JPS5985745A - Laminated shape and its molding method - 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 laminate molded product in which a front fabric and a base fabric are integrally joined via an intermediate layer, and a method for molding the same.

Molded products made of laminates in which a foamed intermediate layer is laminated on an outer material such as woven fabric, and a synthetic resin base fabric is further laminated on the foamed intermediate layer have not yet been seen, but it is possible to achieve a highly decorative effect on the outer material and to cover foam. Due to the cushioning properties of the intermediate layer, it is suitable for various automobile interior parts, and is also expected to be used as furniture and interior linings.

However, even if one welding process is performed to obtain a laminated molded product consisting of the outer material, the intermediate layer, and the base fabric, 4,100 liters is required.
j When forming the mesh layer, the composition of the outer material of the woven fabric may be damaged due to the pressure applied twice when the molded product is press-molded.
The intermediate layer is likely to be crushed and crushed, and in some cases, the repulsive force of the intermediate layer may be significantly reduced. In order to eliminate such defects, it is best to attach the base fabric using an adhesive or to join the molten base fabric to the coat L-U, but the base fabric Adhesion-N] Coating requires skill and time.

This invention was devised to eliminate the drawbacks of the above-mentioned laminate molded product and the molding method for obtaining the same, that is, the above-mentioned conventional methods. The present invention aims to provide a new molding method in which pressurization of the foamed intermediate layer is only required when molding a molded product of a predetermined shape using a freeless mold.

The laminated molded product according to this invention can be made of woven fabric, nonwoven fabric, η111
) A synthetic resin base fabric is further welded to a bonded body formed by integrally bonding a synthetic resin foam layer to the outer fabric and a synthetic resin foam layer.

The above-mentioned joining can be done by adhesion or welding depending on the materials of the outer material and the foamed resin. In the case of welding, it can be easily done by laminating the outer material when extruding the foamed resin. can.

The above-mentioned outer material is made of woven, non-woven, or knitted fabric made of fibers such as nylon, ester ester, or coplon, and the knitted fabric may be either continuous or circular knitted, with an elongation rate of 50 to 250% in both length and width. Monthly 100-100097m
2 is preferred.

” 1. As the foamable resin, low density polyethylene, high density, I? Polyethylene, polypropylene, polyvinyl chloride, polyurethane, and even ethylene-vinyl acetate, t
The foam may be based on a combination of ethylene and fluoropylene, and the foaming ratio may vary depending on the purpose of the molded article, but may be 5 to 50 times. The foaming form may be either crosslinked foaming or non-crosslinking foaming.

Furthermore, the synthetic resin used as the base fabric is moon? Propylene, high-density polyethylene, or 4Φ polymers different from these, such as ethylene-polypropylene, ethylene-
Composites such as vinyl acetate copolymers, or composites of these with mineral fillers, wood flour, No-Topo-1 pulverized products, etc. may be used, and in the case of porin 0 Robyrene, MFR + 1.1 to 3.
．． 0 (10 min, 230'O) is suitable.

1. Welding of the foamed intermediate layer and the base fabric is performed when molding into a molded product using a 7°less mold. Therefore, the foundation
The base 11 and the foamed intermediate layer are bonded (formed) in advance between a pair of press molds consisting of a split mold. It will be done. There are still two preferred methods of supplying the base fabric, one of which is to extrude the base fabric into a sheet form from the extruder's guide and immediately feed it in a molten state between a pair of split molds. . In this case, depending on the extrusion direction of the base fabric, the operating direction of the press mold can be arbitrarily selected, such as underwater direction or vertical direction.

Another method is to melt a sheet-like base fabric that has been preformed and placed at a high temperature, and then set it between split molds.

The above-mentioned press mold is made of steel, aluminum, zinc alloy, etc., and is equipped with cooling water holes, air vents, protrusion devices, etc., and is equipped with a vignette around the product at the engagement part of the mold.
It is preferable to use a mold having a J-cut structure, for example, a mold having a matte 1-shape structure.

Further, during molding, the pressing force is adjusted 17 in order to prevent the foamed intermediate layer from being crushed and deformed due to the resin temperature and mold pressure of the base fabric, thereby reducing the cushioning properties. This adjustment determines the mold clearance based on the product thickness calculated from the desired product dimensions (-7). The hydraulic circuit of the mold is controlled (tall I), and only a dead block is placed in the mold.

The advantages of this invention are that the step of welding the base fabric, which was conventionally performed before molding, is omitted, and deformation of the foamed intermediate layer under pressure can be prevented as much as possible.

Injection molding can be considered as a means of omitting the welding process of the base fabric, but since the resin temperature and injection pressure are high in injection molding, it cannot be applied to materials where the intermediate layer is not a foam material. However, if the foam is a package, it will often be crushed regardless of the foam structure, and the cushioning effect will be lost, making it impossible to put it to practical use.

The present invention will be explained in detail below using illustrated examples.

In the figure, reference numeral 1 denotes a laminate, which is made up of an outer fabric 2 made of woven fabric, a foamed intermediate layer 3 made of low-circulation polyethylene, and a base fabric 4 made of propylene sorted in a molded type.

``1. To mold a molded product using the laminate 1, dozu'' 1
The outer material 2 and the foamed intermediate layer 3 are bonded together via the adhesive layer 5 to form a bonded body 6.

Next, the joined body 6 is brought into a molten state (16
Together with the sheet-like base fabric 4 at a temperature of 0 to 230°C,
Set between press molds 70. This ” zygote, zygote 6
The size of the base fabric 4 used is larger than the projected area of the molded product.

” 2. The recessed mold 7 has a cavity mold 7a of the required depth.
and a core mold 7b, and has a warp, an interlocking portion d, and a cut-off edge. Although not shown in the drawings, each of the pair of molds is separated and connected to a hydraulically operated pressurizing mechanism.

A bottle in which the cavity mold 7a and the core mold 7b are closed.
The cavity clearance generated in the laminate IK is equal to or slightly smaller than the thickness of the laminate IK, and the cavity and core form a single shape there, and undue pressure is not applied to the laminate IK. Preferred dimensions are approximately

The base fabric 4 is placed on the foamed intermediate layer side i5: L, so that when the press mold 7 moves in the mold closing direction, it contacts the core mold 71) and further contacts the foamed intermediate layer side by the core mold. It is preferable to provide a slight gap between the mold 7b and the foamed intermediate layer 3.

When the press mold 7 is closed, the base fabric 4 in a molten state is first pressed by the core mold 7b and comes into contact with the foamed intermediate layer 3, and welding occurs there. The whole is then pressed into the cavity mold 7a and molding occurs to form the desired molded article 8 as shown in FIG. The periphery of the molded product 8 is cut by a cut-off edge, and the freeless mold 7 is held in that state until the molded product 8 is cooled and solidified.

The laminated molded product of this invention has 1i1i property and cushioning property.
As mentioned above, the molding method for Aare, Dimensions is to weld the 2N intermediate layer to the base fabric and weld the base fabric under an appropriate IW pressure using a press mold. Since the molding into the desired molded product is carried out at the same time, the cushioning properties of the foamed intermediate layer are not lost, and even if the outer material is still a woven fabric, it does not deform, and it has decorative and cushioning properties. It is possible to obtain a molded product that is suitable for automotive interior parts, etc., which has a high tlG (tlG).Since the step of joining the base fabric is omitted, the molding cycle can be shortened and labor can be saved. have

[Brief explanation of the drawing]

The drawings illustrate the laminate molded product and the molding method according to the present invention, and FIG. 1 is a partial vertical cross-sectional view of the laminate, and FIGS. 2 and 3 show a press mold and molded product to explain the molding process. FIG. ■...Laminated body, 2...Outer material, 3...Foamed intermediate layer, 4...Base fabric, 5...Adhesive layer, 6...Joint body, 7...・)0less type, 8... Molded product. Patent Initiator: Showa Denko Co., Ltd. Figure 1, Tue 21, Tue 1, No. 31

Claims (2)

[Claims] (1) Consisting of an outer material such as woven fabric, non-woven fabric, or woven fabric, a foamed intermediate layer integrally bonded to the outer material, and a synthetic resin base fabric pressure-welded to the foamed intermediate layer, and the base fabric is A laminated molded product that is formed into a predetermined shape during pressure welding. (2) The outer material such as woven fabric, non-woven fabric, or woven fabric and the Hanzan intermediate layer are joined together, and the joined body is placed between the resin molds, and the light (1a intermediate layer' A base fabric of synthetic resin molded into a notebook shape was placed on 1B:1 in an IH state, and the above bonded body and base fabric were pressurized with a press mold to form the 11 gun intermediate layer described in 1. 1. A method for forming a laminate molded product, which comprises welding a base fabric and a base fabric together, and at the same time forming a molded product in a predetermined shape.