JPH0549025B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a packing method for forming a backing material such as rubber on the back side of a base fabric of an automobile mat.

(Prior Art) Conventionally, as a backing method of this type, there has been a method of pasting a synthetic resin sheet coated with an adhesive on the back side of a fiber mat. However, in this method, since the fiber mat and the synthetic resin sheet were bonded together using adhesives with different physical properties, the fiber mat lined therein could become distorted due to temperature changes.

Therefore, as a bucking method that is less likely to cause this distortion, the method disclosed in Japanese Patent Publication No. 37047/1983 has been proposed. It is shown in Figure 43 and 4.
As shown in Fig. 4, the resin coated in the mold 2 by the resin coating device 6 is heated by the heating device 3 provided at the bottom of the trolley 5 to semi-gel, and then a fiber mat 9 is placed on the top surface of the resin. This is a backing method in which the fiber mat 9 is cooled by a cooling device 8 and a pressurizing device, and the fiber mat 9 is compressed without being exposed to heat, thereby gelling the resin in the mold 2.

(Problem to be solved by the invention) However, in this bucking method, a sol-like resin is applied inside the mold and the mold is heated from below to change the resin from semi-gelling to gelling. At the same time, the fiber mat is cooled and pressurized on the semi-gelled resin to bond the fiber mat to the resin to prevent distortion of the automobile mat. When these air bubbles are present, the fiber mat and resin of the automobile mat that has been backed through the above-mentioned process may peel off, or the resin on the back side of the fiber mat may crack. .

Additionally, automobile mats have a large number of small tapered holes drilled in them to form protrusions that prevent the mat from slipping, but these air bubbles may prevent the resin from filling the small tapered holes. In this case, it was not possible to form projections with accurate shapes.

For this reason, there was a problem in that it was not possible to obtain the intended effect of preventing the mat from slipping.

In addition, in this backing method, the fiber mat is placed on a semi-gelled resin and simply pressurized, so wrinkles may occur in the base fabric on the back of the mat during crimping. Therefore, a problem has arisen in which the fiber mat of the manufactured automobile mat and the resin as the backing material peel off.

This invention was developed in view of the above problems, and is intended to prevent cracks in the resin on the back side of automobile mats caused by air bubbles existing in the resin, and to prevent protrusions formed to prevent slippage. The object of the present invention is to provide a method for backing an automobile mat that can prevent deformation and also prevent the fiber mat of the automobile mat from peeling off from the resin backing material.

(Means for solving the problem) That is, the present invention applies a sol-like resin onto a mold that can be heated and cooled, and deaerates the resin applied onto the mold. Fill the mold and heat the mold directly from the bottom to semi-gel the resin.
Next, a release mat is pressure-bonded under tension onto this semi-gelled resin, and the mold is further heated directly from the bottom, and then the mold is directly cooled from the bottom to gel the resin into a rubber-like state. This is a method for bucking automobile mats, which is characterized by peeling off the mats from a mold.

(Example) The method for buckling an automobile mat of the present invention will be explained below in order of steps with reference to Figures 1 to 7 of the drawings.

First, a mold 11 of a predetermined shape that can be heated and cooled is selected and assembled to the assembly frame 13 of the mold 11 mounted on a table (not shown). In the present embodiment, a mold 11 was used which can form a plurality of small tapered holes 12 on the upper surface and form protrusions for preventing slippage in the resin 14 on the back surface of the automobile mat.
A sol-like resin 14 is applied onto this mold 11.
The resin 14 may be any resin as long as it has the property of gelling when heated, but it is preferably one that is relatively heat resistant, resistant to thermal deformation, and has high strength when gelled. In the case of this example, 30~2-octylhexyl phthalate or n-octyl phthalate was added to the vinyl chloride resin as a plasticizer.
Plastisol, which was mixed at 35% and made into a sol, was used. The resin 14 is applied by extruding it onto the mold 11 under pressure from a resin application nozzle (not shown). Note that if the coating time is relatively long and the mold 11 is small, the resin 14 may be applied by natural falling.

Next, the applied resin 14 is degassed and filled into the mold 11. A large number of air bubbles 23 are present in the applied resin 14, as shown in FIGS. 2 and 3. Air bubbles 2 in this resin 14
By removing the resin 14, the resin 14 that had been displaced by the air bubbles 23 is reliably filled into the mold 11. The air bubbles 23 are removed by using a plurality of air suction ports 17 in the assembly frame 13 to which the mold 11 is assembled.
is formed, and a vacuum pad 16 to which a hose 15 connected to a vacuum pump (not shown) is attached is brought into close contact with the upper surface. Then, a vacuum pump (not shown) is operated to remove air bubbles 23 in the resin 14 and air between the vacuum pad 16 and the resin 14 through the air suction port 17.

Next, the resin 14 filled in the mold 11 in this way
to semi-gel. Resin 1 applied on mold 11
No. 4 has the property of gelling when heated, but here it is not completely gelled, but left in a semi-gelled state with a slight fluidity remaining. This is done by directly heating the bottom surface of the mold 11 with a heating device 18 provided below the mold. The heating temperature is determined in consideration of the type of resin 14, the material of fiber mat 19, etc.
In the case of this embodiment, the resin 14 in the mold 11
was heated to a surface temperature of 180°C. The mold 11 can be heated not only after the resin 14 is filled into the mold 11, but also after the mold 11 is assembled on a table (not shown) or when the resin 14 is heated on the mold 11.
This may be done after applying 4.

The fiber mat 19 is compressed under tension onto the resin 14 which has been heated to semi-gel.

The fiber mat 19 includes a pile layer and a base fabric, such as a pile made of synthetic fibers tufted onto a base fabric 20 made of non-woven fabric, or a base fabric 20 coated with resin and the resin raised. This fiber mat 19 is placed on a semi-gelled resin 14. The fiber mat 19 is placed with its four corners pulled outward so that the base fabric 20 of the fiber mat 19 is not wrinkled. The fiber mat 19 is pressed by the upper pressure device 21 under tension.
Pressure is applied to press the fiber mat 19 to the resin 14,
The fiber mat 19 and the resin 14 are adhered and integrated without any gaps. Note that one side of the base fabric 20 of this fiber mat 19 is fixed on the assembly frame 13 of the mold 11, and the other side is pushed and stretched by moving a pressing roller along the fiber mat 19 while pressing the fiber mat 19. Stretch and crimp it in this way,
The fiber mat 19 and the resin 14 may be adhered and integrated without any gaps.

The mold 11 is heated again from the bottom. Heating is performed by directly heating the bottom surface of the mold 11 using a heating device 18 provided below a table (not shown), similar to the heating process described above. In this step, the semi-gelled resin 14 is completely turned into a gel.

Next, the mold 11 is directly cooled from the bottom to form the resin 1.
4 into a rubbery state.

Cooling is performed by directly cooling the mold 11 by jetting cold water onto the bottom surface of the mold 11 using a cooling device 22 provided below a table (not shown). As a result, the gelled resin 14 in the mold 11 is rapidly cooled,
It becomes rubbery.

Next, the automobile mat is peeled off from the mold 11. A removal device (not shown) is used to remove mats.
This is done by Note that the pine may be removed directly by the worker.

The above-mentioned process is used to back the mat for automobiles.

Next, a bucking device using the method of buckling an automobile mat of the present invention will be described with reference to the drawings.

FIG. 8 is a plan view showing the entire backing device used in the method of backing an automobile mat according to the present invention.

As shown in FIGS. 8 and 14, a donut-shaped rotary drive table 120 on which a mold 112 is assembled is provided at the center of the bucking device 111, and a mold heating device 130 is provided at the bottom of this rotary drive table 120. and a mold cooling device 150, a resin coating device 170, a degassing device 190,
Fiber mat supply device 210, mold changing device 24
0, a removal device 260, and other devices are provided.

This bucking device 111 can be divided into 15 zones from the functional point of view, namely:
If the position of the resin coating device 170 provided on the outer peripheral edge of the rotary drive table 120 is defined as the first zone, the second zone along the rotation direction of the rotary drive table 120 includes a mold at the bottom of the table 120. A heating device 130 and a deaeration device 190 are provided at the outer peripheral edge, respectively. In the third to sixth zones, a mold heating device 130 is installed at the bottom of the table 120, and in the seventh zone, a mold heating device 130 is installed at the bottom of the table 120, and a fiber mat supply device 210 is installed at the outer peripheral edge. are provided for each. A mold heating device 130 is provided below the table 120 in the 8th to 12th zones, and a mold cooling device 150 is provided below the table 120 in the 13th zone. Further, in the 14th zone, a mold cooling device 150 is provided at the bottom of the table 120, and a mold changing device 240 is provided at the outer peripheral edge. In the 15th zone, a removal device 260 is provided on the outer peripheral edge of the table 120.

As shown in FIG. 8, FIG. 9, FIG. 14, and FIG. 17, the rotary drive table 120 is a donut-shaped rotary disk that is installed on a concrete foundation and has wheels 121 at its upper end. It is placed astride a support stand 122 having a shape and is rotatably supported.
The rotary drive table 120 is intermittently rotated by a DC servo motor 123 provided on the outer peripheral edge thereof, and this rotation is transmitted to the pulley 12 via a transmission 124.
5, this pulley 125 contacts the side of the rotary drive table 120, and the rotary drive table 1
20 rotates intermittently in a direction opposite to the rotation of the pulley 125. In the case of this embodiment, the rotary drive table 120 stops rotating for 30 seconds every time it rotates approximately 24 degrees, and the rotary drive table 120
It is designed to stop 15 times during one revolution. Fifteen assembly frames 126 for assembling the molds 112 are formed at equal intervals on the upper surface of the rotary drive table 120. A hole 127 that is slightly smaller than the mold 112 is formed in the assembly frame 126 . The mold 112, which is replaceably assembled on the top surface of the rotary drive table 120, has a size of 890 mm x 670 mm.
A plate formed with external dimensions of mm x 10 mm,
It is formed to match the size of an automobile mat. There are various types of molds 112 depending on the size of the automobile mat, and they are replaceably assembled into the assembly frame 126 as required. Therefore, in this embodiment, 15 molds can be assembled to the mounting, and up to 15 types of automobile mats can be manufactured. Rotary drive table 120 at each peripheral part of this assembly frame 126
A mold fixture 128 is provided on the upper surface of the mold 1.
12 is fixed to the assembly frame 126 when it is assembled. At the bottom of this rotary drive table 120, the mold 112 is placed on a concrete base independently of the rotary drive table 120.
a mold heating device 130 for heating the mold 11;
A mold cooling device 150 for cooling the molds 2 and 2 is provided, respectively.

As shown in FIGS. 8 to 12, the mold heating device 13
0 is a rotary drive table 1 for each of the 1st to 12th zones of the automobile mat bucking device 111.
It is provided at the bottom of 20. This mold heating device 130 is comprised of a frame 131 fixed on a concrete base and a gas burner 132 provided within this frame 131. In this embodiment, 12 mold heating devices 130 are arranged at predetermined positions below the rotary drive table 120.
Each mold heating device 130 is connected to the resin 17 inside the mold 112.
It is set so that the surface temperature of 1 is approximately 180°C. Further, as the gas burner 132, a gas infrared burner type and a gas pipe burner type are used. A duct 135 is disposed between each mold heating device 130 to which a firing blower and an exhaust fan are respectively attached.

The mold 112 in the assembly frame 126 of the rotary drive table 120 is directly heated from below the table 120.

The rotary drive table 120 is provided with a mold cooling device 150 at the bottom, similar to the mold heating device.

The mold cooling device 150 is installed in the 13th zone and the 14th zone of the automobile mat bucking device 111, respectively, and is connected to a cylinder 154 fixed on a concrete base, a water tank 152, and a water tank 152, as shown in FIGS. 13 to 15. It is comprised of shower nozzles 153 protruding from three locations within a water tank 152. The water tank 152 is formed into a box shape and is supported by four pillars 151. At the bottom of this water tank 152 is a cylinder 154 fixed on a concrete foundation.
The tip of a shaft 155 is attached to the tank 152 so that the water tank 152 moves up and down as the cylinder 154 expands and contracts.

When the mold 112 comes above the water tank 152 due to the rotation of the rotary drive table 120, the cylinder 154 expands, the water tank 152 rises, and the mold attached to the upper surface of the rotary drive table 120 is moved. Cold water is spouted from a shower nozzle 153 in a water tank 152 onto the bottom surface of the mold 112, thereby cooling the mold 112.

Next, a resin coating device provided in the first zone of the bucking device used in the method of bucking an automobile mat of the present invention will be explained.

As shown in FIG. 16, a resin coating device 170
This is a device that applies a sol-like synthetic resin 171 into the mold 112 on the upper surface of the rotary drive table 120.

The resin coating device 170 includes an outer frame 172, an inner frame 173, and a resin tank 174. A box-shaped inner frame 173 is arranged above the table 120 so as to hang over the top surface of the table 120. Two left and right shafts 175 are protruded from both upper ends of the inner frame 173, and these shafts 17
A running roller 176 is rotatably attached to 5. Further, this running roller 176 is supported by an outer frame 172 consisting of a rectangular upper frame 177 on which the roller runs and a column 178 fixed to the outer edge of the table 120 that supports this. Upper frame 177 by a fixed drive motor (not shown)
The inner frame 173 is moved upward toward the center of the rotary drive table 120, and the inner frame 173 is accordingly moved horizontally.

This inner frame 173 has a lifting cylinder 17
9 is fixed, and a plurality of resin coating nozzles 180 are attached to the tip of the shaft of this cylinder 179, and a sol-like resin 171 is applied from these resin coating nozzles 180 into the mold 112 of the rotary drive table 120. It is becoming more and more common.

On the other hand, a resin tank 174 is provided at the outer peripheral edge of the rotary drive table 120 along with the outer frame 172.
is located. This resin tank 174 stores, for example, plastisol, which is a mixture of vinyl chloride resin and 30 to 35% of 2-octylhexyl phthalate or n-octyl phthalate as a plasticizer. This resin 171 is applied to a cylinder 182 for opening/closing a resin coating plug attached to the lower part of the tank 174 in accordance with the rotation of the rotary drive table 120.
Through the applicator plug 183 opened by the operation of
The resin is transferred to a coating pipe 184 by a coating pump (not shown) that is started in conjunction with the resin coating valve opening/closing cylinder 182, and is applied by the resin coating cylinder 180 equipped with the nozzle. And the illustrated coating cylinder 180
From there, resin 171 is applied onto the mold 112 on the upper surface of the rotary drive table 120.

Note that the amount of resin 171 applied is the same as that of resin tank 174.
It is adapted to be adjusted by an applicator stopper 183 placed at the bottom of the holder. Furthermore, since the aforementioned heating device (not shown) is provided at the bottom of the rotary drive table 120 in the first zone, the resin 172 applied onto the mold 112 by the resin coating device 170 is heated by this heating device (not shown). It is then heated and becomes a semi-gelled state, making it easy to weld to the fiber mat 114.

A deaerator 190 is provided above the second zone adjacent to the resin coating device 170.

The degassing device 190 fills the mold with the resin applied onto the mold by the resin coating device. A large number of small tapered holes 10 are bored in the mold to form anti-slip protrusions for an automobile mat, and these small holes 10 need to be filled with resin.

As shown in FIG. 17, the deaerator 190 has a box-shaped frame 191 that covers the upper surface of the mold 112.
2 is installed. An inner frame 193 is installed inside this frame 191, and the shaft of the lifting cylinder 192 is attached to the upper part of this inner frame 193, so that the inner frame 193 moves up and down as the cylinder 192 expands and contracts. There is.
Also, rollers 19 are provided on the sides of this inner frame 193.
4 is rotatably attached to each frame and abuts the frame 191, and as the inner frame 193 moves up and down, the roller 194 rotates while abutting the frame 191. Therefore, when the inner frame 193 moves up and down, there is no rattling, and the inner frame 193 can move up and down smoothly.
Further, the frame 191 is supported by an outer frame 197 consisting of a square upper frame 195 and a column 196 fixed to the outer peripheral edge of the table 120 that supports the upper frame 195.

On the other hand, this inner frame 193 has a vacuum pad 1
98 is installed. The vacuum pad 198 is
It has a trapezoidal shape with a rubber gasket 199 attached to the lower periphery that contacts the edge of the mounting frame 126,
Two air suction ports 200 are formed at the top. One end of a hose 201 is attached to the air suction port 200 of this vacuum pad 198.
The other end of 01 is connected to a vacuum pump (not shown).

Then, when the mold 112 comes below the deaerator 190 due to the rotation of the rotary drive table 120, the lifting cylinder 192 of the frame 191 is operated, and the vacuum pad 198 is moved onto the resin 171, and the mounting frame 126 is moved. It is designed to fit closely to the edge of the

Furthermore, the air in the vacuum pad 198 is removed by a vacuum pump (not shown), and the air bubbles in the resin 171 and the air existing between the mold 112 and the resin 171 are removed. The resin 171 is also reliably filled into the small tapered hole 10. For this reason, it is possible to reliably form small anti-slip protrusions on the back side of the car mat, and it also prevents cracks in the synthetic resin on the back side of the fiber mat, which were caused by air bubbles, and prevents the formation of cracks between the fiber mat and the synthetic resin. This prevents peeling.

Note that a mold heating device is also provided below the rotary drive table at the position of the deaerator 190, and the resin in the mold is maintained in a semi-gelled state.

As shown in FIG. 8 and FIGS. 10 to 12, in zones 3 to 6 adjacent to the degassing device, there are mold heating devices 13 at the bottom of the rotary drive table 120, respectively.
0 is provided to maintain the resin 171 in the mold 112 in a semi-gel state. This mold heating device 130
For those provided in the sixth zone, the mold 112 placed above the rotary drive table 120
The resin 17 is detected by a signal from a radiation temperature detector (not shown) that detects the surface temperature of the resin 171 inside.
The temperature can be adjusted by further heating the resin when the surface temperature of 1 is below 180°C, and lowering the temperature when it exceeds 180°C.

In the seventh zone, a fiber mat supply device 210 is provided on the outer peripheral edge of the rotary drive table 120, which moves in and out of the mold coated with resin and presses the fiber mat onto the resin under tension.

As shown in FIGS. 8 and 18, the fiber mat supply device 210 includes a conveyor device 211, a supply device 212, and a crimping device 213.

The conveyor device 211 is a rotary drive table 120
It is rotatably mounted in the direction of the rotary drive table 120 by a box-shaped pedestal 214 in the shape of a rectangular parallelepiped extending outward from the pedestal 214 and a drive motor (not shown) installed inside the pedestal 214. It is made up of a conveyor 215. This frame 2
Three fiber mats 114 are placed on the upper surface of the 14 conveyors 215 along the longitudinal direction. This fiber mat 114 is made by driving a pile made of synthetic fiber into a base fabric 115, and the edge of the base fabric 115 protrudes from the periphery of the fiber mat 114. The conveyor 215 is rotated by the drive of a drive motor (not shown), and the fiber mat 114 is transferred onto the conveyor 215 in the direction of the rotating drive table 120. The fiber mat 114 transferred by the conveyor 215 is transferred to the semi-gelled resin 1 on the upper surface of the rotary drive table 120 by the supply device 212.
71.

The supply device 212 is arranged above the conveyor device 211, and similarly to the resin coating device described above,
A box-shaped frame 217 is arranged to cover the upper surface of the mold 112, and two left and right shafts 218 are protruded from both ends of the upper part of this frame 217, and running rollers 219 are rotatably mounted on these shafts 218. installed.
Moreover, this roller 219 is attached to the square upper frame 2.
20 and an outer frame 222 consisting of a support 221 fixed to the outer edge of the table 120 that supports it.
The frame 217 moves on the outer frame 222 toward the center of the rotary drive table 120 by a drive cylinder (not shown) fixed to the outer frame 222.
is moving horizontally. This frame 217
A lifting cylinder 223 is attached to the.
On the other hand, the shaft of this lifting cylinder 223 is attached to a box-shaped inner frame 224. Each frame of the inner frame 224 has a roller 225.
are provided in contact with the sides of the frame 227, and when the inner frame 224 is raised and lowered, the rollers 22
Since the inner frame 224 comes into contact with the side of the frame 227, the inner frame 224 is prevented from shaking. Four claw-shaped pins 226 are arranged outward at the four corners of the lower part of the inner frame 224, and a cylinder 2 for rotating the pins is provided at the base of these pins 226.
27 shafts are attached, and the pins 226 are provided so as to rotate outward as the cylinders 227 expand and contract. And conveyor device 2
These pins 226 are rotated and inserted into the four corners of the base fabric 115 protruding from the edge of the fiber mat 114 on the fiber mat 114. Also, the inner frame 224
Four bearings 228 are fixed along the longitudinal direction of the inner frame 224 at the lower part of the inner frame 224, and two threaded rods 229 threaded in opposite directions from the center to both ends are attached to the bearings 228. . Further, two drive motors 230 are fixed to the lower part of the inner frame 224, and the threaded rods 22
9 is adapted to be rotated by this drive motor 230. The bases of the pins 226 are screwed onto both ends of this one threaded rod 229, and as the threaded rod 229 rotates, the two pins 226 move horizontally toward and away from each other along the threaded rod 229. The position of each pin 226 can be adjusted to the four corners of the fiber mat 114 according to the size of the mat 114. In this way, the fiber mat 114 on the conveyor device 211 has pins 22 aligned with the four corners of the base fabric 115 protruding from the edge thereof.
6 is pushed through by rotation, and in this state it is lifted by the lifting cylinder 223 of the inner frame 224 and the cylinder (not shown) of the outer frame 222, and the fiber mat 114 is moved and placed on the resin 171.

Further, the inner frame 224 is further provided with a crimping device 213 in the center thereof. The crimping device 213 presses the fiber mat 1 placed on the resin 171 described above.
Head 2 having a flat shape pressurizing the upper surface of 14
31 and is attached vertically to the upper part of this head 231, and the fiber mat 11 is attached through this head 231.
4 and a pressure cylinder 232 that pressurizes the cylinder. Then, the four corners of the base fabric 115 protruding from the edge of the fiber mat 114 are stretched by the crimping device 213 and the pin 226, and the fiber mat 1 is
14 and the semi-gelled resin 171 are pressurized,
The two are adhered and integrated with no space between them.

As shown in FIGS. 8, 9 and 12, five mold heating devices are installed next to this crimping device.
It is provided at the bottom of the rotary drive table across the zone. Furthermore, the above-mentioned cooling device is installed at the bottom of the rotary drive table in the 13th and 14th zones, and is designed to change the semi-gelled resin to a rubber-like gelled state by cooling it. .

In addition to the cooling device, the 14th zone is also provided with a mold changing device on the outer peripheral edge of the rotary drive table.

As shown in FIGS. 8 and 19, the mold changing device 240 is a device that replaces and replaces the mold on the rotary drive table depending on the automobile mat to be manufactured.

In this mold changing device 240, a box-shaped frame 241 is arranged so as to cover the upper surface of the table 120, and a lifting cylinder 242 is attached to the upper part of this frame 241. Inner frame 243 within this frame 241
is installed inside, and the shaft of the lifting cylinder 242 is attached to the upper part of this inner frame 243,
As the cylinder 242 expands and contracts, the inner frame 24
3 is designed to go up and down. Further, rollers 244 are rotatably attached to the sides of the inner frame 243, and are in contact with the frame 241, so that the rollers 244 move as the inner frame 243 moves up and down.
44 is designed to rotate. Therefore, when the inner frame 243 moves up and down, there is no rattling, and the inner frame 243 can move up and down smoothly. Further, two left and right shafts 252 are protruded from both ends of the upper part of the frame 241, and running rollers 253 are rotatably attached to these shafts 252.
Moreover, this running roller 253 is the running roller 25
The drive cylinder (not shown) is supported by an outer frame 247 consisting of a rectangular upper frame 245 that runs No. 3 and a column 246 fixed to the outer edge of the table 120 that supports this. ), the inner frame 24 moves toward the center of the rotary drive table 120 on the upper frame 245.
3 is designed to move horizontally.

This inner frame 243 has a lifting cylinder 24
2 is attached, and a vacuum suction pad 248 is attached to the tip of the shaft of this lifting cylinder 242.

The vacuum suction pad 248 is bowl-shaped with a rubber gasket 249 attached to the lower peripheral edge that contacts the mold 112, and has an air suction port 250 formed in the upper part. One end of a hose 251 is attached to the air suction port 250 of the vacuum suction pad 248, and the other end of the hose 251 is connected to a vacuum pump (not shown).

When replacing the mold 112, the lifting cylinder 242 of the inner frame 243 and the drive motor (not shown) of the outer frame 247 are operated according to the rotation of the rotary drive table 120, and the vacuum suction pad 248 is activated. Move mold 1 onto mold 112
It is designed to be placed in close contact with 12.

Then, the vacuum pump (not shown) is operated to suction and remove the mold 112, and a different type of mold 112 is attached to the vacuum suction pad 248 and again attached to the mounting frame 126 of the rotary drive table 120. .

As shown in FIGS. 8 and 20, the fiber mat 11 backed with resin is placed in the 15th zone.
A removal device for peeling off the mold 4 from the mold is provided at the outer peripheral edge of the rotary drive table.

The removal device 260 includes a clamp device 261, an inner frame 263, and an outer frame 264. Above the table 120 is a box-shaped frame 26.
2 is arranged so as to cover the upper surface of the mold 112, and an elevating cylinder 270 is attached to the upper part of this frame 262. Inside this frame 262 is an inner frame 263.
is installed inside, and the shaft of the lifting cylinder 270 is attached to the upper part of this inner frame 263,
As the cylinder 270 expands and contracts, the inner frame 26
3 is designed to go up and down. Further, rollers 271 are rotatably attached to the sides of the inner frame 263, and are in contact with the frame 262, so that the rollers 271 move up and down as the inner frame 263 moves up and down.
71 is adapted to rotate while in contact with the frame 262. Therefore, when the inner frame 263 moves up and down, there is no rattling, and the inner frame 263 can move up and down smoothly. Also, frame 262
Two left and right shafts 274 are protruded from both ends of the upper part of the
Traveling rollers 275 are rotatably attached to these shafts 274. Further, this running roller 275 is supported by an outer frame 264 consisting of a rectangular upper frame 272 on which the running roller 275 runs and a support 273 fixed to the outer edge of the table 120 that supports this. A driving cylinder (not shown) fixed to the outer frame 264 rotates on the upper frame 272 and moves toward the center of the table 120, and the inner frame 263 moves horizontally accordingly. ing.

This inner frame 263 has a lifting cylinder 27
0 is fixed, and a clamp device 261 is fixed to the tip of the shaft of this cylinder 270.

The clamping device 261 includes a clamp claw 265 disposed at the lower part of the inner frame 263 on the rotary drive table 120 side, and a support rod 266 that supports the end of the fiber mat 114 while sandwiching it when the claw 265 rotates. An air nozzle 267 is provided further outside the clamp claw 265, that is, on the rotary drive table 120 side, and a shaft 26 is provided at the base of the clamp claw 265, which is disposed on the opposite side of the lower part of the inner frame 263.
It is composed of a cylinder 269 to which the tip of a cylinder 8 is attached.

And, regarding this removal device 260,
According to the rotation of the rotary drive table 120, the inner frame 263 moves horizontally and vertically onto the fiber mat 114 of the rotary drive table 120, and then
One end of the protruding base fabric 115 of the fiber mat 114 from which air is blown out from the air nozzle 267 of the clamp device 261 at the bottom of the inner frame 263 is turned up, and the clamp claw 265 is rotated by the cylinder 269 in the direction of the arrow in the figure. The inner frame 263 is moved horizontally and vertically again with one end of the turned-up fiber mat 114 being gripped between the claw 265 and the support rod 266, and the height of the top surface is always kept constant by the sensor. Drooping table lifter 27
6, a fiber mat 114 is adapted to be moved thereon.

Note that the bucking device 111 using the method for bucking automobile mats of the present invention is not limited to the above-mentioned one;
The devices arranged one after another and provided on the periphery of the table may be provided in pairs on the inside and outside of the table. In this case, the efficiency of backing can be further improved.

Next, another example of a bucking device using the method of buckling an automobile mat of the present invention will be explained with reference to the drawings.

FIG. 21 is a plan view showing another example of a bucking device using the method for bucking an automobile mat of the present invention, FIG. 22 is a front view, and FIG. 23 is a side view. As shown in FIGS. 21 to 23, the bucking device 311 is connected to the mold heating device 32.
0 and a mold cooling device 340 provided adjacent to this mold heating device 320, each device is provided above or to the side thereof.

This bucking device 311 has a box shape,
It can be divided into four parts in terms of function. That is, if the position of the mold heating device 320 is the A zone, and the position of the mold cooling device 340 provided adjacent to this mold heating device 320 is the B zone, then the mold heating device will be in the A zone and the B zone. and a moving table 3 that reciprocates horizontally above the mold cooling device.
60 are provided. Further, a resin coating device 380 is provided on the side of the mold cooling device 340 in the R zone, and a degassing device 400 is also provided above the mold cooling device 340 in the B zone so as to be movable up and down. . Furthermore, the mold cooling device 34 in the B zone
Resin mat 3 that goes in and out on 0 and is bumped
A removal device 350 for removing 13 is adjacent to the D zone.

On the other hand, a fiber mat supply device 420 that enters and exits onto the mold heating device 320 in the A zone and supplies fiber mat 313 onto the resin 312 is provided in the C zone adjacent to the mold heating device 320.

As shown in FIGS. 21 to 24, the mold heating device 320 in the A zone is composed of a frame 321 fixed on a concrete base and a gas burner 322 provided on the frame 321.
In this embodiment, the mold heating device 320 is set so that the surface temperature of the resin on the mold 314 assembled on the moving table 360 is approximately 180°C. Further, as the gas burner 322, a gas pipe burner type is used. A duct (not shown) in which a firing blower and an exhaust fan are respectively attached is arranged outside the mold heating device 320. In the case of the mold heating device 320, when the movable table 360 moves and comes above the mold heating device 320, the mold 314 on the top surface of the movable table 360 is directly heated from below the table 360. ing. In this way, the sol-like resin 312 in the mold 314 is semi-gelled. Furthermore, a radiation temperature detector 324 is provided above the mold heating device 320 to detect the surface temperature of the resin 312 within the mold 314.
When the surface temperature of the resin 312 falls below 180°C based on the signal from the radiation temperature sensor 324, the resin 312 is further heated or the surface temperature is increased.
When the temperature exceeds 180℃, the temperature can be controlled by cooling it.

In addition, the set temperature of the radiation temperature detector 324 is 180
It is determined not only by °C but also by taking into consideration the type of resin, the material of the fiber mat, etc.

As shown in FIGS. 21 to 24, a mold cooling device 3 is located in the B zone adjacent to the mold heating device 320.
40 are provided. In the case of the mold cooling device 340, a water tank 3 fixed on a concrete foundation is used.
41, and a shower nozzle 342 protruding inside this water tank 341. Water tank 341
is box-shaped. As the moving table 360 moves, the fiber mat 313 backed by the resin 312 is transferred to the mold cooling device 34.
0, cooling is jetted from the shower nozzle 342 in the water tank 341 of the mold cooling device 340 onto the bottom surface of the mold 314 assembled on the top surface of the moving table 360, and the mold 314 is cooled. There is.

As shown in FIG. 21 and FIGS. 23-25, A
A moving table 360 is provided to horizontally reciprocate above the mold heating device 320 and mold cooling device 340 in the zone and B zone. There are two moving tables 360, an upper moving table 361 and a lower moving table 371.

The upper moving table 361 is provided so as to straddle the mold heating device 320 and the mold cooling device 340 described above. This upper moving table 361
An elevating body 362 having an internal elevating motor (not shown) is attached to the four corners of the figure. This elevating body 362 is screwed onto threaded rods 364 that are vertically provided at the four corners of the table 361 and extend in parallel to the vertical direction. As the elevating motor (not shown) rotates, the elevating body 362 is moved by the threaded rod 36.
4, and the upper moving table 361 moves up and down.

Racks 365 are attached to the upper surface of both ends of the upper moving table 361. Also, the above-mentioned A
Side walls 315 on both sides of the mold heating device 320 and mold cooling device 340 in the zone and B zone
A rotating shaft 367 with pinions 366 attached on both sides is horizontally installed on the support frame 316 erected thereon. Then, the upper moving table 361 moves to the 25th
By rising in the S direction in the figure, the rack 365
are adapted to be screwed into pinions 366 at both ends of a rotating shaft 367. As a result, the mold heating device 3
Power from a drive motor 368 disposed on the outside of the lower part of the 20 is transmitted to the rotating shaft 367 via a chain 369, causing the pinion 366 to rotate. A moving table 361 is adapted to move in the horizontal direction. This upper moving table 3
Two assembly frames 317 for mounting molds 314 are formed on the upper surface of 61. This assembly frame 3
A hole slightly smaller than the mold 314 is formed in the mold 17 . The mold 314, which is replaceably assembled on the upper surface of the upper moving table 361, has a size of 120 mm×
It is a plate formed with external dimensions of 80 mm x 10 mm, and is formed to match the size of an automobile mat. There are various types of molds 314 depending on the size of the automobile mat, and the molds 314 are replaceably assembled into the assembly frame 317 as required. Therefore, including the lower moving table described later, there are four molds 3 in this embodiment.
14 can be assembled into the device, and up to four types of automobile mats can be manufactured at the same time.

The lower moving table 371 is the upper moving table 3
61, is provided below the upper moving table 361, and is movable independently of the upper moving table 361. Two wheels 372 are rotatably supported at both ends of the lower moving table 371, respectively. This wheel 372 is placed on the upper surface of the both side walls 315, and is adapted to move horizontally on this upper surface.

On the other hand, racks 373 are attached to the lower surface of both ends of the lower moving table 371. This rack 373 is a rotary shaft 3 horizontally installed between both side walls 315.
It is adapted to be screwed into pinions 375 at both ends of the pinion 74. Power from a drive motor (not shown) is transmitted to the rotating shaft 374 via a chain (not shown) to rotate the pinion 375.
A lower movable table 371, which has racks 373 screwed into binions 375 on both lower surfaces thereof, is adapted to move in the horizontal direction.

Next, a resin coating device in a bucking device using the method of buckling an automobile mat of the present invention will be explained.

As shown in FIGS. 21 to 23 and 26, in the resin coating device 380, the movable table 360 on which the mold 314 is assembled is located in the mold cooling device 340 in the B zone.
When moved upward, this device moves in and out toward the A zone on this moving table 360 and applies resin 312 onto the mold 314.

The resin coating device 380 includes an inner frame 381 and a resin tank 391. Inner frame 381
A plurality of resin application nozzles 382 are attached to the. A sol-like resin 3 is applied from these resin application nozzles 382 onto the mold 314 of the moving table 360.
12 is applied in a compressed state. A rotating shaft 3 is provided at both ends of the lower part of the inner frame 381.
86 is installed horizontally, and pinions 387 are attached to both ends of this rotating shaft 386. This pinion 387 is screwed into a rack 385 mounted on the side walls 315, and the power of a drive motor 388 mounted on the upper part of the inner frame 381 is transmitted to the chain 38.
9 to the rotating shaft 386, the pinion 387 rotates, and the inner frame 381 moves horizontally on the rack 385. As the inner frame 381 moves horizontally in this way, the plurality of resin coating nozzles 382 of the inner frame 381 move on the mold cooling device 340 and move in and out on the moving table 360, so that the resin 312 is applied onto the mold 314. is being applied.

On the other hand, the resin tank 391 includes a cylinder 392 for opening and closing the resin coating plug and a coating plug 393. Inside this resin tank 391, a plastil sol prepared by mixing 30 to 35% of 2-octylhexyl phthalate or n-octyl phthalate as a plasticizer with vinyl chloride resin is stored. As the moving table 360 moves, this resin 312 passes through a coating stopper 393 opened by the operation of a cylinder 392 for opening and closing the resin coating stopper attached to the lower part of the tank 391, and is interlocked with the cylinder 392 for opening and closing the resin application stopper. The resin is transferred to a coating pipe 394 by a coating pump (not shown) that is started, and is applied onto the mold 314 from a resin coating nozzle 382.

Note that the amount of resin 312 applied is based on the resin tank 391.
It is adapted to be adjusted by a coating stopper 393 arranged at the bottom of the screen.

A deaerator is provided above the mold cooling device together with the resin coating device.

The degassing device fills the mold with the resin coated on the mold by the resin coating device. A large number of small tapered holes 10 are bored in the mold to form anti-slip protrusions for an automobile mat, and these small holes 10 need to be filled with resin.

As shown in FIG. 27, the degassing device 400 is configured to operate the mold 3 with two box-shaped vacuum pads 401 lined up.
14 is arranged so as to cover the top surface. Elevating cylinders 402 are attached to the upper portions of the vacuum pads 401, respectively. These lifting cylinders 402 are supported by support frames 316 on both side walls 315.
It is attached to a rectangular upper plate 403 supported by. Further, two drip prevention covers 404 that cover each vacuum pad 401 from below are rotatably attached to the upper plate 403.

The vacuum pad 401
It has a trapezoidal shape that comes into contact with the assembly frame 317 of the two molds 314, and a rubber gasket 40 is attached to the lower periphery.
6 is attached. Two vacuum suction ports 407 are formed at the top of the vacuum pad 401. One end of a hose 408 is attached to the air suction port 407, and the other end of the hose 408 is connected to a pump (not shown).

After the resin 312 is applied onto the mold 314 by the resin coating device, the deaerator 400
The vacuum pad 401 is lowered by the operation of the lifting cylinder 402, and is brought into close contact with the assembly frame of the mold 314.

Furthermore, the air in the vacuum pad 401 is removed by a vacuum pump (not shown), air bubbles in the resin 312 and air present between the mold 314 and the resin 312 are removed, and the mold 314 is filled with air. The small tapered holes 10 are also reliably filled with resin. This makes it possible to reliably form small anti-slip protrusions on the back of the automobile mat, and also prevents cracks in the synthetic resin on the back of the fiber mat and separation of the fiber mat from the synthetic resin, which were caused by air bubbles. This will be prevented before it happens.

The C zone is provided with a fiber mat supply device that goes in and out of the mold heating device in the A zone and presses the fiber mat onto the upper surface of the resin in the mold under tension.

This fiber mat supply device 420 has the 21st to 2nd
As shown in FIG. 3 and FIGS. 28 to 31, resin is applied inside the mold by a resin coating device in zone B,
Next, after filling the mold with resin using the same degassing device in zone B, the movable table is moved onto the mold heating device in zone A, and the mold is heated at a predetermined temperature for a predetermined time by the mold heating device. The fiber mat is pressed onto the upper surface of the resin in the mold, which has been semi-gelled.

This fiber mat supplying device 420 is equipped with four support frames 421 vertically arranged in parallel at the four corners of the C zone, and an inner frame 422 provided within the support frames 421.

The inner frame 422 is formed into a plate shape. The inner frame 422 has claws 435 at the four corners that can be hooked onto the fiber mat 313.
A lifting cylinder 427 for lifting and lowering the fiber mat 313 and a crimping cylinder 442 for lifting and lowering the head 443 for pressurizing the fiber mat 313 are attached.

A drive motor 431 is mounted on the upper surface of the inner frame 422.
is installed. Similarly, a rotating shaft 429 is fixed to both ends of the upper surface of the inner frame 422, and a chain 432 is hooked to both ends. Rotating shaft 42
A pinion 430 is attached to both ends of the drive shaft 9, and power from the drive motor 431 is transmitted to the drive shaft 429 through a chain 432, causing the pinion 430 to rotate.

A rack 428 installed horizontally on the support frames 316, 421 so as to span the A zone and C zone is screwed into this pinion 430.
0 rotation, an inner frame 422 with racks 428 attached to both ends of the upper part moves horizontally within the A zone and B zone. Furthermore, two shafts 438 are protruded from both sides of the upper surface of the inner frame 422, and running rollers 439 are attached to these shafts 438.
is installed. This running roller 439 runs parallel to the rack 428 and supports the support frame 31.
It is designed to run on rails 433 attached to 6,421.

Lower frame 43 below this inner frame 422
Toothbrush-like claws 435 with a plurality of needles 434 arranged in parallel are attached to the four corners of 6. these nails 4
A shaft 437 of a rotation cylinder 436 for rotating the pin is attached to the base of the pin 35, and as the rotation cylinder 436 expands and contracts, the claw 43 is rotated outward.
5 is provided to rotate. Then, the fiber mat 31 on the workbench 440 placed below
A claw 435 rotates and pierces the base fabric 319 that protrudes from the edge of 3.

In this way, the fiber mat 313 on the workbench 440
The lower frame 443 is lifted from the lifting cylinder 427 with the claws 435 stuck into the base fabric 315 of the lower frame 443. Then, the fiber mat 313 is moved onto the resin 312 of the mold 314 by the horizontal movement of the inner frame 422, and the fiber mat 313 is moved onto the resin 312 of the mold 314 again.
27 on the resin 312.

A pressure cylinder 442 attached to the inner frame 422 has a flat head 443 that presses the upper surface of the fiber mat 313. Then, by the head 443 and the claws 435, the fiber mat 313 is pressed against the semi-gelled resin 312 in a stretched state, and the two are completely welded without any gaps.

After the semi-gelled resin and the fiber mat are welded together by the fiber mat supply device in this manner, the resin is further heated by the mold heating device in order to completely gel the resin. . After being sufficiently heated, the moving table is moved onto the mold cooling device in the B zone, the mold is cooled, and the gelled resin changes to a rubber-like gelled state by cooling.

The D zone is provided with a removal device for peeling off the resin-backed fiber mat from the mold.

As shown in FIGS. 21 to 23 and 32 to 35, the removal device 450 consists of four support frames 4 erected vertically in parallel at the four corners of the D zone.
51, an inner frame 452 provided within this support frame 451, and a clamp device 453.

The inner frame 452 is formed into a plate shape. A drive motor 461 is attached to the upper surface of the inner frame 452. Similarly, rotating shafts 459 are fixed to both ends of the upper surface of the inner frame 452, and a chain 462 is hooked to both ends. Rotating shaft 459
A pinion 460 is attached to both ends of the drive motor 461, and the power of the drive motor 461 is transmitted to the drive shaft 459 through a chain 462, causing the pinion 460 to rotate.

A rack 458 installed horizontally on the support frames 316, 451 so as to span the B zone and D zone is screwed into this pinion 460.
As the frame 458 rotates, the inner frame 452 with the racks 458 attached to both ends thereof moves horizontally within the B zone and the D zone. Furthermore, two shafts 456 are provided at both ends of the upper surface of the inner frame 452.
are provided protrudingly, and running rollers 457 are attached to these shafts 456. This running roller 4
57 is adapted to run parallel to the rack 458 on a rail 463 attached to the support frames 316, 451.

A clamp device 4 is attached to the tip of the shaft of the lifting cylinder 464 fixed to the inner frame 452.
53 is fixed.

The clamping device 453 includes a plurality of clamp claws 465 disposed on the movable table 360 side at the bottom of the inner frame 452, and a plurality of clamp claws 465 that support the fiber mat 313 by sandwiching the end thereof when the clamp claws 465 rotate. Support plate 466 and air nozzle 4
67, and a cylinder 469 in which the tip of a shaft 468 is attached to the base of the clamp claw 465.

And, regarding this removal device 450,
Fiber mat 31 backed with resin
3 is moved onto the mold cooling device 340 in the B zone by the moving table 360, and this mold cooling device 3
40 to turn the resin 312 of the fiber mat 313 from a semi-gelled state to a gel, the drive motor 461 of the inner frame 452 is driven to move the inner frame 452 horizontally, and the fibers of the moving table 360 are It is moved onto the mat 313.

Then, the lifting cylinder 464 is extended, the clamp device 453 at the lower part of the inner frame 452 is lowered, air is ejected from the air nozzle 467, and one end of the base fabric 319 of the fiber mat 313 is turned up. At this time, the clamp claw 465 is rotated by the cylinder 469 in the direction of the arrow in the figure, and one end of the turned-up fiber mat 313 is held between the claw 465 and the support plate 466. The clamp device 453 holding the fiber mat 313 in this manner rises, and the inner frame 452 moves horizontally again to move the fiber mat 313 onto a table lifter (not shown).

A sensor (not shown) is provided between the plurality of support plates 466 of the clamping device 453, so that when the clamping device 453 does not completely clamp the fiber mat 313, the fiber mat 313 is removed again. It's getting old.

As shown in FIG. 36, a mold changing device 480 is provided outside the A zone to replace and replace the mold 314 on the movable table 360 depending on the automobile mat to be manufactured. There is.

In addition, in the bucking device 311 using the method for bucking an automobile mat of the present invention, each of the above-mentioned devices can be operated separately. For example, in the B zone, the resin supply device and the deaeration device apply resin onto the mold on the upper moving table and fill the mold with resin, and at the same time, in the A zone, the mold heating device 453 The resin on the mold of the lower moving table is semi-gelled, a fiber mat is supplied onto this resin by a fiber mat supply device, and the resin is further heated for a predetermined period of time by a mold heating device. Then move the upper moving table to A
zone, move the lower table to the B zone. In the A zone, the resin is heated and the fiber mat is supplied as described above. In zone B, a mold cooling device and a removal device cool the resin and remove the fiber mat. If each device is programmed in this way and controlled by a computer to operate, it is possible to further improve bucking efficiency. Furthermore, when the number of fiber mat bucking jobs is small, the device may be operated for each process.

Next, another bucking device using the method of buckling an automobile mat of the present invention will be described in detail with reference to the drawings.

FIG. 37 is a front view showing the whole bucking device.

As shown in FIGS. 37 to 42, the bucking device 511 has a mold heating device 520 at its center, and above or to the side of this mold heating device 520 there is a mold cooling device 530, a moving table 540, and a resin coating device 550. , a deaerator 560 and a fiber mat supply device 570 are provided.

This backing device 511 has three functions in terms of functionality.
It can be divided into two parts. That is, if the mold heating device 520 is located in the X zone, the mold cooling devices 5 provided on both sides of the mold heating device 520
The position of one mold cooling device 530 of 30 can be set to the Y zone, and the position of the other mold cooling device 530 can be set to the Z zone. These mold heating devices 520
And mold cooling devices 530, 530 are Z zone,
Support stand 5 arranged across the zone and Y zone
It is located inside 17. A movable table 540 is placed in the X zone and Y zone or the X zone and Z zone in this support table 517, and is formed to a size that covers the upper surface of the mold heating device 520 and one of the mold cooling devices 530. It is provided to horizontally reciprocate on the support stand 517. Further, resin coating devices 550 are provided on the outside of the mold cooling devices 530 and 530 in the Y zone and the X zone, respectively.
Similarly, the mold cooling device 53 in the Y zone and Z zone
On the upper side of 0, there is a deaeration device 5 that can be raised and lowered in the vertical direction.
60 are provided respectively.

On the other hand, on the mold heating device 520 in the X zone,
The movable table 540 is moved in and out of the mold heating device 520 and is coated with the resin 514.
A fiber mat supply device 570 is provided to press the fiber mat 512 onto the resin 514 of the fiber mat supply device 570 .

As shown in FIGS. 37 to 42, the X-zone mold heating device 520 is comprised of a frame 521 fixed on a concrete base and a gas burner 522 provided within the frame 521. In this embodiment, the mold heating device 520 is set on the mold 513 assembled on the moving table 540 so that the surface temperature of the resin 514 is 180°C. Further, as the gas burner 522, a gas pipe burner type is used. A duct (not shown) is installed outside the mold heating device 520 to which a firing blower and an exhaust fan are respectively attached. When the movable table 540 moves and comes over the mold heating device 520, the mold 513 coated with the resin 514 on the movable table 540 is directly heated by the lower part of the movable table 540, and the sol inside the mold 513 is heated. Resin 5
14 has become semi-gelled. Further, a radiation temperature detector (not shown) is provided above the mold heating device 520 to detect the surface temperature of the resin 514 within the mold 513. The signal from this radiation temperature sensor (not shown) causes the resin 514 to
When the surface temperature of the resin is below 180℃, the resin 514
Temperature control is now possible by heating the surface further, or cooling it when the surface temperature exceeds 180°C.

Note that the set temperature of the radiation temperature detector (not shown) is not limited to 180° C., but is determined in consideration of the type of resin 514, the material of fiber mat 512, and the like.

As shown in FIGS. 37 to 42, mold cooling devices 530 and 530 are provided in the Y zone and Z zone on both sides of the mold heating device 520, respectively. This mold cooling device 530 is comprised of a water tank 531 fixed on a concrete foundation and a shower nozzle 532 protruding into the water tank 531. Then, when the movable table 540 with the buckled fiber mat 512 placed thereon comes over the mold cooling device 530, the movable table 540
A water tank 531 is placed on the bottom of the mold 513 assembled to 40.
Cold water is spouted from the shower nozzle 532 inside.
The mold 513 is designed to be cooled.

As shown in FIGS. 37 to 42, this moving table 540 is formed in a size that covers the upper surface of the mold heating device and one of the mold cooling devices. Furthermore, the movable table 540 has a mold heating device 520 in the X zone and a Y zone or a Z zone designed on both sides of the mold heating device 520 by attaching molds to the upper surface of the movable table 540 so as to be replaceable.
It is provided so as to move horizontally over each of the zone mold cooling devices 530, 530.

For example, a mold 5 is placed on the top surface of the moving table 540.
Two assembly frames 518 are formed to which 13 are attached, and one mold 513 assembled in these assembly frames 518 is heated in the X zone, and the other mold 513 is cooled in the Z zone. . A hole (not shown) slightly smaller than the mold 513 is formed in the assembly frame 518. The mold 513, which is replaceably assembled on the upper surface of the moving table 540, is a plate having an outer size of 120 mm x 80 mm x 10 mm, and is formed to match the size of an automobile mat. There are various types of molds 513 depending on the size of the automobile mat, and the assembly frame 513 can be used as needed.
It is replaceably assembled inside. Therefore, in this embodiment, two molds 513 can be assembled on the moving table 540, and a maximum of two molds 513 can be assembled on the moving table 540.
Various types of automobile mats can be manufactured.

In addition, at both ends of the moving table 540, there are two
A wheel 541 is rotatably supported. This wheel 541 is placed on the support stand 517, and the moving table 540 is moved by a driving cylinder (not shown) attached to the side wall of the moving table 540.
is adapted to move horizontally on the support stand 517.

Y zone and Z zone mold cooling device 530,
A resin coating device 550 is provided on the outer side of each of the resin coating devices 530 .

As shown in FIGS. 37 to 42, the resin coating device 5
50 is a moving table 54 on which a mold 513 is assembled.
Mold cooling device 53 where 0 is the Y zone or Z zone
This device moves in and out of the moving table 540 in the direction of the arrow in the figure in the direction of the X zone when moving above 0,530, and coats the resin 514 onto the mold 513.

In the resin coating device 550, the resin tank 55
3, the resin 51 is connected from the resin supply pipe 552 to the upper part of the resin supply pipe 552.
A supply port 556 for inserting the resin tank 5 is provided.
A plurality of nozzles 554 for applying resin 514 onto the mold 513 are formed at the bottom of the mold 53 . These nozzles 554 are opened and closed by electromagnetic valves 555. This resin tank 553 is adapted to move horizontally as a moving cylinder 551 attached to the side expands and contracts. As the resin tank 553 moves, the electromagnetic valve 555 opens, and the resin 514 in the resin tank 553 is applied onto the mold 513 by gravity.

Note that inside this resin tank 553, for example, 2-octylhexyl phthalate or n-octyl phthalate is added to vinyl chloride resin as a plasticizer.
Contains plastil sol, which is made into a sol by mixing 30-35%.

Note that the amount of resin 514 applied is the same as that of the resin tank 553.
It is adapted to be regulated by a solenoid valve 555 disposed at the bottom of the.

Along with this resin coating device 550, Y zone and Z
Deaerators 560, 560 are provided above the mold cooling devices 530, 530 in the zones.

The degassing device 560 fills the mold 513 with the resin 514 coated on the mold 513 by the resin coating device 550. A large number of small tapered holes 10 are bored in the mold 513 for forming anti-slip protrusions of an automobile mat, and it is necessary to fill these small holes 10 with resin 514.

As shown in Figures 37-42, the Y zone and Z
The zone deaerator 560 is a box-shaped vacuum pad 5
61 covers the upper surface of the mold 513.
placed above. Elevating cylinders 562 are attached to the upper portions of the vacuum pads 561, respectively. These lifting cylinders 562 are connected to the support base 5
It is attached to a support frame 563 erected on 17. Further, the vacuum pad 561 comes into contact with the assembly frame 518 of the mold 513 of the movable table 540, and a rubber pad 56 is attached to the lower periphery.
4 is attached. This vacuum pad 561
A plurality of air suction ports 566 are formed in the upper part of the holder. Air suction port 566 of this vacuum pad 561
One end of a hose 565 is attached to the holder, and the other end of the hose 565 is connected to a vacuum pump (not shown).

Then, the mold 51 is coated by the resin coating device 550.
3, the vacuum pad 561 of the deaerator 560 is moved to the lifting cylinder 56.
2, it descends and comes into close contact with the assembly frame 518 of the mold 513.

Furthermore, the air in the vacuum pad 561 is removed by a vacuum pump (not shown), air bubbles in the resin 514 and air present between the mold 513 and the resin 514 are removed, and the mold 513 is installed. The small tapered holes 10 are also reliably filled with the resin 514. Therefore, small anti-slip protrusions on the back side of the automobile mat can be reliably formed, and cracks in the synthetic resin 514 on the back side of the fiber mat 512 that were caused by air bubbles can be fixed. This prevents the film from peeling off.

A fiber mat supply device is provided in the X zone and the Y zone, which moves in and out of the mold heating device and presses the fiber mat onto the resin of the moving table that is moved while the resin is coated on the mold heating device. ing.

This fiber mat supply device 570 has the 37th to 4th
As shown in FIG. 2, the movable table 5 is
The resin 514 is applied inside the mold 513 of No. 40, and then the deaerator 56 of the Y zone or Z zone is applied.
After filling the resin 514 into the mold 513 by 0,560, the movable table 540 is moved and one mold 513 of the movable table 540 coated with the resin 514 is placed on the mold heating device 520 in the X zone. The mold 513 is then heated by a mold heating device 520 at a predetermined temperature for a predetermined time to press the fiber mat 512 onto the upper surface of the semi-gelled resin 514.

In this fiber mat supply device 570, a horizontally moving cylinder 57 arranged on the side of the support stand 517
The second shaft is connected to the fiber mat mounting table 571, and as the horizontal movement cylinder 572 expands and contracts, the fiber mat mounting table 571 reciprocates over the mold heating device 520 in the X zone and the mold cooling device 530 in the Y zone. I'm starting to do that. In this embodiment, the fiber mat mounting table 571 is normally located on the X zone, and is moved to the Y zone only when the fiber mat 512 is supplied onto the resin 514. A fiber mat 512 is placed on the fiber mat mounting table 571 with the base fabric 516 protruding from the side. This fiber mat mounting table 571
A pressing cylinder 574 is attached to one end of the cylinder. A pressing roller 573 extending parallel to the widthwise side of the fiber mat 512 is rotatably supported on the shaft of the pressing cylinder 574.

On the other hand, a clamping cylinder 575 is installed parallel to the pressing cylinder 574 and above the support base 517 in the X zone. A dogleg-shaped clamping claw 576 is attached to the shaft of this clamping cylinder 575, and this clamping claw 576 holds the fiber mat 512.
The movable table 54 is sandwiched between the base cloth 516 of
The fiber mat 512 is fixed by coming into contact with a clamping plate 577 attached to the edge of the fiber mat 512.

And the movable table 5 coated with resin 514
When one mold 513 of 40 comes onto the X zone, the clamping cylinder 575 lowers the base cloth 516 of the fiber mat 512 on the fiber mat mounting table 571 on the X zone, and the clamping cylinder 575 is attached to the clamping cylinder 575. Claw 576 and clamping plate 57 of moving table 540
It is fixed with scissors between 6 and 6. At the same time, the pressure roller 573 is lowered by the expansion of the pressure cylinder 574, and presses the base fabric 516 of the fiber mat 512.

After this, the shaft of the horizontal movement cylinder 572 contracts, and the fiber mat mounting table 571 and the pressing roller 5
73 moves horizontally in the direction of the Y zone. Along with this movement, one end of the base cloth 516 is moved to the moving table 54.
The fiber mat 512 fixed on the mold 513
At the same time, the pressing roller 573 moves horizontally while pressing the fiber mat 512. In this way, the fiber mat 512 is pressed onto the semi-gelled resin 514 by the pressing roller 573, and the resin 514 is completely welded to the back surface of the fiber mat 512 without any gaps.

After the semi-gelled resin 514 and the fiber mat 512 are welded by the fiber mat supply device 570, the resin 514 is further heated by the mold heating device 520 in order to completely gel it. ing. After the movable table 540 is sufficiently heated, the cooling device 5 in the Y zone
30, the mold 513 is cooled, and the gelled resin 514 changes to a rubber-like gelled state due to cooling. After the resin 514 has completely become rubber-like after being cooled for a predetermined period of time, the fiber mat 512 is removed from the mold 513.

In addition, in the bucking device 511 using the method of bucking an automobile mat of the present invention, each of the above-mentioned devices can be operated separately. For example, in the Y zone, the resin coating device 5
50 and a deaerator 560, the movable table 54
At the same time, at the same time, in the The resin 514 is semi-gelled, and a fiber mat 512 is placed on the resin 514 by a fiber mat supplying device 570.
The resin 5 is further supplied by the mold heating device 520.
14 is heated for a predetermined time. And moving table 5
One mold 513 of the moving table 540 is moved to the X zone, and the other mold 513 of the moving table 540 is moved to the Z zone. In the X zone, heating of the resin 514 and supply of the fiber mat 512 are performed as described above. In the Z zone, the buckled fiber mat 512 is removed, and the mold cooling device 530, the resin coating device 550 provided on the outer side of the mold cooling device 530, and the removal provided on the upper side of the mold cooling device 530 are removed. The resin 5 is heated again by the air device 560.
14 coating, degassing, and cooling are performed. If each device is programmed in this manner and operated under computer control, it is possible to further improve the efficiency of the bucking operation of automobile mats.
Further, when the number of backing operations of the fiber mat 512 is small, it is sufficient to operate the device for each process.

In the bucking device using the method for bucking an automobile mat of the present invention, the device for horizontal movement or vertical movement is not limited to the one described above, and any device may be used.

It should be noted that two bucking devices using the method for bucking automobile mats of the present invention are installed side by side in the horizontal direction, and a horizontal movement cylinder for horizontally moving each device is shared by the two bucking devices. The two bucking devices may be simultaneously moved horizontally as the buckling device expands and contracts to perform bucking operations. This makes it possible to highly efficiently buckle automobile mats in a small space.

(Effects of the Invention) As detailed above, this invention applies a sol-like resin onto a mold that can be heated and cooled, heats the mold directly from the bottom to semi-gel the resin, and then The fiber mat is crimped under tension onto the semi-gelled resin, the mold is heated directly from the bottom, and then the mold is cooled directly from the bottom to gel the resin into a rubber-like state, making it suitable for automobiles. No distortion occurs in the mat.

In addition, in the method for buckling automobile mats of the present invention, since the resin applied to the mold is deaerated and the resin is filled into the mold, air bubbles in the resin are removed and air bubbles are removed. It is possible to prevent cracks in the resin on the back surface of an automobile mat and deformation of the protrusions formed to prevent displacement, which would otherwise occur due to this.

In addition, in the method for backing automotive mats of the present invention, since the fiber mat is crimped onto the semi-gelled resin in a tensile state, wrinkles do not occur in the base fabric of the fiber mat at the crimped characters. It is possible to prevent the fiber mat of the pine from peeling off from the resin serving as the lining material.

[Brief explanation of drawings]

Figures 1 to 7 are partially enlarged cross-sectional views showing the process of backing the back side of a fiber mat using the method for backing an automotive mat of the present invention, and Figure 8 shows backing using the automotive mat bucking method of the present invention. FIG. 9 is a plan view showing the entire apparatus, FIG. 9 is a side view showing the drive device and rotary drive table of the bucking device using the method for bucking an automobile mat of the present invention, and FIG. 10 is a backing method of the automobile mat of the present invention. FIG. 11 is a front view of the mold heating device, FIG. 12 is a side view, and FIG. 13 is a plan view of the mold heating device of the bucking device using the method. A perspective view of the mold cooling device of the bucking device used, FIGS. 14 and 15 are side views also showing the mold cooling device, and FIG. 16 is a diagram of the bucking device using the method of bucking an automobile mat of the present invention. Perspective view showing the resin coating device, No. 17
Figure 18 is a perspective view showing a deaeration device of a bucking device using the method of bucking automobile mats of the present invention, and Fig. 18 shows a fiber mat supply device of a bucking device using the method of bucking automobile mats of the present invention. A perspective view, FIG. 19 is a perspective view showing a mold changing device of a bucking device using the method for bucking an automobile mat of the present invention, FIG.
Figure 21 is a perspective view showing a fiber mat removal device of a bucking device using the method of bucking automobile mats of the present invention, and Fig. 21 shows the whole of another bucking device using the method of bucking automobile mats of the present invention. 22 is a front view, FIG. 23 is a side view, and FIG. 24 is a mold heating device and a mold cooling device of another bucking device using the method of buckling an automobile mat of the present invention. FIG. 25 is a side view showing a movable table of another bucking device using the method for bucking an automobile mat of the present invention, and FIG. 26 is a cross-sectional view showing the method for bucking an automobile mat of the present invention. FIG. 27 is a perspective view showing a resin coating device of another bucking device using the method of buckling an automobile mat of the present invention; FIG.
Fig. 8 is a front view showing a fiber mat supply device of another bucking device using the automobile mat bucking method of the present invention, Fig. 29 is a front view of the same fiber mat supply device, and Fig. 30 is a front view of a fiber mat supply device also using the method of backing mats for automobiles according to the present invention. FIG. 31 is an enlarged side view of the main parts of the fiber mat supply device; FIG. 32 is a front view showing another bucking device removal device using the automobile mat bucking method of the present invention; FIG. 33 is a side view showing the removal device, FIGS. 34 and 35 are enlarged side views of main parts showing the process of removing the fiber mat by the removal device, and FIG. 36 is a perspective view showing the mold supply device. Third
Fig. 7 is a plan view showing the whole of yet another bucking device using the method of bucking an automobile mat of the present invention, Fig. 38 is a side view of the same, and Fig. 39 is a diagram showing the bucking method of an automobile mat of the present invention. FIG. 40 is an enlarged partial sectional view showing the mold cooling device, resin coating device, and moving table of yet another bucking device used, and FIG. FIG. 41 is an enlarged partial cross-sectional view showing a mold cooling device, a degassing device, and a moving table, and FIG. FIG. 42 is an enlarged partial cross-sectional view showing the fiber mat supplying device feeding fiber mat onto resin, and FIG. 43 is a conventional automotive mat supply device. FIG. 44 is a plan view showing a bucking device using the mat bucking method, and a side view of the bucking device. Explanation of codes, 11, 112, 314, 513...
... Mold, 14,171,312,514 ... Resin, 18,130,320,520 ... Mold heating device, 19,114,313,512 ... Fiber mat, 21 ... Pressure device, 22, 150,34
0,530...Mold cooling device, 170,380,
550...Resin coating device, 190,400,56
0... Deaerator, 23... Air bubbles, 210, 42
0,570...Fiber mat supply device.

Claims (1)

[Claims] 1. A sol-like resin is applied onto a mold that can be heated and cooled, and the resin applied on the mold is degassed to fill the resin into the mold, and the mold is heated directly from the bottom. The resin is made into a semi-gel by using the resin, and then a fiber mat is crimped under tension on the semi-gelled resin, the mold is heated directly from the bottom, and then the mold is directly cooled from the bottom to turn the resin into a rubber-like state. gelatinized,
A method for bucking an automobile mat, which comprises then peeling off the automobile mat from above the mold.