JPH11165339A - Manufacture of lengthy product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To remarkably improve an external appearance quality in a method for manufacturing a lengthy product to be manufactured by an extrusion molding method. SOLUTION: First, a resin material of a plasticized state is extruded by a known extrusion molding method to obtain a base material 14 having a predetermined sectional shape. Then, the material 14 is fed to a film adhering step, in which a film 19 is adhered to the material 14. Then, the material 14 to which the film 19 is adhered is fed to a sizing step. At this time, the material 14 and the film 19 are evacuated in vacuum from below by sucking it by a sucking unit. Thus, the material 14 is strongly brought into contact with a bottom wall 37 together with the film 19. Simultaneously, a predetermined pressure is applied to the material 14 by a roller 46 from above. Accordingly, a recess and protrusion part is effectively absorbed to be suitably shaped. Thereafter, it is cut in a predetermined length, and the film 19 is released, thereby obtaining a side molding.

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 long product such as a molding used as an exterior component of an automobile.

[0002]

2. Description of the Related Art Conventionally, various long products have been known as exterior parts of automobiles, and typical examples thereof include moldings such as side moldings, roof moldings, window moldings, bumper moldings, and header trims. In manufacturing such a molding, a known extrusion molding method is adopted (Japanese Patent Application Laid-Open No. 61-37411).

In such an extrusion molding method, a resin material in a softened state is extruded from an opening of a die having a predetermined shape, and a base material having a predetermined cross-sectional shape is obtained. Thereafter, the base material is cooled and solidified, and cut into a predetermined length to obtain a long molding. However, if only the extrusion molding is used, the cross-sectional shape may slightly change continuously in the longitudinal direction due to a change in the discharge pressure or the like. For this reason, there is a possibility that unevenness is generated on the design surface visually recognized from the outside, and the appearance quality is reduced.

[0004] As a technique for preventing such a reduction in appearance quality, a technique called sizing by evacuation is known. That is, as shown in FIG. 16, the base material 91 immediately after extrusion is continuously supplied into sizing dies 94 and 95 having predetermined molding surfaces 92 and 93, and the surface of the base material 91 is The base material 91 is slid in the longitudinal direction so as to contact the molding surfaces 92 and 93 of the molds 94 and 95. At this time, softening is still performed by simultaneously evacuating from the holes (including slits) formed in parts of the molding surfaces 92 and 93, that is, from the design surface side and the non-design surface side of the base material 91 at the same time. The base material 91 in a state
Is strongly pressed against the molding surfaces 92 and 93 of the molds 94 and 95 around the metal. Thus, even if some irregularities occur during extrusion molding, the surface of the base material 91 is shaped following the molding surfaces 92 and 93.

[0005]

However, in the above technique, when a resin material having a relatively high crystallinity, such as polypropylene, is used, the discharge amount tends to be different. It will be big. Therefore, even if the sizing is performed, the irregularities cannot be completely absorbed, and it may be difficult to perform appropriate shaping. As a result, even when sizing is performed by vacuum evacuation, shaping cannot be performed properly, and there is a possibility that the appearance quality may be deteriorated.

As another technique, a technique is known in which a substrate immediately after extrusion as described above is coated with a glossy resin film (PET film) in order to impart gloss to the product surface. (JP-A-62-1517, JP-A-1-283121, JP-A-63-12)
No. 6727). It is conceivable that this technique is performed before the sizing process. Thereby, when sizing is performed, the surface properties of the resin film are transferred to the surface of the base material that is still in a softened state (the film is usually peeled off after the transfer). For this reason, the glossiness of the surface of the molding finally obtained increases.

However, even in such a technique, when the above-described resin material is used, air is interposed between the film and the base material due to the relatively large unevenness, so that appropriate shaping is performed. In addition, there is a problem that transfer cannot be performed.

[0008] The present invention has been made in view of such circumstances, and an object of the present invention is to provide a method for manufacturing a long product manufactured by an extrusion molding method in which the appearance quality is dramatically improved. An object of the present invention is to provide a method for manufacturing a long product that can be manufactured.

[0009]

In order to achieve the above object, according to the first aspect of the present invention, a step of obtaining a long base material by extruding a resin material in a softened state; Formed on a part of the molding surface while sliding the substrate in the longitudinal direction so that at least the design surface visible from the outside of the substrate immediately after extrusion contacts the molding surface of the sizing mold. While performing vacuum evacuation from the hole made, applying a predetermined pressure to the surface opposite to the design surface, at least a step of shaping the design surface, a step of cooling the base material, and And a step of cutting into a predetermined length.

[0010] In the second aspect of the present invention,
By extruding a resin material in a softened state, a step of obtaining a long base material, of the base material immediately after extrusion,
A step of coating at least the design surface visible from the outside with a glossy film, so that the film on the design surface side abuts the molding surface of the sizing mold so that the base material covered with the film is elongated. While sliding in the direction
A step of shaping at least the design surface by applying a predetermined pressure to a surface opposite to the design surface while performing vacuum evacuation from a hole formed in a part of the molding surface, and cooling the base material And a step of cutting the base material into a predetermined length.

Further, according to a third aspect of the present invention, in the method of manufacturing a long product according to the second aspect, a step of peeling the film is provided after the shaping step. And

[0012] In addition, according to the invention described in claim 4, in the method for manufacturing a long product according to any one of claims 1 to 3, when the predetermined pressure is applied in the shaping step, The gist is to use rollers.

According to the first aspect of the present invention, a resin material in a softened state is extruded to obtain a long base material. Further, the base material is slid in the longitudinal direction such that at least the design surface visible from the outside of the base material immediately after extrusion contacts the molding surface of the sizing mold. At this time, a vacuum is drawn from a hole formed in a part of the molding surface, and a predetermined pressure is applied to a surface opposite to the design surface, so that at least the design surface is shaped. Thereafter, the base material is cooled and cut into a predetermined length to obtain a long product.

Here, depending on the resin material used,
During extrusion molding, large irregularities may be formed on the substrate. On the other hand, according to the present invention, at the time of sizing, a vacuum is performed in a state where at least the design surface of the base material is in contact with the molding surface, and a predetermined pressure is applied to the surface opposite to the design surface. Is added. For this reason, even if large irregularities are formed on the substrate, at least the design surface side of the substrate is strongly pressed against the molding surface, and the irregularities are absorbed and appropriate shaping is performed.

According to the second aspect of the present invention, a long base material can be obtained by extruding a resin material in a softened state. In addition, at least the design surface of the base material immediately after extrusion, which is visible from the outside, is covered with a glossy film. Then, such that the film on the design surface side contacts the molding surface of the sizing mold,
The substrate covered with the film is slid in the longitudinal direction. At this time, a vacuum is drawn from a hole formed in a part of the molding surface, and a predetermined pressure is applied to a surface opposite to the design surface, so that at least the design surface is shaped. Thereafter, the substrate is cooled,
By cutting to a predetermined length, a long product is obtained.

[0016] Therefore, basically, the same effects as those of the first aspect of the present invention can be obtained, and as a finally obtained product, a product having a gloss coated with a film can be obtained. Can be

Further, according to the third aspect of the present invention,
In addition to the effect of the invention described in claim 2, the film is peeled at a later stage of the shaping step. For this reason, the final product does not have a film, but during the sizing, the surface properties of the film are transferred to the surface of the base material that is still in a softened state.
The substrate surface will be protected. Therefore, the irregularities are absorbed and appropriate molding is performed, and the finally obtained product surface has a gloss.

In addition, according to the invention described in claim 4,
In addition to the effect of the invention according to claims 1 to 3, in the shaping step, by using a roller,
A predetermined pressure is applied. Therefore, it is possible to apply a constant pressure relatively easily, and the above operation is reliably achieved.

[0019]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIGS. As shown in FIG. 2, the side molding 11 as a long product in the present embodiment includes a core layer 12 and a skin layer 13 covering the core layer 12 and has a semicylindrical cross section. Core layer 12
Is made of polypropylene having a low linear expansion coefficient, and the skin layer 13 is made of highly crystalline polypropylene. The side molding 11 has a long shape as a whole, and has a gloss at least on a design surface side (curved surface side: upper surface side in the drawing) which can be visually recognized from the outside.

As shown in FIG. 3, the side molding 11 in the present embodiment goes through an extrusion step using a known extrusion molding method, a film sticking step, a sizing step, a cooling step, a cutting step, and a film peeling step. It is manufactured by

A well-known technique is employed for the extrusion step. That is, the base material 14 having a predetermined cross-sectional shape (see FIG. 8)
The design surface (curved surface) is continuously extruded and sent out such that the lower surface is on the lower side.

Next, a description will be given of a sticking device used in the film sticking step. As shown in FIGS. 4, 5, 6, and 7, the attaching device 15 includes a first station 16, a second station 17, and a third station 18. As shown in FIGS. 5 and 8, a resin film 19 wound in a roll shape is set in the first station 16 in advance. This film 19 is made of polyethylene terephthalate, and its surface (both sides) has a predetermined gloss. The first station 16 includes a supply base 21 and a supply device (not shown) so that the film 19 can be continuously supplied. Then, the first station 16 feeds the film 19 from the supply pedestal 21 with a supply device so as to support the curved surface of the base material 14 continuously sent from the extrusion device. .

As shown in FIGS. 6 and 9, the second station 17 has a bottom wall 22 conforming to the curved surface of the substrate 14 and side walls 23 extending inward and upward from both ends thereof.
Is provided. And the second
The station 17 supports the film 19 and the base material 14 sent from the first station 16 on the bottom wall surface 22, and at the boundary between the bottom wall surface 22 and the side wall surface 23 (corner portion). 19 can be bent inward. Thus, the substrate 14 is wrapped with the film 19 at least on the curved surface.

Further, as shown in FIGS. 7 and 10, the third station 18 has a bottom wall 25 conforming to the curved surface of the substrate 14 and side wall surfaces 26 extending upward from both ends thereof.
And a sticking roller device 28 is provided. The sticking roller device 28 includes:
A pair of shafts 2 erected on both left and right sides of the support base 27
9, a support bar 31 attached to the shaft 29,
A roller 33 is rotatably supported on the support bar 31 via a bearing 32. And the third
The station 18 supports the film 19 and the base material 14 sent from the second station 17 on the bottom wall surface 25 and bases the bent portion of the film 19, which is inwardly bent, on the roller 33. It can be pressed against the flat part of the material 14. Through these series of steps, the film 19 is adhered to the base material 14 on the curved surface and a part of the flat surface.

Next, a sizing apparatus used in the sizing step will be described. FIGS. 11, 12, 1
As shown in 3 and 14, the sizing device 34 has a lower die 35 for sizing and a pressure roller device 36.
The lower die 35 for sizing includes a bottom wall 37 substantially conforming to the curved surface of the base material 14 and side walls 38 extending upward from both ends thereof.
have. Also, inside the lower mold 35 for sizing,
A vacuum room 39 is formed, and the vacuum room 39 is connected to a suction device (not shown) via a communication path 41. The bottom wall 37 has a plurality of slits 42 forming a hole communicating with the vacuum room 39.
(In the present embodiment, a hole is formed by the slit 42). The pressure roller device 36 is
A plurality of pairs of shafts 43 erected on the left and right sides of the lower die 35 for sizing, a support bar 44 attached to the shaft 43, and rotatably supported by the support bar 44 via bearings 45. And a roller 46 capable of applying a predetermined load downward by an urging force of a spring (not shown) or the like. And the sizing device 34
Slides in the longitudinal direction while supporting the film 29 and the base material 14 sent from the attaching device 15 on the bottom wall 37. At this time, the lower die 35 for sizing performs vacuum evacuation of the base material 14 and the like from the slits 42 by suction by the suction device, and a predetermined surface (plane) opposite to the curved surface by the rollers 46. Pressure can be applied.

It is to be noted that any of various devices used in the cooling step, the cutting step, and the film peeling step can employ a known technique, and thus the description thereof will be omitted.

Next, in this embodiment, a method of manufacturing the side molding 11 using the various devices will be described. First, polypropylene in a plasticized state is extruded from a die opening of an extruder (not shown) by a known extrusion molding method. Thereby, the base material 14 having a predetermined cross-sectional shape is continuously extruded such that its design surface (curved surface) is on the lower side.

Next, the extruded substrate 14 is subjected to a film sticking step. That is, first, in the first station 16 of the attaching device 15, a flat film 19 is formed.
Are sent out continuously, and as shown in FIG.
The base material 14 is placed so that the curved surface portion is placed thereon.
Is sent out.

In the second station 17, as shown in FIG. 9, the film 19 and the substrate 14 sent from the first station 16 are
The film 19 is bent inward at both boundary portions (corner portions) of the bottom wall surface 22 and the side wall surface 23 while being supported.

Further, in the third station 18, while the film 19 and the base material 14 sent from the second station 17 are supported by the bottom wall surface 25, the bent portion of the film 19 is moved by the rollers 33. It is pressed against the flat part of the substrate 14. Then, through these series of steps, the film 19 is attached to the base material 14 on the curved surface and a part of the flat surface portion. However, at this stage, the base material 14 is still in a softened state.

Subsequently, the substrate 14 to which the film 19 has been attached is subjected to a sizing step. That is, the film 29 and the base material 14 sent from the attaching device 15 are slid in the longitudinal direction while being supported by the bottom wall 37 of the lower die 35 for sizing as shown in FIG. At this time, the substrate 14 and the film 19 are sucked by the suction device.
Is evacuated from below. Thereby, the substrate 1
4 is a bottom wall 37 as a forming surface together with the film 19.
Press strongly against. At the same time, a predetermined pressure is applied by the roller 46 from above.

Here, in the present embodiment, since polypropylene is used as the resin material forming the base material 14, compared with the case where the base material 14 is made of polyvinyl chloride or the like,
Large irregularities are likely to be formed on the base material 14 during extrusion molding. On the other hand, according to the present embodiment, due to the characteristic sizing, the design surface side of the
9 and is strongly pressed against the bottom wall 39, so that the irregularities are reliably absorbed and proper shaping is performed.

Further, by the pressing, the surface properties of the glossy film 19 are transferred to the surface of the base material 14 which is still softened. Thereafter, in the cooling step, the base material 14 is cooled. Thereby, the base material 14 is solidified. Further, in the next cutting step, the base material 14 and the film 19 are cut into a predetermined length by a cutting device (not shown). Then, in the next film peeling step, as shown in FIG. 15, the film 19 is peeled.
Through these steps, the side molding 11 as a final product is obtained.

Next, the operation and effect of this embodiment will be described. In the present embodiment, even when large irregularities are formed on the base material 14 during extrusion molding, the design surface side of the base material 14 is strongly pressed against the bottom wall 39 together with the film 19 due to the characteristic sizing described above. It will be. For this reason, the irregularities are reliably absorbed, and appropriate shaping is performed. As a result, there is no unevenness in the side molding 11 finally obtained, so that the appearance quality can be significantly improved.

Also, in the present embodiment, due to the pressing, the surface properties of the glossy film 19 are transferred to the surface of the base material 14 which is still in a softened state. Therefore, the surface of the side molding 11 finally obtained by peeling the film 19 not only has no irregularities but also has a beautiful luster. As a result, the appearance quality can be further dramatically improved.

Further, in this embodiment, pressure is applied using the rollers 46 in the sizing step. Therefore, it is possible to apply a constant pressure relatively easily and reliably. As a result, it is possible to reliably absorb the unevenness, and it is possible to ensure the effect of improving the appearance quality.

It should be noted that the present invention is not limited to the above-described embodiment, and may be implemented as follows, with a part of the configuration appropriately changed without departing from the spirit of the invention. (1) In the above-described embodiment, the film 19 is finally peeled off, but a product with the film 19 adhered may be used as a final product. In the case of such a configuration, as a finally obtained product, a product having a gloss coated with the film 19 can be obtained, and even in such a case, the unevenness can be reliably absorbed, and the appearance quality is improved. There is an effect that the operation can be performed.

(2) Film 1 in the above embodiment
The step of attaching 9 may be omitted. In other words, a configuration in which the process of transferring the gloss of the film 19 may not be provided may be provided, and even in such a case, the above-described effects can be obtained.

(3) The method of attaching the film 19 is not limited at all. For example, the film 19 may be attached manually. (4) In the above embodiment, the side molding 11 is constituted by the core layer 12 and the skin layer 13.
It may have any configuration as long as the basic cross-sectional shape is formed by extrusion. In addition, the material is not limited to polypropylene, and any thermoplastic resin material such as polyester, polyamide, thermoplastic elastomer, and other polyolefins may be used.

(5) In the above embodiment, when a predetermined load is applied by the roller 46, an urging force such as a spring is used. However, the pressure may be applied only by the load of the roller. Alternatively, a pressure sensor may be provided separately to control the pressure.

Further, instead of the rollers 46, pressure may be applied by applying a predetermined load using, for example, a block. (6) In the above-described embodiment, the present invention is embodied in the side molding 11 as a long product, but the molding such as a roof molding, a window molding, a bumper molding, a header trim, and other long moldings may be provided outside the side molding. It can also be embodied in a product.

[0042]

As described in detail above, according to the present invention,
In the method for manufacturing a long product manufactured by the extrusion molding method, an excellent effect that the appearance quality can be dramatically improved can be achieved.

[Brief description of the drawings]

FIG. 1 is a partial perspective view showing a sizing process using a sizing apparatus according to one embodiment.

FIG. 2 is a partially broken perspective view showing a side molding.

FIG. 3 is a process chart for explaining a manufacturing process.

FIG. 4 is a side view showing the attaching device.

FIG. 5 is a sectional view showing a first station.

FIG. 6 is a sectional view showing a second station.

FIG. 7 is a sectional view showing a third station.

FIG. 8 is a sectional view showing a base material and the like passing through a first station.

FIG. 9 is a sectional view showing a base material and the like passing through a second station.

FIG. 10 is a sectional view showing a base material and the like passing through a third station.

FIG. 11 is a perspective view showing a lower die for sizing.

FIG. 12 is a partial perspective view showing a sizing device.

FIG. 13 is a sectional view taken along line JJ of FIG. 12;

FIG. 14 is a sectional view taken along the line KK of FIG. 12;

FIG. 15 is a cross-sectional view showing a substrate and the like when a film is peeled off.

FIG. 16 is a cross-sectional view showing a sizing mold and the like in the related art.

[Explanation of symbols]

11 ... side molding as long product, 14 ... base material, 1
9: film, 34: sizing device, 35: lower die for sizing, 36: pressure roller device, 42: slit forming a hole, 46: roller.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29L 31:30

Claims (4)

[Claims] 1. A step of obtaining a long base material by extrusion-molding a resin material in a softened state, and a sizing mold for at least a design surface of the base material immediately after extrusion that is visually recognized from the outside. As the base material is slid in the longitudinal direction so as to abut against the molding surface, vacuum is evacuated from a hole formed in a part of the molding surface, and the surface opposite to the design surface is evacuated. Applying a predetermined pressure to at least shaping the design surface; cooling the base material; and cutting the base material to a predetermined length. . 2. A step of obtaining a long base material by extruding a resin material in a softened state, and at least a design surface of the base material immediately after extrusion, which is visually recognized from the outside, is made glossy. A step of coating with a film having a design surface, while sliding the base material covered with the film in the longitudinal direction such that the film on the design surface side contacts the molding surface of the sizing mold, Vacuuming from the hole formed in the part, applying a predetermined pressure to the surface opposite to the design surface, shaping at least the design surface, and cooling the base material, Cutting the base material to a predetermined length. 3. The method for manufacturing a long product according to claim 2, wherein a step of peeling off the film is provided after the shaping step. 4. The method for manufacturing a long product according to claim 1, wherein a roller is used when applying the predetermined pressure in the shaping step.