JPS596230B2 - Manufacturing method of composite molded body - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a composite molded article consisting of a hard layer (substrate) and a soft layer laminated together, and an object of the present invention is to finish the edges of the molded article with a nice and beautiful finish.

For example, interior materials such as vehicle door trims, front seat panels, ceiling lining panels, dashboards, etc. are generally constructed by laminating a base layer 1 of a hard material with appropriate strength and rigidity and a soft material 2. Composite molded bodies are used. Composite molded bodies having the above-mentioned layer structure are also frequently used in various other interior materials for buildings, furniture, exterior members for electrical appliances, and the like. Specific materials for the base layer 1 include various hard and semi-hard resins such as vinyl chloride, resin bead foams such as polystyrene, metal plates, resin felt, cardboard, condensed plant material, and lamination of such hard materials. Examples include complexes.
Specific materials for the soft layer 2 include various soft resin foams such as vinyl chloride, polyethylene, polypropylene, and polyurethane, various cushioning sheets 21 such as felt, and protective and decorative skin materials 22 on the surface of such cushioning sheets 21. Various soft resin sheets such as vinyl chloride, cloth,
Examples include laminations of reinforced paper, soft leather, soft synthetic leather, etc., and laminated composites of various soft materials. Conventionally, the production of the above-mentioned composite molded bodies generally involves forming a laminated flat plate, in which all of the constituent layers are bonded together, into the desired shape by means such as vacuum forming, press forming, plug forming, etc. This is done simultaneously with the processing and molding, or by cutting and removing (trimming) unnecessary edges around the molded body after demolding.

In this case, some products can be produced by trimming the unnecessary edges, but if only trimming is performed, the laminated end surfaces of each constituent layer will be exposed on the cut surface 3 around the composite molded body, and especially the base layer 1
Or, if the soft layer 2 or both layers 1 and 2 are composites, many layer end faces will appear on the cut surface 3 and the appearance will be poor. In some cases, the cut surface of the composite molded product may be further concealed after the above trimming due to the danger of exposing the edge of the wire mesh and the risk of peeling due to the peeling of each layer at the cut surface. Process and finish the edges to create a product. In this case, as shown in FIG. 1b, the periphery of the soft layer 2 is extended 2', the extended part 2' is folded back to the back side of the base layer 1, and the cut surface is fixed with adhesive or the like. The best appearance and beautiful edge finish is to leave the edges covered.

However, it is not possible to manufacture a composite molded article with the above-mentioned edge-treated form using the conventional method that uses a laminated flat plate as a raw material in which all the constituent layers are bonded together in advance. Conventionally, in cases where the cut surface 3 needs to be concealed, the cut surface is generally concealed by attaching separately produced molding material around the edge of the trimmed composite molded body, but the process for attaching the molding material This is time-consuming and costly. Furthermore, the edges of the molded body are often framed with molding material, which is not preferred as a form. The present invention has been proposed in view of the above, and an object of the present invention is to efficiently and inexpensively mass-produce a composite molded product having an edge treatment configuration as shown in FIG. 1b without using a molding material.

A detailed explanation will be given below with reference to the drawings.

The present invention prepares a pair of male and female first and second facing molds 4 and 5 for molding the front side and the back side of a composite molded body, respectively,
When the material to be molded is pressed between the opposing surfaces of both dies 4 and 5, the effective molding surface area a of both dies is made such that the part of the molding material existing between them is not pressed on the mold opposing surface area b around the outer periphery of the molding surface area a. A structure in which a gap α (FIG. 3) is created between opposing surfaces is used.

In the illustrated example, the effective molding surface area a of the mold 4 is the outer peripheral area b.
The above-mentioned gap α is formed by forming the surface to be sloped downward with respect to the horizontal plane on the mold 5 side.

Then, the first mold 4 is equipped with a vacuum forming mechanism by opening a number of vacuum holes 41 on its molding surface, and the thermoplastic soft layer material 2 is vacuum-formed by the mold 4 and held as it is on the mold surface. (Figure 2).

Next, a hard base layer material 1 such as a press-formable metal plate or resin felt plate is inserted between the mold 4 and the second mold 5, and the molds are clamped (pressed) (FIG. 3). Then, the hard base layer material 1 is press-molded between the molding surface of the mold 5 and the back surface of the soft layer material 2, and both materials 1 and 2 are joined together in the effective molding area a, and the surrounding area outside the area is press-molded. Material part 1
'', 2/, a composite molded body in a non-adhesive state is obtained without being pressed.The integral joining of the two materials 1 and 2 in the above region a is performed in advance by applying pressure to one or both of the opposing surfaces of the two materials 1 and 2. This is achieved by applying a suitable layer of adhesive.

Next, as shown in FIG. 4, the hard base layer material 1 of the molded body is trimmed to remove unnecessary material around the outside of the effective molding area a, and the soft layer material 2 is trimmed to remove the unnecessary material around the outside of the effective molding area. 2'' is folded back to the back side of the hard base layer 1 and fixed with adhesive or the like.

If the length of the material portion 2' to be folded is unnaturally long, it is trimmed to an appropriate length before being folded. As a result, the desired composite molded article whose edges are neatly and neatly treated as shown in FIG. 1b can be obtained.

When the base layer material 1 is a vacuum-formable material such as a thermoplastic resin plate, the second mold 5 is also equipped with a vacuum molding function by forming vacuum holes 51 on its molding surface. By vacuum forming and holding the base layer material 1 (FIG. 5), and clamping the mold 5 and the first mold 4 which vacuum formed and held the soft layer material 2, both materials 1,
The two effective molding surface areas a are joined together with an adhesive interposed therebetween. Then, in the same manner as in FIG.
Process by wrapping. Soft layer material 2 is cushion material layer 2
1 and a skin material layer 22 bonded to the surface thereof, the thickness of the cushion material layer 21 is quite thick. Therefore, in FIG. 1
If the overall thickness of the folded edge of the composite molded body becomes thick when folded to the back side of the composite body, causing a problem, the first
As shown in FIG. c, only the skin material layer 22 may be extended 22' and the extended portion may be folded back toward the back side of the base layer 1 for edge treatment.

FIG. 6 shows an example of manufacturing a composite molded body for performing such edge treatment, in which the skin layer material 22 is
is vacuum formed to hold it. Further, the second mold 5 holds the base layer material 1 which has been previously formed into a desired shape and has been trimmed. Then, the cushion layer material 21 is inserted between the molds 4 and 5, and the molds are clamped. Alternatively, if the base layer material 1 is made of a material with air permeability, such as hardened felt or hardened plant material, the cushion layer material 21 is vacuum-suctioned onto the surface of the base layer material 1 by utilizing its air permeability. After wearing it, the mold is tightened. As a result, the base layer 1, the cushion material layer 2
1. The skin layer materials 22 are integrally bonded to each other in the effective molding area a by an adhesive previously interposed between the materials, and the cushion layer material portion 2 around the outside of the effective molding area a is formed.
A non-adhered composite molded body is obtained for the skin layer material portion 2g. Thereafter, the cushion layer material portion 2'' is removed by trimming, and the skin layer material portion 22' is folded back to the back side of the base layer 1 and fixed, thereby forming the cushion layer material 2 as shown in FIG. 1c.
Even if the thickness of No. 1 is large, the desired composite molded product with a beautiful and attractive finish on the edges can be obtained.

In addition, for the purpose of laminating the base layer 1 and the soft layer 2 without causing so-called air pockets therebetween, the second,
In the case of the process shown in Fig. 3, for example, a large number of air suction holes (for example, about 0.31L11fP) are opened on the molding surface of the mold 5, and the base layer material 1 is made of a breathable material or the base layer material It is preferable to use a mold 1 which has a number of ventilation holes formed in advance to provide ventilation, and to draw air through the air suction holes of the mold 5 during the pressing state shown in FIG. In this case, the air between the base layer material 1 and the soft layer material 2 is removed through the thickness of the breathable base layer material 1, thereby preventing the formation of air pockets. In addition, in the case of a method in which the base layer material 1 is vacuum-formed using a mold 5 as in the process shown in FIG.
The mold 5 is provided with a plurality of retractable pins 6 (FIG. 7) that protrude from the molding surface of the mold and are used to form ventilation holes in the base layer material 1. First, the pins 6 are retracted and the tips are moved from the mold. 5, the base layer material 1 is vacuum-formed on the molding surface of the mold and held as it is on the molding surface.

Next, while the molding material 1 still maintains its softness, each pin 6 is operated to project so that its tip end passes through the molding material 1 and projects as shown in FIG. Next, by retracting each pin 6 again, a vent hole 11 is formed in the material 1, and outside air passes through the vent hole 11 and then the pin guide hole 61, and is brought into a suction state. Next, a mold 5 holding the material 1,
By clamping and pressing the mold 4 holding the material 2 (FIG. 8), the air between the two materials 1 and 2 is eliminated, thereby preventing the formation of air pockets. In addition, in the case of the process shown in FIG. 6, a mold 5 equipped with pins 6 for forming vent holes is used as in FIGS. The cushion layer material 21 is vacuum-formed onto the surface of the base layer material using the through-holes of the base layer material as vacuum holes to cover the base layer material. At the same time, a vent hole is formed in the cushion layer material 21 by protruding the pin 6.

Next, the pins are moved back to clamp the mold 5 holding the materials 1 and 21 and the mold 4 holding the skin layer material 22. At this time, the air between the cushion layer 21 and the skin layer 22 is sucked and removed through the ventilation hole of the cushion layer 21 → the ventilation hole of the base layer 1 → the guide hole 61 of the pin 6, and the air between the two materials 21 and 22 is sucked out. The occurrence of accumulation is prevented. As described above, according to the method of the present invention, (1) A mold as shown in FIG. It is possible to easily produce a composite molded article with a beautiful and beautiful edge treatment without using.

(2) In addition, in the conventional method described above, when heating and softening a laminated flat plate for vacuum forming, the thermal properties of each constituent layer of the laminated plate are significantly different, so the overall quality of the laminated plate is good. Softening treatment requires advanced technology and takes time.

Since the present invention employs a method in which the hard and soft constituent layer materials are molded separately and then integrated, each material can be thermally softened easily and quickly. (3) In addition, in the conventional method, the material cut and removed during trimming is a combination of hard and soft different materials, which can be melted and reused (in the case of thermoplastic resin, etc.) as a raw material for manufacturing laminates. is not possible in most cases, resulting in low material utilization and a significant impact on product costs.

In the case of the present invention, since each component layer material is separately molded and trimmed, the waste material is a single material, which can be melted and reused as a raw material, thereby reducing costs. This is an effective and suitable method for producing this type of composite molded body.

[Brief explanation of the drawing]

Figure 1a is a cross-sectional view of an example of a composite molded product, Figures b and c are enlarged cross-sectional views showing edge treatment, Figure 2 is a cross-sectional view before mold clamping, and Figure 3 is a cross-sectional view after mold clamping. , Figure 4 is a cross-sectional view of the base layer with trimming, Figures 5 and 6 are cross-sectional views of other manufacturing examples before mold clamping, and Figures 7 and 8 are bonding of materials without air pockets. An explanatory diagram of an example in which this is done. 1 is a base layer, 2 is a soft layer, and 4 and 5 are molds.

Claims (1)

[Scope of Claims] 1. In manufacturing a composite molded body consisting of a hard base layer 1 and a soft layer 2 bonded together, a pair of male and female first and Second facing type 4
, 5 is prepared, and when the material to be molded is pressed between the opposing surfaces of both molds, the part of the material to be molded existing between the effective molding surface area a of both molds and the mold opposing surface area b around the outer periphery is pressed. In addition, the first mold 4 is equipped with a vacuum forming function, and the soft layer material 2 is vacuum formed by the first mold 4 and held in the mold as it is. By inserting the hard base layer material 1 between the mold 4 and the second mold 5 and clamping the molds, the hard base layer material 1 is pressed, and the hard base layer material 1 and the soft layer material 2 form an effective molding area. The two material parts 1' and 2' around the outside of the area are joined together through an adhesive interposed between them to form a non-adhesive composite molded body, and then the hard base layer material of the molded body is bonded together. 1
The material portion 1' around the outside of the effective molding area is trimmed to create the material portion 2 around the outside of the effective molding area of the soft layer material 2.
1. A method for manufacturing a composite molded article, which comprises folding and fixing the material 1 to the back side of the hard base layer 1. 2. In manufacturing a composite molded body consisting of bonding a hard base layer 1 and a soft layer 2, a pair of male and female first and second opposing molds are used to respectively mold the front side and back side of the composite molded body. 4
, 5 is prepared, and when the material to be molded is pressed between the opposing surfaces of both molds, the part of the material to be molded existing between the effective molding surface area a of both molds and the mold opposing surface area b around the outer periphery is pressed. In addition, both molds 4 and 5 are equipped with a vacuum forming function, and the first and second molds 4 and 5 form the soft layer material 2 and the hard base layer material 1, respectively. By vacuum forming and holding in respective molds, and then clamping and pressing those molds, the hard base layer material 1 and the soft layer material 2 release the adhesive interposed between them in the effective molding area. The two material parts 1', 2' around the outside of the area are joined together through a non-adhesive composite molded body, and then the material part 1 around the outside of the effective molding area is bonded to the hard base layer material 1 of the molded body. A method for manufacturing a composite molded article, which comprises trimming the material 2' and folding the material portion 2' around the outside of the effective molding area of the soft layer material 2 to the back side of the hard base layer 1 and fixing it.