JPH0626853B2 - Method for manufacturing laminated molded body - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for producing a laminated molded body of a synthetic resin sheet and a nonwoven fabric, and more specifically, to produce a laminated molded body having sound insulation, sound absorption, and vibration damping effects. Regarding the method.

Prior art On the cabin side of the dash panel at the boundary between the engine room and the cabin of a car, apply asphalt to the panel,
A sound insulation sheet made of vinyl chloride was laid via felt to prevent vibration and noise generated by the rotation of the engine from being transmitted into the passenger compartment.

Problems to be Solved by the Invention The asphalt applied to the dash panel softens and adheres to the panel due to the temperature during the paint baking work during exterior coating, but its surface remains viscous even after cooling. This viscosity itself is necessary to maintain the vibration damping effect of the panel, but when assembling various interior parts in the vehicle, the viscosity of the asphalt interferes with the workability. In addition, asphalt sometimes flowed down when the panel was close to the vertical direction.

The asphalt that is installed on the asphalt layer is a kind of non-woven fabric that is a kind of non-woven fabric composed of natural fibers such as hemp and cotton and synthetic fibers such as suf and nylon that are intertwined, but this asphalt has a sound absorbing effect. However, it has a drawback that it easily absorbs moisture and that the fibers are melted to generate dust.

This non-woven fabric layer is generally attached to a molded sound-insulating synthetic resin sheet layer and then attached to an asphalt-treated panel, but a bulky non-woven fabric layer is formed into a panel shape. It took a long time to get used to it.

In the so-called stacking method as described above, each step such as forming an asphalt layer, forming a sound insulating synthetic resin sheet layer, and attaching a non-woven fabric layer has to be carried out separately, which is a complicated step.

Means for Solving the Problems The method for producing a laminate of the present invention is extruded from an extruder,
Alternatively, a synthetic resin sheet layer that has been rolled from the roll gap and is still in a thermoformable melt-softened state is impregnated with an asphalt emulsion and then dried, and is continuously rotated through a breathable and moldable nonwoven fabric layer. The conventional problems can be solved because both layers are vacuum-formed integrally by the vacuum forming die.

Operation Since the method for producing a laminate of the present invention is configured as described above, a non-woven fabric layer impregnated with an asphalt emulsion is stuck to a synthetic resin sheet layer, and not a so-called conventional stacking method. Since it is molded in the same manner, the process is simplified, and the workability at the time of assembling the interior material due to the adhesiveness of the asphalt layer is reduced, and the poor adhesion between the non-woven fabric layer and the asphalt layer can be improved. did it.

The synthetic resin sheet layer is extruded from an extruder, or rolled from a roll gap and vacuum-formed in a melt-softened state that is still thermoformable, so that a preheating step for vacuum forming is not particularly required, and a sound insulation effect is obtained. Since the inside of the synthetic resin sheet layer in which a large amount of the filler is blended for the purpose of increasing is uniformly melted and softened, uneven molding shrinkage hardly occurs in the molded article after vacuum molding, and molding distortion does not remain.

Furthermore, since the non-woven fabric layer is impregnated with asphalt, even felt made of natural fibers, for example, will not absorb moisture and rot, and even if it is mechanically bound by needle punching etc., the felt fibers can be unraveled. There is no.

This non-woven fabric layer is moldable and can be vacuum-formed into a predetermined shape by laminating it with a non-breathable thermoformable sheet layer.

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

FIG. 1 is a side view showing an outline of an apparatus for producing a laminated molded body of the present invention, and FIG. 2 is a plan view thereof.

The whole equipment is mainly the equipment 1 for manufacturing the synthetic resin sheet layer 1.
0, a device 20 for laminating the synthetic resin sheet layer 1 and the non-woven fabric layer 2, a rotary continuous vacuum forming device 30, and a molded product part 4
It comprises a take-up device 40.

An apparatus 10 for manufacturing a synthetic resin sheet layer 1 includes an extruder 11 having a sheet die 12 attached to its tip and three rolls 1.
3, 14, 15 and kneaded in the extruder 11,
The molten synthetic resin is guided to the sheet die 12 and extruded into a sheet shape there. The extruded synthetic resin is drawn out as the synthetic resin sheet 1 at a constant speed while the thickness is adjusted by the three rolls 13, 14, 15 and moves on the conveyor 16 to be guided to the laminating apparatus 20.

The laminating device 20 is composed of two rolls 21 and 22, and the synthetic resin sheet layer 1 and the non-woven fabric layer 2 in which asphalt is infiltrated are pressed together in the gap between them to form a laminated sheet layer 3. .

The rotary continuous vacuum forming apparatus 30 includes a plurality of (four in this example) vacuum forming dies 33a, 33b, 33c, 33d at equal intervals around a rotating body 32 that is driven to rotate in the direction of the arrow around a shaft 31. In a state in which the rotating body 32 is rotationally driven at substantially the same speed as the conveying speed of the laminated sheet layer 3, the laminated sheet layer 3 is continuously applied to the periphery thereof by the rolls 21 and is rotated. Individual vacuum forming dies 33 of body 32
In a to d, the laminated sheet layers 3 are successively and continuously vacuum-formed. Suction holes (not shown) are formed at important points on the molding surfaces of the individual vacuum molding dies 33a to 33d, and mold cooling pipes are formed within the thickness of the molds. Further, the vacuum suction system and the cooling water circulation system are not shown, but the shaft 31 of the rotor 32 is not shown.
Made through.

Reference numeral 34 denotes a rotary chain or a belt (hereinafter referred to as a rotary chain) that is disposed on the left end side and the right end side of the peripheral surface of the rotating body 32 and presses the left and right edges of the laminated sheet layer 3 against the rotating body 32. Note that the left and right rotating chains 34 are the rotating bodies 3 respectively.
2 is fitted in a circumferential annular groove 35 (FIG. 2) formed on the left end outer peripheral surface and the right end outer peripheral surface of the rotating body 32, and the rotating peripheral speed of the rotating body 32 is substantially equal to one rotation range. It is rotationally driven in the direction of the arrow at a speed synchronized with. Reference numeral 36 is a horizontal bar for holding the laminated sheet layer 3 in the lateral direction, which is attached between the left and right rotary chains 34 along the chains at predetermined intervals, and each horizontal bar 36 moves as the rotary chain 34 rotates. Then, when it moves around to the outer peripheral side of the rotating body 32,
It is adapted to engage with the lateral groove portion 37 just in opposition to the lateral groove portion 3 formed in the rotor generatrix direction at a position between the vacuum forming die on the outer circumference of the rotating body and between the vacuum forming dies.
38 is a suspension tension sprocket of the rotating chain.

In this way, the laminated sheet layer 3 conveyed from the roll 21 to the rotary body 32 has its left and right edges wound around the outer circumferences of the left and right rotary chains 34 and the rotary body 32, respectively, and moved. By the horizontal bar 36, the laminated sheet layer 3 portion between the vacuum forming die around the outer periphery of the rotating body and the vacuum forming die is pressed between the horizontal bar 36 and the horizontal groove 37 on the rotating body 32 side. That is, the laminated sheet layers 3 conveyed from the roll 21 to the rotating body 32 are successively rotated by the left and right rotating chains 34 and the horizontal bars 3.
By 6 and 6, it moves in synchronization with the rotation of the rotator 32 in a state where it is pressed against the outer periphery of the rotator 32 and sealed. During the movement, the individual vacuum forming dies 33a to 33d are sequentially operated, and the laminated sheet layer 3 portion corresponding to each individual die is vacuum formed. In this case, the synthetic resin sheet layer portion of the laminated sheet layer 3 sequentially applied from the roll 21 to the outer periphery of the rotating body 32 still retains sufficient heat energy during extrusion molding and is in a high temperature heat softened state. Through the non-woven fabric layer 2 impregnated with the air-permeable asphalt, the vacuum forming dies 33a to 33d are evacuated to be sufficiently satisfactorily formed.

The vacuum-molded molded product portion 4 is cooled by an external cooling means such as a cooling pipe in the mold and a cooling water spray nozzle (not shown) which is arranged as necessary, until the rotary body 32 makes one round. The temperature becomes a demoldable temperature or a solidified state.

The molded part 4 that has been vacuum formed and cooled is the rotating body 32.
When the rotating chain 34 and the horizontal bar 36 press the rotating body 32 approximately once, the sliding guide roll 39 sequentially removes the rotating body 32 from the outer peripheral surface, that is, from each vacuum forming die surface. The left and right edges thereof are guided by a pair of upper and lower belt type conveying tools 41 and 42 to a punching process of a vacuum forming portion (not shown) to complete a laminated formed body.

The synthetic resin sheet layer 1 material used in the present invention is a vinyl chloride resin, polyethylene, polypropylene, ethylene vinyl acetate copolymer resin, a thermoplastic resin such as a thermoplastic elastomer, alone or in a blend thereof. In some cases, a filler having a large specific gravity such as barium sulfate or metal powder, an extender such as wood powder, and other natural short fibers may be added.

In the above-mentioned examples, the synthetic resin sheet layer 1 was shown to be produced by extrusion molding, but it may be produced by rolling from a roll gap with another calender or two rolls, and its thickness is 1 The specific gravity is 1.2 to 2.8.

The non-woven fabric layer 2 is made by cutting a fiber thread made of natural fibers such as cotton waste, jute, woolen scraps, hemp, etc. and synthetic fibers such as nylon, polyester, polypropylene etc. into 5 to 50 mm and mechanically binding or adhering the web. It has a flat structure and is of natural fiber type, which has long been known as felt. This non-woven fabric layer 2 has a weight of 10 to 300 g / m.
^{In 2} , the thickness is appropriately selected in consideration of the shape of the molded body and the degree of vacuum forming followability of the nonwoven fabric layer 2.

The non-woven fabric layer 2 which can be molded in this manner is impregnated with an asphalt emulsion and dried before being bonded to the synthetic resin sheet layer 1. The asphalt emulsion has a softening point of 30 to 110 ° C., a penetration of 30 to 200 ° C. and natural asphalt having 4 asphalt content.
It is emulsified with an anionic or cationic emulsifier so as to be 0 to 60% by weight, and 80 to 10 after impregnation.
It was dried at 0 ° C. for 5 to 20 minutes. The drying does not necessarily have to be completely dried. Further, the fiber yarns of the nonwoven fabric layer 2 adhere to the synthetic resin sheet layer 1 which is in a melted and softened state to cause a so-called anchor effect, and the adhesive may be applied to the joint surface before the synthetic resin sheet layer 1 is adhered. If a part of the fibers of the non-woven fabric layer 2 is mixed and spun with the same material as the synthetic resin sheet layer 1, the adhesive strength is improved.

In the continuous continuous vacuum forming of the laminated sheet layer 3, the vacuum forming molds 33a to 33d are illustrated as the same for convenience in the above-mentioned embodiment, but the respective shapes of the molded products may be different, and the vacuum forming mold 33a may be different. The lengths of the rotating bodies 31 to 31 in the circumferential direction may be changed. In the latter case, the total length of the rotary chain 34 must be an integral multiple of the circumferential length of the rotating body 32 so that the horizontal bar 36 can be accurately adapted to the position of the horizontal groove 37. Although the nonwoven fabric layer 2 is a continuous sheet in the embodiment, the nonwoven fabric layer 2 cut into only the effective portion of the laminated sheet layer 3 is intermittently continuous with the synthetic resin layer 1 and the rotor 31.
It may be sandwiched between and.

The laminated molded body thus molded is locked and installed on the dash panel so that the non-woven fabric layer side is in contact with the dash panel, for example, by using a stopper or the like. There is also a case where a laminated skin is further laminated on the synthetic resin sheet layer side, that is, on the passenger compartment side via a nonwoven fabric or urethane resin foam sheet having a thickness of 5 to 15 mm. In this case, sound insulation and sound absorption are further improved. Such lamination of the skin layers can be carried out, for example, by adhering it to the lower surface of the synthetic resin sheet layer 1 in advance on the transport conveyor 16 shown in FIG.

In addition to being used for vehicles, the laminated molded article of the present invention can be used as a covering material for various outdoor structures by using its synthetic resin sheet layer as an outer surface and making good use of its sound insulation and waterproof properties. it can.

EFFECTS OF THE INVENTION The present invention is a method for continuously vacuum-forming a thermoformable synthetic resin sheet layer in a melt-softened state through a breathable nonwoven fabric layer impregnated with an asphalt emulsion to obtain a laminated molded article. Therefore, it has the following effects.

The synthetic resin sheet layer does not particularly require a residual heat step for vacuum forming, has a large heat capacity in which a large amount of a filler is blended in order to enhance the sound insulation effect, and even in the case of a material having a small cutting elongation during melt softening, Since it is evenly softened up to the thickness direction part, uneven molding shrinkage and molding distortion do not occur in the molded product. In addition, even with a material containing a large amount of filler, even if the material has a high specific gravity, the sheet partially hangs and is stretched due to gravity before vacuum forming, and the thickness has already partially changed before vacuum forming. Never disconnect.

Since the non-woven fabric layer is impregnated with asphalt, it does not absorb moisture and thus rot, and the fibers do not come loose. Also, its cushioning property does not deteriorate after installation.

Since the synthetic resin sheet layer and the non-woven fabric layer are integrally joined and then simultaneously molded into the shape of the laying position, the laminated molded product can be closely adhered to the laying surface. The sound absorbing properties and the vibration damping properties are further synergistically exerted by stacking.

[Brief description of drawings]

FIG. 1 is an example of an apparatus for specifically carrying out the method for producing a laminated molded body according to the present invention, and an overall schematic side view thereof,
FIG. 2 is a plan view thereof. 1 ... Synthetic resin sheet layer, 2 ... Nonwoven fabric layer, 33a-d
... Vacuum forming mold

Claims (1)

[Claims] 1. A synthetic resin sheet layer extruded from an extruder or rolled from a roll gap, which is still thermoformable and in a melt-softened state, is impregnated with an asphalt emulsion and then dried, and is breathable and moldable. A method for producing a laminated molded body, in which both layers are integrally vacuum-formed with a vacuum forming die that continuously rotates through a non-woven fabric layer.