JPH03143624A - Preparation of skin having foamed layer - Google Patents

Abstract

PURPOSE:To make a manufacturing process without enlarging a manufacturing facilities and with making a space less and a cost advantageous by forming a skin layer consisting of a non-foamable resin material from the first distribution process to a press process and forming another skin layer consisting of a foamable resin material on the rear face side of the above described skin layer from the second distribution process to a cooling process. CONSTITUTION:A molding plate heating process, the first distribution process, the first heating process, a press process, the second distribution process, the second heating process, a cooling process and a mold releasing process are successively performed. A non-foamable resin mate rial 3 is scattered on a transfer face 10 of the molding plate 1 the temp. of which is elevated at 200-230 deg.C by the molding plat heating process to form the first powder layer 30, which is heated at 220 deg.C and is made into a gel in the first heating process to form a skin layer 31. The thickness is unified by compression between a cooling plate 6 and a molding plate 1 in the press process. In the second distribution process, the second powder layer 70 is formed by scattering a powdery foamable resin material 7 on the rear face 31b of the skin layer 31. In the second heating process, a foam layer 71 integrally bound with the rear face 31b of the skin layer 31 by heating at about 190 deg.C. In the cooling process, the molding plate 1 on which the skin 9 is placed is delivered in a cooling bath, wherein it is cooled.

Description

[Detailed description of the invention] [Industrial application field] The present invention relates to a method for manufacturing a skin with a foam layer.

[Prior Art] Conventionally, in order to give a sense of luxury to automobile interior parts such as instrument panel pads, console doors, trims, and pillar garnishes, a skin layer with a textured pattern was formed on the surface and a foam layer was applied on the back side. Motsu epidermis is used.

Known methods for producing skins having a foam layer include, for example, the powder sludge method and the vacuum forming method using a rolled sheet with extrusion texture.

[Problems to be solved by the invention] (1) According to the conventional powder sludge uni method described above, although it is possible to obtain a skin with good appearance quality, for example, a skin without graininess, it requires large equipment and the product cost is high. However, there are other problems, such as the installation space for the Z2 equipment becoming larger.

(2) In addition, when using a method of vacuum forming a skin from a rolled sheet with extrusion texture, when the sheet 1~ is used as a material, it is cured to the outer circumferential shape of the desired product and cut out for use. This leaves unused parts. The material left over after the cutting process cannot be reused because it contains the foam layer and the skin layer.

An object of the present invention is to provide a method for manufacturing a skin having a foam layer that solves the above-mentioned conventional problems.

[Means and effects for solving the problems] The method for manufacturing a skin having a foam layer of the present invention includes heating a molded plate having a transfer surface of a reverse pattern of the surface pattern of the target product to a predetermined temperature. A first step is to use a shaped plate having a perforated part that follows the outer circumferential shape of the target product, and to disperse powdered non-foamable resin material almost uniformly onto the transfer surface of the molded plate through the perforated part.
a first distribution step of forming a powder layer; a first heating step of heating the first powder layer from both sides to gel it to form a skin layer; a pressing step that presses a cooling plate whose temperature is lower than that of the skin layer and compresses the skin layer between the cooling plate and the molded plate to make the wall thickness uniform; a second distributing step in which a powdered foamable resin material is almost uniformly spread on the back surface of the skin layer to form a second powder layer, and the second powder layer is heated and foamed to form an integral part with the skin layer. a 271n thermal step of forming a combined light collector layer; a cooling step of cooling the skin layer and the foam layer together with the molded plate; and releasing the skin layer with the foam layer from the molded plate. It is characterized by consisting of a mold release step.

The molded plate heating step includes the step of heating a molded plate having a transfer surface with an inverted pattern that is an inversion of the pattern on the surface of the target product to a predetermined temperature.

The manufacturing method of the present invention includes a molded plate heating step, a first distribution step, a first heating step, a pressing step, a second distribution step, a second heating step, a cooling step, and a mold release step. A skin having a foam layer is manufactured by sequentially carrying out the following steps.

The forming plate used in the forming plate heating process has a transfer surface having a pattern that is an inversion of the pattern on the surface of the target product. This transfer surface can be formed with a textured pattern or other pattern. Further, in order to heat the molded plate to a predetermined temperature, it is preferable to heat it from both sides. When heating the molded plate, a high frequency heating device, an electric heater device, or other heating device can be used. It is preferable to use a heating device that can freely control the heating temperature of one side of the molded plate and the heating temperature of the other side.

In the first dispensing step, a shaped plate with perforations that follow the outer circumferential shape of the target product is used, and the powdered non-foaming resin material that is sprinkled onto the transfer surface of the molded plate through the perforations is pre-measured. Polyvinyl chloride, thermoplastic urethane, etc., each having a particle size of 80 to 150 μm, can be used.

The thickness of the first body layer formed by dispersing the material in the first dispensing step is generally 0.3-Q, 7 mm. Further, the size of the shaped plate is preferably such that non-foaming and resinous materials adhering to the flat surfaces other than the punched holes can be recovered. The recovered materials can be used repeatedly and there is no waste.

When using a shaped plate with perforations that follow the outer periphery of the target product and dispersing the powder material almost uniformly through the perforated parts, it is possible to use a distribution device disposed above the shaped plate to spread the powder material. preferable. This distribution device allows the powdered material to be almost uniformly distributed to the target position through the hole in the shaped plate. Therefore, a first powder layer having a substantially uniform thickness is formed.

The distribution device includes a distributor having a mesh-like transmission hole;
It is possible to use a vibrating device that is connected to a part of the distributor and vibrates the distributor, and a moving device that can move the distributor in a two-dimensional direction parallel to the shape plate.

In the first heating step, in order to gel the first powder layer by heating it from both sides, the first powder layer is heated to a predetermined temperature (18
A heating device for heating to a temperature in the range of 0 to 240 degrees is used. As this heating device, the same device as used in the forming plate heating step can be used. In this first heating step, the first powder layer is heated with its top surface open.

Therefore, the air inside escapes upward as it gels,
This prevents air from remaining between the skin layer and the molded plate.

In the pressing step, a cooling plate having a temperature lower than that of the skin layer is pressed against the back side of the gelled skin layer to compress the skin layer between the cooling plate and the forming plate.

By compressing the skin layer, its thickness can be made uniform and the thickness can be set to a preset value.

It is usually sufficient for the cooling plate to suppress the back side of the skin layer within 2 seconds. When the cooling plate is pressed against the back surface of the skin layer which is in a high temperature state, it is easy to adhere to the back surface of the skin layer if the temperatures of both are the same. To prevent this, the temperature of the cooling plate is preferably about 100 to 200 degrees lower than the temperature of the skin layer.

The shape plate used in the second distribution step can be the same as that used in the first distribution step. In this case, after the shaped plate is used in the first distribution step, it is cleaned and used without the powdered non-foamable resin material attached thereto.

The powdered foamable resin material is measured in advance, and polyvinyl chloride, thermoplastic urethane, etc. having a particle size of 80 to 150 μm can be used. The thickness of the second powder layer formed in the second distribution step is generally 2 to 3 mm. Further, in the second distribution step, when dispersing the material, it is preferable to use a distribution device in the same manner as in the first distribution step described above.

Note that it is preferable to use resin materials of the same type as the non-foamable resin material and the foamable resin material. This is because it becomes possible to integrate the two without using an adhesive between them.

The heating temperature for heating and foaming the second powder layer in the second heating step to form a foam layer integrally combined with the skin layer is preferably in the range of 180 to 240 degrees. The heating device used for the ha heat in this second heating step can be the same as that used in the first heating step.

When cooling the skin pattern and foam layer together with the molded plate during the cooling process, a device is used that cools the skin layer and foam layer by jetting a fluid such as water or gas directly onto the skin layer and foam layer to remove heat from their surfaces. can.

When the skin with the foam layer is released from the molding plate in the M-type process, it can be handled directly by a worker, or it can be performed using an industrial robot or a crushing device.

The skin with the released foam layer is shaped into a predetermined shape by vacuum forming or the like. At this time, since the skin has a shape that follows the outer circumferential shape of the vacuum mold surface, no material is wasted.

[Effects] According to the method for producing a skin with a foam layer of the present invention, a skin layer made of a non-foamable resin and a foam layer made of a foamable resin on the back side of the skin layer are formed on one molded plate. Since it can be formed, there is no need to increase the size of manufacturing equipment, and the installation space for the equipment is small, which is advantageous from one point of view.

In addition, the first charge (formed in the first distribution process) is closed and the second charge is
The second powder sheet formed in the dispensing process is formed into the same shape as the outer circumference of the target product by using a mold-shaped plate having a hole that follows the outer circumference of the target product through the hole. Therefore, after forming the first powder layer and the second powder layer, there is no need to dispose of excess material.

In addition, in the first distribution step and the second distribution step, each powder material sprinkled through the hole in the shaped plate is placed on the upper part of the mold plate in addition to the hole in the Vll, and the spread powder material is heated. It is economically advantageous because it can be collected and reused as it is since it is not degraded or degraded.

In other words, there is no waste of materials and it is advantageous in terms of cost. Further, it is possible to eliminate the problem of producing recycled material in which non-foamable resin material and foamable resin material are mixed.

[Example] A method for manufacturing a skin having a foam layer according to this example will be explained based on FIGS. 1 to 8.

The method for manufacturing a skin having a foam layer according to this embodiment includes a forming plate heating step, a first distribution step, a first heating step, a pressing step, a second distribution step, a second heating step, and a cooling step. process and
It consists of a mold release process. In the first distribution step, a skin layer made of non-foamable resin material and having the outer peripheral shape of the target product is formed.
A skin layer made of a foamable resin material and having the outer peripheral shape of the target product is formed on the back side of the skin layer by a pressing process, and is formed by a second distribution process and a cooling process.

Each step of the manufacturing method of this example will be explained below.

In the forming plate heating process, as shown in FIG.
is fixed, and a second heating plate 12 is attached to a movable member (not shown) of the press device.

This allows the first heating plates 13 and 14 to move relative to each other in a direction toward or away from each other.

On this first heating plate 13, a molding plate 1 having a transfer surface 10 having an inverted pattern of the surface pattern of the target product is placed. is placed on the first heating plate 13. After this, the first heating plate 13 and the second
The heating plate 14 is heated by an open circuit high frequency heating device.

Then, the second heating plate 14 is moved to a position where the transfer surface 10 side can be heated. Then, the temperature of the molded plate 1 increases due to heat conduction from the first heating plate 13 and the second heating plate 14 heated by the open circuit high-frequency heating device, and the temperature rises to 200 degrees or more.
It is maintained at a temperature range of 230 degrees. Once the molded plate 1 is heated by the first heating plate 13 and the second heating plate 14 as described above, it can be maintained in the heated state within the temperature range only by the first heating plate 13. In addition, the second heating plate] 4 is moved to a position where it does not interfere with the next process in preparation for the next process.

The first heating plate 13 and the second heating plate 14 are set to a size that allows the entire molded plate 1 to be heated to and maintained within the above temperature range.

In the first distribution step, as shown in FIG. 2, a shaped plate 2 having a hole 20 that follows the outer circumferential shape of the target product is used. This shaped plate 2 is placed on top of the shaped plate 1 placed on the first heating 113 as shown in FIG. A distribution device 4 is provided for substantially uniform distribution on the transfer surface 10. The distribution device 4 is connected to a distributor 40 having a mesh portion and a part of the distributor 40 disposed in the horizontal position.
A vibrator 41 that vibrates 0, a distributor 40, and a vibrator 4
1 in the Xl-X2 direction and the Yl-Y2 direction parallel to the shape plate 2, respectively.

As a result, the distributor 40 receives the powdered non-foamable resin material 3 discharged from the container 33, and transmits the non-foamable resin material 3 while being vibrated by the vibrator 41.
is moved in the Xl-X2 direction and Yl-Y2 direction at a constant speed. The non-foamable resin material 3 that has passed through the distributor 40 can be evenly and almost uniformly spread onto the transfer surface 10 of the molded plate 1 from the position of the hole 20 of the shaped plate 2. Note that as the non-foamable resin material 3, polyvinyl chloride powder with a particle size of 100 μm is used.

Through this first distribution step, the transfer surface 10 of the molding plate 1, which has been heated to a predetermined temperature by the heating process of the molding plate h0 through the punched hole 20 along the circumferential shape of the target product.
On top, the non-foaming resin material 3 was uniformly heated for 30 seconds.
As a result, a substantially uniform first powder garden 30 having the outer peripheral shape of the target product and having a thickness of about 0.6 mm is formed on the transfer surface 10. In this case, some of the powdered non-foamable resin material 3 discharged from the dispensing device 4 sprinkles onto the upper surface 21 of the shaped plate 2. It can be dispensed through the distributor 40.

In the first heating step, as shown in FIG. 3, a first powder layer 30 formed on the transfer surface 10 of the forming plate 1 in the first distribution step
In this case, the surface 30a side of the transfer surface 10 having an inverted pattern is
The back surface 30b side of the first powder layer 30 is heated by the heater 5 disposed above for about 60 seconds, so that the back surface 30b side of the first powder layer 30 has a
The skin layer 31 is formed by heating and gelling. The air between the first powder layer 30 and the molded plate 1 escapes upward as it gels, so the skin layer 31 and the molded plate 1 are in close contact with each other, resulting in an inverted pattern of the grain pattern on the transfer surface 10. skin layer 31
will be transferred reliably. Further, since the first layer 30 has a substantially uniform thickness, the thickness of the skin layer 31 also becomes substantially uniform.

In the pressing step, as shown in FIG. 4, a cooling plate 6 at a temperature lower (40 degrees) than the temperature of the skin layer 31 (220 degrees) is opened on the back surface 31b side of the skin layer 31 that has been gelled in the first heating step. The skin layer 31 is pressed against the back surface 31b of the skin layer 31 while being attached to the movable member of the press mounting section.As a result, the skin layer 31 is compressed by the cooling plate 6 and the molding plate 1, so that the average wall thickness is Q, 5 mm. The compression time in the skin diagram 31 is 2 seconds.At this time, the cooling plate 6 is
Due to its low temperature, when it is pressed against the back surface 31b of the skin layer 31, it does not adhere to the back surface 31b.

Therefore, the skin layer 31 can form an intermediate product having the desired product shape without causing delamination due to adhesion.

In the second distribution step, the first distribution step (
As shown in FIG. 2), a shaping plate 2 and a distributor @4 are arranged parallel to the upper part of the shaping plate 1. Then, the powdered foamable resin material 7 (light-absorbing vinyl chloride) discharged from the container 73 is dispersed almost uniformly on the back surface 31b of the skin layer 31 by the distributor 40 to obtain the desired product shape and thickness. 2
．． A substantially uniform second powder layer 70 of 5 mm is formed.

In the second heating step, as shown in FIG. 6, the molded plate 1 is heated for 60 seconds by the heater 5 disposed above it in the same way as in the first heating step (shown in FIG. 3). The second powder layer 70 is foamed when the temperature reaches about 190 degrees, and the foam layer 71 is integrally bonded to the back surface 31b of the skin figure 31.
is formed.

In the cooling step, cooling [8] shown in FIG. 8 is prepared. This cooling tank 8 includes a plurality of conveyance rollers 83 for conveyance disposed in a space between an inlet portion 81 and an outlet portion 82, and an upper nozzle 84 that spouts cooling water downward from above. It consists of a lower nozzle 85 that spouts cooling water from below to above. Then, in the second heating step, as shown in FIG. 7, the molded plate 1 on which the skin 9 consisting of the skin layer 31 and the foam layer 71 is placed is conveyed in the cooling tank 8 in the direction of arrow P by the conveying roller 83. Then, the molded metal 9 and the molded plate 1 are passed through and cooled by the cooling water jetted from the upper nozzle 84 and the lower nozzle 85.

In the mold release step, the skin 9, which has been sufficiently cooled in the cooling step, is released from the mold on the molding plate I.

According to the manufacturing method of this embodiment, care has been taken in advance to avoid any material remaining that would be disposed of, so the manufactured skin 9 is made of a powder non-foaming resin material 3.
Moreover, the foamable resin material 7 can be manufactured into a product while being effectively utilized, and there is no waste such as throwing away excess material after molding the product. That is, in the first distribution process and the second distribution process, only the amount of the art materials 'F43 and 7 necessary for molding is dispersed through the hole 20 of the shape plate 2 and used, so that the excess amount is used for molding. Never.

Further, when the material 3 or 7 is sprinkled through the punched hole 20, it can be collected as it is on the top surface 21 of the shaped plate 2 other than the punched hole 20, and used repeatedly. Therefore, there is no waste of materials and it is advantageous in terms of cost.

Further, the thickness of the skin layer 31 and the foam layer 71 can be varied depending on the purpose by controlling the dispersion time of the powdered material in the first distribution step and the second distribution step. The thickness can be easily set for that purpose.

Furthermore, the pattern on the surface of the skin layer can be formed very easily since the pattern on the transfer surface 10 of the molded plate 1 is transferred.

Therefore, the equipment used in the conventional powder sludge uni method becomes larger and the installation space becomes wider.
Problems such as high product costs can be solved.

In addition, it is possible to eliminate problems such as waste of materials caused by the conventional method of vacuum forming a skin from a rolled sheet with extrusion and texture.

As described above, according to the method of this embodiment, a sheet having a constant wall thickness and in which the skin pattern and the foam layer are reliably integrated can be manufactured in the final desired product shape.

[Brief explanation of the drawing]

FIGS. 1 to 9 explain the steps involved in the method of manufacturing a skin having a foam layer according to this embodiment, and FIG. 1 is a perspective view showing the forming plate heating step. FIG. 2 is a side view showing the first distribution step. FIG. 3 is a side view showing the first heating step. FIG. 4 is a side view showing the pressing process. FIG. 5 is a side view showing the second distribution step. FIG. 6 is a side view showing the second heating step. FIG. 7 is a perspective view showing the molded product and molded plate after the second heating step. FIG. 8 is a side view showing the cooling process. FIG. 9 is a perspective view showing the mold release process. 1... Molded plate 10... Transfer surface 11...
First heating plate 12...Second heating plate 2...Shape plate
20... Hole removal part 3... Non-foaming resin material (
powder) 30...first powder layer 31...skin layer 4...
Distribution device 40...Distributor 41...Vibrator
42...X-Y moving device 5...J-Yu
6...Cooling plate 7...Foamable resin material (powder)

Claims (1)

[Claims] (1) A molded plate heating step of heating a molded plate having a transfer surface of an inverted pattern of the surface pattern of the target product to a predetermined temperature; and a molded plate having a perforated part that follows the outer circumferential shape of the target product, and the perforated part a first distributing step of spreading a powdered non-foamable resin material almost uniformly onto the transfer surface of the molded plate to form a first powder layer; and heating the first powder layer from both sides. a first heating step of gelling to form a skin layer; pressing a cooling plate at a temperature lower than the temperature of the skin layer on the back side of the gelled skin layer to cool the skin layer to the cooling plate and the molding plate; and a pressing step to make the wall thickness uniform by compressing the skin layer, and forming a second powder layer by spraying powdered foamable resin material almost uniformly on the back surface of the skin layer through the hole in the shaped plate. a second distribution step of heating and foaming the second powder layer to form a foam layer integrally bonded to the skin layer; and a second heating step of heating and foaming the second powder layer to form a foam layer integrally bonded to the skin layer. A method for producing a skin having a foam layer, comprising: a cooling step of cooling together with a molded plate; and a mold release step of releasing the skin layer having the foam layer from the molded plate.