JPH07214716A - Composite molded body and manufacture thereof - Google Patents

Abstract

PURPOSE:To keep an inner foam layer unexposed on peeling-off of a skin material layer and base layer at their end faces, wrap up strongly the end faces of a composite molded body and simplify the manufacturing process thereof. CONSTITUTION:A composite obtained by sticking a skin material sheet and foam sheet to each other is heated at a moldable temperature, a press blade 5 whose blade height of the crushing sheet 6 is made lower than the blade height of the crushing sheet 6 is added to the inside of the a blanking blade 4, which is pressed from the skin material sheet side, and cut-off for formation of a stepped part on an end face by the crushing sheet 6.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite molded article having a skin material layer, a foam layer and a base material layer, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, various composite molded products comprising a foam layer which imparts cushioning properties and a skin material layer which protects the foam layer and at the same time makes it beautiful have been sold and implemented.

In order to obtain these composite molded products, first, a composite body which is a laminated sheet in which a skin material sheet and a foam sheet are integrally bonded is prepared. After vacuum forming or press forming, the desired composite molded product is manufactured by cutting into a predetermined shape.

In the composite molded product produced by this conventional method, the cut surface of the foam layer is exposed, and therefore a composite product having a good appearance cannot be obtained. The foam on the peripheral portion is peeled off, and the peeled front skin material is wound around the back side of the foam and fixed with a suitable adhesive to maintain the beautiful appearance of the composite molded article itself. Other recent technologies, for example, JP-A-5-185544
No. includes a foam layer and a skin material layer adhered to it,
A step of preparing a composite body in which the skin material layer covers the end surface of the foam layer in an adhesive state with the foam layer, and a laminated sheet in which the foam sheet and the skin material sheet are adhered; And a step of pressing the heated laminated sheet with a press blade having a thickness of 0.1 to 10 mm from a side of the skin material sheet into a predetermined shape and cutting the composite sheet. . In such a technique, since the end face of the foam layer is covered with the skin material layer, the appearance is good, and even if the manufacturing process can be simplified, the end face of the foam layer is covered with the skin material by using this press blade. In the case of cutting so as to cover with a layer, even if the press blade temporarily serves as crushing and punching, if the thickness of the composite body including the skin material layer and the foam layer becomes thicker, the skin material is inevitably inevitably removed. Since the joint area (crushed area) between the layer and the foam layer is small,
Furthermore, since the cut surface is smooth, a peeling phenomenon occurs between the two layers, and the foam layer has a recognizable defect.

[0005]

However, in the composite molded body and the manufacturing method thereof proposed by the present invention, there are problems in the conventional method, such as the step of cutting after molding and the step of winding and fixing the skin material. It was developed in view of the defects that cannot be reduced in cost by maintaining a good appearance or the defects that the end face covered with the skin material layer peels off. It is an object of the present invention to provide a composite molded article in which the end surface of the foam layer is securely and firmly covered and the peeling phenomenon does not occur even if the thickness of the composite molded article is good I am trying.

[0006]

In order to achieve the above object, in the composite molded article and the method for producing the same according to the present invention, a skin material layer 1, a foam layer 2 and a base material layer 3 are provided. The composite molded body A comprising the base material layer 3 and the foam layer 2 on the upper surface of the base material layer 3 is covered with the stepped portion 7 in a pressure-bonded state by the skin material layer 1. Further, the composite B formed by adhering the skin material sheet 11 and the foam sheet 12 is heated to a temperature at which it can be molded to a thickness of 0.1 to 10.
mm punching blade 4 and a thickness of 0.1 to 1 attached to the inside
The crushed plate 6 of 0 mm is pressed and cut into a predetermined shape from the skin material sheet 11 side of the composite B by the press blade 5 set lower than the height of the punching blade 4, and the crushed plate 6 is formed on the end face. A press molding machine 8 characterized by a method of manufacturing a composite molded body for forming a stepped portion 7, and for molding a composite molded body A having the stepped portion 7 by using both-sides vacuum molding using a male and female molding die and press molding It is characterized by a method for producing a composite molded article using.

[0007]

In the composite molded body composed of the skin material layer, the foam layer and the base material layer, the end faces of the foam layer and the base material layer are covered with the step portion having a stepped shape by the skin material layer. There is no risk that a foam layer will appear by peeling from the end face, and a tough end face can be easily produced in a pressure-bonded state. By setting the height of the press blade having the function of a crushed plate to be lower than that of the punching blade, the end faces of the foam layer and the base material layer are compressed by the press blade and cut by the punching blade. Therefore, the step portion can be easily produced.

[0008]

EXAMPLES Next, one example of implementation of the composite molded article and the method for producing the same according to the present invention will be described in detail.

A is a composite molded body produced according to the present invention. The composite molded body A is shown in a front perspective view in FIG. 1, and its sectional shape is clarified in the sectional view of FIG. . The composite molded body A is formed by bonding the skin material layer 1 located on the front side, the foam layer 2 located in the middle part, and the base material layer 3 located further on the back side.

The so-called skin material layer 1 here is a polyolefin resin sheet or polyvinyl chloride sheet which satisfies the light resistance, scratch resistance, and beauty of the composite molded body A itself.
A well-known material such as a synthetic resin, a polyurethane resin-based synthetic leather, a woven fabric, a non-woven fabric, and a suede-like fiber is appropriately used, and the foam layer 2 is a well-known foam such as a closed cell foam or an open cell foam. The body is applied, but is not particularly limited, polyethylene-based foam, polypropylene-based foam,
Polyvinyl chloride foam and polyurethane foam are used. The base material layer 3 is used for the purpose of maintaining the shape of the composite molded body A, and various plastic sheets such as polypropylene resin, polyethylene resin and ABS resin,
A low expansion-ratio product of the foam forming the foam layer 2 and the cardboard, the fiber board, is used.

The composite molded article A of the present invention has a base material layer 3 on the back side.
In addition, the end faces of the foam layer 2 on the upper surface of the skin layer 1
It is covered under pressure-bonded by, but at that time, both end faces are formed in the step portion 7 so as to have a stepwise shape with the skin material layer 1. By forming in the step portion 7, the joint area between the skin material layer 1 and the foam layer 2 is expanded, and the peeling phenomenon can be eliminated even if the thickness of the composite molded body A is increased. Can be provided.

According to the present invention, the punching blade 4 is installed in the forming die on the side of the skin material sheet 11 by using both vacuum forming and press forming.
It is characterized in that it is punched at the same time as molding to obtain a product in which the skin material sheet 11 is rolled up. However, when cut using only the simple punching blade 4 shown in FIG. There is a defect that the sheet 11 is peeled off and the foam sheet 12 appears, and as a result of earnest study on this point,
The crushing plate 6 is attached along the inner surface of the normal punching blade 4 on the cutting edge side as shown in FIG.

That is, as shown in FIGS. 6 to 7, since the step portion 7 is formed on the end face in the present invention, the punching blade 4 is used.
The crushing plate 6 is attached along the inside of the, and the desired composite molded body A is produced through the steps from the crushing of the end surface to the punching, and the punching blade 4 has a thickness of 0.1 to 10.
The press blade 5 having a thickness of 10 mm and capable of forming the crush plate 6 on the inside has a thickness of 0.1 to 10 mm, but at least the press blade 5 is set lower than the blade height of the punching blade 4. Has been done. The punching blade 4 of the present invention is made of metal, and when the thickness is 0.1 mm or less, it does not withstand the pressure of the press and the blade spills, and when the thickness is 10 mm or more, the foam produced at the time of pressing The gas of the layer 2 is present between the skin sheet 11 and the foam sheet 12, and the skin layer 1 cannot be smoothed due to strain. The material of the press blade 5 is not limited to metal.

In the present invention, it is premised that the punching blade 4 with the press blade 5 playing the role of the crushing plate 6 attached and fixed inside is installed in the press molding machine 8, and a double-sided vacuum using male and female molding dies. Composite molded body A using both molding and press molding
The production method of the above is also included, and the vacuum forming method, the press forming method, and the combined use thereof are well known in the conventional forming method.
It is often required that the surface on the side of the skin material sheet 11 has a desired shape and the back surface is smoothed. In this case, in the conventional molding method, depending on the shape of the surface. However, there is a concern that it may lead to the occurrence of dents on the back surface and that the corners of the molded product tend to be crushed, and that a satisfactory product cannot be produced. In the present invention, both male and female molds are evacuated and pressed. Therefore, the above-mentioned defects can be eliminated.

Next, the method for producing the composite molded article according to the present invention will be described in detail.
Foam sheet 12 using mm-thick polyvinyl chloride sheet
As a base material sheet 13, a polyethylene foam sheet having a 10 times foaming thickness of 10 mm and a polyethylene foam sheet having a 10 times foaming thickness of 4 mm are used as the base sheet 13. Was produced.

The composite B is set in the press molding machine 8 shown in FIG. The press-molding machine 8 is one in which a vacuum die having a punching blade 4 attached to a lower table 9 is placed, and a punching underlaying plate 14 is attached to an upper table 10, and the composite B is
The mixture was heated at 60 ° C. for 3 minutes using a desired heating means, and the heated composite body B was placed on the press molding machine 8 to perform vacuum press molding. The composite molded product A produced by such a method was completely punched out, but the skin material sheet 1
1 was peeled off in some places between the base sheet 1 and the base sheet 13 and the foam layer 2 contained therein was visible.

Therefore, the vacuum die used above is equipped with a press blade 5 attached with a crushing plate 6 having a thickness of 2 mm inside the punching blade 4, which is set 1 mm lower than the height of the punching blade 4. When improved to a vacuum type and molded by the same method as described above, the end faces of the base material layer 3 and the foam layer 2 are surely covered with the stepped step portion 7 in a pressure-bonded state, and the foam layer is peeled off. 2 is not recognized, and the skin material sheet 11 and the base material sheet 1
Although the composite molded body A which was completely adhered to No. 3 and was not peeled off was obtained, a dent due to vacuum from the skin material sheet 11 side was recognized on the back surface of the composite molded body A.

When vacuum holes 15 are formed in the punching underlaying plate 14 of the upper table 10 of the press forming machine 8 and simultaneous male and female vacuum press forming is performed, the skin material sheet 11 is obtained. It was possible to produce a composite molded article A in which the adhesion between the base sheet 13 and the base sheet 13 was perfect, and the back surface was smooth, which was extremely satisfactory.

[0019]

According to the present invention, the punching blade 4 and the crushing plate 6 attached to the inside of the punching blade 4 are used together with the press blade 5 having a height lower than that of the punching blade 4, and punching is carried out simultaneously with the molding, thereby forming a composite molding. In order to obtain the body A, therefore, the end face of the composite molded body A is formed in a crimped state by the stepped step portion 7 due to the use of the press blade 5, and thus has a thickness.
However, as a result of the joint area (crushed area) between the skin material layer 1 and the foam layer 2 being expanded, there is no possibility that the foam layer 2 will separate from the end face and appear as in the conventional product, It is possible to form an end face that is tough and does not peel off.

Molding of the composite molded body A having the step portion 7
Since both sides vacuum forming using both male and female forming dies and press forming are used together, both front and back surfaces are surely smoothed and compressed by the press blade 5 and cut by the punching blade 4 at the same time. Therefore, the composite molded body A can be produced extremely easily in a small number of steps.

[Brief description of drawings]

FIG. 1 is a perspective view of a composite molded body of the present invention.

FIG. 2 is a sectional view taken along line aa of FIG.

FIG. 3 is a cross-sectional sketch drawing of a conventional punching blade.

FIG. 4 is a cross-sectional sketch drawing of a punching blade equipped with a press blade of the present invention.

FIG. 5 is a vertical cross-sectional view of a composite body used for producing a composite molded body.

FIG. 6 is a schematic vertical sectional view showing an intermediate manufacturing step of the composite molded body.

FIG. 7 is a vertical cross-sectional view showing a step of cutting into a composite molded body.

FIG. 8 is a schematic view of a press molding machine used for manufacturing a composite molded body.

[Explanation of symbols]

 1 skin material layer 2 foam layer 3 base material layer 4 punching blade 5 press blade 6 crushing plate 7 stepped portion 8 press molding machine 9 lower table 10 upper table 11 skin material sheet 12 foam sheet 13 Base sheet A Composite molded product B Composite

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Claims (3)

[Claims] 1. A composite molded article (A) comprising a skin material layer (1), a foam layer (2) and a base material layer (3), wherein the base material layer (3) and the foam on the upper surface thereof. A composite molded article, characterized in that each end face of the layer (2) is covered with the step portion (7) in a pressure-bonded state by the skin material layer (1). 2. A composite (B) obtained by adhering a skin material sheet (11) and a foam sheet (12) is heated to a moldable temperature to a thickness of 0.1 to 10 mm. A punching blade (4),
A crush plate (6) with a thickness of 0.1 to 10 mm attached to the inside of the plate
With the press blade (5) set lower than the height of the punching blade (4), the skin material sheet (1) of the composite body (B).
1) A method for producing a composite molded article, which comprises pressing and cutting from a side to a predetermined shape and forming a stepped portion (7) by a crushed plate (6) on an end face. 3. A composite molded article (A) having a step (7).
The method for producing a composite molded article according to claim 2, wherein the molding is performed by using a press molding machine (8) that uses both sides vacuum molding using a male and female molding die and press molding.