JPS59136255A - Manufacture of composite shape - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a composite molded body A consisting of a laminated base layer 1 and a skin material layer 2, in which the peripheral edge of the molded body A is layered with one skin material as shown in FIG. 1C. The purpose of the present invention is to efficiently manufacture a product having an attractive and beautiful edge finish using a thin-walled extension piece 2' of a layer 2.

Here, the base layer l is, for example, a hard or semi-hard synthetic resin, a rigid resin foam such as polystyrene beads, or the like. The skin material layer 2 may be made of a single layer material such as a soft solid fleshed or foamed synthetic resin sheet, woven fabric, knitted fabric, nonwoven fabric, or synthetic leather, or a soft synthetic resin foam on the back side of the single layer material 2a.・It is a laminated material lined with a cushioning material layer such as felt and 2 bt of other intermediate material layers.

Layer structure work as above ・2. The composite molded body A (2a, 2b) is, for example, a door trim board, which is an interior part for a vehicle.
It is widely used for various interior construction materials such as front seat panels, ceiling lining boards, dash boards, furniture, and exterior materials for electrical appliances.

The general manufacturing method is to use a laminated flat plate in which each of the constituent layers 1 and 2 are laminated together in advance as a raw material, and then use an appropriate forming method such as vacuum forming, pressure forming, hot press forming, press forming, etc. It is molded into the required three-dimensional shape. Then, at the same time as the molding, or after demolding, remove unnecessary material around the molded object (edge around the molded object).

Remove cutting (trimming process). Although some products are made into final products after this process, the laminated surfaces of each component R1 and R2 are exposed on the cut end surface 3 (FIG. 1a) at the periphery of the molded product, making it unsightly. In order to avoid peeling of layers 2a and 2b from the cut end surface, after the trimming process around the molded article, an edge finishing process is applied to the page to hide the trimmed end surface to obtain the final product.

Specifically, as shown in Fig. 1a, a separately produced molding material 4 is attached to the peripheral edge of the trimmed molded body to conceal the trimmed end surface 3 and finish the edge to produce the final product. However, installing the molding material requires materials and labor, resulting in high costs. Furthermore, since the molded body is surrounded by a frame-like frame when the molding material 4 is attached, this is not a desirable form in many cases.

Therefore, if such an edge finish form is not preferred, the base layer 1 and the skin layer 2, which are the constituent layers of the composite molded body, are molded separately, and the base layer 1 is molded into the desired external shape. The skin material layer 2 is a molded body with an external shape slightly larger than the required external shape, and the image molded bodies are overlapped in a fitting manner and bonded together, and the excess extension around the molded body of the skin material layer 2 is formed. As shown in FIG. 1, the portion 2' is wrapped around the back side of the base layer 1 and fixed with an adhesive or the like to finish the edges.

In this way, if the peripheral edge of the skin material layer 2 of the molded body is made into an extension piece 2'/ and the extension piece is wound around the back side of the base layer 1 and fixed, and the edge treatment is performed, the end face of the molded body will be in line with the surface of the molded body. This becomes an extended surface of the skin layer, and the disadvantages of using the molding material 4 are eliminated.

However, if the skin material layer 2 (2a or 2a+2b) is relatively thick, the cross-sectional shape of the rolled-up portion will not be sharp due to the thickness, resulting in a thick edge finish. There is a problem. In addition, in the case of a molded product whose outer circumferential portion is largely bent, when the thick skin layer extension piece 2 is rolled up, wrinkles tend to occur at the rolled-up part due to the bending. It takes a lot of skill and effort to wrap the entire circumference of the product uniformly.

The present invention has been proposed in view of the above-mentioned latter case, and has a form in which the peripheral edge of the skin material layer 2 is extended and the extended portion is wrapped around the back side of the base layer 1 to finish the edge. In this method, the composite molded body is manufactured by actively thinning the extended portion of the skin material layer 2 for winding on the back side of the base layer in the process of manufacturing the composite molded body, and by thinning the skin material layer 2. Processing extension piece 2
(Fig. 1C) is rolled onto the back side of the base layer 1, so that even if the skin material layer 2 itself is thick, the molded body A
The present invention provides a method for easily mass-producing this type of composite molded article, which has a sharp edge without thickening and a beautiful edge finish without wrinkles.

That is, in the present invention, for each of the base layer 1 and the skin material layer 2 of a composite molded body A consisting of a laminated base layer 1 and skin material layer 2, the base layer 1
The skin material layer 2 is molded as a molded body with a desired external shape, and the skin material layer 2 is molded as a molded body with an extra extension material portion 2'' left around the desired external shape, and both layers 1 and 2 are laminated and integrated. The peripheral edge extra extension material part 2 is a press-formed part provided in the mold when molding the skin material layer 2 or when laminating and integrating both the layers 1 and 2,
The thin wall is rolled or stretched in a vacuum forming section, a pressure forming section, or a combination forming section thereof, and the extra extended material portion 2' around the thinned skin material layer is wound around the back surface side of the base layer l. The gist of this invention is a method for manufacturing a composite molded body, which is characterized in that the edges of the molded body A are finished by inserting and stopping the molded body.

Below, various examples will be specifically explained.

, Example 1 (Figs. 2 to 4) In this example, a thermoplastic resin sheet or a woven fabric, knitted fabric, non-woven fabric, etc. 2a having good thermal extensibility is used as the skin material layer 2, and a thermoplastic resin foam material is used as the intermediate material layer on the back side of the woven fabric, knitted fabric, non-woven fabric, etc. 2a. Cushion sea 1-2b (
A relatively thick material is used for the entire bonded cushioning material layer (hereinafter referred to as "cushion material layer"), and this is formed by vacuum forming. This is an example in which a plastic resin is formed and adhered by injection molding (or pressure molding), and the extra extended material portion around the effective molding area of the skin layer 2 is thinned by vacuum forming and pressing.

In FIG. 2, 5 and 6 are first and second molding surfaces that, when clamped together, constitute a cavity with a spatial shape that substantially matches the three-dimensional shape of the entire composite molded product A to be manufactured between the opposing effective molding surfaces 51 and 61. This is a second pair of split molds. Here, the first mold 5
A mold is used to form the back side of the composite molded body A (the back side of the base layer 1), and a second mold 6 is used to form the front side (the surface of the skin material layer 2). Also, the first mold 5 is a fixed mold, and the second mold 5 is a fixed mold.
Mold 6 is used as a movable mold to clamp and open both molds (
(The mold opening/closing mechanism is omitted from the diagram).

The effective molding surface 51 of the first mold 5 has a thermoplastic resin injection hole 5.
2 is opened (the resin injection machine is omitted from the figure). A large number of small vacuum suction holes 62 are opened in the effective molding surface 61 of the second mold 6. Further, a relatively deep annular groove 54 is formed around the effective molding surface 51 of the first mold 5 on the mold matching surface 53 with the second mold 6, surrounding the effective molding surface 51. It is.

When the second mold 6 is clamped to the first mold 5, the effective molding surface 61 of the second mold 6 has a mold mating surface 63 with the first mold 5 on the outer periphery. An opposing annular protrusion 64 that fits into the annular groove 54 is formed.

A small vacuum suction hole 62 is also opened on the outer surface of this annular convex portion 64.

55 and 65 are cooling water pipes buried in the respective wall thicknesses of the first and second molds 5 and 6, and P is a vacuum pump.

The first and second molds 5 and 6 are opened to each other, and the material sheet 2 for the skin material layer is heated and softened in advance, and the second mold 6 is equipped with a vacuum forming function as described above. The mold is then vacuum formed and held on the mold surface as it is (Fig. 2). By vacuum forming the skin material layer material sheet 2, the material sheet portion 2 corresponding to the annular convex portion 64 of the second mold 6, that is, the extra extended material portion around the outer periphery of the effective molding portion of the skin material layer 2 is formed into an annular convex portion. The outer surface of 64 is stretched and formed into a considerably thinner state.

Next, the second mold 6 holding the vacuum-formed body of the skin material layer is clamped to the first mold 5 (FIG. 3). Due to this mold clamping, the annular convex part 64 on the second mold 6 side fits into the annular groove 54 on the first mold 5 side, and the skin material layer extra extension material part on the outer surface of the annular convex part 64 becomes the convex part 64. It is pressed between the concave grooves 54 by clamping force to further reduce the thickness 2.

After the first and second molds 5 and 6 are clamped, molten resin is injected into the mold cavity from the resin injection hole 52 on the first mold 5 side. Then, the injected molten resin flows between the effective molding surface 51 of the first mold 5 and the back surface of the effective molding area of the skin material layer vacuum-formed body 2 on the second mold 6 side, and the base layer 1 is formed and the skin material Layer 2 and 171 layer are integrated.

Then, after a predetermined cooling time has elapsed, the mold is opened and the molded body is taken out. As shown in the fourth figure, the removed molded body has a thinned extra extension material part 2 of the skin material layer 2 around the effective molded part.
This is a form in which these are arranged in series. Therefore, the extra extension material is trimmed to an appropriate width c-cL, rolled onto the back side of the base layer of the molded body as shown by the two-dot chain line, and fixed using an appropriate means such as an adhesive or a fastener. . This allows the first
As shown in Figure C, use the thin-walled extension piece 2 of the skin material layer to create a beautiful and sharp appearance.A composite molded article A with edge finishing treatment is obtained.

In addition, for the purpose of smoothly and well press-thinning the excess extension material portion of the skin material layer by the annular groove 54 and the annular convex portion 64 of the first and second molds, for example, as shown in the figure, the first mold A heater 5 for heating and softening the skin material layer is placed in the annular groove 54 portion of the mold 5.
6 is recommended. If there is a risk that the heat of the molten resin injected into the mold cavity will cause an adverse effect such as deformation on the foamed structure of the cushioning material layer 2b on the skin material layer 2 side, the free surface of the cushioning material layer 2b may be further thickened. It is preferable to form resin sheet layers in a laminated manner. Further, it is preferable to attach a heat shielding/pressure resistant piece such as metal foil to the back side of the skin material R2 facing the resin injection hole 52 before clamping the mold.

Example 2 (Figures 5 to 8) In this example, layers 2a and 2b were used as the skin material layer 2 in the same manner as in Example 1.
Using a sheet material consisting of a laminated sheet material, this is molded by vacuum forming, the base layer 1 is a resin foam molded body using foamable resin beads such as polystyrene beads, and the periphery of the effective molding area of the skin material layer 2 is formed. This is an example in which the extra extended material portion is made thinner by vacuum forming and pressure forming.

In FIG. 5, 5 and 6 indicate cavities having a spatial shape that substantially matches the overall three-dimensional shape of the composite molded body to be manufactured between the opposing effective molding surfaces 51 and 61 when the mold is clamped in the same manner as in Example 1. They are a first fixed mold and a second movable mold. 7 is an auxiliary mold that is fitted into the second mold 6, and when the second mold 6 into which the auxiliary mold 7 is fitted is clamped to the first mold 5, the first mold 5 becomes effective. A cavity having a spatial shape substantially matching the shape of the base layer 1 of the composite molded body A is formed between the molding surface 51 and the free surface 71 of the auxiliary mold 7.

The first mold 5 has a foamable resin bead introduction pipe 57 opened on an effective molding surface 51, and has a large number of small holes 5 for ejecting hot air such as steam.
8 is opened. S is a hot air supply source. Further, the molding surface 53 of the first mold 5 which is connected to the second mold 6 or the auxiliary mold 7 on the outer periphery of the effective molding surface 51 has a relatively deep surface surrounding the effective molding surface 51. An annular groove 54 is formed, and a small vacuum suction hole 59 is opened at the bottom of the groove.

A large number of small vacuum suction holes 62 are opened in the effective molding surface 61 of the second mold 6 and the mold matching surface 63 with the first mold 5. Also, on the mold matching surface 63 of the second mold 6, which corresponds to the annular groove 54 of the first mold 5, a large number of air or hot air jets are provided along the outer periphery of the effective molding surface 61. The hole 66 is opened. a is the air or hot air supply source.

Then, the auxiliary mold 7 is fitted into the $2 mold 6, and the second mold is clamped to the second mold 5. Beads are introduced and filled into the cavity between the auxiliary mold 7 and the first mold 5 through the foamable resin bead introduction v57, and then hot air is jetted out from the hot air jet small holes 58. Then, the beads filled in the cavity are thermally foamed and welded together to form a base layer 1 made of resin bead foam (FIG. 6). Effective molding surface 6 of second mold 6
A hot air ejection hole is also formed in 1, and correspondingly, a small communicating hole is formed by penetrating the wall thickness of the auxiliary mold 7, or the auxiliary mold 7 is made of a porous fleshy body. Second mold 6
If hot air is introduced from the side into the mold cavity filled with foamable resin beads, the beads can be foamed more efficiently.

After that, after a predetermined cooling time has passed, the molded substrate layer 1 is held on the molding surface 51 of the first mold 5 and molded,
The auxiliary mold 7 is removed from the second mold 6 and removed.

Next, with the first and second molds 5 and 6 in the opened state, the material sheet 2 for the skin material layer, which has been subjected to heat softening treatment in advance, is transferred to the second mold 6 equipped with a vacuum forming function as described above. The mold is vacuum formed and held on the mold surface as it is (
Figure 7).

Next, the second mold 6 holding the molded skin layer 2 is re-clamped to the first mold 5 holding the molded base 1. Then, the clamping force of the molds 5 and 6 causes the molded base layer 1 and the molded skin layer 2 to press into close contact with each other in a fitting manner, and - the back surface of the skin material layer 2 or the surface of the base layer 1 or its Both layers 1 and 2 are bonded to each other by an adhesive layer applied to both surfaces in advance (Figure 88).

When the base layer 1 and the cushioning material layer 2b of the skin material layer 2 are made of materials that can be heat-sealed to each other, the bonding surfaces of the base layer 1 and/or the skin material layer 2 are bonded together before the molds 5 and 6 are clamped. No adhesive is required if heat treatment is performed beforehand, such as by blowing hot air.

On the other hand, after re-clamping the first and second molds 5 and 6, the vacuum suction hole 59 on the bottom of the annular groove 54 of the first mold 5 is brought into a vacuum suction state, and the air on the second mold 6 side is Or hot air blowout hole 66
Air or hot air is blown out from. Then, the portion 2'' of the extra extension material of the skin layer that is in close contact with the mold matching surface 63 of the second mold 6 and corresponds to the annular groove 54 of the first mold 5 is vacuum formed and pressure formed. It is stretched to the surface of the annular groove 54, becomes thinner 2, and comes into close contact with it (
-Fig. 8).

Then, after a predetermined cooling time has elapsed, the mold is opened and the molded body is taken out. As in the case of Example 1, the molded body taken out has a form in which a thinned extra extension material portion 2 of the skin material layer 2 is continuously provided around the effective molded portion as shown in the fourth figure.

Therefore, by trimming the extra extension material to an appropriate width dimension and rolling it onto the back side of the base layer 1, the first
A composite molded article A having a good-looking edge finish treatment such as 1χC is obtained.

In addition, the skin material layer extra material portion 2'! The thinning may be performed only by vacuum forming using the vacuum suction hole 59 or only by pressure forming using the air or hot air blowing hole 66. In addition, for the purpose of smooth and good elongation of the extra material portion 2 of the skin material layer during thinning processing by vacuum forming, pressure forming, or both, for example, the skin to be thinned as shown in the figure. It is preferable that a heater 67 for heating and softening the skin material layer is disposed at a position on the second mold surface corresponding to the position of the excess material portion of the material layer.

The base layer 1 is a foamable resin bead introduction pipe 57 on the first mold 5 side.
As shown in FIG. 9, the molten resin injection (or pressure feeding) hole 52 may be made into a resin injection molding method. In this case, in order to prevent the injected resin from going around into the annular groove 54, the auxiliary mold 7 is fitted into the annular groove 54 as shown by the two-dot chain line in FIG. 5 or shown in FIG. It is possible to form an annular convex portion 72 that fills the area.

The auxiliary mold 7 does not have to be a part that fits into the second mold 6, but can be constructed as a thick third mold as shown in FIG. The third mold 7 is clamped and executed, then the molding base layer is held on the first mold 5 side and the mold is opened, the third mold 7 is retracted to the side, and then the molding base layer is A method may be adopted in which the skin material layer 2 is vacuum-formed and held by the first mold 5 which is held, and then the second mold 6 is clamped. In FIG. 9, 8 is a fixed gou plate, 9 is a movable gou plate that is driven forward and backward along the guide rod 10,
Reference numeral 11 denotes a third mold holding member that is driven forward and backward along the guide rod 12, and the third mold 7 is free to slide relative to this holding member 11 in a direction perpendicular to the plane of the drawing, and is attached to the third mold holding member 11 relative to the first mold 5. When the two molds 6 are to be clamped, the two molds 5 and 6 can be evacuated laterally from between the two molds 5 and 6.

In addition to the above-described embodiments, the present invention also provides the base layer 1 as a molded body with a desired external shape, and the skin material layer 2 as a molded body with an extra extension material portion left around the desired external shape, respectively. The molded base layer 1 and the molded skin layer 2 are bonded and bonded by fitting and holding them into mating molds for male and female press lamination, and clamping the mating molds. It also includes a method of rolling or stretching the outer peripheral extra extension material portion of the molded skin material layer 2 into a thin wall in a press forming section, vacuum forming section, pressure forming section, or a combination forming section thereof provided in a mating mold.

Furthermore, the present invention is applicable not only to the case in which the entire periphery of the molded body is wrapped and finished with the thinned extension piece 2' of the skin material layer 2, but also to the case where a part of the periphery of the molded body is finished as described above depending on the form of the objective composite molded body. This also includes finishing the edges.

As described above, according to the method of the present invention, as shown in FIG.
Composite molded body A with a shape with a beautiful and beautiful edge finish
It is possible to mass-produce efficiently, the intended purpose is well achieved, and it is an effective and suitable method for manufacturing this type of composite molded article.

-4. Brief description of the drawings Figures 1 a*b*c are cross-sectional views of various edge finishing forms, Figures 2 to 4 show the mold configuration and process of the first embodiment, and the second The figure is a cross-sectional view of the half-way part of the surface material layer vacuum-formed with the open movable mold, Figure 3 is the same view of the mold with the mold closed to form the base layer, and Figure 4 is the same diagram as above. 5 to 8 are cross-sectional views of the edge of the composite molded product taken out from the mold, and show the mold configuration and process of the second embodiment. Figure 5 shows the opening of the mold used. FIG. 6 is a cross-sectional view of the half of the road in the state, and FIG.
Figure 7 is the same diagram as above of the mold after the mold has been opened and the skin material layer has been vacuum-formed with the movable mold, Figure 8 is the same diagram as above of the mold after it has been re-clamped, and Figure 9 is the same diagram as above of the mold in the state where the mold has been re-clamped. The same figure as the above of a modification.

5. 6 is the first and second mold, 7 is the auxiliary mold or the third mold.

Claims (1)

[Claims] (1) Regarding the base layer (1) and the skin material layer (2) of the composite molded article (A) consisting of a lamination of the base layer (1) and the skin material layer (2), the base layer (1) has the required external shape. As a molded product, the skin material layer (2) is molded as a molded product with an extra extension material portion (2) left around the required external shape, and both layers (1) and (2) are laminated and integrated to form the skin material layer. (2) The above-mentioned peripheral edge extra extension material part (2γ is formed during molding of the skin material layer (2) or both the above-mentioned layers (1
)・The thinned skin material layer is formed by rolling or stretching into a thin layer in the press forming section, vacuum forming section, pressure forming section, or combination forming section provided in the mold during lamination and integration in (2). Excess extension material on the periphery (2) is attached to the base layer (1)
A method for manufacturing a composite molded body, which comprises rolling the molded body (A) onto the back side thereof and finishing the edges of the formed body (A).