JPH11156875A - Production of laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the width of a graining groove to hide a color parting line in the graining groove in a method for integrally molding a laminate having different surface colors across the graining groove. SOLUTION: The thermoplastic sheet 30 m becoming the skin 30 of a laminate consists of a thin dense surface layer 30a and a rear layer 30b of a foamed synthetic resin and a slit 30c is formed to the rear layer in the thickness direction thereof along the position corresponding to the color parting line C on the surface of the surface layer. The heated and softened thermoplastic sheet is sucked to the upper molding surface 11 of a first mold 10 in a close contact state so that the parting line of the surface layer of the thermoplastic sheet coincides with the leading end edge of the ridge 12 of the upper molding surface 11 of a first mold 10 and, thereafter, a second mold 20 is allowed to approach the first mold 10 from above to fill the gap between the rear surface of the thermoplastic sheet and the molding surface 21 on the rear side of the second mold 20 with a heated and softened thermoplastic plate material 31m becoming a base material 31. The thermoplastic plate material is guided and supported by the second mold 20 and the outer peripheral part thereof may be supported by a base material holder having the opening permitting the rear molding surface to pass.

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 a vehicle door trim, a vehicle interior material, a house interior material, a furniture exterior material, etc., and in particular, a wood grain groove formed on a surface of a skin covering a base material. The present invention relates to a method for producing a laminate having a surface having a different color or pattern on both sides of the laminate.

[0002]

2. Description of the Related Art In a laminate, such as an automobile door trim, in which the surface of a base material is covered with a skin, the upper half and the lower half have different surface colors in order to enhance decorativeness. In that case, usually, after preparing the thing with a different skin color by molding the upper half and the lower half separately,
This is integrated by caulking or screwing. In the case where such a laminated body is manufactured by suction-bonding the heat-softened skin material to the surface of the integrally molded base material by negative pressure, the upper half and the lower half are separated by the color cutoff line. It is also conceivable to use skin materials having different surface colors.

[0003]

However, the first problem is to be solved.
In the prior art, there is a problem in that the forming process is required separately for the upper half and the lower half, and the assembling process is also required, so that the manufacturing cost increases. Further, in the second prior art, the manufacturing cost is reduced, but the skin material is slightly displaced along the surface of the base material at the time of suction bonding, so that the color cutoff line shape is meandering and the appearance is reduced, and the flat door trim is reduced. However, there is a problem that a luxurious feeling cannot be given because the surface is simply colored or patterned. In order to solve this latter problem, it is conceivable to provide a wood-groove groove at the position of the color-marking line on the surface of the skin material so that the color-marking line can enter the groove. However, this does not solve the former problem, so that the meandering color parting lines are partially exposed from the wood-groove grooves and may be rather unsightly. Also, if a foam layer is provided on the back side of the skin to enhance the feel, the thickness of the skin increases and the radius of curvature of the groove bottom of the wood grain groove, and hence the width of the wood grain groove increases, so the groove bottom can be seen and the appearance There is also the problem of lowering.

The present invention reduces the width of the wood grain groove and integrally hides the color cut-off line in the wood grain groove when integrally forming such a laminated body having a different surface color from the wood grain groove. Thus, it is an object to solve each of such problems.

[0005]

According to a method of manufacturing a laminate according to the present invention, a thermoplastic sheet serving as a skin having a surface having a different color or pattern at a borderline is heated and softened to form a surface. After approaching the front side molding surface of the first mold, a second side having a back side molding surface opposed to the front side molding surface.
The mold is moved closer to the first mold, and the thermoplastic sheet and the second mold are moved together.
The present invention relates to a method for producing a laminate in which a base material is covered by a skin by filling a heat-softened thermoplastic plate material serving as a base material interposed between molding dies between a back surface and a back side forming surface of a thermoplastic sheet. The thermoplastic sheet is composed of a thin dense synthetic resin surface layer on the front side and a foamed synthetic resin back layer on the back side, and the back layer is located at a position corresponding to the color cutoff line on the surface layer surface. A cut is formed along the entire surface of the first mold along a color-cutting line, and a ridge having a narrow leading edge that abuts the surface of the surface layer is formed along the color parting line. A concave stripe is formed on the back molding surface of the second molding die along a position corresponding to the projection. When the thermoplastic sheet is brought into close contact with the front molding surface of the first molding die, the color parting line abuts on the leading edge of the ridge and is bent to form a grained groove.
A cut is formed in the part corresponding to the color parting line on the back layer, so that only the thin surface layer can be bent, it is extremely easy to bend and there is no bend in other parts, and the ridge is Since the width is small, the radius of curvature of the groove bottom of the grained groove becomes extremely small.

[0006] In the invention of the preceding paragraph, before the second mold approaches the first mold, the surface of the surface layer of the thermoplastic sheet is subjected to the first mold.
It is preferable to bring the mold into close contact with the front molding surface of the molding die.

In the invention of the preceding two aspects, the first mold is a lower mold,
The second mold is an upper mold, and the heat-softened thermoplastic plate material has a peripheral part held by a substrate holder having an opening wider than the rear molding surface of the upper mold, and the substrate holder is more than the second mold. First, it is preferable that the lower mold is positioned closest to the lower mold, and that the rear molding surface is filled with a thermoplastic plate material between the lower mold and the rear surface of the thermoplastic sheet through the opening.

According to the invention of the preceding paragraph, the upper die is provided with a plurality of guide bars fixed to the peripheral portion thereof and extending downward, and the substrate holder is guided and supported by the guide bars so as to be able to move up and down and at least a predetermined distance from the upper die. Is preferably prevented by contacting the head formed at the lower end of the guide bar.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiment shown in FIGS.
1 shows an example in which the method for producing a laminate according to the present invention is applied to the production of door trim for automobiles. As in the semi-finished product shown in FIG. 6, the door trim formed according to the present invention is obtained by covering the outer surface of a rigid base material 31 having a substantially constant thickness with a skin 30. As shown in FIG. 5, a back surface layer 3 made of a sheet-like synthetic resin foam having high elasticity is provided on the back surface of the surface layer 30a made of a soft, dense and thin thermoplastic resin.
0b is laminated. On the surface side of the skin 30 covering the base material 31, a straight or slightly bent wood grain groove 32 which is almost horizontal in the attached state is formed over the entire width in the horizontal direction, and the color or pattern of the surface is formed on the upper side and the lower side. Is different. For example, the vertical and horizontal dimensions are about 600mm x 9
In the case of a door trim of 00 mm, the thickness of each part is 2.5 to 6.0 mm for the base material 35 and 4.45 mm or less for the skin 30, and thus 6.95 to 10.45 mm for the entire door trim.

First, a molding apparatus used in this embodiment will be described with reference to FIGS. This molding apparatus includes a first fixed-side mold support member (not shown) mounted on a lower side.
A molding die (lower die) 10, a second molding die (upper die) 20 attached to an upper movable side mold support member (not shown), and a base supported by the second molding die 20 via a guide bar 23. A material holder 25 is provided. A front molding surface 11 having a shape corresponding to the surface of the skin 30 of the door trim is formed above the first molding die 10, and an outer peripheral surface 11 a extending outward is formed outside the molding surface 11. On the front side forming surface 11, a ridge 12 having a constant cross-sectional shape with a narrow leading edge is formed straight or slightly bent along a position corresponding to the wood groove 32 of the door trim. A vacuum source 14 including a vacuum pump, a vacuum tank, and an on-off valve is provided in the first mold 10.
A suction line 13 connected to the suction line 1 is provided.
The other ends of a large number of narrow channels 13a (only a part is shown in the figure) branched from 3 are distributed over substantially the entire front side forming surface 11 and open. The ridge 12 is the first mold 1 as shown in the figure.
0 may be formed integrally, or a plate may be implanted and fixed.

The second mold 20 can be approached and separated from the first mold 10 from above. FIGS. 2 and 3 show the separated state, and FIG. 4 shows the closest state. Second mold 20
A lower molding surface 21 facing the front molding surface 11 on the upper side of the first molding die 10 is formed on the lower surface of the first molding die 10, and the gap between the rear molding surface 21 and the front molding surface 11 becomes the thickness of the door trim in the closest state. . The back side molding surface 21 includes the front side molding surface 11
A concave ridge 22 is formed at a position corresponding to the protruding ridge 12 formed at the bottom.

As shown in FIGS. 1, 3 and 4, four base bars 23 fixed to the four corners of the second molding die 20 and extending downward guide and support a base member holder 25 in a vertically movable manner. ing. The base material holder 25 has a planer outline shape substantially the same as that of the second molding die 20, has an opening 26 which is slightly wider than the rear molding surface 21, and bushes 27 provided at four corners slide on each guide bar 23. When the second molding die 20 is separated from the first molding die 10 by a certain distance or more below the first molding die 10 as shown in FIG. 3, the bush 27 is attached to the head 23a formed at the lower end of each guide bar 23. And the base holder 25 is prevented from lowering further with respect to the second mold 20. A large number of locking needles 28 are erected and implanted on the upper surface of the base material holder 25 which is three sides of the opening 26, and a clamper 29 is provided on the other one.

The thermoplastic sheet 30m which is bonded to the surface of the base material 31 to form the skin 30 is a thin sheet-shaped surface layer 30a (for example, a 0.35 mm thick polypropylene) made of a dense solid layer of a soft thermoplastic resin. On the back surface of a resin sheet or the like, a back surface layer 30b made of an elastic sheet-like synthetic resin foam (for example, a polypropylene resin foam sheet having a thickness of 2 to 3 mm) is laminated and bonded in advance to form a sheet. is there. Surface layer 30 of thermoplastic sheet 30m
As shown in FIG. 2, the surface of a is separated from one side (upper half) A by a straight or slightly bent color parting line C that matches the plane shape of the ridge 12 of the front molding surface 11. The side (lower half) B has a different surface color or pattern, and a grain such as a leather pattern is formed to enhance the design effect. Backside layer 3 of thermoplastic sheet 30m
As shown in FIG. 5, a cut 30c is formed on the surface of the surface layer 30a over substantially the entire thickness thereof along a position corresponding to the color parting line C, as shown in FIG. This break 30
c may be formed by cutting a thermoplastic sheet 30m into a predetermined shape and then using a mold having a knife-shaped cutting blade.

The thermoplastic plate material 31m serving as the base material 31 is obtained by mixing polypropylene and wood flour and compressing by heating to form a plate (the mixing ratio is, for example, 50:50 by weight, and the thickness is, for example, 2.5 mm). It is. The thermoplastic plate material 31m is cut in advance into a rectangle larger than the opening 26 of the base material holder 25,
The three sides are pierced by the locking needles 28 of the substrate holder 25, and one side is sandwiched by the clamper 29 to be supported by the substrate holder 25.

Next, a manufacturing method using the molding apparatus described above will be described with reference to FIGS. First, the thermoplastic sheet 30m is held by sandwiching the outer peripheral portion between the holding frames 19 so that the surface with the color parting line C is on the lower side, and is softened by heating (for example, 120 ° C.) with a far infrared heater or the like. Let it. Then, the holding frame 19 is lowered, and the thermoplastic sheet 3
The outer peripheral portion of 0 m is brought into contact with the outer peripheral surface 11a of the first mold 10 to substantially seal the space between the front molding surface 11 and the thermoplastic sheet 30m. The horizontal position of the thermoplastic sheet 30m in this state is, as shown in FIG. 2 and FIG. 5 (a), the ridge 12 in which the color parting line C of the surface layer 30a of the thermoplastic sheet 30m projects from the front side molding surface 11. Is to be directly above. When a negative pressure from the vacuum source 14 is applied to the lower side of the thermoplastic sheet 30m through the suction pipe 13 and the narrow pipe 13a, as shown by the two-dot chain line 30A in FIG. 2 and the solid line in FIG. The surface of the surface layer 30a is brought into close contact with the front molding surface 11 of the first molding die 10 by suction, and the narrow leading edge of the ridge 12 is brought into contact with the surface of the surface layer 30a along the color parting line C.

As a result of the suction adhesion, as shown in an enlarged view in FIG. 5B, the surface layer 30a is bent by the color cut-off line C of the surface abutting against the leading edge of the ridge 12, and the wood grain groove 32 is formed. Although formed, the part of the color parting line C where the cut 30c is formed in the back surface layer 30b is bent only by the thin surface layer 30a and is extremely easily bent, so that it is in close contact with the leading edge of the narrow ridge 12 having a small width. As a result, the radius of curvature at the bottom of the groove 32 becomes extremely small. Also,
Since the portion other than the color parting line C is thicker by the thickness of the back surface layer 30b and is difficult to bend, even if the leading edge of the ridge 12 comes into contact with a position slightly deviated from the color parting line C, it bends in color. Along the parting line C, the position of the thermoplastic sheet 30m is corrected by the subsequent suction adhesion in such a manner that the color parting line C is locally shifted in a direction coincident with the leading edge of the ridge 12.

Next, as shown in FIG. 3, the thermoplastic plate material 31m is supported by the base material holder 25 with three edges stuck to the locking needle 28 and the other edge sandwiched by the clamper 29.
After being softened by heating (for example, 220 ° C.) with a far-infrared heater or the like, the second mold 20 is lowered together with the substrate holder 25 toward the first mold 10. Base material holder 25
After the lower surface thereof contacts the thermoplastic sheet 30m on the outer peripheral surface 11a of the first molding die 10 and reaches the closest position to the first molding die 10, the lowering is stopped, and the second molding die 20 is stopped.
Then, only the guide bar 23 is lowered, and as shown in FIG. 4, the tip of the head 23a at the lower end of the guide bar 23 of the second molding die 20 comes into contact with the first molding die 10, and between the two molding surfaces 11 and 21. When the gap becomes the closest approach to the thickness of the door trim, stop. As a result, the thermoplastic sheet material 31m that has been heated and softened and is interposed between the thermoplastic sheet 30m and the rear molding surface 21 of the second molding die 20 becomes the rear molding surface 21 of the second molding die 20 and the back surface of the thermoplastic sheet 30m. Compression-filled without gaps between

The temperature of the molding surfaces 11 and 21 is lowered by heat transfer to the inside of the molding dies 10 and 20, and the thermoplastic sheet 30m and the thermoplastic plate 31m are cured to form the skin 30 and the base material 31. By the way, if the second mold 20 and the substrate holder 25 are raised, the surface layer 30a and the back layer 3
The semifinished door trim in which the skin 30 made of Ob and the base material 31 are integrated is raised together with the base material holder 25. The semi-finished product is detached from the substrate holder 25 by removing the clamper 29 and lifting it up. Then, if unnecessary portions outside the cutting line D shown in FIG.
2, the door trim having a different surface color or pattern on both sides of the wood trim groove 32 formed on the surface of the skin 30 is completed. The base 31 is formed with a ridge so as to surround the wood-groove groove 32 by the concave streak 22 of the back side molding surface 21 of the second molding die 20, so that the thickness of the base 31 in this portion is reduced and the strength is reduced. Does not decrease.

According to the above-described embodiment, door trims in which the color or pattern of the skin 30 is different from the grained groove 32 can be integrally manufactured by substantially one step.
In addition, the front surface layer 30a along the color parting line C, which is bent when the leading edge of the narrow ridge 12 abuts, is the back surface layer 3
Since the cut 30c is formed at 0b and it is extremely easy to bend, the radius of curvature of the groove bottom of the wood groove 32 formed by this bending becomes extremely small, and the groove bottom becomes hard to be seen from the outside. Further, since the portion other than the color parting line C has a large thickness by the amount of the back surface layer 30b and is hard to bend, even if the leading edge of the ridge 12 comes into contact with a position slightly deviated from the color parting line C, it bends. Is along the color cutoff line C. The deviation is corrected so that the bent portion coincides with the leading edge of the ridge 12, and the color cutoff line C coincides with the groove bottom of the grained groove 32. The line C is not exposed to the outside from the wood groove 32. Therefore, a door trim excellent in appearance can be easily manufactured.

In the above embodiment, before the second mold 20 approaches the first mold 10, the thermoplastic sheet 30 m
Is adhered to the front molding surface 11 of the first molding die 10 by the suction pipe 13 and the narrow pipe 13a and the vacuum source 14, so that when the leading edge of the ridge 12 is slightly deviated from the color parting line C, The effect of correcting the displacement is relatively free. When such suction adhesion is not performed, the thermoplastic sheet 30m with respect to the front molding surface 11 of the first molding die 10 is used.
Is performed by the heat-softened thermoplastic plate material 31m that is compressed and filled between the back mold surface 21 of the second mold 20 and the above-described operation of correcting the displacement is performed by the back surface layer of the skin 30. Although it becomes weak due to the viscous resistance of the thermoplastic plate material 31m attached to 30b, it is not lost.

Further, in the above-described embodiment, the peripheral portion of the thermoplastic plate material 31m is held and softened by holding the substrate holder 25 having a wide opening, and in this case, the heat-softened thermoplastic plate material 31m is formed. Since the handling is simplified, the production of the laminate is facilitated. However, in the present invention, a thermoplastic plate material 31m made of a molten resin extruded in a plate shape from an extrusion die is supplied onto a thermoplastic sheet 30m which is brought into close contact with or close to the front molding surface 11 of the first molding die 10. Thus, the thermoplastic sheet 30m and the second mold 2
It is also possible to carry out the present invention by interposing it between the back molding surfaces 21 of 0, and even in such a case, the respective effects described above can be obtained.

In the above embodiment, guide bars 23 extending downward are fixed to the four corners of the second mold 20 as the upper mold.
The substrate holder 25 is guided and supported by the guide bar 23 so as to be able to move up and down, and the lowering of the second molding die 20 by a predetermined distance or more is prevented by contacting the head 23a formed at the lower end of the guide bar 23. According to this, it is not necessary to provide a special device for operating the substrate holder 25, so that the structure of the device used for molding the door trim is simplified. However, the present invention may be implemented by providing a device that supports and lifts the substrate holder 25.

In the above embodiment, the first mold 10 is a lower mold and the second mold 20 is an upper mold.
It is also possible to implement the first mold 10 as an upper mold and the second mold 20 as a lower mold.

[0024]

According to the present invention, it is possible to integrally manufacture door trims in which the color or pattern of the surface of the skin is different from that of the grained groove in substantially one step. In addition, the skin is very easy to bend at the color cut-off line due to the cut formed on the back surface layer, and is hard to bend at other portions. There is no danger, and the radius of curvature of the groove bottom of the grained groove becomes extremely small, so that the width of the grained groove is reduced and the groove bottom is no longer visible. This makes it possible to improve the appearance of the laminate in which the color or pattern of the surface is different on both sides of the wood grain groove formed on the surface of the skin covering the base material.

According to the structure in which the thermoplastic sheet is brought into close contact with the front molding surface of the first molding die before the second molding die is brought close to the first molding die, the thermoplastic sheet is brought into contact with the first molding die during the suction adhesion. Even if the leading edge of the ridge abuts at a position slightly deviated from the color parting line because it is not attached to the thermoplastic plate material, the color parting line is free to align with the leading edge of the ridge due to subsequent suction adhesion Therefore, the possibility that the color cutout line is shifted from the groove bottom of the grained groove and exposed outside the grained groove is further reduced.

According to the invention, the first molding die is a lower mold, and the peripheral portion of the heat-softened thermoplastic plate material is held by the base holder having a wide opening. Since the handling is simplified, the production of the laminate is facilitated.

In the above invention, a plurality of guide bars extending downward are fixed to the periphery of the upper die, the substrate holder is guided and supported by the guide bars so as to be able to move up and down. According to the structure in which the structure is prevented by contacting the head formed at the lower end, there is no need to provide a special device for operating the substrate holder. Simplified.

[Brief description of the drawings]

FIG. 1 is a plan view of a molding apparatus used in an embodiment of a method of manufacturing a laminate according to the present invention, from which a second molding die and a thermoplastic material are removed.

FIG. 2 is a cross-sectional view taken along line XX of FIG. 1, showing a state in which a thermoplastic sheet is brought into close contact with a first molding die and is suction-adhered to a front molding surface.

FIG. 3 is a cross-sectional view taken along line XX of FIG. 1, showing a state where the second mold and the base material holder are approaching the first mold.

FIG. 4 is a cross-sectional view taken along line XX of FIG. 1, showing a state in which a second mold and a substrate holder are closest to the first mold.

FIG. 5 is a partially enlarged sectional view of a main part in each stage of the apparatus shown in FIGS.

FIG. 6 is a cross-sectional view of a semi-finished door trim manufactured by one embodiment of the method for manufacturing a laminate according to the present invention.

[Explanation of symbols]

10: first molding die, 11: front molding surface, 12: ridge, 2
0: second molding die, 21: back molding surface, 22: concave streak, 23
... Guide bar, 23a ... Head, 25 ... Substrate holder, 26
... opening, 30 ... skin, 30a ... surface layer, 30b ... backside layer, 30c ... cut, 30m ... thermoplastic sheet, 31 ...
Base material, 31 m ... thermoplastic plate material, C ... color parting line.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29C 51/30 B29C 51/30 // B29K 23:00 105: 16 B29L 9:00 31:58

Claims (4)

[Claims] 1. A thermoplastic sheet which has a surface having a different color or pattern and borders on a parting line is heated and softened to bring the surface closer to the front molding surface of the first molding die. A second molding die having a back molding surface facing a front molding surface is brought close to the first molding die, and a heat-softened thermoplastic plate material interposed between the thermoplastic sheet and the second molding die and serving as a base material In the method of manufacturing a laminate comprising a base material covered by a skin by filling the back surface of the thermoplastic sheet between the back surface and the molding surface, the thermoplastic sheet is a thin dense synthetic resin of the front side A front surface layer and a back surface layer of a foamed synthetic resin to be a back surface side, wherein the back surface layer forms a cut over substantially the entire thickness along a position corresponding to the color parting line on the surface layer surface,
On the front molding surface of the first molding die, a ridge having a narrow leading edge that abuts on the surface of the surface layer is formed along the color parting line, and on the rear molding surface of the second molding die, A method for manufacturing a laminate, wherein a concave stripe is formed along a position corresponding to the ridge. 2. The method according to claim 1, wherein the surface of the surface layer of the thermoplastic sheet is brought into close contact with the front side molding surface of the first molding die before the second molding die approaches the first molding die.
The method for producing a laminate according to the above. 3. The substrate holder, wherein the first mold is a lower mold, the second mold is an upper mold, and the heat-softened thermoplastic plate material has an opening wider than a rear molding surface of the upper mold. The base member is held by the second
2. The method according to claim 1, further comprising: setting the closest molding position to the lower mold before the molding die, wherein the rear molding surface is filled with the thermoplastic plate material between the thermoplastic resin and the rear surface of the thermoplastic sheet through the opening.
Alternatively, the method for producing a laminate according to claim 2. 4. The upper mold is provided with a plurality of guide bars fixed to a peripheral portion thereof and extending downward, and the substrate holder is guided and supported by the guide bars so as to be able to move up and down and at least a predetermined distance from the upper mold. 4. The method for manufacturing a laminate according to claim 3, wherein the lowering of the guide bar is prevented by contacting a head formed at a lower end portion of the guide bar.