JPH03193430A - Manufacture of composite-layer molded body - Google Patents
Manufacture of composite-layer molded bodyInfo
- Publication number
- JPH03193430A JPH03193430A JP33610089A JP33610089A JPH03193430A JP H03193430 A JPH03193430 A JP H03193430A JP 33610089 A JP33610089 A JP 33610089A JP 33610089 A JP33610089 A JP 33610089A JP H03193430 A JPH03193430 A JP H03193430A
- Authority
- JP
- Japan
- Prior art keywords
- layer
- base material
- material layer
- skin layer
- molded body
- 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.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 238000000465 moulding Methods 0.000 claims abstract description 14
- 239000006260 foam Substances 0.000 claims abstract description 13
- 229920003002 synthetic resin Polymers 0.000 claims abstract description 13
- 239000000057 synthetic resin Substances 0.000 claims abstract description 13
- 238000003466 welding Methods 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 20
- 229920001169 thermoplastic Polymers 0.000 abstract description 3
- 239000004416 thermosoftening plastic Substances 0.000 abstract description 3
- 238000010438 heat treatment Methods 0.000 abstract description 2
- 239000000919 ceramic Substances 0.000 abstract 1
- 229920000098 polyolefin Polymers 0.000 description 6
- 238000000034 method Methods 0.000 description 4
- 239000004800 polyvinyl chloride Substances 0.000 description 3
- 229920000915 polyvinyl chloride Polymers 0.000 description 3
- 239000004604 Blowing Agent Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 150000001451 organic peroxides Chemical class 0.000 description 2
- -1 polypropylene Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229920002725 thermoplastic elastomer Polymers 0.000 description 1
- 238000007666 vacuum forming Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
- B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/12—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor of articles having inserts or reinforcements
Abstract
Description
【発明の詳細な説明】
（産業上の利用分野）
本発明は表皮層、発泡層および基材層を一体的に備えた
複層成形体の製造方法に関する。DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for producing a multilayer molded article integrally comprising a skin layer, a foam layer and a base material layer.
（従来技術）
この種の複層成形体は自動車等のドアトリム、インスト
ルメントパネル、ルーフ、その他各種の内装材として使
用されるもので、当該成形体の基材層の一側面にはそれ
自体の他の部材への組付は用のブラケット、他の部材の
組付は用のブラケット、その他の機能部材が固着される
ことが多い。(Prior art) This type of multilayer molded product is used as door trims, instrument panels, roofs, and other various interior materials of automobiles, and one side of the base layer of the molded product has its own layer. Other functional members are often fixed using brackets for attaching to other members, brackets for attaching other members to other members, and other functional members.
また、当該成形体は例えば特開平１−９５０３２号公報
に示されているように、成形体の両型にて前記３つの層
を一体的に加熱成形することにより形成する製造方法が
採られ、がっその後各種のウェルド法にて前記機能部材
を基材層の一側面に熱溶着する固着方法が採られている
。In addition, the molded body is manufactured by a manufacturing method in which the three layers are integrally heat-formed in both molds of the molded body, as shown in, for example, Japanese Patent Application Laid-Open No. 1-95032, After that, the functional member is thermally welded to one side of the base layer using various welding methods.
（発明が解決しようとする課題）
ところで、当該成形体において機能部材を固着するなめ
上記の固着方法を採用した場合には、新たに加わる熱に
より基材層に熱変形が生じて成形体の表皮層側に凹凸が
顕在化して成形体の表面を損うおそれがあり、また固着
工程が付加されることにより製造工程が煩雑となりがっ
コストの上昇をまねく。したがって、本発明はこれらの
問題を解消することにある。(Problem to be Solved by the Invention) By the way, when the above-mentioned fixing method is adopted for fixing the functional component in the molded article, thermal deformation occurs in the base material layer due to newly applied heat, causing the skin of the molded article to deteriorate. There is a risk that irregularities will appear on the layer side and damage the surface of the molded article, and the addition of a fixing step will complicate the manufacturing process, leading to an increase in cost. The present invention therefore seeks to eliminate these problems.
（課題を解決するための手段）
本発明は、表皮層、発泡層および熱可撓性合成樹脂製の
基材層を一体的に備え、かつ同基材層の一側面に機能部
材を備えてなる複層成形体の製造方法であり、前記３層
を成形型の両型にて一体的に成形する間前記基材層を加
熱状態に保持してその一側面に前記機能部材を熱溶着す
ることを特徴とするものである。(Means for Solving the Problems) The present invention includes a skin layer, a foam layer, and a base layer made of thermoflexible synthetic resin integrally, and a functional member on one side of the base layer. In this method, the functional member is thermally welded to one side of the base layer while the three layers are integrally molded using both molds, while the base layer is kept in a heated state. It is characterized by this.
（発明の作用・効果）
かかる製造方法を採用すれば、機能部材を成形体を成形
する間に固着させるものであって成形後に成形体を加熱
することがないため、成形後に成形体の表面が損われる
ことは全くなく、また従来の製造方法に比較して工程数
が減少して製造工程が簡単化されかつコストが低減する
。(Actions and Effects of the Invention) If such a manufacturing method is adopted, the functional component is fixed to the molded body during molding, and the molded body is not heated after molding. There is no damage, and compared to conventional manufacturing methods, the number of steps is reduced, simplifying the manufacturing process and reducing costs.
（実施例）
以下本発明に係る複層成形体の製造方法について具体的
に説明するに、第１図（ａ）〜（ｄ）には当該製造方法
の各製造工程が示され、第２図には第１図（ｄ）の矢印
■−■線方向の拡大部分断面図が示され、かつ第３図に
は当該製造方法にて製造された複層成形体である自動車
用のドアトリムが示されている。(Example) The method for manufacturing a multilayer molded body according to the present invention will be specifically explained below. FIGS. 1(a) to (d) show each manufacturing process of the manufacturing method, and FIG. 1(d) is an enlarged partial cross-sectional view in the direction of the arrow ■-■, and FIG. 3 shows an automobile door trim which is a multilayer molded product manufactured by the manufacturing method. has been done.
ドアトリム１０は第１図〜第３図に示すように表皮層１
１、発泡層１２および基材層１３からなる３層構造のも
ので、基材層１３の一側面には複数のりテーナブラケッ
ト１４が固着されている。The door trim 10 has a skin layer 1 as shown in FIGS.
1. It has a three-layer structure consisting of a foam layer 12 and a base layer 13, and a plurality of glue retainer brackets 14 are fixed to one side of the base layer 13.
表皮層１１は合成樹脂シートであり、例えば熱可塑性エ
ラストマー、ｐｖｃ、ｐｖｃとＡＢＳ樹脂との混合物等
の０．１〜１ｍｍ程度の厚みの合成樹脂シートが通常用
いられている。本実施例においては前者の合成樹脂製シ
ートを用いている。発泡層１２は合成樹脂の発泡体であ
り、例えば発泡ポリオレフィン、発泡ポリウレタン、発
泡ポリ塩化ビニール等の１〜５ｍｍ程度の厚みの合成樹
脂発泡体が用いられている。本実施例においては発泡ポ
リウレタンを用いている。基材層１３は各種の熱可塑性
合成樹脂板または合成樹脂発泡体で、本実施例において
は未発泡の発泡性ポリオレフィンシート１３ａを素材と
した発泡ポリオレフィン（ポリプロピレン）が用いられ
ている。なお、発泡性ポリオレフィンシート１３ａとは
、ポリオレフィン、架橋剤および／または架橋助剤、発
泡剤、有機過酸化物等を含んで成る組成物を、発泡剤お
よび有機過酸化物が分解しない温度でシート状に形成さ
れたものである。リテーナブラケット１４は予め成形さ
れた合成樹脂性のもので、本実施例においては基材層１
３との接着性を考慮してポリオレフィン製（ポリプロピ
レン）のものを用いている。The skin layer 11 is a synthetic resin sheet, and for example, a synthetic resin sheet having a thickness of about 0.1 to 1 mm, such as thermoplastic elastomer, PVC, or a mixture of PVC and ABS resin, is usually used. In this embodiment, the former synthetic resin sheet is used. The foam layer 12 is a synthetic resin foam, and for example, a synthetic resin foam with a thickness of about 1 to 5 mm, such as foamed polyolefin, foamed polyurethane, or foamed polyvinyl chloride, is used. In this example, foamed polyurethane is used. The base material layer 13 is made of various thermoplastic synthetic resin plates or synthetic resin foams, and in this embodiment, foamed polyolefin (polypropylene) made from an unfoamed polyolefin sheet 13a is used. Note that the foamable polyolefin sheet 13a is a sheet made of a composition containing polyolefin, a crosslinking agent and/or a crosslinking aid, a blowing agent, an organic peroxide, etc. at a temperature at which the blowing agent and organic peroxide do not decompose. It is formed in the shape of The retainer bracket 14 is made of pre-formed synthetic resin, and in this embodiment, the retainer bracket 14 is made of a pre-formed synthetic resin.
A material made of polyolefin (polypropylene) is used in consideration of adhesion with No. 3.
成形体を製造する場合には、予め表皮層１１、発泡層１
２および発泡性シート１３ａを第１図（ａ）に示すよう
に貼り合わせ、この状態で同図（ｂ）に示すよ、うに真
空成形機のセラミックヒータ２１にて加熱して発泡性シ
ート１３ａを発泡させるとともに、表皮層１１を軟化さ
せる。なお、発泡性シート１３ａは発泡して数倍の厚み
の発泡体である基材層１３となる。When producing a molded article, a skin layer 11 and a foam layer 1 are prepared in advance.
2 and the foamable sheet 13a are pasted together as shown in FIG. 1(a), and in this state, as shown in FIG. While foaming, the skin layer 11 is softened. Note that the foamable sheet 13a is foamed to become the base material layer 13 which is a foam several times the thickness.
かかる加熱処理の後これらの３層構造体を直ちに、第１
図（ｃ）に示すように真空成形機の成形型の上型２２と
下型２３間にセットし、同図（ｄ）に示すように真空下
でプレス成形する。このプレス成形に際しては上型２２
の嵌合凹所２２ａにリテーナブラケット１４が容易に離
脱可能に嵌合され、かつ表皮層１１の表面温度が１８０
℃、基材層１３の表面温度が２１０℃となるよう温度が
設定される。かかるプレス成形によりドアトリムとして
の成形体が形成され、表皮層１１の表面は美麗な化粧表
面に仕上がり、かつ基材層１３の一側面の所定の部位に
リテーナブラケット１４が熱溶着される。第２図には同
ブラケット１４の熱溶着部の断面が示されている。Immediately after such heat treatment, these three-layer structures are
As shown in Figure (c), it is set between the upper mold 22 and lower mold 23 of a vacuum forming machine, and press-molded under vacuum as shown in Figure (d). During this press molding, the upper die 22
The retainer bracket 14 is easily removably fitted into the fitting recess 22a, and the surface temperature of the skin layer 11 is 180°C.
℃, and the temperature is set so that the surface temperature of the base material layer 13 is 210°C. A molded body as a door trim is formed by such press molding, the surface of the skin layer 11 is finished with a beautiful decorative surface, and the retainer bracket 14 is thermally welded to a predetermined portion on one side of the base material layer 13. FIG. 2 shows a cross section of the heat-welded portion of the bracket 14.
このように、本発明にかかる製造方法によれば、リテー
ナブラケット１４をドアトリム１０のプレス成形特同時
に基材層１３の一側面に熱溶着するものであるから、成
形後のドアトリム１０を加熱することがなくてドアトリ
ム１０の表皮層１１の化粧表面が損なわれることがなく
、また成形後の加工工程が不要となって製造工程が簡単
化されかつコストが低減する。As described above, according to the manufacturing method of the present invention, since the retainer bracket 14 is thermally welded to one side of the base material layer 13 at the same time as the press molding of the door trim 10, it is not necessary to heat the door trim 10 after molding. Since there is no such thing, the decorative surface of the skin layer 11 of the door trim 10 is not damaged, and a processing step after molding is not required, which simplifies the manufacturing process and reduces costs.
また、当該製造方法において、基材層１３に対するリテ
ーナブラケットの固着強度を高めるためには、第４図に
示すリテーナブラケット１５を採用することが好ましい
、このリテーナブラケット１５は両側のフランジ部１５
ａに断面路Ｖ形の貫通孔１５ｂを備えており、プレス成
形特基材層１３の一部分が溶融または軟化状態で貫通孔
１５ｂに侵入して固化する。この結果、貫通孔１５ｂに
侵入した基材層１３の一部分がアンカー効果を発揮し、
リテーナブラケット１５の固着強度を高める。In addition, in the manufacturing method, in order to increase the adhesion strength of the retainer bracket to the base material layer 13, it is preferable to employ the retainer bracket 15 shown in FIG.
A is provided with a through hole 15b having a V-shaped cross section, and a portion of the press-molded special base material layer 13 enters the through hole 15b in a molten or softened state and solidifies. As a result, a portion of the base material layer 13 that has entered the through hole 15b exhibits an anchor effect,
To increase the fixing strength of the retainer bracket 15.
なお、本発明の製造方法はドアトリムに限らず、各種の
内装材の製造に採用することができ、また基材層につい
ては各種の熱可塑性の合成樹脂板を採用することができ
、かつリテーナブラケットに換えて各種の機能部材を採
用することができる。The manufacturing method of the present invention is not limited to door trims, but can be applied to the manufacturing of various interior materials, and various thermoplastic synthetic resin plates can be used for the base material layer, and retainer brackets Various functional members can be used instead.
テーナブラケットの変形例を示す第２図に対応する部分
断面図である。FIG. 3 is a partial cross-sectional view corresponding to FIG. 2 showing a modification of the retainer bracket.
符号の説明
１０・・・ドアトリム、１１・・・表皮層、１２・発泡
層、１３・・・基材層、１３ａ・発泡性シート、１４．
１５・・・リテーナブラケット、２１・・・ヒータ、２
２．２３・・・型。Explanation of the symbols 10...Door trim, 11...Skin layer, 12-Foam layer, 13...Base material layer, 13a-Foam sheet, 14.
15... Retainer bracket, 21... Heater, 2
2.23...type.
Claims (1)
体的に備え、かつ同基材層の一側面に機能部材を備えて
なる複層成形体の製造方法であり、前記３層を成形型の
両型にて一体的に成形する間前記基材層を加熱状態に保
持してその一側面に前記機能部材を熱溶着することを特
徴とする複層成形体の製造方法。3. A method for producing a multilayer molded article, which integrally includes a skin layer, a foam layer, and a base layer made of a thermoflexible synthetic resin, and a functional member on one side of the base layer; A method for producing a multi-layer molded body, comprising: maintaining the base layer in a heated state while integrally molding the layer with both molds of a mold, and thermally welding the functional member to one side of the base layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1336100A JP2809455B2 (en) | 1989-12-25 | 1989-12-25 | Method for producing multilayer molded article |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1336100A JP2809455B2 (en) | 1989-12-25 | 1989-12-25 | Method for producing multilayer molded article |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH03193430A true JPH03193430A (en) | 1991-08-23 |
| JP2809455B2 JP2809455B2 (en) | 1998-10-08 |
Family
ID=18295695
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1336100A Expired - Fee Related JP2809455B2 (en) | 1989-12-25 | 1989-12-25 | Method for producing multilayer molded article |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2809455B2 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006151042A (en) * | 2004-11-25 | 2006-06-15 | Kasai Kogyo Co Ltd | Interior part for automobile |
| JP2006272890A (en) * | 2005-03-30 | 2006-10-12 | Kasai Kogyo Co Ltd | Interior finishing part for automobile |
| WO2013068586A1 (en) * | 2011-11-11 | 2013-05-16 | Recticel N. V. | Method to manufacture a panel comprising a substrate and at least one component adhered thereto, panel and mould system |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH01123722A (en) * | 1987-11-09 | 1989-05-16 | Shigeru Kogyo Kk | Manufacture of panel |
-
1989
- 1989-12-25 JP JP1336100A patent/JP2809455B2/en not_active Expired - Fee Related
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH01123722A (en) * | 1987-11-09 | 1989-05-16 | Shigeru Kogyo Kk | Manufacture of panel |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006151042A (en) * | 2004-11-25 | 2006-06-15 | Kasai Kogyo Co Ltd | Interior part for automobile |
| JP2006272890A (en) * | 2005-03-30 | 2006-10-12 | Kasai Kogyo Co Ltd | Interior finishing part for automobile |
| WO2013068586A1 (en) * | 2011-11-11 | 2013-05-16 | Recticel N. V. | Method to manufacture a panel comprising a substrate and at least one component adhered thereto, panel and mould system |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2809455B2 (en) | 1998-10-08 |
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