JPH0952246A - Production of laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate such as a door trim in which the base material and a skin medium are unified in a simple process without forming the skin medium into a sheet shape and to prevent the appearance of the finished laminate from being deteriorated by preventing formation of a flow mark on the surface of the skin medium. SOLUTION: A base material 11 formed into the shape of a door trim is set on a top force 32. On one side, molten resin 12melt is supplied to a bottom force 31 adjusted at a temperature of a prescribed range. Molten resin 12melt is spread on the surface of the base material 11 by overlapping and pressing the top force 32 and the bottom force 31, solidified and molded and simultaneously both the base material 11 and the surface material 12 are stuck. Sticking of the base material and the skin medium is performed by a bonding means, a melt-sticking means and a means for utilizing anchor effect.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a laminated body used for a vehicle door trim, a vehicle interior material, an indoor interior material and the like.

[0002]

2. Description of the Related Art As a laminate used for the above-mentioned applications, 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, or a foamed layer is formed on the base material. It is known that a resin layer is coated with the resin. As a specific example of such a laminated body, a door trim in which a skin sheet is applied to the entire surface of a base material made of a wooden hardboard formed in the shape of a door trim, or a foamable sheet is bonded to the surface of the base material, There is a door trim in which the base material and the foamable sheet are entirely covered with a skin sheet.

In the process of manufacturing the above-described door trim in which the surface of the base material is covered with a skin sheet, first, as shown in FIG.
As shown in (a), the base material 71 is attached to the lower die 7 of the vacuum forming die.
5, the surface is provided with a predetermined design pattern, and a sheet-shaped skin sheet 72 is disposed on the base material 71 and pressed between the upper mold 76 and the lower mold 75. As a result, the base material 71 and the skin sheet 72 are bonded and integrated with the adhesive. After the two members 71 and 72 have been bonded and integrated in this manner, the skin sheet 72 is cut so that its ends are slightly protruded from the base material 71, as shown in FIG. 7B. The protruding portion 72 of the skin sheet 72
a is the base material 7 as shown in FIG.
The adhesive treatment is performed so that the end portion of 1 is rolled up, and the skin sheet 7
2 is formed so as not to protrude and spoil the appearance.

Further, in the above-described method of manufacturing a door trim having a foamable sheet between a base material and a skin sheet, as shown in FIG. 8A, a foamable sheet 83 is attached to a base material 81. A skin sheet 84, which is formed into a sheet with a predetermined design pattern on the surface, is placed on the foamable sheet 82, and pressed between a lower die 85 and an upper die 86 of a vacuum forming die. By doing so, the base material 81, the foamable sheet 82, and the skin sheet 83 are bonded and integrated with an adhesive. After the three members 81, 82, and 83 have been integrated in this way, the skin sheet 83 has its protruding portion 8 as shown in FIGS. 8B and 8C, as described above.
3a is processed.

[0005]

In the conventional door trim manufacturing method described above, the skin sheet 72 to be adhered to the base material 71, and the foamable sheet 82 and the skin sheet 83 to be adhered to the base material 81 are formed into a sheet shape in advance. Must be molded and therefore the skin sheet 72,
There is a problem in that a separate device and process for molding 83 and the foamable sheet 82 are required, and the number of a series of manufacturing devices and manufacturing processes increases and becomes complicated.

Therefore, the applicant first supplies a molten resin material serving as a skin material to the surface side of a base material set between a pair of molding dies, and subsequently polymerizes and presses both molding dies. A method for producing a laminate by spreading a molten resin material over the entire surface of a substrate and curing it (Japanese Patent Application No. 6-1360).
No. 72 and Japanese Patent Application No. 6-164106), or by supplying a foamable molten resin-based material as a skin material to the surface side of a base material set between a pair of molding dies, and subsequently polymerizing both molding dies. The expandable molten resin-based material is spread over the entire surface of the base material by pressing with a press and the molds are separated by a predetermined amount to foam the expandable molten resin-based material, and a foam layer is formed on the skin material. And method for producing a laminate having a skin layer (Japanese Patent Application No. 6-161594 and Japanese Patent Application No. 6-16)
No. 4106) is proposed.

However, according to this method, the temperature of the surface side of the substrate to which the molten resin-based material or the expandable molten resin-based material is supplied, that is, the temperature of the surface of the substrate and the molding surface of the molding die is usually low. The molten resin-based material or the foamable molten resin-based material supplied to these surfaces will be cooled. Then, in this state, when both molds are polymerized to spread the molten resin-based material to form a skin material, a flow mark, which is a mark of resin flowing on the surface of the finished skin material, may be formed. There has been a problem that the appearance as a product is impaired.

[0008]

SUMMARY OF THE INVENTION Therefore, the present invention has been made to solve the above problems, and is to manufacture a laminated body such as a door trim by a simple process without forming a skin sheet or a foamable sheet into a sheet shape. Another object of the present invention is to provide a method for producing a laminated body, which can prevent flow marks from being formed on the surface of the skin material and prevent the finished laminated body from being damaged in appearance.

[0009]

A common feature of the present invention, which has been made to achieve the above object, is a laminate comprising a base material and a skin material which entirely covers the front surface of the base material. In the manufacturing method, the base material is set on the molding surface of the upper mold, and a molten resin material serving as the skin material is supplied to the molding surface of the lower mold adjusted to a predetermined temperature to supply the upper mold and the lower mold. This is to press between the molds to spread the molten resin-based material to solidify it, and at the same time to fix the base material and the skin material.

According to the present invention described in claim 1,
Adhesion is adopted as a means for fixing the base material and the skin material.

Further, in the present invention as set forth in claim 2, the expandable molten resin material is employed as the molten resin material which becomes the skin material, and the skin material is the same foamable molten resin material between the pair of molding dies. A foam layer on which the expandable molten resin material on the base material side is formed and cured by spreading the material over the entire surface of the base material and then separating the pair of molding dies by a predetermined amount, and on the foam layer The foamable molten resin material is characterized by comprising a skin layer that is cured without foaming, and adopts adhesion as a means for fixing the base material and the skin material.

The present invention according to claim 4 is characterized in that a base material made of a resin material is used as the base material, and welding is used as a means for fixing the base material and the skin material. .

Further, in the present invention described in claim 5, a base material made of a resin-based material is used as the base material, and a foamable molten resin-based material is used as the molten resin-based material as the skin material. The skin material is formed by pressing the foamable molten resin material between the pair of molds over the entire surface of the substrate and then separating the pair of molds by a predetermined amount. A resin layer is formed of a foam layer that is foamed and cured, and a skin layer in which the foamable molten resin material on the foam layer is cured without foaming, and welding is performed as a means for fixing the base material and the skin material. It is characterized by being adopted.

Further, in the present invention as set forth in claim 7, the porous base material is used as the base material, and the adherence between the porous base material and the skin material spreads over the entire surface of the porous base material. The obtained molten resin material is solidified and molded in a state where at least the front side inside the porous substrate is impregnated.

Further, in the present invention described in claim 8, a porous base material is used as the base material, a foamable molten resin-based material is used as the molten resin-based material to be the skin material, and the skin material is , A foaming property on the side of the porous base material formed by pressing the foamable molten resin material between the pair of molding dies over the entire surface of the porous base material and then separating the pair of molding dies by a predetermined amount. The molten resin-based material comprises a foamed layer that is foamed and hardened, and a skin layer that is the same foamable molten resin-based material on this foamed layer that has hardened without foaming, and that the porous base material and the skin material are fixed together. It is characterized by being solidified and molded in a state where at least the front side inside the porous substrate is impregnated.

The manufacturing method described in claim 1 or claim 2 or claim 7 or claim 8 is characterized in that the base material is made of a resin material or a wood material. Further, claim 4 or claim 5, or claim 7
Alternatively, in the manufacturing method according to claim 8, the surface of the base material is treated with a surface modifier before the molten resin material serving as the skin material is supplied. Further, the laminated body of the present invention is preferably a vehicle door trim or a vehicle interior material.

[0017]

According to the method for producing a laminate of the present invention thus constructed, the base material is set in the upper mold and the resin material constituting the skin material is melted on the molding surface of the lower mold. It is supplied, and since the molten resin-based material is solidified and molded between these molds, the base material and the skin material are fixed at the same time,
It is not necessary to form the skin material in a sheet shape in advance, and a laminated body such as a door trim can be manufactured by a simple process.

Further, in the present invention, the temperature of the lower mold is cooled when the molten resin-based material or the expandable molten resin-based material supplied to the molding surface of the lower mold is spread by a press, and the finished skin material is obtained. Since the flow mark, which is a mark of the resin flowing on the surface of, is adjusted within a predetermined range, the appearance of the manufactured laminate as a product is not impaired.

As a means for fixing the base material and the skin material, for example, when the base material is a wood-based base material or a material such as metal or resin which is not suitable for welding, an adhesion means using an adhesive may be adopted. Alternatively, when the base material is made of a weldable resin, a welding means may be used. Fixing by welding is particularly preferable because it is not necessary to use an adhesive.

Further, when the substrate is a porous substrate,
At least the surface of the porous base material is directly impregnated with the resin-based material that constitutes the surface material, and is cured, that is, it can be fixed using the anchor effect. In the laminated body manufactured using this fixing means, only two materials constituting the skin material and the porous base material are involved in the joint portion,
Since the two materials are directly bonded by the anchor effect, no strain is generated in the adhesive layer unlike the case where the conventional adhesive is used. Therefore,
Even if this laminate is used for a long period of time, the skin material and the porous substrate will not be peeled off. 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.

Further, a step of adopting a foamable molten resin material as the skin material and spreading the same foamable molten resin material over the entire surface of the base material between a pair of molding dies, and the pair of molding dies The molten resin material near the interface that is in contact with the mold hardens without foaming because it cools relatively quickly by passing through the step of separating by a fixed amount, while the molten resin material near the surface of the base material cools. Since the speed is slow, the film is foamed and cured to form a skin layer and a foamed layer, respectively. Therefore, according to such a manufacturing method of the present invention, it is not necessary to perform the steps of forming the skin sheet and the foamable sheet, which are essential in the conventional manufacturing method, and the manufacturing process can be simplified. The two layers constituting the skin material formed in this way are not separate members adhered to each other, and therefore the two layers cannot be peeled off. In addition, since the thickness and porosity of the foam layer of the skin material can be made uniform, and the surface of the skin layer can be molded uniformly along the mold surface, it provides a nice-looking laminate with uniform elasticity and touch. can do.

In the manufacturing method in which the base material and the skin material are fixed to each other by welding, in particular when the wettability between the molten resin material forming the skin material and the resin material forming the base material is poor, the melting By pre-treating the surface of the base material with the surface modifier before supplying the resin material, it is possible to ensure the welding between the skin material and the base material.

Also in the manufacturing method in which the skin material is fixed to the porous substrate by utilizing the anchor effect, at least the surface side of the inside of the porous substrate is modified before the impregnation with the molten resin material. By treating with a substance, the wettability of the molten resin material as the skin material with respect to the porous substrate can be improved.

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A vehicle door trim manufacturing method is employed as an embodiment of the laminated body manufacturing method of the present invention, and the manufacturing method will be described below with reference to the drawings.

[Embodiment of the Invention Described in Claim 1 (First to Third Embodiments Below)] The door trim manufactured by the invention described in claim 1 of the present application is shown in FIGS. A door trim 10 for an automobile as shown in Fig. 1, which is a base material 11 made of a thermoplastic ABS resin formed in the shape of a door trim, and a thermoplastic polypropylene resin which entirely covers the front surface of the base material 11. Made of skin material 1
2 and a part of the skin material 12 is decorated with an ornament 13 as needed. The joint portion between the base material 11 and the skin material 12 is adhered with a chloroprene adhesive.

[First Embodiment: One Embodiment of "Manufacturing Method of Laminated Body" Described in Claim 1] FIGS. 1 and 2 are shown in FIG.
A method of manufacturing the door trim 10 shown in FIG. 1, that is, the first embodiment (hereinafter, referred to as the first embodiment of the invention according to claim 1
The figure for demonstrating 1st Example) is shown. According to the manufacturing method of the first embodiment, the front molding surface 3 in which the grain for forming the design pattern on the surface of the skin material 12 is carved is formed.
A pair of upper and lower molding dies 31 and 32 including a lower mold 31 having the 1a formed therein and an upper mold 32 having the back side molding surface 32a of the door trim 10 formed therein are used. In manufacturing, the upper mold 32, which is adjusted to a temperature of 20 ° C to 40 ° C in advance.
First, the base material 11 in which the ABS resin is molded in the shape of a door trim is set on the molding surface 20a of 1., then the surface of the base material 11 is coated with a chloroprene-based adhesive, and then the temperature of 40 ° C. to 60 ° C. is preset. The lower surface of the lower die 31 is adjusted to the surface 31a of the polypropylene resin 12melt to be the skin material.
In a molten state (180 ° C. to 220 ° C.) using the discharge device 33 at a discharge rate of 1500 g / min and a supply time of 12 seconds / sheet. At this time, the polypropylene resin 12melt has a thickness of about product thickness + 0.1 mm, and a supply width of product width × 0.
It is supplied according to the shape of the door trim so as to be about 95. Then, melt polypropylene resin 12melt (resin temperature has dropped to 140 ° C to 160 ° C) is applied to the upper mold 3
A pressing pressure of 30 kgf / cm ² or more is applied between 2 and the lower mold 31 and pressing is performed for a pressing time of 2 to 3 seconds to spread the molten polypropylene resin 12melt on the entire surface of the base material 11.
In this state, the molten polypropylene resin 12melt covering the base material 11 is immediately cured by being held for about 30 seconds and cooled, and is adhered to the base material 11 with an adhesive. Thus, the skin material 12 in which the entire front surface of the base material 11 is made of resin
The door trim 10 covered with is formed.

[Second Embodiment: One Embodiment of "Manufacturing Method of Laminated Body" Described in Claim 1] FIG. 4 shows a second embodiment of the invention described in claim 1 (hereinafter, referred to as "second embodiment"). It is a figure for explaining a manufacturing method of door trim 10 (refer to Drawing 1 and Drawing 2) which is a 2nd example). In this manufacturing method of a 2nd example, front side molding surface 41a is formed as a pair of molds. Lower mold 41 and upper mold 4 on which the back side molding surface 42a is formed
2 is used. In the manufacturing method according to the second embodiment and the manufacturing method according to the first embodiment described above, the lower mold 41 includes the front molding surface 4
A resin supply passage 44 opened at positions dispersed throughout the entire 1a (note that a heater 45 is provided in the resin supply passage 44 in order to prevent the temperature of the molten resin 12melt from dropping during the supply). Is different in that the molten resin 12melt is supplied to the molding surface 41a of the lower mold 41 by injecting the molten resin 12melt from the injection device 43 into the resin supply passage 44.

[Third Embodiment: One Embodiment of "Manufacturing Method of Laminated Body" Described in Claim 1] FIG. 5 shows a third embodiment of the invention described in claim 1 (hereinafter, referred to as "third embodiment"). FIGS. 3A to 3C are views for explaining a method of manufacturing the door trim 10 according to the third embodiment, and in the manufacturing method of the third embodiment, a lower mold 51 having a front molding surface formed as a pair of molding dies and a back molding surface. The upper die 52 having the formed 52a is used. The manufacturing method of the third embodiment and the manufacturing method of the first embodiment described above are
A resin supply passage 54 in which the upper die 52 is opened at positions dispersed over the entire back side molding surface 52a (Note that the heater 55 is provided in the resin supply passage 54 in order to prevent the temperature of the molten resin 12melt from dropping during the supply. Is provided, the supply of the molten resin 12melt to the molding surface 51a of the lower mold 51 is performed by the injection device 53 from the molten resin 12me.
lt is injected into the resin supply passage 54 to form the molding surface 51 of the lower mold 51.
The only difference is that it is performed by dropping it to a.

[Effects of First to Third Embodiments] Therefore, the door trim manufacturing method of the first to third embodiments as described above is indispensable in the conventional manufacturing method. It is not necessary to perform the step of forming the skin sheet, and the manufacturing process can be simplified. Further, in these examples, the temperatures of the lower molds 31, 41 and 51 are different from those of the upper molds 32,
Since the temperature is set to 40 ° C. to 60 ° C. higher than the temperatures of 42 and 52, the molding surfaces 31 a and 4 of the lower molds 31, 41 and 51 are formed.
The molten resin 12melt supplied to 1a and 51a is not cooled so much, and when the molten resin 12melt is spread by a press, a flow mark which is a trace of the molten resin 12melt flowing on the surface of the finished skin material 12 is formed. Never be done. Therefore, the design of the door trim is not impaired.

[Embodiment of the Invention Described in Claim 2 (4th to 6th Embodiments Below)] The door trim manufactured by the invention described in claim 2 of this application is shown in FIG.
Corresponding to. ) Door trim 60 for automobiles as shown in
And the thermoplastic A formed in the shape of the door trim
A base material 61 made of a BS resin and a skin material 62 made of a thermoplastic polypropylene resin that entirely covers the front surface of the base material 61 are included. If necessary, a part of the skin material 62 is used for the ornament 13 Is decorated with. The skin material 62 is composed of a foamed layer 62a obtained by foaming and curing a polypropylene resin which is a thermoplastic resin, and a skin layer 62b obtained by curing the resin without foaming, and the base material 61.
The joint between the skin material 62 and the skin material 62 is bonded with an adhesive.

As an embodiment for manufacturing the door trim having the above-mentioned structure shown in FIG.
The fifth embodiment corresponds to the first embodiment (see FIG. 3) according to the invention described in 1., the fifth embodiment corresponds to the second embodiment (see FIG. 4),
The sixth embodiment corresponds to the third embodiment (see FIG. 5). These fourth to sixth embodiments are different from the first to third embodiments in that a foamable molten resin-based material is used as a material for forming the skin material, and the foamable molten resin-based material is used between a pair of molding dies. The difference lies only in that the foam layer 62a and the skin layer 62b are formed by a step of separating the pair of molds by a predetermined amount after the material is spread over the entire surface of the base material. Fourth to sixth embodiments will be described below.

[Fourth Embodiment: One Embodiment of "Manufacturing Method of Laminated Body" in Claim 2] First, in the manufacturing method of the fourth embodiment, the same mold as that shown in FIG. 3 is used. Mold 3
1, 32, and the discharge device 33 can be used, and therefore these molds and supply devices will be described below using the same reference numerals as those shown in FIG. Before manufacturing this door trim 60,
Molding surface 20a of upper mold 32 adjusted to a temperature of 40 ° C
First, after setting a base material 61 (corresponding to reference numeral 11 in FIG. 3) formed of ABS resin in the shape of a door trim, a chloroprene-based adhesive is applied to the surface of the base material 61, and then in advance. Polypropylene resin 62melt (corresponding to reference numeral 12melt in FIG. 3) serving as a skin material is melted (180 ° C to 220 ° C) on the molding surface 31a of the lower mold 31 adjusted to a temperature of 40 ° C to 60 ° C. Discharge rate of 1500 g / min using the discharge device 33, supply time of 12
Supply in seconds / sheet. Then, by pressing between the upper mold 32 and the lower mold 31, the molten resin 12melt is melted into the base material 1
Spread over the entire surface of 1. At this time, the molten resin 62melt is instantly spread in about 1 second so that the distance between the base material 61 and the lower mold 31 is about 1 mm. When the mold 31 and 32 are held in this state for about 1 second and then the space between the molds 31 and 32 is expanded by about 1 mm, the molten resin 62melt in the vicinity of the surface of the lower mold 31 in contact with the molding surface 31a has a high cooling rate, The design pattern due to grain is carved and hardened as it is, while the molten resin 62melt in the vicinity of the base material 61 is hardened while foaming due to the slow cooling rate, so that the skin layer 62b and the foamed layer 62a (FIG. 6), respectively.
And) are formed. Then, in this state, the molten resin 62melt is cooled and hardened by being held for about 30 seconds, and is adhered to the base material 61 by the adhesive applied to the surface of the base material 61. Thus, the door trim 60 in which the entire front surface of the base material 61 is covered with the skin material 62 is formed.

[Fifth Embodiment: One Embodiment of "Manufacturing Method of Laminated Body" Described in Claim 2] The manufacturing method of the fifth embodiment is shown in FIG. 4 (second embodiment). Since the same molds 41 and 42 and the injection device 43 as the mold can be used, these molds and injection device will be described below using the same reference numerals as those shown in FIG. . The manufacturing method of the fifth embodiment and the manufacturing method of the fourth embodiment described above are the same as the molding surface 4 of the lower mold 41 of the molten resin 62melt.
1a is supplied from the injection device 43 by the same molten resin 62melt.
Are only injected into the resin supply passage 44.

[Sixth Embodiment: One Embodiment of "Manufacturing Method of Laminated Body" Described in Claim 2] The manufacturing method of the sixth embodiment is shown in FIG. 5 (third embodiment). Since the same molds 51 and 52 and the injection device 53 as the mold can be used, these molds and injection device will be described below using the same reference numerals as those shown in FIG. . The manufacturing method of the sixth embodiment and the manufacturing method of the fourth embodiment described above are the same as the lower mold 51 and the molding surface 5 of the molten resin 62melt.
1a is supplied from the injection device 53 by the same molten resin 62melt.
Is injected into the resin supply passage 54 to form the molding surface 51a of the lower mold 51.
Only differs in that it is done by dropping it on.

[Effects of Fourth to Sixth Embodiments] Therefore, according to the door trim manufacturing method of the fourth to sixth embodiments as described above, it is essential in the conventional manufacturing method. Since it is not necessary to perform the steps of forming the skin sheet and the foamable sheet, the manufacturing process can be simplified. Further, in these examples, the temperature of the lower molds 31, 41, 51 is 40 ° C. which is higher than the temperature of the upper molds 32, 42, 52.
Since the temperature is set to 60 ° C., the molten resin 6 supplied to the molding surfaces 31a, 41a, 51a of the lower molds 31, 41, 51
The 2melt is not cooled so much, and when the same molten resin 62melt is spread by pressing, a flow mark which is a trace of the molten resin 62melt flowing on the surface of the finished skin material 62 is not formed. Therefore, the design of the door trim is not impaired. Since the two layers 62a and 62b forming the skin material 62 thus formed are not separate members, the two layers 62a and 62b cannot be peeled off. Further, the foam layer 6 of the skin material 62
The thickness and porosity of 2a can be made uniform, and the skin layer 6
Since the surface of 2b can be uniformly molded along the mold surface, it is possible to provide a good-looking laminate having uniform elasticity and touch.

[Embodiment of the Invention Described in Claim 4 (7th to 9th Embodiments Below)] The invention is manufactured by the 7th to 9th embodiments of the invention described in claim 4 of this application. The door trim uses a thermoplastic polypropylene resin as a base material, and is only joined to the skin material made of polypropylene resin by welding, and the door trim for an automobile shown in FIG. 2 (according to the first to third embodiments). Door trim manufactured) is different.

[Seventh to ninth embodiments: Examples of "method for producing laminated body" described in claim 4] The seventh to ninth embodiments of the invention described in claim 4 are The first to third embodiments of the invention described in claim 1 described above, the point that the base material is made of polypropylene resin, and by welding the skin material and the base material without supplying an adhesive to the base material. The only difference is that they stick.

[Effects of the seventh to ninth embodiments] According to such a manufacturing method, the manufacturing method can be simplified by omitting the step of molding the skin material, and no adhesive is used. There is no need to perform an adhesive coating step, and the reduction of materials used by not using an adhesive is also a special effect. Further, in these examples, the temperatures of the lower molds 31, 41, 51 are set to the upper molds 32, 4
Since the temperature is set to 40 ° C. to 60 ° C., which is higher than the temperatures of 2, 52, the molding surfaces 31 a, 41 of the lower molds 31, 41, 51.
The molten resin 12melt supplied to the a and 51a is not cooled so much, and when the molten resin 12melt is spread by a press, a flow mark which is a trace of the molten resin 12melt flowing on the surface of the finished skin material 12 is formed. Never be done. Therefore, the design of the door trim is not impaired.

[Embodiment of the Invention Described in Claim 5 (10th to 12th Embodiments Below)] The invention is manufactured by the 10th to 12th embodiments of the invention described in claim 5 of this application. The door trim uses a thermoplastic polypropylene resin as a base material, and a skin material made of a foamable polypropylene resin and the base material are joined together by welding.
2 is different from the vehicle door trim (door trim manufactured by the fourth to sixth embodiments) shown in FIG.

[Tenth to twelfth embodiments: claim 5]
Examples of "Manufacturing Method of Laminated Body" described in the above] In the example of manufacturing the door trim having such a configuration, the fourth to sixth examples of the invention described in claim 2 are , Using a thermoplastic polypropylene resin as the base material,
The only difference is that the skin material made of a foamable polypropylene resin and the base material are joined by welding without supplying an adhesive to the base material.

[Effects of Tenth to Twelfth Embodiments] According to such a manufacturing method, the effect that the manufacturing method can be simplified by not performing the step of molding the skin material, and the skin material 62 is constituted. Since the two layers 62a and 62b are not separate members adhered to each other, the two layers 62a and 62b are not peeled off, and the thickness and porosity of the foam layer 62a of the skin material 62 can be made uniform. At the same time, since the surface of the skin layer 62b can be uniformly molded along the mold surface, in addition to the effect of providing a good-looking laminate having uniform elasticity and touch, no adhesive is used. As a result, the reduction of materials used is also a special effect. Further, in these examples, the temperatures of the lower molds 31, 41, 51 are set to the upper molds 32, 42, 52.
Since the temperature is set to 40 ° C. to 60 ° C., which is higher than the temperature of 1, the molding surfaces 31a, 41a, 5 of the lower molds 31, 41, 51 are formed.
The molten resin 62melt supplied to 1a is not cooled so much, and when the molten resin 62melt is spread by a press, the molten resin 62melt is formed on the surface of the finished skin material 62.
Flow marks, which are marks of melt flow, are not formed. Therefore, the design of the door trim is not impaired. And both layers 62 constituting the skin material 62 formed in this way
Since separate members are not adhered to a and 62b, both layers 62a and 62b cannot be peeled off.
Further, the thickness and porosity of the foam layer 62a of the skin material 62 can be made uniform, and the surface of the skin layer 62b can be uniformly molded along the mold surface, so that it has uniform elasticity and touch.
It is possible to provide a good-looking laminated body.

[Embodiment of the invention described in claim 7 (the following thirteenth to fifteenth embodiments)] The invention is manufactured by the thirteenth to fifteenth embodiments of the invention described in claim 7 of this application. The door trim uses a wood-based porous base material formed by maintaining the porosity of an aggregate in which 93% of a main material such as wood fiber or powder is mixed as a base material with 7% of a phenol resin as a binder. In addition, the joint between the skin material made of polypropylene resin and the porous base material is in the form of being cured with the polypropylene resin of the skin material impregnated and filled in the pores inside the porous base material. That is, the door trims for automobiles (door trims manufactured by the first to third embodiments) shown in FIGS. 1 and 2 are different only in that both members are joined by an anchor effect.

[Thirteenth to fifteenth embodiments: claim 7]
Embodiments of "Manufacturing Method of Laminated Body" Described in the Invention] The thirteenth to fifteenth embodiments of the invention described in claim 7 are the first to third embodiments of the invention described in claim 1 described above. Example and the point that the substrate is composed of a wood-based porous substrate, and cured in a state where the pores on the front surface of the porous substrate are impregnated with the molten resin without supplying an adhesive to the porous substrate. The difference is only in that the skin material and the porous base material are bonded to each other due to the anchoring effect of this.

[Effects of the thirteenth to fifteenth embodiments] According to such a manufacturing method, the manufacturing method can be simplified by omitting the step of molding the skin material, and an adhesive is used. In addition to the effect of not using materials and reducing the number of adhesive application steps,
There is also an effect that the skin material and the porous base material can be firmly bonded by the anchor effect. Further, in these examples, the temperature of the lower molds 31, 41, 51 is set to the upper mold 3
Since the temperature is set to 40 ° C. to 60 ° C., which is higher than the temperatures of 2, 42, 52, the molding surface 31 of the lower molds 31, 41, 51
The molten resin 12melt supplied to the a, 41a, and 51a is not cooled so much, and is pressed by the molten resin 12melt.
When is spread out, flow marks which are marks of the molten resin 12melt flowing on the surface of the finished skin material 12 are not formed. Therefore, the design of the door trim is not impaired.

[Embodiment of the Invention Described in Claim 8 (16th to 18th Embodiments Below)] The 16th to 18th embodiments of the invention described in claim 8 of this application are manufactured. The door trim is a point where the base material is made of a wood-based porous base material, and is cured in a state where the pores on the front surface of the porous base material are impregnated with the molten resin without supplying an adhesive to the porous base material. This is different from the vehicle door trim shown in FIG. 6 (door trim manufactured according to the fourth to sixth embodiments) only in that the skin material and the porous base material are joined by the anchor effect.

[Sixteenth to eighteenth embodiments: claim 8]
Examples of "Manufacturing Method of Laminated Body" described in the above] In the example of manufacturing the door trim having such a configuration, the fourth to sixth examples of the invention described in claim 2 are , The base material is composed of a wood-based porous base material, and by curing the resin impregnated in the pores on the front surface of the porous base material without supplying an adhesive to the porous base material. The only difference is that the skin effect and the porous base material are joined by the anchor effect.

[Effects of Sixteenth to Eighteenth Embodiments] According to such a manufacturing method, the effect that the manufacturing method can be simplified by not performing the molding step of the skin material, and the skin material 62 is constituted. Since the two layers 62a and 62b are not separate members adhered to each other, the two layers 62a and 62b are not peeled off, and the thickness and porosity of the foam layer 62a of the skin material 62 can be made uniform. At the same time, since the surface of the skin layer 62b can be uniformly molded along the mold surface, it is possible to provide a good-looking laminated body having uniform elasticity and touch, and the use of no adhesive. In addition to the effect that the use of materials can be reduced and the number of adhesive application steps can be reduced, the skin material and the porous base material can be firmly bonded by the anchor effect. Furthermore, in these examples, the temperature of the lower molds 31, 41, 51 is set to 40 ° C. to 60 ° C., which is higher than the temperature of the upper molds 32, 42, 52.
Molding surfaces 31a, 41a, 51a of the lower molds 31, 41, 51
The molten resin 62melt supplied to is not cooled so much,
When the molten resin 62melt is spread by pressing, the molten resin 62melt is formed on the surface of the finished skin material 62.
A flow mark, which is a trace of the flow, is not formed. Therefore, the design of the door trim is not impaired. And both layers 62 constituting the skin material 62 formed in this way
Since separate members are not adhered to a and 62b, both layers 62a and 62b cannot be peeled off.
Further, the thickness and porosity of the foam layer 62a of the skin material 62 can be made uniform, and the surface of the skin layer 62b can be uniformly molded along the mold surface, so that it has uniform elasticity and touch.
It is possible to provide a good-looking laminated body.

In order to form a design pattern on the skin material 12 (or 62) on the front side molding surfaces 32a, 42a, 52a used in the manufacturing method of each of the above embodiments, as shown in each drawing. Because of the texture of
Skin material (or 12) on the porous substrate 11 (or 61)
It is possible to form a design pattern on the surface of the skin material 12 (or 62) at the same time as coating is formed. Further, the molding surfaces 31a, 32a, 41a, 42a, 51a, 52a of the two molds 31, 32, 41, 42, 51, 52 of these examples.
Is the end surface 11a (or 61a) of the porous substrate 11 (or 61) and the molding surfaces 31a, 32a, 41a, 42a,
Molten resin 12melt (or 62) between 51a and 52a
The resin forming the skin material 12 (or 62) is formed so as to have a gap to which the melt) is supplied, and therefore the end surface 11a (61) of the porous base material 11 (or 61).
Since a) can be completely covered, a manufacturing method in which the above-mentioned conventional skin material is adhered to and integrated with a porous substrate (FIG. 7).
(See FIG. 7 (b)), and a step of cutting the end of the skin material so that the end of the skin material slightly protrudes from the base material (see FIG. 7B) It is not necessary to perform the step (see FIG. 7C) of performing the above step, and it is possible to process the end portion of the door trim 10 at the same time as forming the skin material 12 so as not to spoil the appearance.

In the second embodiment (or fifth embodiment, eighth embodiment, eleventh embodiment, fourteenth embodiment, seventeenth embodiment), the opening position of the resin supply passage 44 to the molding surface is set as follows. If instead of the position shown in FIG. 4, a terminal part of the door trim or a part to which an ornament is attached, burrs are generated at the part corresponding to the position where the resin supply passage on the surface of the skin material is open. However, since it cannot be seen from the outside, the design of the door trim attached to the door of an automobile is not impaired.

In the manufacturing methods of the above-mentioned seventh to eighteenth examples, when the wettability between the molten resin-based material forming the skin material and the substrate or the porous substrate is poor, the molten resin-based material is used. Prior to impregnation, at least the surface of the substrate or porous substrate is coated or impregnated with a surface modifier such as a modified olefin to improve the wettability, thereby ensuring the bonding between the skin material and the substrate. be able to. For example, when the base material is polypropylene resin and the skin material is vinyl chloride, a primer based on chlorinated polyolefin is used as the surface modifier.

In the first to sixth embodiments according to the first and second aspects of the invention, the ABS resin is used as the thermoplastic resin for the base material 11, but other materials such as polyamide resin and ASA resin are used. You may use the thermoplastic material of. Further, a wood-based molded product obtained by molding an aggregate obtained by adding and mixing a phenol resin as a binder to a main material such as wood chips, fibers or powder can also be used.

On the other hand, in the seventh to twelfth embodiments according to the inventions of claims 4 and 5, the thermoplastic polypropylene resin is used as the base material, but it is welded to the resin constituting the skin material. Other thermoplastic olefin resins can also be used as long as they are resins that can be used. Also,
It is also possible to use a molded body containing these resins as a main component, to which a filler, a reinforcing material such as glass fiber, etc., and a conductive agent for preventing static electricity, such as calcium silicate or calcium carbonate, are added.

In addition, in the thirteenth to eighteenth embodiments according to the seventh and eighth aspects of the present invention, a wood-based molded product obtained by mixing wood fiber and phenol resin at 93: 7 as a porous base material and molding. Although 80% of wood fiber, 10% of phenol resin, and 10% of olefin fiber are mixed, a wood-based molded product can also be preferably used. In addition to this, a porous resin-based molded article made of hard urethane foam or the like may be used, and a thermosetting material such as phenol resin, epoxy resin, polyester resin, or a thermoplastic resin such as polypropylene resin or ABS resin is mainly used. As a porous resin-based molded body to which a reinforcing agent or a conductive agent for antistatic is added as appropriate, a porous molded body formed by pressure molding of metal fibers, a molded body made of a carbon material, a lath metal or a non-woven fabric, etc. A molded product in which a porous resin is carried or laminated on a support can also be used. When the wettability between the base material made of these materials and the resin constituting the skin material is poor, the surface of the base material is coated with or impregnated with a surface modifier such as a modified olefin to form a porous group. By improving the permeability of the molten resin into the holes of the material, the joint strength between the two can be increased. For example, when the substrate is polypropylene resin and the skin material is vinyl chloride, a chlorinated polyolefin-based primer is used as the surface modifier.

Although polypropylene resin was used as the skin material in the above thirteenth to eighteenth examples, 10% to 50% of ethylene propylene rubber was added to the polypropylene resin to form the resin (formability) and texture (flowability). (Hardness) may be adjusted. Particularly, it is preferable to add 40% of ethylene propylene rubber. Table 1 below shows evaluations regarding moldability (flowability) and texture (hardness) when the compounding ratio of polypropylene resin and ethylene propylene rubber was changed.

[0055]

[Table 1]

As the skin material, other olefin resin such as vinyl chloride, polyethylene, ethylene-propylene copolymer, 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.

Further, the molding dies 31, 32, 41, 4 described above
2, 51, 52 are made of Al, for example, iron or ZAS
A mold formed of resin (trade name of zinc alloy manufactured by Mitsui Mining & Smelting Co., Ltd.) or resin may be used.

[Brief description of drawings]

FIG. 1 is a perspective view of a door trim manufactured according to first to third embodiments (or seventh to ninth embodiments, or thirteenth to fifteenth embodiments) of the present invention.

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

FIG. 3 shows a first embodiment of the present invention (or fourth, seventh,
It is a figure for explaining a manufacturing method of a 10th, 13th, 16th example) door trim.

FIG. 4 is a second embodiment of the present invention (or fifth, eighth,
It is a figure for explaining the manufacturing method of the 11th, 14th, 17th example) door trim.

FIG. 5 shows a third embodiment (or sixth, ninth, or third embodiment of the present invention.
It is a figure for demonstrating the manufacturing method of the 12th, 15th, 18th Example) door trim.

FIG. 6 is a fourth to sixth embodiment (or a tenth embodiment) of the present invention.
FIG. 12 is a vertical cross-sectional view (corresponding to FIG. 2) of the door trim manufactured by the door trim manufacturing method according to the twelfth embodiment to the sixteenth to eighteenth embodiments.

7 (a), (b) and (c) are process drawings for explaining a conventional method for manufacturing a door trim.

8A, 8B, and 8C are process drawings for explaining a conventional door trim manufacturing method.

[Explanation of symbols]

10, 60 ... Door trim, 11, 61 ... Porous substrate, 1
2, 62 ... Skin material, 162a ... Foam layer, 62b ... Skin layer, 12melt, 62melt ... Molten resin, 31, 32, 4
1, 42, 51, 52 ... Mold, 31a, 32a, 41
a, 42a, 51a, 52a ... Molding surface, 33 ... Discharge device, 43, 53 ... Injection device.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display location B60J 5/00 501 B60J 5/00 501A B60R 13/02 B60R 13/02 B // B29K 105: 04 B29L 9:00 31:58 (72) Inventor, Kazunori Kuse, 25, Kamifujiike, Yoshihara-cho, Toyota-shi, Aichi, Araco Co., Ltd. 72) Inventor Makoto Horiba 25 Kamifujiike, Yoshihara-cho, Toyota-shi, Aichi Araco Co., Ltd.

Claims (11)

[Claims] 1. A method for producing a laminate comprising a base material and a skin material which entirely covers the front surface of the base material, wherein the base material is set on a molding surface of an upper die, and a predetermined range is set. The molten resin-based material to be the skin material is supplied to the molding surface of the lower mold adjusted to the temperature of, and pressed between the upper mold and the lower mold to press the molten resin-based material on the entire surface of the base material. A method for producing a laminated body, which comprises spreading and solidifying and simultaneously bonding the base material and the skin material. 2. A method for manufacturing a laminate comprising a base material and a skin material which entirely covers the front side surface of the base material, wherein the base material is set on a molding surface of an upper die, and a predetermined range is set. The expandable molten resin-based material to be the skin material is supplied to the molding surface of the lower mold adjusted to the temperature of and is pressed between the upper mold and the lower mold to form the expandable molten resin-based material of the base material. After being spread over the entire surface, the foamable molten resin material on the base material side is foamed and cured to form a foamed layer by separating the upper mold and the lower mold by a predetermined amount, and the same on the foamed layer. A method for producing a laminate, wherein an expandable molten resin material is cured without being foamed to form a skin layer, and the base material and the skin material are adhered to each other. 3. The substrate according to claim 1, wherein the base material is made of a resin material or a wood material.
The method for producing a laminate according to the above. 4. A method for producing a laminate, comprising a base material made of a resin material and a skin material that entirely covers the front surface of the base material, wherein the base material is set on the molding surface of the upper mold. On the other hand, the molten resin-based material to be the skin material is supplied to the molding surface of the lower mold adjusted to a temperature within a predetermined range and pressed between the upper mold and the lower mold to apply the molten resin-based material to the base material. A method for producing a laminated body, which comprises pressing the base material and the skin material at the same time as spreading and solidifying by spreading over the entire surface of the base material. 5. A method for producing a laminate, comprising a base material made of a resin material and a skin material that entirely covers the front surface of the base material, wherein the base material is set on the molding surface of the upper mold. On the other hand, the expandable molten resin-based material serving as the skin material is supplied to the molding surface of the lower mold adjusted to a temperature within a predetermined range and pressed between the upper mold and the lower mold to form the same expandable molten resin-based material. After spreading over the entire surface of the base material, the foamable molten resin material on the base material side is foamed and cured to form a foamed layer by separating the upper mold and the lower mold by a predetermined amount. A method for producing a laminate, wherein the foamable molten resin material on the foam layer is cured without foaming to form a skin layer, and the base material and the skin material are welded together. 6. The method according to claim 4 or 5, wherein the surface of the base material made of a resin material is treated with a surface modifier before the molten resin material used as the skin material is supplied. Of the laminated body of. 7. A method for producing a laminate comprising a porous base material and a skin material that entirely covers the front side surface of the porous base material, wherein the porous base material is provided on the molding surface of the upper mold. The molten resin-based material to be the skin material is supplied to the molding surface of the lower mold, which is adjusted to a temperature within a predetermined range, and is pressed between the upper mold and the lower mold to press the molten resin-based material into the porous surface. A method for producing a laminate, which comprises expanding the entire surface of a porous base material and solidifying the porous base material so that at least the front side of the porous base material is impregnated. 8. A method for producing a laminate comprising a porous base material and a skin material which entirely covers the front surface of the porous base material, wherein the porous base material is formed on the molding surface of the upper mold. Set the foamable molten resin system material to be the skin material on the molding surface of the lower mold that has been adjusted to a temperature within a predetermined range, and press between the upper mold and the lower mold to form the foamable molten resin system. After the material is spread over the entire surface of the porous base material to impregnate at least the front side inside the porous base material, the upper die and the lower die are separated by a predetermined amount, thereby the porous base material side. The foamable molten resin-based material is foamed and cured to form a foamed layer, and the foamable molten resin-based material on the foamed layer is cured without foaming to form a skin layer. Production method. 9. The method for manufacturing a laminate according to claim 7, wherein the porous substrate is made of a resin material or a wood material. 10. The method according to claim 7, wherein at least the front side of the inside of the porous substrate is treated with a surface modifier before the molten resin material serving as the skin material is supplied. The method for producing a laminate according to any one of items. 11. The method for manufacturing a laminate according to claim 1, wherein the laminate is a vehicle door trim or a vehicle interior material.