JPH05131475A - Method and device for forming laminate - Google Patents

Abstract

PURPOSE:To ensure the fixing strength by curlingly contact bonding the peripheral edge part of skin. CONSTITUTION:Ultrasonic horns 23 or heaters or rods having sharp projections at their tips are installed at proper circumferential intervals on the curlingly contact bonding part of the peripheral edge part of skin of a lower mold 4 or of an upper mold 3. At the curlingly contact bonding of the peripheral edge part 15a of skin, ultrasonic wave is applied to the peripheral edge part 15a of skin with the ultrasonic horns 23 or the peripheral edge part 15a of skin is heated with the heaters so as to spot-weld the peripheral edge part 15a of skin. Or the peripheral edge part 15a of skin is bit into base material 5 with the sharp projections.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a laminate for forming a laminate to be used as an interior material for automobiles by laminating a skin on a resin base material and winding and crimping the peripheral edge of the skin. It relates to the device.

[0002]

2. Description of the Related Art In the case of manufacturing interior materials for automobiles, generally, a skin is attached to the surface of a resin base material such as plastic, and the peripheral portion of the skin is wound around the back surface of the base material and pressure-bonded to form a laminate. I try to shape my body.

An example of a laminate forming apparatus for forming the above-mentioned laminate is shown in Japanese Patent Application Laid-Open No. 3-101921, as shown in FIG.
As shown in the outline of FIG. 7, mainly, an upper mold 3 provided on the lower surface of the movable bolster 1 that can be raised and lowered, a lower mold 4 provided on the fixed bolster 2, and a molten resin on the lower mold 4. 5a
And an extruder (not shown) arranged between the upper and lower molds 3 and 4 so as to be able to feed in.

The lower mold 4 is a lower outer mold 6 having a shape in which the inner peripheral shape of the upper surface is made to match the shape of the substrate 5 to be press-molded from the molten resin 5a, and ascending / descending in the lower outer mold 6. A lower inner mold 7 that is fitted as much as possible, and the lower inner mold 7 is a body part 7a that is moved up and down by the operation of a cylinder 8 installed on the fixed bolster 2, and a cylinder installed on the fixed bolster 2. By the operation of 9, the supporting member 10
And a slide portion 7b fitted to the outer periphery of the main body portion 7a so that the main body portion 7a and the slide portion 7b are engaged with each other and the upper surface of the slide portion 7b is the main body portion 7a. A concave portion 11a and a convex portion 11b for preventing the upper outer die 12 from protruding upward from the upper surface of the upper outer die 12 and the outer peripheral surface of the lower outer die 6 when the upper die 3 descends. A cutter 13 is attached so as to be able to slide on the surface, and further, at the lower part of the inner peripheral surface of the lower outer mold 6, the outer peripheral surface of the upper surface of the slide portion 7b is located above the upper surface of the lower outer mold 6 to cover the base material 5. The stopper 14 for limiting the lowering of the lower inner die 7 is fixed at a position where the lower inner die 7 is pulled downward by an amount substantially equal to the thickness.

The upper die 3 has a frame-shaped upper outer die 12 whose inner peripheral surface at the lower end is located outside the inner peripheral surface of the lower outer die 6 by an amount substantially equal to the thickness of the skin 15. The upper inner mold 16 is fitted in the upper outer mold 12 so as to move up and down by the operation of the cylinder 20 installed on the lower surface of the movable bolster 1, and the lower outer peripheral portion of the upper outer mold 12 has the above-mentioned structure. An inner blade 17 for cutting the skin 15 is formed in cooperation with the cutter 13, and the upper outer mold 12 is connected to a pressure source 18 and is opened at the inner circumference of the lower end of the upper outer mold 12. The gas pipeline 19 is installed.

When a laminated body is molded by such a laminated body molding apparatus, in the state shown in FIG. 5, the skin 15 is introduced to the lower surface side of the upper mold 3 with the back surface facing downward,
The upper mold 3 is set by a suction device (not shown) or the like.
Next, after a required amount of molten resin 5a is supplied onto the lower inner mold 7 by the nozzle at the tip of the extruder, the nozzle is retracted from between the upper and lower molds 3 and 4. Then, when the upper mold 3 is lowered, the molten resin 5a is press-molded according to the shape of the lower inner mold 7, the base material 5 is molded, and at the same time, the surface skin 15 is pressure-bonded to the surface of the base material 5. It At this time, the periphery of the outer skin 15 protruding from the outer peripheries of the upper and lower molds 3 and 4 is cut off by the cutter 13 and the inner blade 17, and the outer skin 15 is cut into a predetermined shape. Next, when the upper inner mold 16 and the lower inner mold 7 are raised by the contracting operation of the cylinder 20 and the expanding operation of the cylinders 8 and 9 while the base material 5 and the skin 15 are pressed, the upper outer mold is obtained. The peripheral edge portion 15a of the outer skin 15 is drawn into the gap formed between the inner peripheral surface of 12 and the outer peripheral surface of the slide portion 7b of the lower inner mold 7, and is bent down toward the base material 5 side. Be done. When the peripheral edge portion 15a of the epidermis 15 is completely suspended,
After the main body portion 7a of the upper inner die 16 and the lower inner die 7 is held in that position, and then the cylinder 9 is contracted to lower the slide portion 7b, as shown in FIG. When the gas is injected from the above to the peripheral portion 15a of the skin 15 through the gas conduit 19, the peripheral portion 1 of the skin 15
5a is wound around the back surface of the base material 5. In this state, when the slide portion 7b is raised again by the extension operation of the cylinder 9, as shown in FIG. 7, the periphery of the skin 15 is formed on the back surface of the base material 5 between the slide portion 7b and the upper inner die 16. The portion 15a is pressure-bonded to form a laminated body.

[0007]

However, in the case of the above-mentioned laminated body forming apparatus, there is a problem that the pressure bonding strength of the skin peripheral portion 15a cannot be sufficiently obtained depending on the material and thickness of the skin 15.

Therefore, the present invention is intended to provide a method and apparatus for molding a laminate capable of securely fixing the peripheral edge portion of the skin to the back surface of the base material regardless of the thickness of the material of the skin. To do.

[0009]

In order to solve the above problems, the present invention performs molding of a base material from a molten resin between upper and lower molds and at the same time bonding of a skin and winding and pressure bonding of a peripheral edge of the skin. In the laminate molding method to do so, at the time of winding and pressure bonding of the skin peripheral edge portion, ultrasonic waves are applied to the skin peripheral edge portion or heated to spot-weld the skin peripheral edge portion to the base material, or the skin peripheral edge portion. A method for forming a laminate is characterized in that a step of partially engaging the base material is added.

In addition, in a laminate molding apparatus in which a base material is formed from a molten resin between upper and lower molds and at the same time, a skin is bonded and a peripheral edge of the skin is wound and pressure-bonded to each other. The wound crimping portion of the die facing the wound skin edge, an ultrasonic horn for applying ultrasonic waves to the skin edge, or a heater for heating the skin edge, or, A rod having a pointed projection at its tip is vertically movably incorporated.

[0011]

[Operation] When ultrasonic waves are applied to the peripheral edge of the skin or the peripheral edge of the epidermis is heated when the peripheral edge of the epidermis is wound and bonded between the upper and lower molds, the peripheral edge of the epidermis is spot-welded to the base material. In addition, when the peripheral edge of the epidermis is bitten into the base material, the pressure bonding force is strengthened, and the peripheral edge part of the epidermis is firmly fixed to the base material as a whole.

If an ultrasonic horn for applying ultrasonic waves to the peripheral edge of the epidermis, a heater for heating the peripheral edge of the epidermis, or a rod having a pointed projection at the tip is incorporated in the winding and crimping part of the die, It becomes possible to carry out the press-bonding treatment on the peripheral edge portion of the skin in the mold, thereby saving labor and manpower.

[0013]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 shows an embodiment of the present invention. Similar to the one shown in FIGS. 5 to 7, a base material 5 is molded from a molten resin between an upper mold 3 and a lower mold 4. At the same time, in a laminated body molding device configured to bond the outer skin 15 and roll-in and press-bond the outer peripheral edge portion 15a, the lower mold 4 that faces the outer peripheral edge portion 15a wound on the back surface side of the base material 5 is wound. The crimping portion, that is, the slide portion 7b of the lower inner mold 7 is provided with vertical holes 21 that are opened in the upper surface of the slide portion 7b at appropriate intervals in the circumferential direction, and the lower end portion is provided in each vertical hole 21. The ultrasonic horn 23 supporting the air cylinder 22 is incorporated so as to be projected from the upper surface of the slide portion 7b by the extension operation of the air cylinder 22, and the ultrasonic horn 23 is attached when the skin peripheral edge portion 15a is wound and pressure-bonded. Epidermal periphery 15 by making out
It is pressed against a so that the skin peripheral edge portion 15a can be welded to the base material 5 by ultrasonic vibration. The vibrator portion at the tip of the ultrasonic horn 23 has a flange shape matching the diameter of the vertical hole 21 to prevent molten resin from entering the vertical hole 21 at the time of molding the base material and to prevent the vibrator from vibrating. It is designed to prevent damage accidents caused by directly hitting the sliding part.

The peripheral portion 1 of the skin 15 is located between the upper and lower molds 3 and 4.
5a is wound on the back side of the base material 5 and pressure-bonded, as shown in FIG.
As shown in FIG. 5, the slide portion 7b of the lower inner mold 7 that serves as a roll-in crimping portion in a state where the base material 5 and the skin 15 are held between the main body portion 7a of the upper inner mold 16 and the lower inner mold 7. Is raised by the extension operation of the cylinder 9 so that the skin peripheral edge portion 15a is pressure-bonded to the back surface of the base material 5 between the upper surface of the slide portion 7b and the peripheral edge portion of the lower inner die 7, but at the same time, While the ultrasonic horn 23 incorporated in the slide portion 7b is projected upward by the expansion operation of the air cylinder 22 and pressed against the epidermal peripheral edge 15a, ultrasonic vibration (for example, 40 horn) is applied to the epidermal peripheral edge 15a. Try to give. In this way, when ultrasonic waves are applied to the skin peripheral edge portion 15a by the ultrasonic horn 23, that portion can be firmly welded in a spot manner. Therefore, the peripheral edge portion 15a of the skin 15 can be reliably fixed to the base material 5 without being affected by the material and thickness of the skin 15 by the pressing force by the upper surface of the slide portion 7b and the welding force by the application of ultrasonic waves.

Next, FIG. 2 shows another embodiment of the present invention. Instead of the ultrasonic horn 23 in the embodiment of FIG. 1, a cartridge type heater 24 and a slide portion 7b are used.
It is incorporated in the vertical hole 21 of the above.

In the case of the embodiment shown in FIG.
By energizing the heater 24 at the time of winding and crimping a, and causing the heater 24 to project by the expansion operation of the air cylinder 22 and press it against the skin peripheral edge portion 15a, the skin peripheral edge portion 15a can be spotwise heated and welded. .. Therefore, as in the case of the embodiment shown in FIG.
It is possible to secure the fixing strength of a to the base material 5.

Next, FIG. 3 shows still another embodiment of the present invention. Instead of the ultrasonic horn 23 and the heater 24 in each of the above-mentioned embodiments, a rod 25 having a pointed projection 25a at its upper end (tip) is shown. Is incorporated in the vertical hole 21 of the slide portion 7b. The pointed protrusion 25a provided on the upper end of the rod 25 may be, for example, (a) or (b) in FIG.
A shape as shown in (c) can be adopted.

In the case of the embodiment shown in FIG. 3, the rod 25 is raised by the extension operation of the air cylinder 22, and the pointed protrusion 2 at the upper end is raised.
When 5a is pressed against the peripheral edge portion 15a of the epidermis, the pointed protrusion 25
As a penetrates the base material 5 by penetrating the skin peripheral part 15a, the skin peripheral part 15a partially digs into the base material 5. The crimping force of 15a can be strengthened. Therefore, in the case of this method, it is particularly advantageous to arrange the rod 25 so as to correspond to the straight portion excluding the corner portion and the step portion of the base material 5.

According to the present invention, in the above embodiment, the skin 15
Although the peripheral portion 15a of the upper mold 3 is wound and crimped on the lower mold 4 side, when the upper mold 3 is wound and crimped, the ultrasonic horn 23 and the heater 24 are attached to the wound crimping part of the upper mold 3. The rod 25 having the pointed projections 25a may be incorporated, and in the embodiment, the ultrasonic horn 23, the heater 24, and the air cylinder 22 is used as a vertically moving device for vertically moving the rod 25. But
Needless to say, a hydraulic cylinder, an electric device, or the like may be used, and various changes may be made without departing from the scope of the present invention.

[0021]

As described above, according to the present invention, when the peripheral edge of the epidermis is wound and pressure-bonded, ultrasonic waves are applied or heated to the peripheral edge of the epidermis, whereby the base material is circumferentially spread over the peripheral edge of the epidermis. Since it was spot welded to the base material, or the peripheral edge of the epidermis was made to partially penetrate into the base material,
It is possible to secure the overall adhesion strength to the base material at the peripheral edge of the skin without being affected by the material and thickness of the skin, and to apply ultrasonic waves to the peripheral edge of the skin at the winding and crimping part of the mold. By adopting an ultrasonic horn, a heater that heats the peripheral edge of the epidermis, or a rod that has a pointed protrusion at the tip, it is possible to reliably perform the crimping treatment of the peripheral edge of the epidermis in one mold. It is possible to save labor,
It has excellent effects such as saving labor.

[Brief description of drawings]

FIG. 1 is an enlarged cross-sectional view of a wound crimping portion showing an embodiment of a laminated body molding apparatus of the present invention.

FIG. 2 is an enlarged cross-sectional view of a wound crimping portion showing another embodiment of the present invention.

FIG. 3 is an enlarged cross-sectional view of a wound crimping portion showing still another embodiment of the present invention.

FIG. 4 is a view showing a tip portion of a rod used in the embodiment of FIG. 3, and (a), (b) and (c) are views showing examples of the shape of a pointed projection.

FIG. 5 is a schematic view showing an example of a conventional laminate forming apparatus.

FIG. 6 is a schematic view showing an operating state different from that in FIG.

FIG. 7 is a schematic diagram showing an operating state different from that in FIG. 6;

[Explanation of symbols]

 3 Upper mold 4 Lower mold 5 Base material 5a Molten resin 7b Sliding part (roll-in crimping part) 15 Skin 15a Edge of skin 22 Air cylinder (vertical movement device) 23 Ultrasonic horn 24 Heater 25 Rod 25a Pointed protrusion

Claims (5)

[Claims] 1. A method for forming a laminate, which comprises simultaneously laminating a base material from a molten resin between upper and lower molds and simultaneously adhering a skin and winding and crimping the peripheral edge of the skin. At the same time, a method for forming a laminate is characterized in that a step of applying ultrasonic waves to the peripheral edge of the skin or heating the peripheral edge of the skin to spot-weld the base material is added. 2. A laminate molding method in which a base material is molded from a molten resin between upper and lower molds, and at the same time, a skin is attached and a peripheral edge portion of the skin is wound and pressure-bonded. At the same time, the method for forming a laminate is characterized in that the peripheral edge portion of the skin is made to partially penetrate into the base material. 3. A laminated body molding apparatus in which a base material is formed from a molten resin between upper and lower molds, and at the same time, a skin is attached and a peripheral edge portion of the skin is wound and pressure-bonded. A characteristic is that an ultrasonic horn for applying an ultrasonic wave to the peripheral edge of the skin is incorporated at an appropriate interval in the circumferential direction in the wound crimping portion of the mold that faces the peripheral edge of the wound skin. And a laminated body forming device. 4. The laminate molding apparatus according to claim 3, wherein a heater for heating the peripheral edge portion of the skin is incorporated instead of the ultrasonic horn. 5. A laminated body molding apparatus in which a base material is formed from a molten resin between upper and lower molds, and at the same time, a skin is attached and a peripheral edge of the skin is wound and pressure-bonded. A laminate molding characterized by incorporating a rod having a pointed projection at the tip and a vertical movement device for moving the rod up and down in the winding and crimping portion of the die facing the peripheral edge portion of the wound skin. apparatus.