding pressure will not be sufficiently transmitted to the cloth 4, so the cloth 4 will not fit into the mold surface of the injection mold and wrinkles etc. will appear on the surface. This will cause problems to occur. Next, when a laminate molded product is manufactured using a normal urethane foam (slab urethane) and a compressed urethane foam obtained by compressing this slab urethane to approximately 5 times the size, the appearance of the two products is compared in Table 2. .
【表】
○ 良好
× 不良
表２におけるスラブウレタンの厚みは３mm，密
度0.026ｇ／cm3，通気度146c.c.／cm2・secであり、
圧縮ウレタンフオーム５の数値はスラブウレタン
フオーム10mmを圧縮加工し板厚2.4mmに圧縮加工
し、密度0.13ｇ／cm3，通気度10c.c.／cm2・secであ
る。
次に、第２図に基づき、上記積層成形品の製造
工程について参考までに記載すると、射出成形用
金型を構成する可動側金型６の型面６ａに沿つて
表皮材３を図示しない仮止め手段を用いて仮止め
セツトする。
そして、この可動側金型６が固定側金型７に対
して第２図に示す位置まで接近して、両金型６，
７間にキヤビテイ８を形成する。このとき、キヤ
ビテイ８の板厚は3.5mmであり、表皮材３の板厚
は４mm（クロス４；１mm，圧縮ウレタンフオーム
５；３mm）であり、表皮材１はキヤビテイ８内で
圧縮状態にある。そしてこの状態で、固定側金型
７に形成されたスプル９を通じて、図示しない射
出成形機内で加熱溶融された熱可塑性樹脂がキヤ
ビテイ８内に射出充填され、その後冷却固化され
ることにより、この熱可塑性樹脂が樹脂成形体１
となり表皮材３と一体化し、射出成形用金型６，
７から取り出せば、第１図に示す積層成形品が得
られる。なお、得られた積層成形品１の板厚はキ
ヤビテイ８の板厚3.5mmと等しく、成形品の板厚
の内訳は、樹脂成形体１が2.5mmで表皮材１は１
mmに圧縮されている。
上記樹脂成形体２を構成する熱可塑性樹脂は、
ABS樹脂，ポリプロピレン樹脂，ポリエチレン
樹脂など汎用樹脂で良く、表皮材３と樹脂成形体
２との接合は、圧縮ポリウレタンフオーム５の間
隙内に溶融樹脂が食込むいわゆる投錨効果によ
り、表皮材３と樹脂成形体２とが強固に接合して
いる。
このように、本願によれば、クロスとクロス裏
面に融着あるいは接着される圧縮ウレタンフオー
ムとの積層表皮材を汎用のインサートインジエク
シヨン工法に適用することにより、簡易に製作で
きるとともに、成形品の表面外観ならびに表面感
触が極めて良好なものになる等極めて実用性の高
い考案である。[Table] ○ Good × Bad The thickness of the slab urethane in Table 2 is 3 mm, the density is 0.026 g/cm 3 , the air permeability is 146 c.c./cm 2 sec,
The numerical values for compressed urethane foam 5 are as follows: 10 mm of slab urethane foam was compressed to a thickness of 2.4 mm, and the density was 0.13 g/cm 3 and the air permeability was 10 c.c./cm 2 .sec. Next, based on FIG. 2, the manufacturing process of the above-mentioned laminate molded product will be described for reference. Temporarily set using a fastening means. Then, the movable mold 6 approaches the fixed mold 7 to the position shown in FIG.
A cavity 8 is formed between 7 and 7. At this time, the thickness of the cavity 8 is 3.5 mm, the thickness of the skin material 3 is 4 mm (cross 4: 1 mm, compressed urethane foam 5: 3 mm), and the skin material 1 is in a compressed state within the cavity 8. . In this state, a thermoplastic resin heated and melted in an injection molding machine (not shown) is injected and filled into the cavity 8 through a sprue 9 formed in the stationary mold 7, and is then cooled and solidified. Plastic resin is resin molded body 1
Then, it is integrated with the skin material 3, and the injection mold 6,
7, a laminated molded product shown in FIG. 1 is obtained. The plate thickness of the obtained laminated molded product 1 is equal to the plate thickness of the cavity 8, 3.5 mm, and the breakdown of the plate thickness of the molded product is that the resin molded product 1 is 2.5 mm, and the skin material 1 is 1 mm.
Compressed to mm. The thermoplastic resin constituting the resin molded body 2 is
A general-purpose resin such as ABS resin, polypropylene resin, or polyethylene resin may be used, and the bond between the skin material 3 and the resin molded body 2 is achieved by the so-called anchoring effect in which the molten resin bites into the gap between the compressed polyurethane foam 5. The molded body 2 is firmly joined. As described above, according to the present application, by applying the laminated skin material of cloth and compressed urethane foam that is fused or adhered to the back surface of the cloth to the general-purpose insert-in-extraction method, it is possible to easily manufacture molded products. This is an extremely practical idea, as the surface appearance and feel of the surface are extremely good.
第１図は本考案に係る積層成形品の一実施例を
示す要部断面図、第２図は同積層成形品を製造す
る工程を示す断面図である。
１……積層成形品、２……樹脂成形体、３……
表皮材、４……クロス、５……圧縮ウレタンフオ
ーム、６……可動側金型、７……固定側金型、８
……キヤビテイ、９……スプル。
FIG. 1 is a sectional view of a main part showing an embodiment of a laminate molded product according to the present invention, and FIG. 2 is a sectional view showing a process for manufacturing the same laminate molded product. 1... Laminated molded product, 2... Resin molded product, 3...
Skin material, 4... Cloth, 5... Compressed urethane foam, 6... Movable side mold, 7... Fixed side mold, 8
... Cavity, 9... Sprue.
Claims (1)
着してなる表皮材を金型内にセツトするととも
に、金型のキヤビテイ内に熱可塑性樹脂を射出，
充填し、表皮材と樹脂成形体とを一体化して構成
された積層成形品において、 前記クツシヨン材は、ウレタンフオームを圧縮
加工して、密度0.05〜0.30ｇ／cm3、通気度５〜30
c.c.／cm2・secに設定された圧縮ウレタンフオーム
であることを特徴とする積層成形品。[Scope of claim for utility model registration] A skin material made by adhering or fusing a cushion material to the back of the cloth is set in a mold, and a thermoplastic resin is injected into the cavity of the mold.
In a laminated molded product formed by filling and integrating a skin material and a resin molded body, the cushion material is made by compressing urethane foam, and has a density of 0.05 to 0.30 g/cm 3 and an air permeability of 5 to 30.
A laminated molded product characterized by being made of compressed urethane foam set at cc/cm 2 sec.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP17230086U JPH0314335Y2 (en) | 1986-11-10 | 1986-11-10 |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP17230086U JPH0314335Y2 (en) | 1986-11-10 | 1986-11-10 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS6377719U JPS6377719U (en) | 1988-05-23 |
| JPH0314335Y2 true JPH0314335Y2 (en) | 1991-03-29 |
Family
ID=31108717
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP17230086U Expired JPH0314335Y2 (en) | 1986-11-10 | 1986-11-10 |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0314335Y2 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2505706B2 (en) * | 1993-11-04 | 1996-06-12 | オカモト株式会社 | PP foam for stamping skin material and method of manufacturing the foam |
| JP2505705B2 (en) * | 1993-11-04 | 1996-06-12 | オカモト株式会社 | Stamping skin material and method for manufacturing the skin material |
| JP2002200942A (en) * | 2000-12-28 | 2002-07-16 | T S Tec Kk | Vehicular trimming material |
-
1986
- 1986-11-10 JP JP17230086U patent/JPH0314335Y2/ja not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| JPS6377719U (en) | 1988-05-23 |
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