JPH09309143A - Manufacture of laminate with fitting skin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the appearance quality by bonding a chanel of a fitting section viewed from the skin side of a laminate with a fitting skin. SOLUTION: A sheet-shaped skin material 25A forming a skin 25 is bonded on the surface of a preformed base 20 to cover the surface, and simultaneously a skin material is fitted into a fitting channel 21 formed on the base to manufacture a laminate. The skin material is formed of a sheet-shaped flexible surface layer 25a laminated and bonded with a back layer 25b composed of a sheet- shaped synthetic resin into which a foaming agent is mixed but not foamed yet or forming is suspended half way, and the skin material is fixed and fitted on the surface of the base so that the back layer is formed on the base material side, and then at least the fitting section of the back layer is heated and foamed to increase the back layer thickness, and a channel on the fitting section viewed from the skin side is bonded.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a laminate having a grained skin used for door trim and interior materials of vehicles, interior materials of buildings, exterior materials of furniture, and the like.

[0002]

2. Description of the Related Art In order to produce a laminate having a wood grained skin of this type, for example, an adhesive is first sprayed on the front side and a substrate which has been once dried is placed on a vacuum forming mold, and then a flexible substrate is formed. A synthetic resin is preliminarily formed into a thin sheet, and the periphery of the skin material is held by a holding frame, which is heated by a far infrared heater or the like to be softened and then lowered to abut on the base material and the upper outer peripheral portion of the vacuum forming die. Negative pressure is applied to a large number of intake pipes provided in the vacuum forming die to suck the skin material and adhere it to the entire surface of the base material. Due to this suction, a part of the skin material enters the wood grain groove formed on the surface of the base material and is grained. As the skin material, a sheet-shaped flexible surface layer and a sheet-shaped synthetic resin foam back layer are laminated and adhered so as to give a soft touch to the surface of the laminate.

[0003]

In order to allow the skin material to be wood-grained to the depth of the wood-grain groove when such wood-graining is performed, the width of the wood-grain groove must be increased to some extent. There is a problem that the width of the groove formed on the surface side of the grained portion of the formed skin becomes large and the groove bottom can be seen (see symbol B in FIG. 2), and the appearance quality is deteriorated. If the width of the wood grain groove is reduced to avoid this, it becomes difficult for the skin material to enter the bottom of the wood grain groove, so that the skin material floats at least at a part of the wood grain part, and the appearance quality also deteriorates. Occurs.

[0004] In order to manufacture a laminate having a grained skin, in addition to the above-described vacuum forming method, an upper mold having a molding surface having the same shape as the surface of the completed skin and a grained ridge is used. There is also a method in which the skin material is pressed to perform graining and bonding. However, since the wood grain ridge cannot be made too thin, the problem that the width of the groove formed in the wood grain part of the adhered skin becomes large and the groove bottom is visible and the appearance quality deteriorates is still unavoidable. An object of the present invention is to solve such a problem.

[0005]

According to the method for producing a laminate having a grained skin according to the present invention, a sheet-shaped skin material serving as a skin is adhered to the surface of a preformed base material to cover it. At the same time, in the method for producing a laminate having a grained skin formed by graining a grain material in a grain groove formed in the base material, the grain material does not contain a sheet-like flexible surface layer and a foaming agent. A back layer made of synthetic resin in the form of a sheet of foamed or suspended foaming was laminated and adhered, and a skin material was fixed to the surface of the base material so that the back surface layer was the base material side, and wood grain was applied. After that, at least the wood-grained portion of the back surface layer is heated to foam.

The width of the wood grain groove formed in the base material is set to a value that is necessary and sufficient for the skin material to be wood grained to the depth of the wood grain groove when the wood grain is grained. Accordingly, immediately after the skin material is fixed to the surface of the base material with the wood grain, the width of the groove formed on the surface side of the grain surface of the fixed skin is large.
However, by heating and foaming at least the wood-grained portion of the back surface layer of the skin material, the thickness of the back surface layer at that portion is increased, so that the width of the groove of the wood-grained portion is narrowed or adhered.

It is assumed that the back surface layer of the skin material has foaming interrupted halfway, and after the skin material is fixed to the surface of the base material and the wood is grained, only the wood-grained portion of the back surface layer is heated to further foam. Is preferred. Further, in this case, it is preferable that the heating of the wood-grained portion of the back surface layer is performed by a heater provided in the vicinity of the support-type wood-groove groove that supports the back surface of the base material.

In the present invention, the surface material may be fixed to the surface of the base material and the surface of the back surface layer may be heated and then foamed. Further, in this case, the back surface layer of the skin material may be one in which foaming is interrupted halfway.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention applied to a vehicle door trim will be described below with reference to the accompanying drawings. The door trim formed by the present invention has a substantially constant wall thickness, and is formed by covering the surface of a rigid base material 20 with a thin flexible skin 25. For example, in the case of a door trim having vertical and horizontal dimensions of about 600 mm × 900 mm, the wall thickness of each part is 2.5 to 3.0 mm for the base material 20 and 3.35 mm or less for the skin 25, so that the entire door trim is 5.85 to 6.35 mm. Is.

The base material 20 of the door trim of this embodiment is a porous and air-permeable material, which is hot-press molded by mixing about 7% phenol resin as a binder into finely crushed wood fibers. And its surface is 2
For example, a straight wood grain groove 21 is formed into two parts. The width of the wood grain groove 21 is, for example, 8 mm, and is set to a width that is necessary and sufficient for the skin material 25A to be described later to be bonded to the depth of the wood grain groove 21 when the wood grain is to be described later. The base material 20 may be made of synthetic resin having a large number of small holes for providing air permeability or a large number of irregularities on the surface.

Further, the surface skin 25 is adhered to the surface of the base material 20.
The skin material 25A is a thin sheet-like surface layer 25a (for example, a polypropylene resin sheet having a thickness of 0.35 mm, a vinyl chloride resin sheet, or the like) made of a solid layer of a flexible thermoplastic resin, and a foaming agent (for example, an additive polyacid). A thin back surface layer 25b made of a relatively elastic sheet-like thermoplastic resin (for example, a polyurethane resin sheet having a thickness of 2 to 3 mm) in which foaming is interrupted midway. It is laminated and bonded to form a sheet. Foaming of the back surface layer 25b is interrupted at about half, and the foaming rate is, for example, about 15 times. Grains such as leather patterns are formed on the surface of the surface layer 25a of the skin material 25A in order to enhance the design effect.

As shown mainly in FIG. 1, a vacuum forming die (supporting die) 10 used in this embodiment is attached to a lower supporting member (not shown) of a forming apparatus, and the vacuum forming die 1 is used.
The upper surface of 0 has a support surface 1 having a shape that matches the back surface of the base material 20.
1 and an outer peripheral surface 11a extending to the outside thereof are formed.
A groove portion 1 for receiving a ridge protruding to the back side of the base material 20 corresponding to the wood grain groove 21 on the supporting surface 11 of the vacuum forming die 10.
2 is formed, and the base 20 is supported by the entire support surface 11. Further, a large number of intake pipe lines 16 (only a part of which are shown in the drawing) provided in the vacuum forming die 10 are provided on the support surface 11
The intake pipe lines 16 are connected to a vacuum source 17 including a vacuum pump, a vacuum tank, and an opening / closing valve through a collecting pipe line 15 so that the intake pipe lines 16 are substantially uniformly distributed and opened. The vacuum forming die 10 has a heater 13 along the entire length of the groove 12.
Is provided. In the illustrated embodiment, the heater 13 is an electric heater using a ceramic heating element, but it may be a pipe or the like formed in the vacuum forming mold 10 along the groove 12 and passing heating steam. As will be described later, the heater 13 does not necessarily have to be provided in the vacuum forming die 10.

Next, the manufacturing method according to this embodiment will be described with reference to FIGS. First, an adhesive is applied to the entire surface of the base material 20 by spraying or the like, and after being dried to some extent, the entire back surface of the base material 20 is brought into contact with the supporting surface 11 of the vacuum forming mold 10 and set on the vacuum forming mold 10. . Next, the periphery of the skin material 25A composed of the front surface layer 25a and the back surface layer 25b in which foaming is interrupted is held by the holding frame 29, and is heated (for example, 120 ° C.) by a far infrared heater to be softened. In this state, foaming of the back surface layer 25b of the skin material 25A remains suspended halfway, and further foaming has not been performed yet.

Then, the holding frame 29 is lowered to bring the peripheral portion into contact with the outer peripheral surface 11a of the support surface 11, and then the vacuum source 17
Negative pressure is applied to the lower side of the skin material 25A through the collecting pipe line 15, the intake pipe line 16 and the air-permeable base material 20, and as shown in the two-dot chain line of FIG. 1 and FIG. Is molded into a shape along the surface of the base material 20 and simultaneously bonded. As described above, the wood grain groove 21 formed in the base material 20.
Has a width that is necessary and sufficient for the skin material 25A to be glued to the depth of the wood material.
A groove having a considerable width is formed on the surface side of the portion bonded to the wood grain groove 21 with the wood grain, as shown by reference numeral B in FIG.

Then, for a short time (for example, 15 seconds), the heater 1
3 is energized to locally heat (for example, 140 ° C.) the portion of the back surface layer 25b of the skin material 25A near the wood-grained portion in the wood-grained groove 21 to further foam this portion. This increases the foaming rate of the back surface layer 25b in the vicinity thereof (for example, 30
As a result, the groove formed on the surface side of the surface skin 25 of the grained portion is brought into close contact, as shown in FIG.
After the skin material 25A adhered onto the base material 10 is cooled to some extent, the negative pressure from the vacuum source 17 to the intake pipe line 16 is removed,
When the base material 20 is removed from the vacuum forming die 10, the surface skin 25 is adhered to the surface of the base material 20, and a door trim in which the groove of the wood grain portion viewed from the skin side is closely attached is obtained.

In the above-described embodiment, the heater 13 provided in the vacuum forming die 10 heats the back surface layer 25b of the skin material 25A for further foaming the wood-grained portion in the wood-grained groove 21. Instead of providing such a heater 13 in the vacuum forming mold 10, heating steam or heating air may be blown along the portion indicated by the symbol B in FIG. 2 to cause such foaming.

Further, in the above-described embodiment, the adhesion of the skin material 25A to the base material 20 and the graining are performed by vacuum molding, but the molding surface and the grain-forming ridge having the same shape as the surface of the completed skin 25 are provided. Skin material 2 depending on the upper mold
It is also possible to press 5A to perform graining and adhesion. In this case, the back surface layer 25b of the skin material 25A has a wood-groove 2
Local heating in the vicinity of the grained part in 1 is performed after raising the upper mold. If the surface roughness of the base material 20 is sufficiently large, the adhesion of the skin material 25A to the base material 20 is also performed by the anchor effect of the back surface layer 25b penetrating into the fine gaps on the surface of the base material 20. Application is not always necessary.

Further, according to the present invention, the skin material 2 is formed on the surface of the base material 20.
The heating of the back surface layer 25b after the 5A is bonded with wood grain may be performed by heating not only the wood grain-filled portion of the back surface layer 25b but also the entire surface of the back surface layer 25b. In this case, the back surface layer 2 of the skin material 25A
5b may contain a foaming agent but may be unfoamed. The heating in this case may be performed by a heater provided in the vacuum forming die 10 or may be performed by blowing heated steam or heated air from the skin 25 side.

[0019]

As described above, according to the present invention, even if the width of the wood grain groove is set to a value that is necessary and sufficient for the skin material to be wood grained to the depth of the wood grain groove, the skin to be formed after that. The width of the groove formed on the skin surface side of the wood grain part is narrowed or adheres due to the foaming of at least the wood grain part of the back surface layer of the material, so that the wood grain is completely completed and the appearance quality of the wood grain part is improved. To do.

If the foaming of the back surface layer of the skin material is interrupted midway, even if only the wood-grained portion of the back surface layer is foamed, the surface of the skin can be made completely flexible. Further, in this case, if the heating of the wood-grained portion of the back surface layer is performed by a heater provided in the vicinity of the support-type wood-grooving groove that supports the back surface of the base material, such heating can be performed easily. it can.

[Brief description of drawings]

FIG. 1 is an overall cross-sectional view illustrating one embodiment of a method for manufacturing a laminate having a wood grained skin according to the present invention.

FIG. 2 is a partially enlarged cross-sectional view of the embodiment shown in FIG. 1 during a process.

FIG. 3 is a partial enlarged cross-sectional view of the embodiment shown in FIG. 1 at the time of completing the process.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... Support type | mold (vacuum forming type), 13 ... Heater, 20 ... Base material, 21 ... Groove groove, 25 ... Skin, 25A ... Skin material,
25a ... front surface layer, 25b ... back surface layer.

Claims (5)

[Claims] 1. A wood grain formed by fixing a sheet-shaped skin material serving as a skin on a surface of a preformed base material to cover the same, and at the same time, to grind the skin material into a wood grain groove formed in the base material. In the method for producing a laminate having a skin, the skin material is a back surface made of a sheet-shaped synthetic resin in which a sheet-shaped flexible surface layer and a foaming agent are mixed, but which is unfoamed or foaming is interrupted midway. Layers are laminated and adhered, and the skin material is fixed to the surface of the base material so that the back surface layer is on the base material side and then wood-grained, and then at least the wood-grained portion of the back surface layer is heated. A method for producing a laminate having a wood-embedded epidermis, the method comprising: 2. The back surface layer of the surface material is formed by suspending foaming in the middle, and after the surface material is fixed to the surface of the base material and the wood material is wood-grained, only the wood-grained portion of the back surface layer is formed. The method for producing a laminate having a grained skin according to claim 1, wherein the laminate is heated for further foaming. 3. The wood grain of claim 2, wherein the heating of the wood grained portion of the back surface layer is performed by a heater provided in the vicinity of the wood grain groove of a supporting type that supports the back surface of the base material. A method for producing a laminate having an embedded skin. 4. The laminate having a grained skin as claimed in claim 1, wherein the surface material is fixed to the surface of the base material and grained, and then the entire back surface layer is heated to foam. Body manufacturing method. 5. The method for producing a laminate having a grained skin according to claim 4, wherein the back surface layer of the skin material has foaming interrupted halfway.