JPH09300375A - Manufacture of laminate having surface soft in touch - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a laminate constituted so that a base material is increased in foaming degree especially on its skin side and having a surface soft in touch. SOLUTION: The space between a skin material 25A composed of a synthetic resin molded into a sheet shape and molded into the shape coming into close contact with the molding surface 16 of a mold 15 on a skin side and the molding surface 11 of a mold 10 on a base material side made possible to approach and separate from the mold 15 is filled with a molten synthetic resin 20A becoming a base material 20 to produce a laminate. In this case, a foaming agent is premixed with the molten synthetic resin and, in such a state that both molds are allowed to mutually approach the most approach position, the space between the molding surface of the mold 10 and the skin material closely brought into contact with the molding surface of the mold 15 is filled with the molten synthetic resin under pressure and both molds are mutually separated by a slight distance immediately after compression filling. The skin material is pref. formed by preliminarily laminating and bonding a sheet like soft surface layer 25a and a foam layer 25b.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminate used for door trims and interior materials for automobiles, interior materials for buildings, exterior materials for furniture, and the like, and more particularly to a method for producing a laminate having a surface having a soft feeling.

[0002]

2. Description of the Related Art An example of a conventional method for producing a laminate having such a soft-feeling surface is shown in FIGS. As the skin material 6A that is formed into the skin 6, as shown in FIG. 7, a surface layer 6a made of a thin synthetic resin sheet with a foam layer 6b laminated and bonded in advance on the back surface thereof is used. First,
The molten synthetic resin 5A from the resin supply device 4 is shown in FIG.
As shown in FIG. 3, the resin is supplied onto the molding surface 1a through the resin supply passage 3 formed in the lower mold 1 as shown by the chain double-dashed line.
As shown in the alternate long and two short dashes line, the skin material 6A whose periphery is supported by the holding frame 7 is placed on the lower mold 1 and then the upper mold 2 is lowered to bring the two molds 1 and 2 into the closest state as shown in FIG. As
The synthetic resin 5A in a molten state is spread between the lower mold 1 and the skin material 6A to be compressed and filled, and at the same time, the skin material 6A is molded into a shape in which it is in close contact with the molding surface 2a of the upper mold 2. After cooling until the skin 6 hardens, the upper mold 2 is lifted to take out the laminate A. Instead of covering the lower mold 1 with the skin material 6A, the molding surface 2a is formed by a negative pressure applied through a large number of suction pipe lines (not shown) opening to the molding surface 2a of the upper mold 2.
Alternatively, the upper mold 2 may be lowered to bring it into the closest state.

[0003]

However, in such a molding method, the skin material 6A is stretched and pressed from both sides during molding, and the foamed layer 6b side is in contact with the synthetic resin 5A in a molten state. As a result, the foam layer 6b of the skin material 6A is crushed and the soft feel of the surface of the skin 6 is reduced. For example, in a door trim of an automobile, since the armrest portion B projects, the skin material 6A that covers this portion is particularly greatly stretched. For this reason, as shown in an enlarged view in FIG. 7, the skin 6 covering such an armrest portion B has a thin foam layer 6b, so that the soft feel of the surface is deteriorated and the flexibility of the armrest surface Ba, which is most required, is reduced. There is a problem that the soft feeling is lost.
It is an object of the present invention to solve each of these problems and produce a laminate having a surface having a soft feeling.

[0004]

A method for producing a laminate having a surface having a soft feel according to the present invention is a synthetic resin formed in a sheet shape in advance and is formed into a shape that is in close contact with a forming surface of a skin side forming die. A synthetic resin in a molten state, which is a base material, is filled between a flexible skin material that becomes a skin and a molding surface of a base material-side molding die that can approach and separate from the skin-side molding die. In the method for manufacturing a laminate, a foaming agent is mixed in advance with a synthetic resin in a molten state, and the synthetic resin in a molten state is used as a molding surface of a base material side molding die in a state where both molding dies are brought close to each other. The base material side molding die and the skin side molding die are slightly separated from each other by compression filling between the skin materials which are closely adhered to the molding surface of the skin side molding die, and immediately after this compression filling.

Although the synthetic resin in a molten state compressed and filled between the molding surface of the base-side molding die and the skin material adhered to the molding surface of the skin-side molding die is not yet hardened immediately after the compression filling. While the side opposite to the skin material side comes into direct contact with the base material side molding die to be cooled, the skin material side made of synthetic resin does not come into direct contact with the skin side molding die and heat transfer is hindered and cooled. Therefore, the temperature of the synthetic resin as the base material becomes higher on the skin material side. Therefore, in this state, if the base material side mold and the skin side mold are separated from each other by a certain distance, the foaming agent of the molten synthetic resin foams and becomes soft, and especially the skin material side foams greatly. It is highly flexible.

The skin material is preferably made by laminating and adhering in advance a sheet-like flexible surface layer on the skin side forming die side and a sheet-like flexible foam layer on the substrate side.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments in which the method for manufacturing a laminate having a surface having a soft feeling according to the present invention is applied to the manufacture of automobile door trim will be described below with reference to FIGS. The door trim A manufactured according to this embodiment has an armrest projecting portion B having an armrest surface Ba, which is required to have flexibility, formed on one side. As shown mainly in FIGS. 1 to 3, a manufacturing apparatus used in this embodiment is a lower mold (base material side molding die) 10 attached to a fixed side die supporting member (not shown) at a lower portion of the molding apparatus.
And an upper die (skin side shaping die) 15 attached to a movable side die supporting member (not shown) above the shaping apparatus.
A molding surface 11 for molding the back surface of the base material 20 of the door trim A is formed on the upper surface of the lower mold 10. The resin supply passage 12 formed in the lower die 10 is branched into a plurality of branch passages 12a, each tip of which is opened to the molding surface 11, and the resin supply passage 12 is formed.
Resin supply device (only part of the tip is shown) at the supply port of 1
The tip ends of 3 are joined and the molten synthetic resin 20A is supplied. A heater for heat retention may be provided around the resin supply passage 21 and the branch passage 21a.

Upper mold 1 attached to movable mold supporting member
5 is capable of approaching and separating from the lower mold 10 from above.
Shows the separated state, FIG. 2 shows the closest state, and FIG. 3 shows the state slightly retracted from the closest state. A molding surface 16 having a shape corresponding to the surface shape of the skin 25 of the door trim A is formed on the lower surface of the upper mold 15. Lower mold 10 and upper mold 15
The outer peripheral surface of each of the molding surfaces 11 and 16 is joined to each other via the skin material 25A in the closest state.
16a are formed. In the illustrated embodiment, the door trim A, which is a laminated body, is arranged to be inclined in order to give the armrest surface Ba a soft feel, but depending on the shape of the laminated body A, it is not necessary to arrange such an inclination. .

The synthetic resin 20A, which is supplied from the resin supply device 13 in a molten state and serves as the base material 20, is a thermoplastic resin having a relatively high elasticity such as polypropylene, and is of an additive polyacid type (for example, polythrene EE-205 (5)). (Showa Denko KK
A foaming agent having a relatively slow reaction such as a product name)) is mixed in advance. The skin material 25A serving as the skin 25 is a thin sheet-like surface layer 25 made of a solid layer of a flexible synthetic resin.
a (for example, a thermoplastic plastic olefin resin sheet having a thickness of 0.35 mm) and a sheet-shaped foam layer 25b (for example, a heat-resistant polyethylene foam sheet having a thickness of 2 mm) made of a flexible synthetic resin foam material are laminated in advance. It is a sheet formed by bonding. On the surface of the surface layer 25a of the skin material 25A, in order to enhance the design effect,
Grains such as leather patterns are formed.

Next, the manufacturing method of this embodiment will be described with reference to FIGS. The lower mold 10 and the upper mold 15 are 50 to 8 in advance.
The temperature is adjusted to 0 ° C. First, as shown in FIG.
In a state where the upper die 15 is separated from the lower die 10 upward, the molten state (180 to 200
The synthetic resin 20A of (.degree. C.) passes through the resin supply passage 12 and the plurality of branch passages 12a and is supplied in a lump form onto the molding surface 11 of the lower mold 10. The discharge pressure of the resin supply device 13 and the resin supply passage 1 are adjusted so that the discharge amount of the molten synthetic resin 20A is slightly larger than the volume of the base material 20 to be molded.
2 and the size of the branch passage 12a and a valve (not shown) provided in a part of the supply passage. In this state,
The foaming agent mixed in the synthetic resin 20A is slightly foamed.

Next, the periphery of the lower mold 10 having the molten synthetic resin 20A supplied on the molding surface 11 has a holding frame 26.
The sheet-like skin material 25A supported by is covered (see the prior art in FIG. 5). The skin material 25A may be softened by heating with a far infrared heater or the like. And FIG.
The upper mold 15 is lowered toward the lower mold 10 until it comes to the closest position as shown in FIG. 2, and the molten synthetic resin 20A is spread between the lower mold 10 and the skin material 25A for compression filling, and at the same time, the skin is The material 25A is formed into a shape that is in close contact with the forming surface 16 of the upper mold 15. In this state, both types 10 of skin material 25A,
A portion of the outer side of the molding surfaces 11 and 16 of 15 is thinly compressed by the joint surfaces 11a and 16a of the two molds 10 and 15, and the extra molten synthetic resin 20A is attached to the joint surface 11a of the lower mold 10 and the skin material. It is discharged to the outside from between 25A.

The skin material 25A, the periphery of which is held by the holding frame 26, is heated by a far infrared heater or the like to be softened, and then abutted on the bonding surface 16a around the upper die 15 and opened to the molding surface 16. Apply negative pressure to the road (not shown),
After molding the skin material 25A into a shape in which it is in close contact with the molding surface 16, the upper mold 15 is lowered to spread the molten synthetic resin 20A between the lower mold 10 and the skin material 25A for compression filling. Good. In any case, the skin material 25A is stretched and pressed from both sides during this molding,
Further, since the foam layer 25b is heated by the molten synthetic resin 20A in contact therewith, as shown in the partially enlarged cross-sectional view of FIG. 4 (a), the skin material 25A becomes thin due to the collapse of the foam layer 25b. The soft feel of the surface is reduced.

Immediately after this compression filling (for example, 0.5 to 2 seconds), as shown in FIG. 3, the upper mold 15 is slightly moved up (for example, 1 to 2 mm) to separate the molds 10 and 15 from each other. Then, the distance between the molding surfaces 11 and 16 is slightly increased. In the state immediately after the compression filling, the synthetic resin 2 in the molten state that is compression filled between the lower mold 10 and the skin material 25A.
Although 0A is not yet hardened, the synthetic resin 20A has a side opposite to the skin material 25A and directly contacts the lower mold 10 made of metal to be rapidly cooled, while the upper mold 15 side is made of synthetic resin. Since the material 25A side is interposed and does not directly contact the upper mold 15, heat transfer is hindered and cooling is delayed,
The temperature is higher on the side provided with the skin material 25A. Therefore, by slightly increasing the distance between the molding surfaces 11 and 16 of the two molds 10 and 15, the foaming agent mixed in the uncured synthetic resin 20A foams. As shown in (b), the skin material 25A side is larger, and the flexibility of that portion is increased.

In this state, the molded synthetic resin 20A and the skin material 25A are cooled until they are hardened, and then the upper mold 15 is raised to make the door trim A composed of the base material 20 and the skin 25.
Take out. As shown in FIG. 4, in the skin material 25A, since the foam layer 25b is crushed, the soft feeling due to the skin 25 itself is deteriorated, but the base material 20 has a large degree of foaming in a portion immediately behind the skin 25. As a result, the softness of the outer skin 25 itself is lowered by the increase in the flexibility of the base material 20, and the feel of the surface of the obtained door trim A becomes considerably soft.

In the above embodiment, the armrest surface Ba
Since the door trim A is arranged so as not to be parallel to the moving direction of the upper mold 15, the foaming degree of the base material 20 in the portion immediately behind the armrest surface Ba where flexibility is most required is increased. You can In this case, the side of the armrest portion B opposite to the armrest surface Ba (see FIG.
The surface on the right side of the figure approaches the direction parallel to the moving direction of the upper mold 15, so that the degree of foaming decreases and the soft feel of the surface is lost, but the flexibility of this part is not required in the door trim A. So it won't be a problem.

Further, in the above embodiment, the molten synthetic resin is supplied onto the molding surface of the lower mold through the resin supply passage formed in the lower mold, but the resin provided so as to move above the lower mold. The material may be supplied in the form of a lump or a sheet thicker than the base material from the discharge port of the supply device onto the molding surface. Alternatively, instead of supplying the synthetic resin in a molten state onto the molding surface of the lower mold, lowering the upper mold to the closest state and spreading it between the lower mold and the skin material to perform compression filling, After sandwiching the skin material between them, the upper mold is lowered to the closest state and clamped, and then the molten synthetic resin is injected between the lower mold and the skin material from the resin supply passage provided in the lower mold and compressed. It may be filled. Even in these cases, immediately after compression filling, the upper mold is slightly moved up a distance to foam the synthetic resin in a molten state, cooled until the synthetic resin and the skin material are hardened, and then the upper mold is lifted to form a base material. It goes without saying that the laminate consisting of the skin is taken out.

[0017]

As described above, according to the present invention, since the base material has a particularly large degree of foaming on the epidermis side to increase the flexibility, the feel of the epidermis surface of the obtained laminate is only the epidermis. A softer feel is obtained than that of.

According to the one using the skin material in which the surface layer and the foam layer are laminated and adhered in advance, the obtained laminate has a softer surface feel as much as the foam layer.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of an embodiment of a method for producing a laminate having a soft-feeling surface according to the present invention in a state where a base material side mold and a skin side mold are separated from each other.

FIG. 2 is a cross-sectional view of the embodiment shown in FIG. 1 in a state where a base material side mold and a skin side mold are closest to each other.

FIG. 3 is a cross-sectional view of the embodiment shown in FIG. 1 in a state where the base material side mold and the skin side mold are slightly retracted from the closest position.

FIG. 4 is a partially enlarged sectional view of the state shown in FIGS. 2 and 3, respectively.

FIG. 5 is a cross-sectional view of a method for manufacturing a laminate having a soft-feeling surface according to a conventional technique in a state where an upper die and a lower die are separated from each other.

FIG. 6 is a cross-sectional view of the conventional technique shown in FIG. 5 in a state where the upper die and the lower die are closest to each other.

FIG. 7 is a partial enlarged cross-sectional view of the laminate having a soft-feeling surface manufactured by the conventional technique shown in FIG.

[Explanation of symbols]

10 ... Base material side molding die (lower mold), 11 ... Molding surface, 15 ... Skin side molding die (upper mold), 16 ... Molding surface, 20 ... Base material, 20
A ... synthetic resin in a molten state, 25 ... skin, 25A ... skin material, 25a ... surface layer, 25b ... foam layer.

Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI Technical display location B60R 13/02 B60R 13/02 B E04F 13/18 8913-2E E04F 13/18 A // B29K 105: 04 B29L 9:00 31:10 31:58 (72) Inventor Kazunori Sada 25 Kamifujiike, Yoshihara-cho, Toyota-shi, Aichi Arako Co., Ltd.

Claims (2)

[Claims] 1. A flexible skin material, which is made of a synthetic resin that has been molded into a sheet shape in advance, and is molded into a shape that comes into close contact with the molding surface of the skin-side molding die to form a skin, and a separation distance from the skin-side molding die. In a method for manufacturing a laminate, in which a molten synthetic resin serving as a base material is filled between the molding surfaces of a possible substrate-side molding die, a foaming agent is mixed in advance with the molten synthetic resin. Between the molding material of the base material side molding die and the skin material which is in close contact with the molding surface of the skin side molding die in a state where the two molding dies are brought close to each other to the closest position. A method for producing a laminate having a surface having a soft touch, wherein the base material side mold and the skin side mold are separated from each other by a slight distance immediately after the compression filling. 2. The skin material is obtained by laminating and adhering a sheet-like flexible surface layer on the skin side forming die side and a sheet-like flexible foam layer on the base material side in advance. 2. A method for producing a laminate having a soft-feeling surface according to 1.