JPS601193B2 - Manufacturing method of composite molded body - Google Patents
Manufacturing method of composite molded bodyInfo
- Publication number
- JPS601193B2 JPS601193B2 JP55015094A JP1509480A JPS601193B2 JP S601193 B2 JPS601193 B2 JP S601193B2 JP 55015094 A JP55015094 A JP 55015094A JP 1509480 A JP1509480 A JP 1509480A JP S601193 B2 JPS601193 B2 JP S601193B2
- Authority
- JP
- Japan
- Prior art keywords
- mold
- molds
- cushion material
- molding
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Landscapes
- Laminated Bodies (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Description
【発明の詳細な説明】
本発明は基体層・クッション材層・表皮材層の順次積層
よりなる複合成形体の製造方法に関する。DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a composite molded article comprising sequentially laminating a base layer, a cushioning material layer, and a skin material layer.
例えば車両用内装部品であるドアトリム・フロントシー
トパネル・天井内張り板・ダッシュボード等は、一般に
適当な強度・剛性を有する硬質材料を基本1(第1図)
とし、その表面を当りの柔かし、クッション層2、及び
装飾・保護用の表皮層3で覆った三層貼合せ構成の複合
成形体が利用される。For example, vehicle interior parts such as door trims, front seat panels, ceiling lining panels, dashboards, etc. are generally made of hard materials with appropriate strength and rigidity (Figure 1).
A composite molded article having a three-layer lamination structure is used, in which the surface is covered with a soft material, a cushion layer 2, and a decorative/protective skin layer 3.
その他建築用各種内装材、家具、電気器具外装部材等に
も上記のような層構成よりなる複合成形体が多用されて
いる。従釆一般に上記のような複合成形体は、予め各構
成層1,2,3を一体に貼合せ加工した積層平板を素材
にしてこれを真空成形法・プレス加工法・圧空成形法・
プラグ成形法等により成形型を用いて所要の形状に成形
する。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. Generally, the above-mentioned composite molded products are made from a laminated flat plate in which the constituent layers 1, 2, and 3 are laminated together in advance, and are processed by vacuum forming, press working, pressure forming, or other methods.
It is molded into the desired shape using a mold using a plug molding method or the like.
そしてこの成形と同時に或いは脱型後成形体周囲の不要
綾部を切断除去(トリミング)する。この不要緑部のト
リミングまでで最終製品とするものもあるが、トリミン
グしただけでは切断面(複合成形体外周端面)4に各層
1,2,3の積層端面が露呈して外観体裁が悪いこと、
補強用金網入りのものは切断面4に金網の緑が露呈して
危険であること、各層が切断両部に於てめくれて剥離を
生じ易いこと等の理由から、ものにより上記トリミング
後更に成形品の切断面を隠蔽処理して縁を仕上げて最終
製品とする。Then, at the same time as this molding or after demolding, unnecessary twill portions around the molded body are cut and removed (trimmed). There are some products that can be completed by trimming this unnecessary green area, but if only trimming is done, the laminated end faces of each layer 1, 2, and 3 will be exposed on the cut surface (outer peripheral end face of the composite molded body) 4, resulting in poor appearance. ,
Products with reinforcing wire mesh are dangerous because the green wire mesh is exposed on the cut surface 4, and each layer is likely to peel and peel at both cut ends. The cut surface of the product is concealed and the edges are finished to create the final product.
この場合その切断面4の隠蔽処理形態としては第1図鎖
線示のように表皮層3の周緑を延長し「その延長部3′
を成形体の裏面側へ折返して接着剤等で止めることによ
りクッション層2及び基体1の切断面を覆いかくした状
態にするのが一番体裁がよく美麗な緑仕上げ状態となる
。In this case, the form of concealment treatment for the cut surface 4 is to extend the circumference of the skin layer 3 as shown by the chain line in FIG.
It is best to cover and hide the cut surfaces of the cushion layer 2 and the base body 1 by folding it back to the back side of the molded body and fixing it with an adhesive or the like, which will give the best appearance and a beautiful green finish.
しかし前記従来のように予め各構成層1,2,3を一体
に貼合せ加工した積層平板を素材にして複合成形体を得
るものに於て上記第1図の鎖線示のような縁仕上げ処理
を行なうには、成形体のトリミングを成形体の所定の外
形寸法によりもひと回り大きい寸法で行ない「次いでそ
の成形体周緑の基体1及びクッション層2部分について
上記余分寸法部分をそぎ加工して表皮層3の裏面から除
去し、その結果延長状態となった表皮層周縁3′を成形
体裏側へ折返して止めるという極めて非能率的な作業と
なり、実際には採用し得ない。However, in the case where a composite molded body is obtained using a laminated flat plate in which the constituent layers 1, 2, and 3 are laminated together in advance as in the conventional method, the edge finishing treatment as shown by the chain lines in FIG. In order to do this, the molded body is trimmed to a size that is one size larger than the predetermined external dimensions of the molded body, and then the above-mentioned extra dimensions are trimmed from the green base 1 and cushion layer 2 portions around the molded body to form a skin. This is an extremely inefficient operation in which the layer 3 is removed from the back surface and the skin layer periphery 3', which has become extended as a result, is folded back to the back side of the molded article and stopped, which cannot be used in practice.
そこで従来は切断面4の隠蔽を必要とするものについて
はトリミングした成形体の縁周囲に別生産のモール材を
取付けることにより切断面4を隠蔽し最終製品とするを
一般とするが、モール材の取付け処理に材料と手間を要
しコスト高となる。又成形体の縁がモール材で額縁的に
縁取りされるから形態として好まれない場合が多い。本
発明は上記に鑑みて、モール材を用いず、第1図鎖線示
のような縁処理形態の複合成形体を能率的に安価に量産
することを目的とする。Conventionally, for products that require concealment of the cut surface 4, a separately produced molding material is attached around the edge of the trimmed molded body to hide the cut surface 4 and produce the final product. The installation process requires materials and labor, resulting in high costs. Furthermore, the edges of the molded body are often framed with molding material, which is not preferred as a form. In view of the above, an object of the present invention is to mass-produce efficiently and inexpensively a composite molded article having an edge treatment configuration as shown by the chain line in FIG. 1 without using a molding material.
以下図に基づいて具体的に説明する。A detailed explanation will be given below based on the drawings.
先ず本発明で用いる金型構成について説明する。5,6
は、複合成形体を製造する割り金型で5を複合成形体表
面側を成形する第1の金型、6を同裏面側を成形する第
2の金型とする。First, the mold configuration used in the present invention will be explained. 5,6
5 is a split mold for manufacturing a composite molded body, and 5 is a first mold for molding the front side of the composite molded body, and 6 is a second mold for molding the back side of the composite molded body.
そしてその両金型5,6を型締めしたとき対向成形面5
1,61間に後述表皮材3の真空成形後の厚さd3とク
ッション材2の真空成形後の厚さd2を加えた寸法に略
等しい(若干小さめをむしろ可とする)間隙寸法dの成
形キャビティ7(第4,5図)が形成されるようにキヤ
ビテイを設計する。又その両金型5,6には夫々その成
形面に数多の真空孔52,62を閉口させて真空成形機
能を具備させる。When both molds 5 and 6 are clamped, the opposing molding surface 5
Forming with a gap size d that is approximately equal to the sum of the thickness d3 of the skin material 3 after vacuum forming and the thickness d2 of the cushion material 2 after vacuum forming between 1 and 61 (slightly smaller is actually acceptable). The cavity is designed so that a cavity 7 (FIGS. 4 and 5) is formed. Both molds 5 and 6 are provided with a vacuum forming function by closing a number of vacuum holes 52 and 62 on their molding surfaces, respectively.
又第2の金型6の成形面61には溶融樹脂の射出或は圧
送孔63を開□させる。そしてその両金型により夫々後
述するように表皮材3とクッション材2と真空成形し次
いで型締め(第4図)したときその両金型の有成形面領
域51,61外周囲の両型対向面51′,61′間には
その間に介在する表皮材部分3′とクッション材部分2
′とを互に押圧しないように隙間8が生じる型構成にす
る。図示例は型6側の面61′を傾斜面に形成してテー
パ状の隙間8を形成させたものである。54,64は両
金型5,6の上記面51′,61′に閉口させた真空吸
引孔、65は金型2側に設けた抜気用細パイプで、これ
等については後述する。Further, a hole 63 for injection or pressure feeding of the molten resin is opened in the molding surface 61 of the second mold 6. Then, when the skin material 3 and the cushion material 2 are vacuum-formed using the two molds as described later, and then the molds are clamped (FIG. 4), the two molds face each other around the outer periphery of the forming surface areas 51 and 61 of the two molds. Between the surfaces 51' and 61', there is a skin material part 3' and a cushion material part 2 interposed therebetween.
The mold structure is such that a gap 8 is created so that the two parts are not pressed against each other. In the illustrated example, the surface 61' on the side of the mold 6 is formed into an inclined surface to form a tapered gap 8. Numerals 54 and 64 are vacuum suction holes closed in the surfaces 51' and 61' of both molds 5 and 6, and 65 is a thin pipe for venting provided on the mold 2 side, which will be described later.
次に製造プロセスについて工程を追って説明する。Next, the manufacturing process will be explained step by step.
‘1l第1工程(第2図)
第1及び第2金型5,6を型開きした状態に於て第1金
型5により表皮材3を、第2金型6によりクッション材
2を夫々真空成形しそれ等の各成形材料3,2を夫々型
面にそのまま保持させた状態にする。'1l First step (Fig. 2) With the first and second molds 5 and 6 opened, the first mold 5 molds the skin material 3, and the second mold 6 molds the cushion material 2. Vacuum forming is performed and the molding materials 3 and 2 are held as they are on the mold surface.
表皮材3は各種の軟質又は半硬質の樹脂シート、裏面を
樹脂シートで裏打ちした加熱伸びをZ有する布、欧質合
成皮革などが、又クッション材2は塩化ビニル・ポリエ
チレン・ポリプロピレン等の各種の反発弾性のよい発泡
体シート、樹脂シートで裏打ちしたポリウレタンフオー
ムフェルトなどが利用できる。The skin material 3 is made of various soft or semi-hard resin sheets, cloth with Z heat elongation with the back side lined with a resin sheet, European synthetic leather, etc., and the cushion material 2 is made of various kinds such as vinyl chloride, polyethylene, polypropylene, etc. Foam sheets with good rebound resilience, polyurethane foam felt lined with resin sheets, etc. can be used.
表皮材3が軟質樹Z脂シートである場合には第1の金型
5の成形面に予めシボ等所望の凹凸模様を刻設しておく
ことにより表皮材3面にその凹凸模様を鮮明に表わした
複合成形体を得ることができる。尚表皮材3の裏面又は
/及びクッション材22の表面には予め接着剤9を施こ
しておく。When the skin material 3 is a soft resin Z resin sheet, by carving a desired uneven pattern such as grain on the molding surface of the first mold 5 in advance, the uneven pattern can be clearly formed on the surface material 3. The composite molded article shown can be obtained. Note that adhesive 9 is applied to the back surface of the skin material 3 and/or the surface of the cushion material 22 in advance.
その後着剤9は材料3,2を真空成形のため軟化処理加
熱したときその熱で活性化するものが材料3,2の扱い
上便利である。13は各材料2,3の真空成形用シール
クランプである。It is convenient for the handling of the materials 3 and 2 that the adhesive 9 is activated by the heat when the materials 3 and 2 are softened and heated for vacuum forming. 13 is a sealing clamp for vacuum forming each of the materials 2 and 3.
2{2} 第2工程(第3,4図)上記表皮材3とクッ
ション材2とを夫々真空成形して保持した第1及び第2
の金型5,6を型締めする(第4図)。2{2} Second step (Figs. 3 and 4) The first and second surfaces are formed by vacuum forming and holding the skin material 3 and the cushion material 2, respectively.
The molds 5 and 6 are clamped (Fig. 4).
この型締めにより表皮材3の裏面とクッション材2の表
面とが互に有3効成形面領域に於て押圧接触して接着剤
9を介して一体化する。即ち型締めにより構成される成
形キャビティ7の対向成形面間間隙寸法dを前述したよ
うに表皮材3の真空成形後の厚さd3とクッション材2
の真空成形後の厚さらを加え3た寸法に略等しいものに
してあるから上記金型5,6の型締めにより表皮材3と
クッション層2とはその有効成形面領域に於て互に隙間
を生じることなく押圧接触し接着剤9を介して一体化す
る。 4ただし表皮材
3とクッション材2の各有効成形面領域外周囲の材料部
分3′,2′については、前述したように型締めしたと
きその材料部分3′,2′同士を押圧しないように両型
の有効成形面領域外周因の両型対向面51′,61′間
に隙間8が生じる型構成してあるから部分3′と2′は
互に分離状態が保持される。この分離状態を確実ならし
めるために両金型の有効成形面領域外周囲の両型対向面
51′,61′に夫々真空吸引孔54,64を閉口させ
て表皮材3とクッション材2の上記各部分3′,2′を
夫々上記型対向面51′,61′に積極的に吸引保持す
るようにするを可とする。又表皮材3とクッション材2
の有効成形面領域同士をその間にェァ溜りを生じさせる
こなく密着一体化させるために表皮材3とクッション材
2を型締めにより互に押圧する過程で表皮材3とクッシ
ョン材2との間の空気を積極的に抜気しながら型締めす
るようにするを可とする。By this mold clamping, the back surface of the skin material 3 and the surface of the cushion material 2 are pressed into contact with each other in the effective molding surface area, and are integrated via the adhesive 9. That is, the gap size d between the opposing molding surfaces of the molding cavity 7 formed by mold clamping is determined by the thickness d3 of the skin material 3 after vacuum forming and the cushioning material 2.
Since the dimension after vacuum forming is approximately equal to 3 plus the thickness after vacuum forming, by clamping the molds 5 and 6, the skin material 3 and the cushion layer 2 have a gap between them in their effective molding surface area. They are brought into pressure contact and integrated via the adhesive 9 without causing any friction. 4 However, regarding the material parts 3' and 2' around the outside of each effective molding surface area of the skin material 3 and the cushion material 2, care should be taken not to press the material parts 3' and 2' together when the mold is clamped as described above. Since the mold is constructed such that a gap 8 is created between the opposing surfaces 51' and 61' of both molds due to the outer periphery of the effective molding surface area of the molds, the parts 3' and 2' are kept separated from each other. In order to ensure this separated state, vacuum suction holes 54 and 64 are respectively closed in the facing surfaces 51' and 61' of both molds around the outside of the effective molding surface area of the skin material 3 and the cushion material 2. It is possible to actively suction and hold each portion 3', 2' to the die facing surface 51', 61', respectively. Also, the skin material 3 and the cushion material 2
In the process of pressing the skin material 3 and the cushion material 2 together by mold clamping in order to closely integrate the effective molding surface areas of the skin material 3 and the cushion material 2 without causing any air accumulation therebetween, the space between the skin material 3 and the cushion material 2 is It is possible to tighten the mold while actively removing air from the mold.
図示例は第2の金型6にこれを前後に貫通させて抜気用
細パイプ65を進退動自由に設け、クッション材2の真
空成形はそのパイプ65を後退動させてパイプ65の先
端を成形面61と略面一に保持させて行なう(第2図)
。そしてその真空成形後パイプ65を前進動させてクッ
ション材2の肉厚を貫通さててパイプ先端閉口をクッシ
ョン材2の表面に露出させ(第3図)、その開口から空
気を吸引状態にしながら該金型6と表皮材3を真空成形
して保持した第1の金型5とを型締めする(第3図→第
4図)ことにより表皮材3とクッション材2の間の空気
を積極的に抜気しェア溜りの発生を防止するようにした
ものを示す。型締め終了後はパイプ65を後退動させて
パイプ先端を成形面61と面一の位置に戻す(第4図)
。又材料2,3として夫々長尺のものを繰り出して間欠
送りしながら金型5,6間に導入する方式にした場合は
夫々例えば上記の形締め終了後に図に省略した裁断装置
により裁断して後続の材料部分との縁を切る。31 第
3工程(第5図)
上記型締め終了後その型締め状態をそのまま保持して第
2の金型6の樹脂射出又は圧送孔63から金型内に溶融
樹脂(例えばポリプロレン樹脂・A茂樹脂など)を圧入
する。In the illustrated example, a thin air venting pipe 65 is provided in the second mold 6 by penetrating it back and forth so that it can freely move forward and backward, and when vacuum forming the cushioning material 2, the pipe 65 is moved backward to remove the tip of the pipe 65. This is done by holding it substantially flush with the molding surface 61 (Fig. 2)
. After vacuum forming, the pipe 65 is moved forward to penetrate through the thickness of the cushioning material 2 and expose the closed end of the pipe to the surface of the cushioning material 2 (Fig. 3), and while sucking air from the opening, The air between the skin material 3 and the cushion material 2 is actively removed by clamping the mold 6 and the first mold 5 that holds the skin material 3 after vacuum forming (Fig. 3 → Fig. 4). This shows a device that vents air to prevent air accumulation. After mold clamping is completed, the pipe 65 is moved backward to return the pipe tip to a position flush with the molding surface 61 (Fig. 4).
. In addition, if a method is adopted in which long materials 2 and 3 are fed out and introduced between the molds 5 and 6 while being fed intermittently, each material is cut by a cutting device not shown in the figure after the above-mentioned clamping is completed. Cut the edges with subsequent material parts. 31 Third step (Fig. 5) After the mold clamping is completed, the mold clamping state is maintained as it is, and molten resin (for example, polyprolene resin, etc.) is injected into the mold from the resin injection or pressure feeding hole 63 of the second mold 6. (resin, etc.) is press-fitted.
そうするとその圧入樹脂はクッション材2の弾性に抗し
て該クッション材2を表皮材3方向に圧縮してクッショ
ン材2の裏面と金型6の成形面61間に入り込み。これ
によりクッション材2の有効成形面領域裏面にこれと一
体に樹脂の基体層1が形成される。その基体層1の厚さ
d,は樹脂圧入前のクッション材2の厚さd2と樹脂圧
入により圧縮状態となったクッション材2の厚さd2(
第5図)との差に略等しい厚さとなる。Then, the press-fit resin compresses the cushion material 2 in the direction of the skin material 3 against the elasticity of the cushion material 2 and enters between the back surface of the cushion material 2 and the molding surface 61 of the mold 6. As a result, the resin base layer 1 is integrally formed on the back surface of the effective molding surface area of the cushion material 2. The thickness d of the base layer 1 is the thickness d2 of the cushion material 2 before resin press-fitting, and the thickness d2 (
The thickness is approximately equal to the difference between the two (Fig. 5).
又この樹脂の圧入力により金型5,6間のクッション材
2と表皮材3とが強〈押圧されて両者2,3の貼合せが
強化されると共に、表皮材Z3が金型5の成形面51に
全面的に押圧されて密着し、ハイライト部など細部につ
いても良好な成形が遅せられる。Also, due to the pressing force of this resin, the cushioning material 2 and the skin material 3 between the molds 5 and 6 are strongly pressed, and the bonding of both 2 and 3 is strengthened. The entire surface is pressed and adhered to the surface 51, and good molding is delayed even in details such as highlighted areas.
クッション材層2と基体層1は熱融着により一体化する
。The cushioning material layer 2 and the base layer 1 are integrated by heat fusion.
この場合クッション材層2と基体Z層1とが材質的に相
互熱融着性にとぼしいものであったり、クッション材層
2が金型内に圧入した溶融樹脂の熱と圧力で熔融を生じ
るおそれのあるものである場合にはクッション材層2の
裏面に予め接着層兼断熱層として基体層1と相2互熱融
着性のある。例えば同系の硬質又は半硬質の充実肉質樹
脂シート(図に省略)を一体裏打ち処理しておけばよい
。又金型5,6間に溶融樹脂を圧入したときその溶融樹
脂圧入孔63に対向するクッション材22の裏面部分が
一番強く樹脂圧入圧と熱を受ける。In this case, there is a risk that the cushioning material layer 2 and the base Z layer 1 are made of materials that have poor mutual heat fusion properties, or that the cushioning material layer 2 may melt due to the heat and pressure of the molten resin press-fitted into the mold. In the case where the cushioning material layer 2 has a bonding layer and a heat insulating layer on the back surface thereof, the cushioning material layer 2 has mutual thermal fusion properties with the base layer 1 as an adhesive layer and a heat insulating layer. For example, it may be integrally lined with a similar hard or semi-hard solid resin sheet (not shown). Further, when the molten resin is press-fitted between the molds 5 and 6, the back surface portion of the cushioning material 22 facing the molten resin press-fitting hole 63 receives the resin press-fitting pressure and heat most strongly.
その結果その部分のクッション材に局部的溶融を生じる
おそれのある場合には予め型6の樹脂圧入孔63を中心
とする金型成形面部分に適当な大きさ・厚みの遮熱・抗
圧片‐10、例え3ば両面に粘着剤を施こした金属シー
ト片・厚紙片などを貼付けておくとよい。金属シート片
としては例えばアルミニウムシートが柔軟性があり適当
である。即ちその遮熱・抗圧片10は金型内への樹脂圧
入時孔63から出る樹脂圧によ3り金型成形面61から
離れて孔63と対向するクッション材2の裏面部分に彼
着した状態となりそのクッション材裏面部分に対する溶
融樹脂の圧力及び熱を緩和する。そしてその片1川ま第
6図示のように最終的にはクッション材層2 4と基本
層1との間に埋込まれた状態となる。片10の金型成形
面61に対する貼付けはロボット等で自動化すればよい
。又金型内に圧入した溶融樹脂が型6の成形面61に閉
口している真空成形孔62や抜気用パイプ65の孔に入
り込むおそれがある場合には例えばそれ等の孔62やパ
イプ65の先端部に開閉弁を取付ける等すればよい。As a result, if there is a risk of local melting of the cushioning material in that area, place a heat shielding/pressure-resistant piece of an appropriate size and thickness on the molding surface area of the mold 6 centering on the resin press-fit hole 63 in advance. -10.For example, it is a good idea to attach a piece of metal sheet or cardboard with adhesive on both sides. As the metal sheet piece, for example, an aluminum sheet is suitable because it is flexible. That is, when the resin is press-fitted into the mold, the heat shielding/pressure-resistant piece 10 is moved away from the molding surface 61 by the resin pressure coming out of the hole 63 and attached to the back surface of the cushioning material 2 facing the hole 63. The pressure and heat of the molten resin on the back surface of the cushioning material is alleviated. As shown in FIG. 6, one of the pieces is finally embedded between the cushioning material layer 24 and the base layer 1. The attachment of the piece 10 to the molding surface 61 may be automated using a robot or the like. In addition, if there is a risk that the molten resin press-fitted into the mold may enter the vacuum forming hole 62 closed to the molding surface 61 of the mold 6 or the hole of the venting pipe 65, for example, All you have to do is attach an on-off valve to the tip of the valve.
第8図はその一例として真空成形孔62の先端部に常時
はばね11の押圧力で成形面の関口を閉じ(鎖線)、真
空吸引時はその吸引力でばね11の弾性に抗して内方へ
引き動かされて成形面の開□を開く(実線)弁12を設
けたもので、樹脂圧入時は真空孔62に逆に圧縮空気を
送り込むことにより成形面の真空開口が固く閉じ状態に
なり孔62への樹脂の侵入が阻止される。As an example, FIG. 8 shows that the opening of the molding surface is normally closed at the tip of the vacuum forming hole 62 by the pressing force of the spring 11 (dashed line), and during vacuum suction, the suction force is used to internally resist the elasticity of the spring 11. This device is equipped with a valve 12 (solid line) that opens the molding surface by being pulled toward the molding surface. During resin press-fitting, compressed air is sent into the vacuum hole 62 in the opposite direction, so that the vacuum opening on the molding surface is tightly closed. Intrusion of the resin into the round holes 62 is prevented.
抜気用パイプ65の先端部にも上記と同様の開閉弁を設
けて樹脂圧入時はパイプ65内に圧縮空気を送り込んで
パイプ先端閉口を開状態に保持させればよい。或は第9
図示のように「第2の金型6の有効 ‐成形面61を微
細な連続気孔性のポ−ラス肉質の面部材14で覆う。An on-off valve similar to the above may be provided at the tip of the air venting pipe 65 to feed compressed air into the pipe 65 during resin press-fitting to keep the pipe tip closed in the open state. Or the ninth
As shown in the figure, the effective molding surface 61 of the second mold 6 is covered with a fine continuous porous surface member 14.
該ポーラス面部材14は例えば第2の金型6の有効成形
面61形状の木型等のモデル型面にアルミニウム・亜鉛
等域はそれ等の合金などの金属を溶射すると微細な金属
粒子が結着した微細な連続気孔性ポーラス肉質で、成形
面61の形状に対応した薄肉の面部村が得られるから、
それをモデル型面から雛形して第2の金型6の成形面6
1に舷着する等すればよい。その面部材14には溶融樹
脂の射出或は圧入孔63と、抜気用パイプ65の出入孔
に対応する面部分に予め透孔を或成しておく。上記のよ
うに第2の金型6の有効成形面61をポーラス肉質の両
部材14で覆うことにより真空孔62を空気吸引状態に
すると外気はそのポーラス肉質の薗部材14のボーラス
肉質を通して吸引されクッション材料2の真空成形は支
障なく行なわれる。又溶融樹脂の射出時はその圧力が極
端に高いものでない限り、溶融樹脂は面部材14のポー
ラス肉質内には侵入せず、従って真空孔62への熔融樹
脂の侵入が防止される。又抜気用パイプ65については
第5図に於てそのパイプ65の先端閉口をクッション材
層2の中に突入させてとどめた状態に保持して溶融樹脂
1の射出又は圧入を行なえば強いてパイプ65の先端に
前述の開閉弁を設けろを要さなし・。The porous surface member 14 is formed by thermally spraying a metal such as an alloy of aluminum, zinc, etc. on a model mold surface such as a wooden mold having the shape of the effective molding surface 61 of the second mold 6, for example, to form fine metal particles. A thin surface part corresponding to the shape of the molding surface 61 can be obtained with the fine open-pore porous texture that has been deposited.
The molding surface 6 of the second mold 6 is made into a template from the model mold surface.
All you have to do is berth on board 1. Through holes are previously formed in the surface member 14 in a surface portion corresponding to the injection or press-in hole 63 for the molten resin and the inlet/outlet hole for the venting pipe 65. As described above, when the effective molding surface 61 of the second mold 6 is covered with both porous fleshy members 14 and the vacuum hole 62 is brought into an air suction state, the outside air is sucked through the bolus fleshy of the porous fleshy fillet member 14. Vacuum forming of the cushion material 2 is carried out without any problems. Further, when the molten resin is injected, unless the pressure is extremely high, the molten resin will not enter the porous flesh of the face member 14, and therefore the molten resin will be prevented from entering the vacuum holes 62. As for the venting pipe 65, as shown in FIG. 5, if the molten resin 1 is injected or press-fitted while the closed end of the pipe 65 is held in a state in which it protrudes into the cushioning material layer 2, the pipe is forced to open. There is no need to install the above-mentioned on-off valve at the tip of 65.
勿論弁を設ければより効果的である。■ 第4工程(第
6,7図)溶融樹脂の庄入により形成した基体層1が冷
却により十分に硬化した後真空吸引孔54,64による
表皮材及びクッション材の部分3′,2′の吸引保持を
やめ型開きして成形品を取り出す。Of course, it will be more effective if a valve is provided. ■ Fourth step (Figures 6 and 7) After the base layer 1 formed by pouring the molten resin is sufficiently hardened by cooling, the parts 3' and 2' of the skin material and cushion material are removed by the vacuum suction holes 54 and 64. Stop holding the suction and open the mold to take out the molded product.
該成形品は第6図示のように有効成形部領域に於て基体
層1・クッション材層2・表皮材層3の三者が一体に接
合し、その外周因のクッション材部分2′と表皮材部分
3′については互に分離した形態のものである。又該部
分2′又は/及び3′面の接着剤層9は熱により活性化
するものであれば基体層1の冷却期間中に冷えて接着性
を失なうので、爾後部分2′と3′とが仮に接触しても
相互接着は生じない。クッション材層2は型開きすると
圧縮状態d2′から自己の弾性力で略元の厚さ状態d2
に復元した状態となる。そこで成形品の取出し後有効成
形領域外周函のクッション材部分2′につきこれを基体
層1の周縁に沿って切断13−13(第6図)して除去
する。As shown in Figure 6, the molded product has three parts, the base layer 1, the cushioning material layer 2, and the skin material layer 3, joined together in the effective molding area, and the cushioning material part 2' on the outer periphery and the skin material layer 3 are joined together in the effective molding area. The material portions 3' are separated from each other. Furthermore, if the adhesive layer 9 on the surfaces of the portions 2' and/or 3' is activated by heat, it will cool down and lose its adhesive properties during the cooling period of the base layer 1; Even if they come into contact with each other, mutual adhesion will not occur. When the cushioning material layer 2 is opened, it returns from the compressed state d2' to approximately the original thickness state d2 due to its own elastic force.
The state will be restored to . Therefore, after taking out the molded product, the cushioning material portion 2' of the outer box of the effective molding area is removed by cutting 13-13 (FIG. 6) along the periphery of the base layer 1.
この場合クッション材部分2′の根元部が表皮材部分3
′の根元部に接着剤9を介して接着している状態にあっ
てもその接着幅は小さいからクッション材部分2′を少
し強く引張ることにより表皮材部分3′から容易に美麗
に分離除去することができる。表皮材部分3′はそのま
ま残すか。或は製品化に必要な延長幅1だけ残してトリ
ミング処理する。そして成形体周囲の延長表皮材部分3
′につきこれを第7図のように基体1の裏面側へ折返し
て(まき込んで)基体裏面に対して援着剤或は適当な止
め金具で止めることにより最終製品とするものである。
以上本発明方法に依れば、
{a)有効成形部領域外周囲の表皮材部分3′とクッシ
ョン材2′部分についてははじめから互に分離した形態
の成形品が得られるからそのクッション材部分2′の除
去は極めて容易であり、従って成形品端面4を、表皮層
3の延長片3′の折返しで、蔽被覆した体裁のよい美麗
な緑仕上げ形態の成形品(第1,7図)を容易に能率的
に得ることができる。In this case, the base of the cushion material portion 2' is the skin material portion 3.
Even if it is adhered to the root part of ' with adhesive 9, the adhesive width is small, so by pulling the cushioning material part 2' a little forcefully, it can be easily and beautifully separated and removed from the skin material part 3'. be able to. Should the skin material part 3' be left as is? Alternatively, trimming is performed leaving only the extension width 1 required for commercialization. and extended skin material portion 3 around the molded body.
The final product is obtained by folding (wrapping) this onto the back side of the base body 1 and fixing it to the back face of the base body with an adhesive or a suitable fastener as shown in FIG. 7.
As described above, according to the method of the present invention, {a) Since the skin material part 3' and the cushion material 2' part around the outer area of the effective molded part can be obtained in a form that is separated from each other from the beginning, the cushion material part 2' is extremely easy to remove, and therefore the end face 4 of the molded product is covered by folding the extension piece 3' of the skin layer 3, resulting in a molded product with a nice and beautiful green finish (Figs. 1 and 7). can be obtained easily and efficiently.
(b} 又成形品本体は表皮材3とクッション材2を夫
々射出成形金型5,6の成形面51,61を利用して真
空成形した後型締めにより押圧一体化し、次いでクッシ
ョン材層2の裏面に基体層1を射出成形して一体化する
各層順次成形積層方式であるから予め3層一体積層の複
合材を真空成形する場合よりも成形形状に所謂あまさが
なくハイライト部の明確なシャープな成形品を容易に得
ることができる。(b} The molded product body is obtained by vacuum forming the skin material 3 and the cushioning material 2 using the molding surfaces 51 and 61 of the injection molds 5 and 6, respectively, and then pressing them together by clamping the molds. Since the base layer 1 is injection molded on the back side of the base layer 1 and integrated, each layer is sequentially molded and laminated, so the molded shape is more consistent and the highlighted areas are clearer than when vacuum forming a composite material of three layers and one layer. Sharp molded products can be easily obtained.
‘c} 型締めしたときの成形面51,61間のキャビ
テイ間隙寸法dを真空成形後の表皮材3の厚さd3とク
ッション材2の厚さらを加えた寸法と略同一のものにし
たから型締めにより表皮材3とクッション材2の有効成
形面領域が全体的に接着剤層9を介して良好に密着一体
化し、更に基体層1の成形のため注入した溶融樹脂圧に
より押圧を受けて密着性が強化され層間剥離を生じない
ものが得られる。'c} Because the cavity gap dimension d between the molding surfaces 51 and 61 when the mold is clamped is approximately the same as the sum of the thickness d3 of the skin material 3 and the thickness of the cushion material 2 after vacuum forming. By clamping the mold, the effective molding surface areas of the skin material 3 and the cushion material 2 are fully integrated with each other through the adhesive layer 9, and are further pressed by the pressure of the molten resin injected for molding the base layer 1. A product with enhanced adhesion and no delamination can be obtained.
又型締めの際表皮材3とクッション材2との間の空気を
積極的に抜気することにより層3,2間に所謂エアー溜
りの全くないものを製造することができる。【d1 ト
リミングにより除去された廃村であるクッション材と表
皮材は夫々別々に分離したものであるから夫々回収再利
用(例えば溶融再利用)が可能で材料コストの低減がで
き全く無駄がない。In addition, by actively removing air between the skin material 3 and the cushion material 2 during mold clamping, it is possible to manufacture a product with no so-called air pockets between the layers 3 and 2. [d1 The cushion material and the skin material, which are the waste materials removed by trimming, are each separated separately, so they can be recovered and reused (for example, melted and reused), reducing material costs and eliminating any waste.
‘e} 表皮材3とクッション材2の何熱軟化処理→両
材料3,2の金型5,6間への導入→両材料3,2の真
空成形→型締め→熔融樹脂の圧入→型開きのサイクルを
自動連続化することが容易で目的成形品を低コストに量
産することができる。'e} Heat softening treatment of the skin material 3 and cushion material 2 → Introduction of both materials 3 and 2 into the molds 5 and 6 → Vacuum forming of both materials 3 and 2 → Mold clamping → Press-fitting of molten resin → Mold It is easy to automatically and continuously open the opening cycle, and the desired molded products can be mass-produced at low cost.
等の効果が得られ、この種の積層成形体の製造方法とし
て有効適切である。The following effects can be obtained, and this method is effective and suitable as a method for producing this type of laminate molded product.
尚、金型6の成形面には基体層1の裏面に補強用凸リブ
形成用の凹溝(図に省略)を形成してもよく、この場合
はその凹構内には真空孔62を閉口させないようにする
ことにより凹溝の存在はクッション材2の真空成形に何
等陣害しない。Incidentally, in the molding surface of the mold 6, a groove (not shown in the figure) for forming reinforcing convex ribs may be formed on the back surface of the base layer 1, and in this case, a vacuum hole 62 is closed in the groove. By preventing the groove from forming, the presence of the groove does not harm the vacuum forming of the cushion material 2 in any way.
第1図は製品の一例の断面図、第2図は表皮材とクッシ
ョン材を真空成形した状態の断面図、第3図は抜気しな
がら型締めしている状態の一部の断面図、第4図は型締
め終了状態の一部の断面図、第5図は溶融樹脂を射出し
た状態の一部の断面図、第6図は型開きして取出した成
形品の一部の拡大断面図、第7図は縁処理した状態の同
図「第8図は真空孔の先端部に設けた開閉弁の拡大断面
図、第9図は第2の金型成形面をポーラス面部材で覆っ
た状態の一部の拡大断面図。
1は基体層、2はクッション材層、3は表皮層、5,6
は金型。
第1図
務そ図
第3図
菱?図
券5図
第6図
第7図
繁り図Fig. 1 is a cross-sectional view of an example of the product, Fig. 2 is a cross-sectional view of a state in which the skin material and cushioning material are vacuum-formed, and Fig. 3 is a cross-sectional view of a part of the state in which the mold is clamped while releasing air. Figure 4 is a cross-sectional view of a part of the mold after it has been closed, Figure 5 is a cross-sectional view of a part of the molded product after the molten resin has been injected, and Figure 6 is an enlarged cross-section of a part of the molded product taken out after opening the mold. Figure 7 is the same figure with the edges treated; Figure 8 is an enlarged sectional view of the on-off valve provided at the tip of the vacuum hole; Figure 9 is the second mold molding surface covered with a porous surface member. 1 is a base layer, 2 is a cushioning material layer, 3 is a skin layer, 5, 6
is a mold. 1st figure 3rd figure rhombus? Figure 5, Figure 6, Figure 7
Claims (1)
層よりなる複合成形体を得るに当り、型締めしたとき対
向する有効成形面51,61間に、後述表皮材3の真空
成形後の厚さd_3と真空成形後のクツシヨン材2の厚
さd_2を加えた寸法に略等しい間隙寸法dの成形キヤ
ビテイ7が構成される複合成形体表面側成形用の第1の
金型5と同裏面側成形用の第2の金型6とを調製し、そ
の両金型5,6には夫々真空成形機能を具備させると共
に、第2の金型6の成形面61には溶融樹脂の射出或は
圧送孔63を開口させ、且つ両金型5,6により夫々後
述表皮材3とクツシヨン材2とを真空成形して型締めし
たとき両金型の有効成形面領域外周囲の両型対向面51
′,61′間にはその間に介在する表皮材部分3′とク
ツシヨン材部分2′とを互に押圧しないように隙間8が
生じる型構成とし、上記第1の金型5により表皮材3を
、又第2の金型6によりクツシヨン材2を夫々真空成形
してその成形材料を夫々の型に保持させたまま両金型5
,6の型締めを行なうことにより表皮材3とクツシヨン
材2とを互に有効成形面領域に於て押圧してその間に予
め介在させた接着剤9を介して一体に接合させ、次いで
第2の金型6の成形面61とクツシヨン材2面との間に
溶融樹脂射出域は圧送孔63から溶融樹脂をクツシヨン
材2の弾性に抗して圧入することによりクツシヨン材2
の有効成形面領域裏面に基体層1を形成被着せしめて基
体層1・クツシヨン材層2・表皮材層3の順次積層より
なる複合成形体を作り、次いで型開きして取出した複合
成形体のクツシヨン材層2についてその有効成形領域外
周囲の材料部分2′をトリミングし表皮材層3の有効成
形領域外周囲の材料部分3′を基体層1の裏面側へ折返
して止めることを特徴とする複合成形体の製造方法。 2 第1及び第2の金型5,6に夫々真空成形して保持
させた表皮材3とクツシヨン材2を金型5,6の型締め
により互に押圧する過程で表皮材3とクツシヨン材2と
の間の空気を積極的に抜気するようにした。 特許請求の範囲1項記載の複合成形体の製造方法。3
第1及び第2の金型5,6の有効成形面51,61外周
囲の両型対向面51′,61′に夫々真空吸引孔54,
64を開口させ、表皮材3とクツシヨン材2とを両型6
,6の型締めにより押圧したとき両金型の有効成形面外
周囲の両型対向面間の隙間8に介在する表皮材部分3′
とクツシヨン材部分2′については夫々上記の真空吸引
孔54,64の吸引力により積極的に互に引き離し状態
に保持するようにした、特許請求の範囲1項記載の複合
成形体の製造方法。 4 第2の金型6としてその有効成形面61を連続微気
孔性のポーラス面部材14で覆ったものを用いる。 特許請求の範囲1項記載の複合成形体の製造方法。[Scope of Claims] 1. In obtaining a composite molded article consisting of a base layer 1, a cushion material layer 2, and a skin material layer 3, which are successively laminated, a skin layer (described later) is formed between the opposing effective molding surfaces 51 and 61 when the mold is clamped. The first molding cavity 7 for forming the surface side of the composite molded body is configured with a molding cavity 7 having a gap size d approximately equal to the sum of the thickness d_3 of the material 3 after vacuum forming and the thickness d_2 of the cushion material 2 after vacuum forming. A mold 5 and a second mold 6 for back side molding are prepared, and both the molds 5 and 6 are each equipped with a vacuum forming function, and the molding surface 61 of the second mold 6 is The injection or pressure feeding hole 63 for molten resin is opened, and when the skin material 3 and cushion material 2, which will be described later, are vacuum-formed and clamped using both molds 5 and 6, the effective molding surface area of both molds is Both mold facing surfaces 51 on the outer periphery
A gap 8 is formed between ' and 61' so as not to press the skin material part 3' and cushion material part 2' interposed therebetween, and the skin material 3 is formed by the first mold 5. , the cushion material 2 is vacuum-formed using the second mold 6, and the molds 5 are then molded while the molding materials are held in the respective molds.
, 6, the skin material 3 and the cushion material 2 are pressed against each other in the effective molding surface area and bonded together via the adhesive 9 previously interposed between them. The molten resin injection area is formed between the molding surface 61 of the mold 6 and the cushion material 2 surface by press-fitting the molten resin from the pressure feeding hole 63 against the elasticity of the cushion material 2.
The base layer 1 is formed and deposited on the back side of the effective molding surface area to produce a composite molded body consisting of the base layer 1, cushion material layer 2, and skin material layer 3 sequentially laminated, and then the mold is opened to take out the composite molded body. The material portion 2' of the cushion material layer 2 outside the effective molding area is trimmed, and the material portion 3' of the skin material layer 3 around the outside of the effective molding area is folded back to the back side of the base layer 1 and fixed. A method for manufacturing a composite molded article. 2 In the process of pressing the skin material 3 and the cushion material 2, which are vacuum-formed and held in the first and second molds 5 and 6, respectively, by the mold clamping of the molds 5 and 6, the skin material 3 and the cushion material The air between the two was actively vented. A method for manufacturing a composite molded article according to claim 1. 3
Vacuum suction holes 54 are provided in the opposing surfaces 51' and 61' of the effective molding surfaces 51 and 61 of the first and second molds 5 and 6, respectively.
64 is opened, and the skin material 3 and cushion material 2 are inserted into both molds 6.
, 6, the skin material portion 3' intervening in the gap 8 between the facing surfaces of both molds around the outer periphery of the effective molding surfaces of both molds.
2. The method of manufacturing a composite molded article according to claim 1, wherein the cushion material portions 2' and 2' are actively held apart from each other by the suction force of the vacuum suction holes 54, 64, respectively. 4. As the second mold 6, a mold whose effective molding surface 61 is covered with a continuous microporous porous surface member 14 is used. A method for manufacturing a composite molded article according to claim 1.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP55015094A JPS601193B2 (en) | 1980-02-08 | 1980-02-08 | Manufacturing method of composite molded body |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP55015094A JPS601193B2 (en) | 1980-02-08 | 1980-02-08 | Manufacturing method of composite molded body |
Publications (2)
Publication Number | Publication Date |
---|---|
JPS56111668A JPS56111668A (en) | 1981-09-03 |
JPS601193B2 true JPS601193B2 (en) | 1985-01-12 |
Family
ID=11879245
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP55015094A Expired JPS601193B2 (en) | 1980-02-08 | 1980-02-08 | Manufacturing method of composite molded body |
Country Status (1)
Country | Link |
---|---|
JP (1) | JPS601193B2 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS59150741A (en) * | 1983-02-16 | 1984-08-29 | Sumitomo Chem Co Ltd | Preparation of multi-layered molded article |
JPS6193213U (en) * | 1984-11-26 | 1986-06-16 | ||
US5000903A (en) * | 1989-04-06 | 1991-03-19 | Libbey-Owens-Ford Co. | Method of molding plastic products having chemically bonded protective coatings |
JP2548986B2 (en) * | 1989-07-07 | 1996-10-30 | アトマ インターナショナル インコーポレイテッド | Molding equipment for molding products |
-
1980
- 1980-02-08 JP JP55015094A patent/JPS601193B2/en not_active Expired
Also Published As
Publication number | Publication date |
---|---|
JPS56111668A (en) | 1981-09-03 |
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