JPH0866928A - Laminate and manufacture thereof - Google Patents

Abstract

PURPOSE: To prevent a laminate from being warped and its base material and its skin material from separating from each other due to the difference between the thermal expansion of the base material and the skin material in its manufacturing or during a long term use of the laminate, which is produced by integrating the base material and the skin material with each other in a process wherein the forming process of the skin material into sheet and the use of adhesive are omitted. CONSTITUTION: Porous woody base material 11 is set between a pair of forming molds 20 and 21. The projected parts 20b, 20c, 20d, 20e, 21b, 21c, 21d and 21e of both the forming molds 20 and 21 abut against both the sides of the woody base material 11, while the projected part 21h of the front side forming mold 21 abuts against the forming surface of the rear side forming mold 20. Molten resin 12melt serving as skin material is poured between the woody base material 11 and both the forming molds 20 and 21 and, after that, cooled and hardened to integrate the skin material 12 and the woody base material 11 together by anchoring effect. The holey parts 12b, 12c, 12d and 12e are covered with accessories.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated body used for vehicle door trims, vehicle interior materials, indoor interior materials and the like, and a method for producing the same.

[0002]

2. Description of the Related Art As a laminate used for the above-mentioned applications, there is known one in which a base material made of a wood-based material formed in a predetermined shape is coated with a resin layer. As an example of such a laminated body, as shown in FIGS. 7 and 8, a base material 31 made of a wood-based hardboard formed in the shape of a door trim, and a base material 31 adhered to the surface of the base material 31 And a door trim 30 in which a part of the skin material 32 is covered with an ornament 33 and an inside bezel 34 as necessary.

As shown in FIGS. 9 (a) to 9 (c), the door trim 30 having such a construction is made of a sheet-like skin material 32 and a wood-based material set in a back side molding die 38. The base material 31 and the molding dies 38 and 39 are bonded to each other with an adhesive (see FIGS. 9A and 9B), and then the mounting hole 31a of the inside vessel 34 is attached.
The skin material 32 of the part is punched out, and the skin material 32 protrudes from the end of the wood-based material 31.
It was manufactured by adhering a so as to cover the end face of the wood-based substrate 31 with an adhesive (see FIG. 9C).

[0004]

In the conventional door trim 30 described above, the wood base material 31 and the skin material 32 are used.
Since and are bonded by using an adhesive, the wood-based base material 31, the skin material 32, and three materials forming the adhesive are involved in the bonded portion. Therefore, when the door trim 30 is used for a long period of time, due to the difference in the physicochemical properties such as the thermal expansion coefficient of these three materials, a strain is generated in the bonded portion, particularly the adhesive layer, and the base material 31 and the skin material 32 are separated. There is a possibility that it will come off. Further, in the door trim 30 manufactured by the above-described conventional manufacturing method, there is a possibility that a portion that does not exhibit a sufficient adhesive effect may be formed due to uneven application of the adhesive during manufacturing. Further, such a manufacturing method requires an apparatus and a process for supplying an adhesive to the base material 31 side or the skin material 32 side by coating or the like, and the skin material 32 to be adhered to the base material 31 is formed into a sheet shape in advance. Since it has to be molded, a separate device and process for molding the skin material 32 is also required, and there is a problem that a series of manufacturing devices and the number of manufacturing processes increase and are complicated. .

[0005]

SUMMARY OF THE INVENTION Therefore, the present invention has been made to solve the above-mentioned problems, and is formed by integrating a base material and a skin material without forming the skin material in a sheet shape and using an adhesive. A laminate, wherein the laminate is curved due to the difference in the thermal expansion coefficient between the base material and the skin material when the laminate is manufactured or is used for a long period of time, or the base material and the skin material are peeled off. It is an object of the present invention to provide a laminated body that does not do so, and a method for manufacturing such a laminated body.

[0006]

The present invention has been made in order to achieve the above object. First, the invention described in claim 1 is a porous wood-based material and a wood-based material of the porous wood-based material. A laminate composed of a surface material and a skin material made of a resin-based material that completely covers both surfaces of the same wood-based substrate by providing an uncovered portion on at least one of the front surface and the back surface, respectively. In the joint between the resin-based material forming the skin material and the respective surfaces on both sides of the wood-based material, the resin-based material is impregnated into the holes on the respective surface sides on both sides of the wood-based material. It is characterized by being hardened (hereinafter referred to as bonding by the anchor effect).

According to a third aspect of the present invention, there is provided a method of manufacturing a laminated body according to the first aspect, which comprises a back side molding die provided with a back side molding surface conforming to the shape of the back side surface of the laminated body. A wood-based material is set between these molding tools in a state where a front-side molding die having a front-side molding surface matching the shape of the front-side surface of the laminate is polymerized, and the front surface and back surface of this wood-based material are set. It is characterized in that the skin material is bonded to both sides of the wood base material by an anchor effect by injecting a molten resin material serving as a skin material on the surface.

[0008] In the invention described in claim 1 and the invention described in claim 3, the part where the surface material of the wood-based material is not provided with the skin material is attached to the surface surface of the laminate by an accessory. It is preferably a covered part.

[0009]

In the laminated body of the present invention thus constituted, since the resin-based material constituting the skin material is hardened in a state where at least the surface of the wood-based base material is directly impregnated, At the joint, only two materials that make up the skin material and the wood-based substrate are involved, and since the two materials are directly bonded by the anchor effect, it seems that they are bonded using a conventional adhesive. No strain is generated in the adhesive layer. Therefore, even if the laminated body is used for a long period of time, the joint strength is maintained between the skin material and the wood-based base material without peeling. Further, since no adhesive is used, there is no possibility of forming a part that is not reliably adhered due to uneven application of the adhesive during manufacturing.

Since the wood base material and the skin material are firmly joined by the anchor effect as described above, the wood base material and the skin material are separated from each other due to the difference in their thermal expansion coefficients. Rather than both, there is a greater possibility of bending, but since the resin-based material that constitutes the skin material covers almost all sides of the wood-based material, the wood-based material and the skin material The force caused by the difference in the coefficient of thermal expansion of the wood base material, that is, the force of the skin material to bend the wood base material acts in opposite directions from both sides of the wood base material. This force on the material itself can be offset and prevent the laminate from bending. Since at least one portion on each side surface of the wood-based substrate is provided with a portion not covered with the skin material, the amount of the resin-based material forming the skin material can be reduced.

In addition, such a laminated body is manufactured by the method according to claim 3, that is, a molten resin material serving as a skin material is injected into the front side of a wood-based material set between a pair of molding dies. It can be easily manufactured by a method of impregnating and hardening the molten resin-based material on at least the front side inside the wood-based material.

[0012] Both molds used in this manufacturing method are molded in order to form a part not covered with a skin material on at least one of the front surface and the back surface of the wood-based substrate. On the surface, there are formed convex portions that come into contact with both side surfaces of the wooden base material set between these molding dies, and these convex portions make the gap between the wooden base material and each molding surface constant. It also plays a role in keeping the thickness of the formed skin material uniform.

As described above, according to the method for producing a laminated body of the present invention, it is not necessary to perform the step of applying an adhesive and the step of forming a skin material, which are indispensable in the conventional production method, and the production process is simplified. can do. Further, it is also effective that the amount of materials used can be reduced by not using an adhesive.

In the invention described in claim 1 and claim 3, the part where the surface material of the wood-based material is not provided with the surface material is attached to the surface surface of the laminate by an accessory (for example, an ornament). The covered portion is preferable because it does not impair the aesthetics of the laminate and maintains its design.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A vehicle door trim and its manufacturing method are adopted as an embodiment of the laminated body of the present invention, and the structure and manufacturing process will be described below with reference to the drawings. The door trim of this embodiment is a vehicle door trim 10 as shown in FIGS. 1 to 3, and a base material 11 formed in the shape of the door trim.
And a skin material 1 for covering the entire front surface of the base material 11.
An ornament 13 for decorating a part of the skin material 12 as shown in FIG. 3 as an accessory.
The ornament 13 includes an inside bezel 14 attached to a peripheral portion of a hole 13c formed in the ornament 13 and an armrest 15 attached to a lower side of the ornament 13.

The base material 11 is a wood-based base material 11 formed by maintaining the porosity of an aggregate obtained by mixing and mixing a main material such as wood chips, fibers and powders with a phenol resin as a binder. The wooden base material 11 has an inside bezel 14
Hall part 11h and ornament 13 for attaching
And a groove 11a for graining the peripheral edge of the.

The skin material 12 is made of polypropylene resin, which is a thermoplastic resin, and covers substantially the entire front surface and back surface of the wood-based material 11 and the end surface of the hole 11h. The end surface of the hole portion 11h is covered with the skin material 12
The door trim 10 is formed with a mounting hole 10h for the inside bezel 14 by covering with. The skin material 12 is provided with hole portions 12b, 12c, 12d, 12e as portions that do not cover the front surface and the back surface of the wooden base material 11,
Moreover, a groove part 12a for graining an ornament is formed along the shape of the groove part 11a of the wood-based material 11.

At the joint portion between the porous wood-based material 11 and the skin material 12, the polypropylene resin forming the skin material 12 is impregnated and filled in the holes on both surface sides of the wood-based material 11. It is in a hardened form in the closed state, that is, both members 11 and 12 are joined by the anchor effect.

The ornament 13 attached to decorate a part of the skin material 12 of the door trim 10 is
It is composed of a base portion 13a made of polyurethane foam and a fabric portion 13b bonded to the base portion 13a. As described above, the ornament 13 has the hole portion 13 to which the inside bezel 14 is attached.
c is provided, and the end portion 13d is provided with the wood-based base material 11 and the skin material 12, and the groove portion 1 for wood grain is formed.
It is inserted into 1a and 12a and joined to the resin forming the skin material 12.

In the door trim 10 thus constructed, the polypropylene resin forming the skin material 12 is hardened in a state where the polypropylene resin forming the skin material 12 is directly impregnated into the holes on the front surface side of the wood-based base material 11, so that at the joint portion. Skin material 12 and wood-based material 1
Since only the two materials that make up No. 1 are involved and the two materials are directly bonded by the anchor effect, the adhesive layer is distorted like the one bonded using the conventional adhesive. Never. Therefore, even if the door trim 10 is used for a long period of time, the joint strength is maintained between the skin material 12 and the wood-based base material 11 without peeling. Further, since no adhesive is used, there is no possibility of forming a part that is not reliably adhered due to uneven application of the adhesive during manufacturing.

Since the wood-based base material 11 and the skin material 12 are firmly joined by the anchor effect in this way, the wood-based base material 11 and the skin material 12 are caused by the difference in their thermal expansion coefficients. Therefore, there is a greater possibility that the two will bend rather than peel off, but since the polypropylene resin that constitutes the skin material 12 covers almost all sides of the wood-based substrate 11, Base material 11 and skin material 12
Force generated due to the difference in thermal expansion coefficient between
The force of 2 to bend the wooden base material 11 works in opposite directions from both sides of the wooden base material 11. Therefore, this force applied to the wooden base material 11 itself is balanced and the door trim 10 is It is possible to prevent bending. In addition, the skin material 12 has holes 12b, 12c, 12 which do not cover both side surfaces of the wood-based material 11.
Since d and 12e are provided, it is possible to reduce the usage amount of the polypropylene resin forming the skin material 12. Since the hole portions 12b and 12c formed on the skin material 12 are covered by the armrest 15 which is an accessory of the door trim 10, the hole portion 12d is covered by the ornament 13, and the hole portion 12e is covered by the ornament 13 and the inside bezel 14. Invisible from the outside, the design of the door trim 10 is not impaired.

Next, a method of manufacturing the door trim having the above-mentioned structure, which is an embodiment of the method of manufacturing the laminated body of the present invention, will be described with reference to FIGS. In the method of manufacturing a door trim according to this embodiment, a back side molding die 20 having a back side molding surface conforming to the shape of the back side surface of the door trim 10 and a front side molding surface conforming to the shape of the front side surface of the door trim 10 are provided. The front mold 21 is used. Both molds 2
These molding dies 2 are provided on the molding surfaces 0 and 21, respectively.
Projections 20b, 20c, 20d, 20e, 21 that come into contact with both side surfaces of the wood-based substrate 11 set between 0 and 21.
b, 21c, 21d, 21e are formed, and the front molding die 21 is formed with a convex portion 21h penetrating the hole portion 11h of the wood-based base material 11. Further, inside the backside molding die 20, a molten resin supply passage 23, which is a path for injecting a molten resin 12melt as a skin material from an injecting device 22 between the wood-based substrate 11 and both molding surfaces, and the molten resin 12
A heater 24 is incorporated to prevent the molten resin 12melt from being cooled and hardened during the supply of the melt.

In the manufacturing method of this embodiment, first, the wood base material 11 is provided between the molding surfaces of the pair of molding dies 20 and 21.
Is set. FIG. 4 shows a top view when the upper mold 21 is removed in this step, and FIG. 5 shows a sectional view taken along line 5-5 in FIG. As is apparent from FIG. 5, the convex portions 20b, 20c, 20d, 20e formed on the molding surface of the back side molding die 20 are in contact with the back side surface of the wood-based base material 11, and the molding surface of the front side molding die 21. The convex portions 21b, 21c, 21d, and 21e formed on the surface of the wooden base material 11 are in contact with the front surface of the wooden base material 11, and the intervals between the molding surfaces of the respective molds 20 and 21 and the surface of the wooden base material 11 are increased. Plays a role in keeping the uniform. Also, a wood-based substrate 1
In the first hole portion 11h, the convex portion 21h formed on the front side molding die 21 is in contact with the molding surface of the back side molding die 20.

Next, as shown in FIG. 6, a molten state (180.degree. C. to 200.degree. C.) constituting the skin material 12 between the both surfaces of the wood-based base material 11 and the molding surfaces of the respective molding dies 20 and 21.
C.) polypropylene resin 12melt at a high pressure (100 to 300 k) from the molten resin supply passage 23 by the injection device 22.
g / cm ² ). As a result, molten resin 12melt
1 impregnated into the holes on the surface side of the wooden base material 11 and immediately cooled and hardened, and both surfaces of the wooden base material 11 are almost entirely covered with a skin material 12 made of polypropylene resin.
The door trim 10 shown in FIG. 3 is formed. However,
Convex portions 20b, 20c, 20d, 2 formed on each molding surface
The skin material 12 is not formed on the wood-based material 11 where the 0e, 21b, 21c, 21d and 21e are in contact.
In addition, a skin material 12 is formed on the hole portion 11h of the wooden base material 11 so as to cover the end surface thereof.

According to the method of manufacturing the door trim 10 of the embodiment described here, it is necessary to perform the step of applying the adhesive and the step of forming the skin material 12 into a sheet shape, which are essential in the conventional manufacturing method. Therefore, the manufacturing process can be simplified. Further, it is also effective that the amount of materials used can be reduced by not using an adhesive.

In the above-described embodiment, the portions where the skin material 12 is not formed on both surfaces of the wood-based base material 11, that is, the holes 12b, 12c, 12d, 12 of the skin material 12.
e was provided at a position corresponding to each other on the front side and the back side of the wood-based base material 11. However, as long as the skin material 12 completely covers both surfaces, no matter how many holes there are, any position is provided. May be provided.

Although polypropylene resin is used as the skin material in the above examples, other olefin resins such as vinyl chloride, polyethylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid are used. A polymer or the like, or a thermoplastic resin such as a polyamide resin or an ASA resin may be used alone or in combination of two or more kinds. Further, a gloss-imparting agent that imparts gloss to the skin material, a flame retardant, or the like can be added as appropriate in consideration of the appearance and performance of the finished product.

[Brief description of drawings]

FIG. 1 is a perspective view of a door trim that is an embodiment of a laminated body according to the present invention.

FIG. 2 is a perspective view taken along line 2-2 in FIG.

FIG. 3 is a vertical sectional view taken along line 3-3 in FIG.

FIG. 4 is a step diagram for explaining the method of manufacturing the door trim shown in FIGS. 1 to 3, and is a top view when the upper die is removed.

5 is a cross-sectional view taken along line 5-5 in FIG.

6 shows the next step of the step shown in FIG. 4 and FIG.
It is a cross-sectional view corresponding to FIG.

FIG. 7 is a perspective view of a conventional door trim.

8 is a vertical cross-sectional view taken along the line 8-8 in FIG.

9A to 9C are process diagrams for explaining a method for manufacturing the door trim shown in FIGS. 7 and 8.

[Explanation of symbols]

10, 30 ... Door trim, 10h ... Inside bezel mounting hole portion, 11, 31 ... Wood base material, 11a ...
Grooves, 11h ... Holes, 12, 32 ... Skin material, 12a
... Grooves, 12b, 12c, 12d, 12e ... Holes,
13, 33 ... Ornament, 14, 34 ... Inside bezel, 20, 38 ... Back side mold, 20b, 20c, 20
d, 20e ... convex part, 21, 39 ... front side molding die, 21b,
21c, 21d, 21e, 21h ... Convex portion, 22 ... Injection device, 23 ... Molten resin supply passage, 24 ... Heater.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Reference number within the agency FI technical display location // B29K 105: 20 711: 14 B29L 9:00 31:58 (72) Inventor Kenji Iwase Aichi 25, Kamifujiike, Yoshihara-cho, Toyota

Claims (4)

[Claims] 1. A porous wood-based base material and at least one uncovered portion on each of a front surface and a back surface of the wood-based base material are provided to completely cover both surfaces of the wood-based base material. In a laminated body composed of a skin material made of a resin-based material to be coated on, the resin-based material at the joint between the resin-based material that constitutes the skin and the respective surfaces of both sides of the wood-based base material is A laminated body characterized by being hardened in a state of being impregnated in the holes on both surface sides of the same wood-based material. 2. The portion of the wood-based material where the surface material is not provided on the front surface thereof is a portion covered by an accessory attached to the front surface of the laminate. Laminate. 3. A porous wood base material and at least one uncovered portion on each of the front surface and the back surface of the wood base material are provided to completely cover both side surfaces of the wood base material. A method for manufacturing a laminate constituted by a skin material made of a resin-based material to be coated on a back side molding die provided with a back side molding surface conforming to the shape of the back side surface of the laminate, and the front side of the laminate. The wood-based substrate is set between these molds in a state where a front-side molding die having a front-side molding surface matched to the shape of the surface is polymerized, and the front-side surface and the back-side surface of this wood-based substrate are A method for manufacturing a laminate, comprising injecting a molten resin-based material as a skin material to impregnate and cure the molten resin-based material into the holes on both surface sides of the wood-based substrate. 4. The part of the wood-based material, on the front side surface of which is not provided with a skin material, is a part which is covered by an accessory attached to the front side surface of the laminate. Method for manufacturing laminated body.