JPH045035A - Laminate and molding thereof - Google Patents

Abstract

PURPOSE:To reduce the number of molding processes and to improve productivity by pressing, heating and adhering a layered raw material prepd. by positioning a foamed layer on a core material layer incorporated with a thermosetting resin and positioning a skin layer on the foamed layer. CONSTITUTION:A layered raw material 11 consists of a core material layer 12, a foamed urethane layer 13 and a skin layer 14. The core material layer 12 is obtd. by impregnating a non-woven fabric with a thermosetting resin such as a phenol resin and an epoxy resin. When the layered raw material 11 is pinched and pressed by means of a core mold 15 and a cavity mold 16, the thermosetting resin contg. the non-woven fabric is molded and cured and at the same time, molding if the foamed urethane layer 13 with a thickness distribution corresponding to the mold is simultaneously performed by heating and pressing. A molded item is obtd. by pressing while heat conducted from the core mold 15 is kept so as to obtain a uniform surface temp. by cooling the cavity mold 16. Side edge parts of the core material 12 and the skin layer 14 of a molded item 20 are tightly adhered by pressing to obtain the molded item 20 wherein the foamed urethane layer 13 is not exposed outside.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a laminate for interior parts of automobiles, such as instrument safety pads and soft console boxes, and a method for molding the same.

[Prior Art] Conventional laminates and molding methods thereof include those shown in FIGS. 4 to 6, for example.

This is a molding method for molding a soft console box for an automobile, in which a skin material 1 previously formed by vacuum forming means is set in a predetermined foam cavity mold 2, and then the inside, that is, the skin material An appropriate amount of foamable urethane liquid 3 is injected into the upper part of the mold from a mixing head 4. After this injection, a foaming core mold 6 equipped with a core material 5 that has been separately formed in advance by plastic injection molding or the like is promptly closed in the cavity mold 2, and then the urethane liquid in the mold is foamed. After the mold is released,
A molded product 7 is obtained in which the skin material 1, the foam layer 3°, and the core material 5 are integrated,
As a finishing treatment for the edges of the molded product 7 obtained in this way, the skin material 1
As shown in Fig. 6, the edge 1'' of the frame is manually folded inward, and the folded portion is then glued as appropriate to finish.

[Problems to be Solved by the Invention] However, the laminate 7 obtained by such a conventional molding method requires that the skin material 1 and the core material 5, which are molded in separate processes, are set in the foam mold 2.6. , its skin material 1 and core material 5
Since the foamable urethane liquid 3 is interposed between them to form an integral structure, the skin material 1 and the core material 5, which are molded in separate processes, may have dimensional variations depending on the molding conditions, etc. If the adhesion between the surface of the skin material 1 and the surface of the core mold 6 is impaired, wrinkles may occur, especially in the skin material 1, during foam molding using the foam mold.
There was a problem in that the urethane liquid dripped out from between the core material 5 and the core material 5, resulting in product defects. Another problem is that finishing work on the edges of the molded product must be done manually, which is time-consuming.

[Means for solving the ff problem] The present invention has been made by focusing on such conventional problems, and includes, for example, a core sheet serving as a core material, a foam layer layered on the upper surface of this core sheet, and To provide a molding method in which a three-layer laminate sheet having a three-layer structure consisting of a skin formed on the upper surface of a foam layer is pressurized and heated into a predetermined shape using a core mold and a cavity mold to form a product.

Therefore, the molded product obtained by this molding method is a layered product obtained by one molding method using a set of molds, and does not require multiple sets of molds as in the conventional molding method. Molding equipment can be reduced. Also, traditionally,
- Since it is necessary to set the molded material into a foaming mold, there was a problem in that the above-mentioned product defects were caused due to dimensional errors between the molding material and the foaming mold. Since the molded product is completed by a single pressure molding process using the raw material, it has the advantage that the above-mentioned problems can be eliminated.

[Example of implementation] The present invention will be explained below based on the drawings.

FIG. 1 is a diagram showing an embodiment of the present invention.

First, to explain the structure, reference numeral 11 is a laminated material used for molding a laminated molded product in this embodiment, and this laminated material 11 has a core material layer 12 and a core material layer 12.
It consists of a foamed urethane layer 13 formed on the upper surface and a skin layer 14 formed on the upper surface of this foamed urethane layer 13. The core material layer 12 is obtained by impregnating a nonwoven fabric with a thermosetting resin such as a phenol resin or an epoxy resin. Alternatively, instead of a non-woven fabric, a highly foamed mesh urethane foam material injected with thermosetting resin powder such as phenolic resin powder and sealed may also be used.

In order to mold a molded product as shown in FIG. 4 using the layered material 11 layered in this way, a core mold 15 and a cavity mold 16 as shown in FIG. 2 are used to mold the product. . This core mold 15 is constructed as a heating type with a heater 17 embedded within the mold so that an appropriate heating temperature can be maintained.

Furthermore, the cavity mold 16 is a temperature control type, and has a structure in which a flow path 18 is installed inside the cavity mold 16 so that the temperature can be controlled so that the material 11 to be heated is partially maintained at an appropriate temperature during molding. It has become.

The core mold 15 and cavity mold 16 are heated there.
By sandwiching and pressing the layered material 11, each layer of the layered material 11, that is, the core layer 12, the urethane layer 13, and the skin layer 14, is heated and pressed to form a molded product 20 corresponding to the mold. is obtained. That is, the thermosetting resin containing the nonwoven fabric is molded and cured, and at the same time, the foamed urethane layer 13 is molded to have a thickness and a thinness corresponding to both molds by heating and pressing force. Next, cavity mold 16
A molded product is obtained by cooling the core mold 15 and applying pressure while keeping the heat conducted from the core mold 15 at a uniform surface temperature.

Next, during the edge treatment of the molded product 20 obtained in this way or during heating and pressure molding of the molded product 20, the core material layer 1 is
2 and the edges of the skin layer 14 to form the urethane foam layer 13.
By crushing, the skin layer 14 and the core layer 12 are brought into close contact with each other, making it impossible to obtain a molded article 20 in which the foamed urethane layer 13 is not exposed, as shown in FIGS. 3(a) and 3(b). When crushing the foamed urethane layer 13, it may be crushed from the core layer 12 side as shown in FIG.
As shown in (b), it is possible to selectively crush the skin layer 14 from the side, and the molding shown in FIG. The molding shown in FIG. 3(0) is effective for attaching the molded product 20 to another object in which the edges of the molded product 20 are exposed.

Next, FIGS. 7 to 9 show how to make the layered material 11.
The explanation will be based on the diagram. First, as shown in FIG. 7, the urethane foam layer 13 wound into a roll is sequentially pulled out, and one side of the urethane foam layer 13 is heated and melted by the flame 32 from the gas nozzle 31.
A two-layer sheet 35 is prepared by bonding the skin layer 14 to the heated and melted surface of the sheet 3 using a pressure roll 33. Note that 34 indicates an exhaust duct. Next, as shown in FIG. 8, in the step of transporting the two-layer sheet 35 formed by the above process by a conveyor 36, an adhesive 37 is applied to the surface of the foamed urethane layer 13 of the two-layer sheet 35, and then A separately prepared core layer 12 of non-woven fabric or the like is superimposed on the adhesive coated surface and bonded under pressure using a pressure roll 38 to obtain a three-layer structure 10.

Next, the layer matures! 0 is sent out by the feed roll 39, the laminated body 10 is vibrated by the vibrator 40. During this vibration, an appropriate amount of thermosetting resin powder 41 is injected into the core material layer 12 and the foamed urethane layer 13, and then A coating film 44 is formed by applying a powder 43 using a spraying means 42.
form. Next, this layered material 11 is heated in an oven 4.
The layered material 11 as shown in FIG. 1 is obtained by passing through the material 5 or thermally curing with a heating roll.

For example, as shown in FIG. 2, the layered material 11 thus obtained is interposed between a core mold 15 heated by a heating means 17 and a cavity mold 16, and then, after closing both molds, vacuum suction is applied. At the same time as the molding, the thermosetting resin 41 contained in the core material layer 12 is cured to obtain the desired laminate molded product.

[Effects of the Invention] As described above, the present invention comprises disposing a cushion layer on a non-woven fabric or highly foamed urethane material impregnated with a thermosetting resin (or injected with powder), and disposing a skin on this cushion layer. This is a method of forming a laminate in which the laminate is sandwiched between a core mold and a cavity mold and cured by heating. The laminated material 11 thus formed can be placed in a vacuum molding/pressing mold, etc., and the desired laminated molded product can be obtained by a single vacuum/heating/pressing method in the same mold. Compared to a molding method in which the layer core materials are molded using separate molding methods, placed in a foam mold, and then integrated by injecting foamed urethane material, the molding process is reduced and productivity is significantly improved. Effects can be obtained.

In addition, the conventional method requires a process of placing the molded material into a foaming mold, which could result in product defects due to dimensional errors between the molding material and the foaming mold.
In the present invention, since the laminated material can be completely molded by pressure molding within the same mold, the generation of defective products can be suppressed and the product yield can be increased.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram of the l acid material used in the present invention,
Fig. 2 is an explanatory diagram during molding, Fig. 3<4), (0) is an explanatory diagram of the molded product, Fig. 4 is an explanatory perspective view of the molded product, and Figs. 5 and 6 are explanatory diagrams of conventional examples. 7 to 9 are explanatory diagrams showing the forming process of the layered material. 10... Layered material 11... Layered material 12...
・Core material layer 13...Urethane foam layer 14...
Skin layer 15... Core type 16... Cavity type 17... Heater 18... Channel 1
9... Heat insulation plate 20... Molded product 21... Feed roll 22... Thermosetting resin powder 31... Gas nozzle 32... Flame 33... Pressure roll 34... Exhaust duct 35...Two-layer sheet 36...Conveyor 37...Adhesive 3
8... Pressure roll 39... Feed roll 40...
- Vibrator 41...Thermosetting resin powder 42...Spraying means 43...Paint 44...Coating film 45...Heating oven and 4 others (A)

Claims (1)

[Claims] 1. A layered material in which a foam layer is placed on a core material layer impregnated with a thermosetting resin and a skin layer is placed on this foam layer is heated under pressure in a mold. A laminate characterized by being glued together. 2. The laminate according to claim 1, wherein the core material layer is made of a nonwoven fabric. 3. The laminate according to claim 1, wherein the core material layer is made of a mesh-like foam material injected with thermosetting resin powder and sealed. 4 A foamed layer is placed on a core material layer impregnated with a thermosetting resin, and a layered material formed by placing a skin layer on this foamed layer is sandwiched between a cavity mold and a core mold, and then the core material layer is sandwiched between a cavity mold and a core mold. A method for forming a laminate characterized by heating and curing.