JPH0885124A - Laminate production device - Google Patents

Abstract

PURPOSE: To obtain a device for producing a laminate, such as a door trim, which can cover a peripheral end face of a substrate and an end face of an opening with a skin material without employing a bonding stage and without forming the skin material into a sheet form to integrate the substrate and the skin material. CONSTITUTION: In a production device provided with a pair of molds 20, 21 for pressing a substrate 11 molded into the shape of a door trim and a melt resin 12melt supplied to the surface of the substrate 11 as a molding material of the skin material to integrate the substrate 11 and a skin material 12, movable arrest pieces 24, 26 are provided on the mold 21 for molding the skin material. The movable arrest pieces 24, 26 arrest the flow of the melt resin 12melt in a pressing stage, thereby ensuring that a peripheral end face of the substrate and an end face of an opening are covered with the skin material 12 and preventing that burr is formed in the laminate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for manufacturing a laminate used for vehicle door trims, vehicle interior materials, indoor interior materials and the like.

[0002]

2. Description of the Related Art As a laminate used for the above-mentioned applications, there is known a laminate in which a base material made of a wood-based material or a resin-based material formed in a predetermined shape is coated with a resin layer. As an example of such a laminate, a base material made of a wood-based hardboard formed in the shape of a door trim,
There is a door trim including a skin material that is adhered to the surface of the base material and covers the entire surface of the base material.

In order to manufacture a door trim having such a structure, first, as shown in FIG. 9 (a), an adhesive is applied to the surface of a base material 50 formed into a predetermined shape, and a bottom of a vacuum forming die is formed. The skin material 51, which is set in a mold 52 and formed in a sheet shape with a predetermined design pattern on the surface in advance, is used as a base material 50.
The base material 50 and the skin material 51 are integrally bonded by arranging the base material 50 and pressing between the upper mold 53 and the lower mold 52. After the two members 50 and 51 have been integrated in this way, the skin material 51 has its end at the base material 50 as shown in FIG. 9B.
It is cut off so that it protrudes somewhat from it. The protruding portion 51a of the skin material 51 is subsequently subjected to an adhesive treatment so that the end surface of the base material 50 is rolled up so that the end surface 50a of the base material 50 is not exposed, as shown in FIG. 9C, and the outer peripheral portion of the door trim. Is finished.

[0004]

In the conventional door trim manufacturing method described above, the skin material 51 to be adhered to the base material 50 must be formed into a sheet shape in advance, so that the skin material 51 is preliminarily formed. Separate equipment and steps are required for molding. Further, in order to finish the outer peripheral portion of the door trim so that the end surface of the base material 50 is not exposed, a step of forming the protruding portion 51a of the skin material 51, and bonding the protruding portion 51a so as to cover the end surface 50a of the base material 50. Since it is necessary to perform a treatment step, there has been a problem that a series of manufacturing devices and the number of manufacturing steps at the time of manufacturing a door trim increase and are complicated.

The present invention has been made in order to solve the above problems, and uses a molten resin as a material for the skin material without forming the skin material in a sheet shape in advance and requires a separate processing step. An object of the present invention is to provide a manufacturing apparatus for a laminated body such as a door trim, which can integrally integrate the base material and the skin material by covering the outer periphery of the base material and the end surface of the opening with the skin material without the need.

[0006]

The apparatus for producing a laminate of the present invention, which has been made to achieve the above object, comprises a base material side molding die provided with a molding surface conforming to the shape of the back surface of the base material, and A skin material side molding die which is provided so as to be close to and away from the base material side molding die and covers the surface of the base material And a supply means for supplying a molten resin serving as a skin material between the surface of the base material supported by the molding surface of the base material side molding die and the molding surface of the skin material side molding die. The molten resin supplied to the surface side of the material is pressed between both molds, and then the molten resin is cured to produce a laminate in which the surface and the end surface of the base material are covered with a skin material. The feature is that either one of the two molds is provided so that it can move back and forth in the direction toward the other mold. The mold is elastically urged toward the other mold and the tip of the mold surface of the other mold is located at a position apart from the end face of the base material in the extension direction of the base material while the molds are approaching. Is provided with a movable blocking piece that blocks the molten resin that is elastically pressed and pressed to flow over a predetermined distance.

According to the apparatus for manufacturing a laminated body of the present invention having such a structure, when the skin material side molding die is brought close to the base material side molding die in which the base material is set, one of both molding dies is formed. The tip of the provided movable block piece first comes into contact with the molding surface of the other molding die. The molten resin supplied between the surface of the base material and the molding surface of the skin material-side molding die is spread by the subsequent approach of both molding dies, but the molten resin is moved from the end surface of the base material by the movable blocking piece. It is prevented from flowing over a predetermined distance, filled in the space between the base material and both molds, covers the entire surface and end surface of the base material, and is cured as it is to manufacture a laminate.

In the laminated body manufacturing apparatus according to the present invention, the characteristic portion is provided on the outer peripheral portion of either one of the two molds so as to be able to advance and retreat in the direction toward the other mold so as to face the other mold. Is elastically urged, and the tip is elastically pressed against the outer peripheral portion of the molding surface of the other molding die at a position outwardly separated from the outer peripheral end surface of the base material by a predetermined distance while the molding dies are approaching each other. A loop-shaped movable blocking piece may be provided to prevent the molten resin to be pressed by pressing from flowing outward beyond a predetermined distance from the outer peripheral end surface of the base material.

With this configuration, the molten resin pushed out by the approach of both molds as described above does not flow outward beyond the predetermined distance from the outer peripheral end surface of the base material by the loop-shaped movable blocking piece. The mixture is blocked and filled in the space between the base material and both molds, and the entire surface of the base material and the outer peripheral end surface are covered and cured, whereby a laminate is manufactured. In this case, the loop-shaped movable block piece may be provided on the outer peripheral portion of the skin material side forming die or on the base material side forming die.

Further, in the apparatus for manufacturing a laminated body according to the present invention, the characteristic portion is formed at least in the same position as the opening at the position corresponding to the opening of the molding surface of the base material side molding die while forming the opening in a part of the base material. A recess having a size is provided so that it can move back and forth in the direction toward the other mold at a position corresponding to the opening of one of the molds, and is elastically attached to the other mold. The tip is elastically pressed against a part of the molding surface of the other mold at a position inwardly separated from the inner peripheral end surface of the hole formed in the base material by a predetermined distance while the molds are being approached. A movable blocking piece may be provided to block the molten resin pressed and pressed inward beyond a predetermined distance from the inner peripheral end surface of the hole.

With this arrangement, the molten resin that is spread by the approach of both molds, as described above, will not flow inward beyond the predetermined distance from the inner peripheral end surface of the opening of the base material by the movable blocking piece. After being blocked, the space between the base material and both molds is filled, and the entire surface of the base material and the inner peripheral end surface of the opening are covered and cured, whereby a laminate is manufactured. In this case,
The movable blocking piece may be provided on the skin material side mold or on the base material side mold.

[0012]

According to the apparatus for manufacturing a laminate of the present invention as described above, it is not necessary to perform the step of forming the skin material, which is indispensable in the conventional manufacturing apparatus, and the end surface of the base material is covered with the skin material. It can be covered with a skin material without undergoing the bonding step of (1), and at the same time, the base material and the skin material can be integrated.

Further, since the tip of the movable blocking piece provided on one of the molds is elastically pressed against the molding surface of the other mold, the gap between them is almost zero, and therefore the burrs are formed on the edge of the skin material. Are rarely formed.

According to the one in which the loop-shaped movable blocking piece is provided on the outer peripheral portion of either one of the two molding dies, the outer peripheral end face of the base material is covered with the skin material without undergoing the step of adhering the skin material, as described above. The base material and the skin material can be integrated at the same time. Also in this case, burrs are hardly formed on the outer peripheral edge of the skin material as described above.

Further, an opening is formed in a part of the base material, and a concave portion of at least the same size is provided on the molding surface of the base material side molding die, and a position corresponding to the opening of the molding surface of either one of the two molding dies. According to the structure in which the movable blocking piece is provided, the inner peripheral end surface of the opening of the base material can be covered with the skin material without undergoing the step of adhering the skin material, and at the same time, the base material and the skin material can be integrated. it can. Also in this case, burrs are hardly formed on the outer peripheral edge of the skin material as described above.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention in which a vehicle door trim is an object (laminate) will be described below with reference to the accompanying drawings.

A door trim manufactured by the manufacturing apparatus of this embodiment is a door trim 10 for an automobile as shown in FIGS. 1 and 2, and includes a base material 11 formed in the shape of a door trim and the base material. 11 and a skin material 12 that covers the entire surface of the surface 11, and if necessary, this skin material 1
A part of 2 is decorated with ornament 13. The base material 11 is made of a wood-based molded body formed by maintaining the porosity of an aggregate obtained by adding and mixing a phenolic resin as a binder to a main material such as wood chips, fibers, and powders. The opening 11a is perforated corresponding to. The skin material 12 is made of polypropylene resin which is a thermoplastic resin. At the joint portion between the porous base material 11 and the skin material 12, the thermoplastic resin of the skin material 12 is the porous base material 1
1 is in the form of being hardened in a state of being impregnated and filled in the holes near the surface of 1, that is, both members 11 and 12 are joined by the anchor effect.

The manufacturing apparatus of the first embodiment used for manufacturing the door trim having such a structure is shown in FIGS. 3 and 4, and the apparatus is adapted to the shape of the back surface of the door trim. A lower die 20 having a molding surface 20a (corresponding to the base material side molding die of the present invention), and a skin material 12 including a grain which is provided on the lower die 20 so as to be able to approach and separate from above and to form a design pattern. Molding surface 2 that matches the shape of the surface of
1a is formed on the molding surface 20a of the lower mold 20 so as to face the molding surface 20a of the lower mold 20 (corresponding to the molding material side molding mold of the present invention), and on the molding surface 20a of the lower mold 20 in a state where the upper mold 21 is raised. A supply device 22 (corresponding to the supply means of the present invention) for supplying the molten resin 12melt to be the skin material 12 on the upper surface of the supported porous substrate 11 is a main component.

On the outer peripheral portion of the molding surface 21a of the upper mold 21, a loop-shaped movable blocking piece 24 is provided so as to be movable back and forth in the direction toward the lower mold 20, and a plurality of (at least three) springs 23 are used to form the lower mold. It is elastically biased toward 20. As shown in FIG. 4, the movable blocking piece 24 is provided with pins 24a penetrating at a plurality of locations (at least three locations), and a plurality of groove holes 24b for receiving the pins 24a are formed on the outer peripheral surface of the upper die 21. As a result, the loop-shaped movable blocking piece 24 is attached to the outer peripheral portion of the upper die 21 so as to be able to move forward and backward by a predetermined distance. The inner peripheral edge of the tip end surface of the movable blocking piece 24 is a predetermined distance outwardly from the outer peripheral end surface 11b of the porous substrate 11 when the upper die 21 is moved down to approach the lower die 20 and polymerized (skin material 12 Of the molten resin 12melt supplied by the supply device 22 at a predetermined distance from the outer peripheral end surface 11b of the base material 11 by being elastically pressed against the molding surface 20a of the lower mold 20 at a position apart from the outer peripheral end surface 11b. It prevents it from flowing over.

The molding surface 20a of the lower mold 20 is slightly larger and shallower than the opening 11a at a position corresponding to the opening 11a of the base material 11 supported thereon (similar to the completed thickness of the skin material 12). Depth) A recess 20b is formed. Upper mold 2
The molding surface 21a of No. 1 has openings 1 provided in the porous substrate 11.
At a position corresponding to 1a, a movable blocking piece 26 having a profile slightly smaller than the opening 11a is provided so as to be able to move forward and backward in a direction toward the lower die 20, and is elastically biased toward the lower die 20 by a spring 25. . The urging force of the spring 25 when the two molds 20 and 21 are separated from each other is
It is received by the flange portion 26a (see FIG. 4). The outer peripheral portion of the tip end surface of the movable blocking piece 26 is formed in
When 0 and 21 are polymerized by approaching each other, the lower mold is placed at a position inwardly separated from the inner peripheral end surface 11d of the opening 11a of the porous base material 11 by a predetermined distance (about the same as the completed thickness of the skin material 12). The molten resin 12 supplied by the supply device 22 while being elastically pressed by the recess 20b of the molding surface 20a
The melt is prevented from flowing inward beyond a predetermined distance from the inner peripheral end surface 11d of the base material 11.

Before manufacturing a door trim using the manufacturing apparatus of the first embodiment, 50 ° C. to 80 ° C.
First, a porous base material 11 made of a wood-based molded body in the shape of a door trim is set on the molding surface 20a of the lower mold 20 of the molding dies 20, 21 whose temperature is adjusted to 0 ° C. Polypropylene resin 12melt as a skin material is supplied to the upper surface of the material 11 in a molten state (180 ° C. to 200 ° C.) using a supply device 22. This molten resin 12melt
Should not be supplied to the position of the opening 11a of the porous substrate 11. In this state, as shown in FIGS. 3 and 4A, the outer peripheral end surface 11 b of the base material 11 and the molding surface 2 of the lower mold 20.
A gap 20c is formed between 0a and the outer peripheral end surface 11
Gaps 20d and 20e having a predetermined width are also formed between a part of b (see the right side of FIG. 3 and FIG. 4) and the back surface of the base material 11 of the inner peripheral end surface 11d of the opening 11a and the molding surface 20a. In addition, the base material 11 which is a part of the outer peripheral end surface 11b provided with the gap 20d
A cantilevered rib 11c, which is located in the gap 20d and is in direct contact with the molding surface 20a of the lower die 20, is formed on the back surface of the above.

From this state, the upper mold 21 is lowered to lower the lower mold 2.
When approaching 0, as shown in FIG. 4 (b), first, the front end surfaces of the movable blocking pieces 24 and 26 are moved at the same time or slightly before or after each other, so that the outer peripheral portion of the molding surface 20a of the lower mold 20 and the recess 20b are respectively formed. Abut inside. Although the molten resin 12melt has not reached the outer peripheral end surface 11b of the base material 11 at the initial stage of contact shown in FIG. , 21, and at the same time, the elastic force by which the tip ends of the movable blocking pieces 24, 26 press the molding surface 20a of the lower mold 20 by the springs 23, 25 increases gradually. Then, as shown in FIG. 4C, when the molds 20 and 21 come to the closest position, the molten resin 12melt is further spread, but the molten resin 12melt is moved by the movable blocking piece 24 on the outer peripheral end face 11b. Further, it is blocked so as not to flow further outward, and is blocked so as not to flow further inward by the movable blocking piece 26 at the inner peripheral end surface 11d, so that the space between the base material 11 and both molds 20 is filled. Cover the entire front surface of the base material 11, the outer peripheral end surface 11b and the inner peripheral end surface 11d, and further enter part of the gaps 20d and 20e to cover a part of the rear surface of the base material 11.

In this embodiment, the gap 20d is provided so that the molten resin 12melt is spread over a part of the back surface of the outer peripheral end surface 11b of the base material 11. However, the back surface of the base material 11 is located within the gap 20d. Since the cantilevered ribs 11c that directly contact the molding surface 20a of the lower mold 20 are provided, there is no fear that the outer peripheral portion of the base material 11 provided with the gap 20d is deformed by the pressure during press molding. Similar cantilever rib is base material 1
It may be provided at a position inside the gap 20e on the back surface of the first opening 11a. Then, after the temperature of the skin material 12 is lowered to a predetermined temperature and hardened, as shown in FIG.
Are separated from each other, a door trim in which a predetermined portion of the base material 11 is covered with the skin material 12 is formed.

Therefore, unless the movable blocking pieces 24 and 26 are provided, the molten resin 12melt is melted during the pressing process.
Flows over the molding surface 20a of the lower mold 20 over a predetermined distance from the outer peripheral end surface 11b of the porous substrate 11 and the inner peripheral end surface 11d of the opening 11a to form the skin material 12 between the molds 20 and 21. A burr made of a resin-based material is formed, but since the apparatus of this embodiment is provided with the movable blocking pieces 24 and 26, the molten resin 12melt does not flow over a predetermined distance. No burr is formed. Further, according to the door trim manufacturing apparatus of such an embodiment, it is not necessary to perform a preliminary skin material forming step, which is essential in the conventional manufacturing apparatus, and the conventional skin material is porous. Manufacturing method of adhering to a base material and integrating (see FIG. 9)
In the step (see FIG. 9 (b)) of cutting the end of the skin material so as to slightly protrude from the base material, which is required in the above, and covering the protruding portion of the skin material so as to wrap the end surface of the base material. The outer peripheral end surface 11b of the base material 11 and the inner peripheral end surface 11d of the opening 11a can be processed without performing the process (see FIG. 9C).
Can be covered with the skin material 12.

In the manufacturing apparatus of the first embodiment, the supply device 22 (see FIG. 3) is used as the supply means for supplying the molten resin 12melt to the lower mold 20, but the second embodiment shown in FIG. As shown in the aspect, a resin supply passage 31 (opening at positions dispersed throughout the molding surface 30a supporting the base material 11)
A lower mold 30 (corresponding to the base material side molding mold of the present invention) having a built-in heater 32 is provided in order to prevent the temperature of the molten resin 12melt from dropping during the supply.
As the melt supply means, an injection device 33 (corresponding to the supply means of the present invention) capable of injecting through the resin supply passage 31 may be used.

In order to manufacture the door trim 10 using the manufacturing apparatus of the second embodiment as described above, first, the resin supply passage 31 in the lower mold 30 is injected into the lower mold 30 in which the base material 11 is set by the injection device 33. Through the molten resin 12 on the upper surface of the substrate 11.
The melt is discharged, then the upper mold 21 is lowered toward the lower mold 30, first the movable blocking pieces 24 and 26 are brought into contact with the lower mold 30, and the upper mold 21 is further lowered to push the molten resin 12melt. The target door trim 10 is manufactured by unfolding and molding, and curing the molten resin 12melt in this state.

In the manufacturing apparatus of the first and second embodiments described above, the lower molds 20 and 30 on which the porous substrate 11 can be set and the upper molds 21 provided with the movable blocking pieces 24 and 26 are provided.
Instead of these molding dies 20, 21, 30, a molding die having a molding surface matching the shape of the front side of the door trim as a lower die and having a movable blocking piece installed is used as an upper die. It is also possible to adopt a molding die in which a flexible base material is set, and to configure a manufacturing apparatus that performs a pressing step using these molding dies.

Next, referring to FIGS. 6 and 7, a third embodiment of the present invention will be described. The manufacturing apparatus according to this embodiment is characterized in that a loop-shaped movable blocking piece 28 provided on the outer peripheral end surface 11b of the base material 11 and a movable blocking piece 26 provided corresponding to the opening 11a are both provided on the lower mold 35. This is different from the first and second embodiments.

Also in the manufacturing apparatus of the third embodiment, the lower die 35 (corresponding to the base material side molding die of the present invention) having the molding surface 35a conforming to the shape of the back surface of the door trim is provided. The molding surface 36a that is provided so as to be able to approach and separate from the mold 35 and that matches the shape of the surface of the skin material 12 is the molding surface 35 of the lower mold 35.
The upper die 36 (corresponding to the skin material side molding die of the present invention) formed to face a and the upper surface of the porous substrate 11 supported by the molding surface 35a of the lower die 35 become the skin material 12. A supply device 22 (corresponding to the supply means of the present invention) for supplying the molten resin 12melt is a main constituent member.

As shown in FIG. 6, the loop-shaped movable blocking piece 28 engaged with the outer peripheral portion of the lower mold 35 so as to be slidable in the vertical direction with substantially no space is provided with a circular shape at a plurality of locations (at least three locations). Stepped slide holes 28a are formed, and the slide pins 29a inserted into the respective slide holes 28a are planted in a loop-shaped pedestal 29 provided on the outer peripheral portion of the lower mold 35 below the movable blocking piece 28. The movable block piece 28 in a loop shape is attached to the outer peripheral portion of the lower mold 35 so as to be able to move forward and backward by a predetermined distance. The pedestal 29 is supported on the fixed base B together with the lower die 35, and the plurality of (at least three) springs 27 interposed between the pedestal 29 and the pedestal 29 move the movable blocking piece 28 toward the upper die 36. Elastically biased,
Normally, the head of the slide pin 29a is stopped at the highest position where it engages with the step of the slide hole 28a. The tip end surface of the movable block 28 is pressed against the projecting edge 36b of the outer periphery of the molding surface 36a of the upper mold 36 when the upper mold 36 is lowered and brought close to the lower mold 35 to be superposed. The inner peripheral edge of this abutting portion is a position outwardly separated from the outer peripheral end surface 11b of the porous base material 11 by a predetermined distance (about the same as the completed thickness of the skin material 12), and is thus supplied by the supply device 22. The molten resin 12melt is prevented from flowing outward beyond a predetermined distance from the outer peripheral end surface 11b of the base material 11.

The molding surface 35a of the lower mold 35 is slightly larger and shallower than the opening 11a at a position corresponding to the opening 11a of the base material 11 supported thereon (similar to the completed thickness of the skin material 12). Depth) The concave portion 35b is formed. In this concave portion 35b which is a part of the molding surface 35a, the movable blocking piece 26 having a contour shape, which is located inside the opening 11a by a predetermined distance (about the same as the completed thickness of the skin material 12), faces the upper die 36. The spring 25 is elastically urged toward the upper die 36 so that the spring 25 can move forward and backward. Both types 3
The urging force of the spring 25 in the state where 5 and 36 are separated is received by the flange portion 26a (see FIG. 6) of the movable blocking piece 26. The outer peripheral portion of the tip end surface of the movable block 26 has a structure in which when the molds 35 and 36 are brought close to each other and superposed,
The molten resin 12melt supplied by the supply device 22 is elastically pressed against the molding surface 36a of the upper mold 36 to prevent the molten resin 12melt from flowing inward beyond a predetermined distance from the inner peripheral end surface 11d of the base material 11. There is.

Before manufacturing the door trim using the manufacturing apparatus of the third embodiment, 50 ° C. to 80 ° C.
First, the base material 11 is set on the molding surface 35a of the lower mold 35 of the two molding dies 35 and 36 adjusted to the temperature of ° C, and then the polypropylene resin 12melt which serves as a skin material is formed on the upper surface of the base material 11. Is supplied in a molten state (180 ° C. to 200 ° C.) using the supply device 22. This molten resin 12melt
Should not be supplied to the position of the movable blocking piece 26.
In this state, as shown in FIG. 6 and FIG.
The outer peripheral end surface 11b (left side in FIG. 6) and the rear surface (right side in FIG. 6 and FIG. 7A) of 1 are in contact with the movable blocking piece 28 pushed up to the highest position by the spring 27,
Further, a gap 35e having a predetermined width is formed between the rear surface of the base material 11 on the inner peripheral end surface 11d of the opening 11a and the molding surface 35a.

From this state, the upper die 36 is lowered to move the lower die 3
As shown in FIG. 7 (b), first, the distal end surfaces of the movable blocking pieces 26 and 28 are moved at the same time or slightly before or after each other as shown in FIG. It abuts on the protruding edge 36b of the outer peripheral portion. Figure 7 (b)
Although the molten resin 12melt has not reached the outer peripheral end surface 11b of the base material 11 at the initial stage of contact shown in FIG. It is pushed out and at the same time, both movable blocking pieces 26,
28 is pushed down by the projecting edge 36b of the upper die 36, and is placed between the back surface of the base material 11 (right side of FIG. 6 and FIG. 7) and the outer peripheral end surface 11b of the base material 11 (left side of FIG. 6) and the movable block 28. A gap 35c (see FIG. 7C) is formed, and the elastic force with which the tip surfaces of the movable blocking pieces 26 and 28 press the molding surface 36a of the upper mold 36 by the springs 25 and 27 gradually increases. Then, as shown in FIG. 7C, both molds 35,
When 36 is the closest position, the molten resin 12melt is further spread out.
In b, it is blocked by the movable blocking piece 28 so that it does not flow outward, and in the inner peripheral end surface 11d, it is blocked by the movable blocking piece 26 so that it does not flow inwardly. The space between the molds 35 is filled with the entire surface of the base material 11, the outer peripheral end surface 11b, and the inner peripheral end surface 11.
d, and further enter the gaps 35d and 35e to form the base material 11
Also cover part of the back side of the. Then, after the temperature of the skin material 12 is lowered to a predetermined temperature and hardened, the molds 35 and 36 are separated from each other as shown in FIG. 4D, so that a predetermined portion of the base material 11 is covered with the skin material 12. The door trim is formed.

As in the case of the first and second embodiments,
Also in the third embodiment, the molten resin 12melt is formed on each end face 11
It does not flow beyond a certain distance from b, 11d,
Burrs are not formed by this. In addition, it is not necessary to perform a preliminary step of forming the skin material, and a step of cutting out the end of the skin material by cutting (see FIG. 9B),
Also, the outer peripheral end surface 11b and the inner peripheral end surface 11d of the base material 11 are covered with the skin material 1 without performing the step of covering the protruding portion of the skin material so as to wrap the end surface of the base material (see FIG. 9C).
Can be covered with 2. Also, in the third embodiment, as shown in FIG. 5, a modification is possible in which the molten resin 12melt is injected through the resin supply passage 31 provided in the lower mold 30.

Next, in the fourth embodiment shown in FIG. 8, the protruding edge 36b provided on the outer peripheral portion of the molding surface 36a of the upper mold 36 is omitted, and the loop-shaped outer peripheral end surface 11b of the base material 11 is formed. The protruding edge 28b is provided on the upper surface of the movable blocking piece 28, and the protruding edge 28b is pressed against the outer peripheral portion of the molding surface 36a of the upper die 36, which is the only difference from the third embodiment. Other structures, actions, and effects are the same as those of the third embodiment, so that only corresponding parts will be denoted by corresponding reference numerals and detailed description thereof will be omitted.

As a description of the operation of the manufacturing apparatus of each of the above-mentioned embodiments, the manufacturing method of the door trim in which the molten resin is supplied to the surface of the base material, pressed and then cured as it is, is adopted. Of the same foaming resin in the molten state as the base material
After pressing the pair of molds once to spread the expandable resin on the surface of the base material, and then separating the pair of upper and lower molds by a predetermined amount, the expandable resin on the base material side is removed. If the foamed layer is foamed and cured to form a foamed layer, and the foamable resin on the foamed layer is cured without being foamed to form a skin layer, an elastic skin material made of the foamed layer can be easily manufactured.

Further, although the porous base material made of a wood-based molded body is used in the description of manufacturing the door trim by the manufacturing apparatus of this embodiment, a porous resin-based molded body made of hard urethane foam or the like is used. Good. In addition, a porous resin mainly composed of a thermosetting material such as a phenol resin, an epoxy resin, a polyester resin or a thermoplastic resin such as a polypropylene resin or an ABS resin, to which a reinforcing agent and a conductive agent for preventing static electricity are added. A system molded body, a porous molded body obtained by pressure molding metal fibers, a molded body made of a carbon material, a molded body obtained by supporting or laminating a porous resin on a support made of lath metal, non-woven fabric or the like can also be used. .

When the base material made of these materials and the resin constituting the skin material, or the base portion of the ornament and the resin constituting the skin material have poor wettability, surface modification such as modified olefin is carried out. Bonding of each joint by applying or impregnating the base material surface or the base portion surface of the ornament with a quality agent to improve the permeability of the molten resin into the pores of the porous base material or the base portion of the ornament. Strength can be increased. For example, when the base material is polypropylene resin and the skin material is vinyl chloride, a chlorinated polyolefin-based primer is used as the surface modifier.

In the description of manufacturing the door trim using the manufacturing apparatus of the above-described embodiment, since the porous base material 11 is used as the base material, the base material 11 and the skin material 12 are joined by the anchor effect. It is not necessary to apply an adhesive to the base material side or the skin material side. However, for example, when a non-porous thermoplastic resin such as ABS resin is used as the base material, it is set in the base material side molding die. Steps such as applying an adhesive to the base material in advance are required. On the other hand, if a non-porous material such as a polypropylene resin which is a thermoplastic resin is used as the base material, it is possible to bond the polypropylene with the skin material by welding. At this time, a surface modifier for enhancing the wettability between the base material and the skin material and performing reliable welding can be applied as necessary.

In the description of manufacturing the door trim using the manufacturing apparatus of the above embodiment, polypropylene resin is used as the skin material, but other olefin resins such as vinyl chloride, polyethylene and ethylene-propylene copolymer are used. , Ethylene-vinyl acetate copolymer, ethylene-
Acrylic acid polymers and the like, and thermoplastic resins such as polyamide resins and ASA resins may be used alone or in combination of two or more. 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 manufactured by a laminated body manufacturing apparatus according to the present invention.

FIG. 2 is a vertical sectional view taken along line 2-2 in FIG.

FIG. 3 is a diagram for explaining a door trim manufacturing apparatus that is a first embodiment of the laminated body manufacturing apparatus according to the present invention.

FIG. 4 is a partial enlarged cross-sectional view showing the manufacturing process of the first embodiment shown in FIG.

FIG. 5 is a diagram for explaining a door trim manufacturing apparatus which is a second embodiment of the laminated body manufacturing apparatus according to the present invention.

FIG. 6 is a diagram for explaining a door trim manufacturing apparatus that is a third embodiment of the laminated body manufacturing apparatus according to the present invention.

FIG. 7 is a partial enlarged cross-sectional view showing the manufacturing process of the third embodiment shown in FIG.

FIG. 8 is a partially enlarged cross-sectional view showing a manufacturing process of a door trim manufacturing apparatus which is a fourth embodiment of the laminated body manufacturing apparatus according to the present invention.

9A, 9B and 9C are process drawings for explaining a conventional door trim manufacturing method.

[Explanation of symbols]

10 ... Door trim, 11 ... Base material, 11a ... Opening, 11
b, 11d ... End face, 12 ... Skin material, 12melt ... Molten resin, 20, 30, 35 ... Base material side molding die (lower die), 20
a, 21a, 30a, 35a, 36a ... Molding surface, 20
b, 35b ... Recesses, 21, 36 ... Skin material side molding die (upper die), 22, 33 ... Supplying means (supplying device, injecting device),
24, 26, 28 ... Movable blocking piece, 23, 25, 27 ... Spring.

Continuation of front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display location B32B 27/06 9349-4F 27/32 C 9349-4F 31/20 9349-4F B60J 5/04 // B60R 13 / 02 A B29K 23:00 105: 06 B29L 9:00 31:58 (72) Inventor Yukio Ishihara 25 Kamifujiike, Yoshihara-cho, Toyota City, Aichi Prefecture Arako Co., Ltd. Machikami Fujiike 25 Araco Co., Ltd. (72) Inventor Kazunori Kuse 25, Kamifujiike Yoshiwara-cho, Aichi Prefecture Toyota Araco Co., Ltd.

Claims (7)

[Claims] 1. A base material side molding die having a molding surface conforming to the shape of the back surface of the base material, and a skin material covering the surface of the base material, which is provided so as to be close to and away from the base material side molding die. A skin material side molding die provided with a molding surface matching the shape of the surface facing the molding surface of the base material side molding die, and the surface of the base material supported by the molding surface of the base material side molding die A supply means for supplying a molten resin serving as the skin material between the molding surfaces of the skin material side molding die, and the molten resin supplied to the front surface side of the base material and the base material A manufacturing apparatus for manufacturing a laminate in which the surface and the end surface of the base material are coated with the skin material by curing the molten resin after pressing between, and one of the both molding dies, It is provided so as to be able to move back and forth in the direction toward the other mold, and is elastic toward the other mold. And the tip is elastically pressed against the molding surface of the other mold at a position apart from the end surface of the base material by a predetermined distance in the extension direction of the base material while the molds are approaching each other. An apparatus for manufacturing a laminated body, comprising a movable blocking piece for blocking the molten resin pressed and pressed from flowing beyond the predetermined distance. 2. A base material side molding die having a molding surface conforming to the shape of the back surface of the base material, and a skin material which is provided so as to be close to and away from the base material side molding die and covers the surface of the base material. A skin material side molding die provided with a molding surface matching the shape of the surface facing the molding surface of the base material side molding die, and the surface of the base material supported by the molding surface of the base material side molding die A supply means for supplying a molten resin serving as the skin material between the molding surfaces of the skin material side molding die, and the molten resin supplied to the front surface side of the base material and the base material A manufacturing apparatus for manufacturing a laminate in which the surface and the end surface of the base material are covered with the skin material by pressing the molten resin after pressing between the outer peripheral portion of either one of the molding dies. Is provided so as to be able to move back and forth in the direction toward the other molding die, and to face the other molding die. Is elastically urged, and the tip is elastically attached to the outer peripheral portion of the molding surface of the other molding die at a position outwardly separated from the outer peripheral end surface of the base material by a predetermined distance during the approach of the two molding dies. Laminated body provided with a loop-shaped movable blocking piece for blocking the molten resin pressed by the static pressure and flowing outward beyond the predetermined distance from the outer peripheral end surface of the base material. Manufacturing equipment. 3. The laminated body manufacturing apparatus according to claim 2, wherein the loop-shaped movable block piece is provided on an outer peripheral portion of the skin material side forming die. 4. The apparatus for manufacturing a laminate according to claim 2, wherein the loop-shaped movable block piece is provided on an outer peripheral portion of the base material side mold. 5. A base material side molding die having a molding surface conforming to the shape of the back surface of the base material, and a skin material which is provided so as to be close to and away from the base material side molding die and covers the surface of the base material. A skin material side molding die provided with a molding surface matching the shape of the surface facing the molding surface of the base material side molding die, and the surface of the base material supported by the molding surface of the base material side molding die It comprises a supply means for supplying a molten resin to be the skin material between the skin material side forming dies, and presses the base material and the molten resin supplied to the front surface side of the base material between the two forming dies. After that, the manufacturing apparatus for manufacturing a laminate in which the surface and the end surface of the base material are coated with the skin material by curing the molten resin, and forming an opening in a part of the base material and At least the same size as the opening at the position corresponding to the opening on the molding surface of the base material side mold. A concave portion is provided, and at a position corresponding to the opening of the molding surface of either one of the two molding dies, it is provided so as to be movable back and forth in the direction toward the other molding die and elastic toward the other molding die. The tip of a part of the molding surface of the other molding die is biased by a predetermined distance inward from the inner peripheral end surface of the hole formed in the base material in the middle of the approach of the two molding dies. Is elastically pressed and the molten resin to be pressed is provided with a movable blocking piece for blocking inward flow beyond the predetermined distance from the inner peripheral end surface of the hole. Manufacturing equipment. 6. The apparatus for manufacturing a laminate according to claim 5, wherein the movable blocking piece is provided on the skin material side molding die. 7. The apparatus for manufacturing a laminate according to claim 5, wherein the movable block piece is provided on the base material side mold.