JPS6048350A - Manufacture of composite layer molded body - 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 layer molded body.

More specifically, the layer-constituting materials of the first and second constituent layers constituting the target composite layer molded product are separately molded into predetermined shapes that fit into each other, and the specially molded first
The present invention also relates to a method of manufacturing a composite layer molded body in which the second constituent layers are fitted together and joined together. Hereinafter, this will be referred to as the manufacturing method of each layer molding and joining method.

FIG. 1 is a sectional view showing the layer structure of an example of a composite layer molded product, where A is a general code of the composite layer molded product, and l. The first and second constituent layers are molded and then fitted into each other to be joined and integrated. Hereinafter, for convenience, the first constituent layer l will be referred to as the base layer, and the second constituent layer 2 will be referred to as the skin material layer. / and the skin material layer 2 itself also includes a case where it has a composite layer structure because the material used therein is a composite layer material.

The base layer l is made of, for example, various hard/semi-hard solid/porous resins such as ABS resin, vinyl chloride resin, olefin resin, rubber, resin felt, bead foam such as polystyrene, resin or paper. Synthetic corrugated pole structures such as cardboard, hardened materials for plants, metals, various two-layer and multi-layer combination composite materials of these, etc. The skin material layer 2 is made of various soft resins such as vinyl chloride and olefin resins. , semi-rigid resin, foamed resin, synthetic/natural fiber felt, synthetic/natural political dispute, fabrics (woven/knitted/
(non-woven fabrics, etc.), reinforced paper, and various two-layer and multi-layer composite materials.

The base layer 1 and the skin material layer 2 are formed by using any conventionally known appropriate molding method, such as injection molding, pressure molding, compression molding, cast molding, vacuum molding, air pressure molding, vacuum molding, etc. eMolded and manufactured by air pressure molding method, plug molding method, blow molding method, hot press molding method, press molding method, etc.

The composite layer molded product A as described in ``2'' can be used, for example, in vehicle interior parts such as dora trim boats, front seat puncture panels, ceiling lining boards, instrument panels, etc., as well as various interior materials for construction, furniture materials, and electrical appliances. It is often used for equipment exterior parts, etc.

Therefore, the manufacturing method of such a composite layer molded product A by forming and joining each layer is another typical manufacturing method, which is the method of integrally laminating each layer, that is, by bonding each constituent layer 1 and 2 together in advance. Compared to methods that use laminated flat plates as raw materials and form them into the desired shape by vacuum forming, pressure forming, press forming, etc., the overall shape of the product is even, even with complex uneven surfaces, and is high quality. It also has other great advantages, such as the ability to produce sharp light sections.

By the way, in the manufacturing method of each layer molding and joining method which is the object of the present invention, the base layer 1 as the first constituent layer and the skin material layer 2 as the second constituent layer, which are respectively molded and manufactured separately, are then fitted together. When joining and integrating both layers 1112
It is important that each part be brought into close contact and integrated without creating an air pocket (air entrapment part) between the joint surfaces of the parts. In other words, if there is an air pocket between the joint surfaces, the skin material layer surface area of the air pocket may become locally unnaturally bulged, or even if the bulge is not noticeable at room temperature, for example. When exposed to direct sunlight or the like, the product becomes relatively hot, resulting in a bulge due to the expansion of trapped air, which impairs the appearance, and the base layer 1 and skin layer 2 separate from each other at the air pocket. The peeling range tends to spread, resulting in poor quality.

The present invention also obtains a composite layer molded product by the method of molding and joining each layer, but always produces a high quality product in which each part is tightly joined and integrated without any air pockets between the joint surfaces of the base layer 1 and the skin material layer 2. The purpose is to provide a method that allows stable mass production.

That is, the present invention separately molds the layer constituent materials of the first constituent layer and the second constituent layer constituting the target composite layer molded product into predetermined shapes that fit into each other, and then molds the first constituent layer and the second constituent layer separately.
The constituent layers are each held in a fitting mold with the mutual bonding surface side as a free surface, and the fitting mold holding the first constituent layer and the mold holding the second constituent layer are placed in a vacuum atmosphere. and insert the first and second constituent layers between the fitting molds to form the inner structure J&
The gist of the present invention is a method for manufacturing a composite layer molded product, which is characterized by integrating the layers by fitting them together.

FIG. 2 shows an example of an apparatus for manufacturing a composite layer molded article according to the process of the present invention, and this apparatus will be specifically explained below using this apparatus as an example.

In the figure, 3 is a device base, 4 is a chamber with an open top surface fixedly placed on the base, and 5 is a base housed in a chamber box that can move freely up and down. This is a layer fitting type, and the fitting die 5 is supported by a vertically movable rod 6 passing through the base 3 and the bottom plate of the chamber box, and is moved up and down by upward driving of the rod 6. The rod 6 is vertically driven by a fluid pressure mechanism (not shown) or the like. Reference numeral 7 denotes a vacuum molding mold for forming the skin material layer, which is disposed above the chamber box 4 with the molding surface facing downward and can move vertically. It is supported by the do end of the moving rod 8.

41 is a vacuum suction pipe opened in the chamber box 4, and when the valve 42 is opened to the first corner position, it communicates with the vacuum pump P and becomes a vacuum suction state, and when the valve 42 is opened to the second corner position, it is exposed to the atmosphere. It becomes a communicating open shape jE.

Reference numeral 71 designates a number of vacuum suction holes formed in the downward molding surface of the vacuum molding die. When the valve 72 is opened to the first corner position, it communicates with the vacuum pump P and enters the air suction state, and when the valve 72 is opened to the first corner position, it is in an air suction state. When opened, it is open to the atmosphere.

As shown in the second diagram, the vacuum forming mold 7 is normally lifted and waiting at a position above the chamber box 4 at a predetermined distance (hereinafter this state will be referred to as the mold open state), and the base layer The fitting mold 5 is waiting at a home position where its lower surface is lowered to a position where it almost touches the bottom plate surface of the chang/lou box 4.

Then, the vacuum forming mold 7 moves downward relative to the chamber box 4 in response to the descending start signal, and finally the lower surface of the outer periphery of the effective molding surface of the mold comes into contact with the upper edge of the peripheral wall of the chamber box 4. The structure is such that it covers the channel box 4 like a lid, closes the top opening of the channel box 4, and air-tightly nitrides the inside of the channel box 4 (hereinafter, this state is referred to as the mold clamping state). ) 643 indicates a seal packing material such as a rubber strip fixed to the upper edge of the peripheral wall of the chamber box 4. Matachan z<-Hornjis 4
When the fitting mold 5 for the base layer is moved up two times while the vacuum molding mold 7 is clamped against the chamber pump 4, its upper surface side becomes the downward molding surface of the vacuum molding mold 7. It has a relational structure that fits in with the other. Reference numeral 44 indicates a sealing material for the through hole of the rod 6 that moves the mold 5 up and down.

(2) Molding of the base layer 1 and setting to the fitting mold 5 (FIG. 2) The base layer 1 is molded into a predetermined shape using an appropriate material and molding means in advance in a separate process. Then, the base layer 1 is inserted between the open vacuum forming mold 7 and the chamber box 4, and is fitted and set by covering the base layer fitting mold 5 in the chamber box. The setting of the base layer 1 to the mold 5 may be done manually or may be automated using a robot device.

II. Molding of the skin material layer 2 (Fig. 2) A #1 sheet material for the skin material layer, which has been heat-softened in advance, is introduced between the vacuum molding mold 7 in the open state and the chamber box 4, and the vacuum molding mold is formed. The material sheet material is vacuum formed in a vacuum forming mold 7 according to a conventional method, and the formed skin material layer 2 is maintained as it is on the molding surface of the mold 7 by vacuum suction.

73 indicates a clamp frame for the material sheet material. The vacuum forming process of this skin material layer 2 can also be automated.

(3) Bonding between the base layer 1 and the skin material layer 2 (Figs. 3 and 4) The vacuum forming mold 7 holding the molded skin material layer 2 is lowered to a clamped state against the chamber box 4 (
Figure 3). Next is Chan/Kupo.

Valve 42 of vacuum suction pipe 41 opened in lath 4
open to the first corner position. Then, the knob 41 communicates with the vacuum pump P, and the air inside the hermetically nitrided channel box 4 is exhausted from the clamping of the vacuum forming mold 7, and the inside of the box is evacuated. After the inside of the box is evacuated as much as possible, the mold 5 in the chamber box into which the base layer is fitted is moved upward. As the mold 5 rises, the base layer 1 fits into the molded skin material layer 2 held on the vacuum mold 7 side, and both l.
2 fit into each other and are inserted between the molds 5 and 7 to be joined and integrated (FIG. 4).

The above-mentioned base layer 1 and skin material layer 2 are mutually adhesively integrated.
・The materials of the mutual joining surfaces of 2 are materials that can be bonded by heat and pressure to each other, and when both 1 and 2 are fitted and joined, one or both of 1 and 2 still retains a considerable amount of molding heat, and the joining surface is When it has a soft viscosity, or before joining both parts 1 and 2, one or both of the joint surfaces of both parts 1 and 2 are heat-treated by heating means such as hot air blowing or heat ray irradiation. By doing so, both parts 1-2 can be well bonded to each other by heat pressure and integrated without using an adhesive. When using an adhesive, apply a hot-melt or solvent-based adhesive layer to one or both of the front surface of the base layer 1 and the back surface of the skin material layer material in advance, and then fit layers 1 and 2 together. Before joining, one or both of the surfaces to be joined may be automatically sprayed with adhesive.

Therefore, the bonding of both layers 1 and 2 is carried out in an airtight, evacuated, and evacuated chamber box 4, that is, in a vacuum atmosphere, but an air pocket is created between the bonding surfaces of both layers 1 and 2. Each part is tightly joined and integrated without any distortion.

Immediately after the joining of layers 1 and 2 by the upward movement of the mold 5, the valve 72 of the vacuum forming mold 7 is opened to the second corner position to open the vacuum suction holes 71 to the atmosphere, and the skin material layer 2 is released through each vacuum suction hole.
Atmospheric pressure acts on the surface of the
Therefore, the joining between the users 1 and 2 is performed more effectively. Alternatively, a path C/74 (Fig. wS4) for introducing compressed air into the vacuum suction hole 71 may be provided so that the force of the compressed air acts on the surface of the skin material layer 2 with a pressing force equal to or higher than atmospheric pressure. (in this case,
(The valve 72 in the vacuum path is closed).

C indicates a compressor, and 74 indicates a path opening/closing valve.

■, Taking out the composite layer molded product, valve 4 of the vacuum suction pipe 41 of the post-processing chamber box 4
2 to the second corner position, the chamber box 4
The vacuum is released by opening the inside to the atmosphere. Next, the vacuum forming mold 7 is moved upward to open the mold from the chamber box 4. The composite layer molded product is formed through the vacuum suction hole 71 of the vacuum mold 7.
is released from the molding surface of the layer 7 by being exposed to the atmosphere or by introducing compressed air, and remains on the side of the base layer fitting mold 5 on the side of the chamber pin lath 4. The composite layer molded body is molded into mold 5.
6. The mold 5 is removed from the mold and is moved backward and downward. Since the removed molded body has an unnecessary material portion 2 around the outside of the effective molding surface of the skin material layer 2, the unnecessary material portion 2 is then trimmed. Or the unnecessary material part 2'
The edge is finished by rolling it onto the back side of the base layer l as shown by the two-dot chain line in FIG. 1 and fixing it with an adhesive or a fastener such as a rivet. The unnecessary material portion 2 can be trimmed by, for example, disposing a trimming blade in an annular shape around the fitting mold 5 for the base layer, so that the layer 5 rises to fit and connect the layers 1 and 2, and at the same time the skin material layer 2 is removed. The unnecessary material portion 2 can be trimmed.

(2) Modifications (a) The skin material layer 2 may be formed using the chamber box 4, and the skin material layer 2 may be formed by vacuum/pressure air forming by air pressure forming. FIG. 5 shows the procedure. When the chamber box 4 lowers the base layer fitting mold 5 housed inside the chamber box 4 to the Baum position where its lower surface is almost in contact with the bottom surface of the box 4, the upper surface of the mold 5 shall protrude from the top opening of the box and have no depth. Moreover, an air pressure feeding pipe 45 is opened in the box 4 separately from the vacuum pipe 41. When the valve 46 is opened, it communicates with the compressor C and enters a pneumatic feeding state.

After the vacuum forming mold 7 is opened from the chamber box 4 and the base layer l is fitted and held in the mold 5 in the chamber box 4, the space between the chamber box 4 and the vacuum forming mold 7 is Then, the sheet material 2a for the skin material layer which has been heat-softened in advance is introduced, and the vacuum forming mold 7 is brought into a clamped state with respect to the chamber box 4 (the state shown by the solid line in FIG. 5). Next, the vacuum suction hole 7e of the vacuum forming mold 7 is set to a vacuum suction state or an open state to the atmosphere, and the air pressure feeding pipe 4 is
The valve 46 of No. 5 is opened to pump air into the chamber box 4. As a result, the skin material layer sheet material 2a is vacuum-pressure-formed or pressure-formed on the molding surface of the mold 7 as shown by the two-dot chain line. Next, the molded skin material layer 2 is held in close contact with the surface of the mold 7 by vacuum suction, and while the mold 7 is clamped to the chamber box 4, the inside of the chamber box 4 is evacuated using the vacuum pipe 41, Next, the mold 5 is moved upward to fit and join the layers 1 and 2 together.

b. The base layer 1 has several ventilation holes 1a penetrating through its thickness as shown in FIG. By forming the communicating ventilation holes 5a at the surface positions exactly corresponding to the respective ventilation holes 1a of layer 1, when layer 1 and layer 2 are fitted together, the thin air that tends to remain between the joining surfaces to some extent, or The solvent vapor of the adhesive also flows through the ventilation hole la of the base layer l from between the bonding surfaces.
, and the vent 5a on the side of the mold 5 that communicates with the vent 5a to exit and be removed.

In the device of Example C1, the vacuum forming mold 7 for forming the skin material layer was also used as a holding and fitting mold for the formed skin material layer.
Similarly to the base layer 1, the skin material layer, which has been molded and manufactured by appropriate means in a separate process, may be held in a dedicated holding and fitting mold. Further, as for the holding and fitting type of the base layer 1 and the skin material layer 2, the molds for forming and manufacturing these layers may also be used as the holding and fitting type.

d. As shown in FIG.
The chamber box 4 and the vacuum forming mold 7 in which the skin material layer 2 was formed constitute a sealed chamber, and the valve 42 is placed in the first
Place it in the corner position and move it to the chamber by vacuum pump P - Box 4
It is also possible to press-form the base layer 1 with the base layer molding fitting mold 5 and the vacuum mold 7 by arranging the rods 6 in a row while creating a vacuum atmosphere inside, so as to bring it into close contact with the molded skin material layer 2.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view showing an example of the layer structure of a composite layer molded product, FIG. 2 is a cross-sectional view of the mold in an open state, and FIG. 3 is a cross-sectional view of the mold in a closed state.
Fig. 4 is a cross-sectional view of the first and second constituent layers integrated by fitting, Fig. 5 is a cross-sectional view of a modified example, and Fig. 6 is an enlarged cross-sectional view of a portion of an example in which ventilation holes are formed. 7 are sectional views of an example in which the base layer is press-molded and simultaneously bonded to the skin material layer. 1 is a base layer as a first constituent layer, 2 is a skin material layer as a second constituent layer, 4 is a chamber box, 5 is a base layer fitting type, and 7 is a skin material layer vacuum fitting type. Figure 3↓ Figure 1 Figure 2

Claims (2)

[Claims] (1) The first constituent layer and the second constituent layer constituting the desired composite layer molded product
For the constituent layers, the respective layer constituent materials are separately molded into a predetermined shape that fits into each other, and the first constituent layer and the second constituent layer are held in a fitting shape with the mutual bonding surface side as a free surface,
The fitting mold holding the first constituent layer and the fitting die holding the second constituent layer are fitted in a vacuum atmosphere, and the first and second constituent layers are sandwiched between the fitting molds. 1. A method for producing a composite layer molded product, comprising: integrating inner constituent layers by fitting and joining each other. (2) The first constituent layer, the second constituent layer, or the inner constituent layer is held by the vacuum suction force of the vacuum suction hole formed by opening on the surface of the mating mold in the fitting mold, and the first constituent layer is held. The fitted mold holding the second constituent layer and the fitted mold holding the second constituent layer are fitted together in a vacuum atmosphere, the first and second constituent layers are inserted between the fitting molds, and the inner constituent layers are fitted together. After the mating, the vacuum suction hole on the surface of the mating mold is opened to the atmosphere, or compressed gas is introduced into the chain hole to apply atmospheric pressure or compressed gas pressure to the first and second constituent layers between the mating molds. The method for producing a composite layer molded article according to claim (1), characterized in that the method comprises: