JPS6051433B2 - Manufacturing method of composite molded body - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a composite molded article A having a three-layer lamination structure consisting of a base layer (base material) 1, an intermediate material layer 2, and a skin material layer 3 as shown in the example in FIG.

For example, vehicle interior parts such as door trim boards, front seat panels, ceiling lining boards, instrument panels, etc. generally have a hard or semi-hard base layer 1 with appropriate strength and rigidity, and other desired properties such as a soft cushioning material. A composite molded body is used, which consists of a three-layer laminate of an intermediate material layer 2 and a skin material layer 3 for purposes such as decoration and surface protection.

As an example, FIG. 1 shows a longitudinal section of a door trim board in which an armrest part a is integrally formed. In addition, composite molded bodies having the above-mentioned layer structure are often used for various interior materials for buildings, furniture, exterior materials for electrical appliances, and the like.

Specific examples of materials for each of the layers 1 to 3 are described below.

Base layer 1: Various hard/semi-hard solid or porous resins, resin felt, bead foams such as polystyrene,
Rigid cardboard structures made of resin, paper, etc., cardboard, hardened plant material, metal plates, composites of various combinations of these, etc. Intermediate material layer 2: polyurethane, polyvinyl chloride, polyolefin resin, etc. Skin material layer 3: Various soft resin sheets such as various soft solid or foamed resin sheets, synthetic/natural felt sheets, composite sheets of different materials, etc. Various soft resin sheets such as vinyl chloride and olefin resin, cloth (woven fabrics and knitted fabrics)・Non-woven fabric), reinforced paper, soft natural leather, soft synthetic leather, carpets, semi-rigid resin sheets such as vinyl chloride semi-rigid sheets, composite sheets of different materials, etc.

The skin material 3 is generally decorated with a desired coloring, printing pattern, or embossing pattern. Conventional methods for producing the composite molded product A can be roughly divided into a board molding method in which each layer is laminated in one piece, and a method in which each layer is laminated sequentially.

The former method uses a laminated flat plate in which the constituent layers 1, 2, and 3 are laminated together in advance, and shapes it into the desired shape by thermoforming (vacuum forming, pressure forming, plug forming, etc.), press forming, etc. It is molded into

In the latter method, the material of the base layer 1 is formed into a desired shape by an appropriate means, and the surface shape of the workpiece 1 is formed, and then the intermediate material layer 2 and then the skin material layer 3 are formed in sequence. The product is obtained by forming and bonding the intermediate material layer 2 and the skin material layer 3 which have been bonded together in advance, or by covering the surface of the processed product 1 with materials 2 and 3 in a wrapping manner. . However, the board forming method in which each layer is integrally laminated is ◎ Since the constituent layers 1 to 3 of the material board have different properties, the heat softening treatment of the board when forming the board by thermoforming is difficult. It takes a high degree of skill, skill, and time to achieve uniformity throughout the entire body. ◎Whether forming is done by thermoforming or by press forming, as the thickness of the material plate increases, ◎
The amount of material removed by trimming is large, and the material removed by trimming is an integrated body of different material layers 1 to 3 of different materials, so it is almost impossible to remelt it and use it in cycles as a raw material. Therefore, there are disadvantages such as low material utilization rate and high product cost.

In addition, in the case of a molding method in which each layer is integrally laminated into a plate, the edges of the molded product A are trimmed at the same time as molding or after demolding, by cutting off (trimming) unnecessary edges around the molded product.

There are some products that are completed by this trimming, but if only the trimming is done, the cut surface (outer peripheral end surface of the composite molded body) 4
The laminated end faces of each layer 1, 2, and 3 are exposed and the appearance is bad.In the case of a reinforcing wire mesh, the edge of the wire mesh is exposed at the cut surface 4, which is dangerous. For some reasons, such as the possibility of peeling due to curling, after the above trimming, the cut surface of the molded product is further concealed and the edges are finished to produce the final product. In this case, the form of concealment treatment for the cut surface 4 is as shown in the chain lines in FIG. 1 and as shown in FIG.
The cut surfaces of the intermediate material layer 2 and the base layer 1 are made by extending the peripheral edge of the intermediate material layer 2 and the base layer 1 by folding the extended portion 3'' to the back side of the molded body, wrapping it around the back side of the base layer 1, and fixing it with adhesive or the like. It is best to cover the edges and create a beautiful edge finish.

However, in order to perform the above-mentioned edge finishing treatment in cases where a composite molded body is obtained using a laminated flat plate formed by laminating the constituent layers 1, 2, and 3 together in advance, it is necessary to trim the molded body. Then, the extra dimensions of the base layer 1 and intermediate material layer 2 at the periphery of the molded product are shaved off and removed from the back surface of the skin material layer 3. As a result, the extended peripheral edge 3'' of the skin material layer must be folded back to the back side of the molded body, which is an extremely inefficient operation and cannot be used in practice.

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. On the other hand, the method of laminating each layer sequentially requires manual labor and is low in productivity.Moreover, for products with a complex uneven surface shape, if the intermediate material layer 2 and the skin material layer 3 are attached to the base layer 1 with the complex uneven surface shape. This makes it difficult, or even impossible, to make beautiful bonding by adhering each part to each other, and is limited to manufacturing small quantities of articles with relatively simple shapes.

Even in the case of this method, when forming and covering the molded base layer 1 with a composite sheet in which the intermediate material layer 2 and the skin material layer 3 are laminated, it is necessary to wrap the skin material layer 3 onto the back side of the base layer 1. This also involves the difficult work of scraping off the intermediate material layer 2 from the back surface of the extension of the skin material layer 3.

Furthermore, even if the intermediate material layer 2 and the skin material layer 3 are trimmed along the periphery of the base layer 1, it is almost impossible to recycle the trimmed scraps. The present invention was proposed in view of the above, and although it is classified as a method of laminating each layer sequentially, it combines a vacuum forming method, an injection molding method, a pressure molding method, or a resin bead foam molding method. Through a series of continuous processes, we can efficiently mass-produce products with complex uneven shapes according to the designed shape. It is an object of the present invention to provide a new method for producing this type of composite molded article, which has other great features such as easy edge finishing by molding.

A detailed explanation will be given below based on an embodiment shown in the drawings. This example is based on the manufacture of the composite molded body A shown in FIG. 1, that is, a door trim board having a three-layer lamination structure. Further, in the present invention, the base layer 1 of the composite molded product A is formed by a synthetic resin injection molding method, a pressure molding method, or a resin bead foam molding method, but this example uses a resin bead foam molding method. shows. First, the mold configuration (FIG. 2) will be explained. 5.6
5 is a split mold for molding the target composite molded body A; 5 is a mold for molding the surface side of the molded body A (hereinafter referred to as the first mold);
Reference numeral 6 denotes a mold for modeling the back side (hereinafter referred to as a second mold).

When the two molds 5 and 6 are clamped together, a cavity having a spatial shape substantially matching the overall shape of the target composite molded body A is formed inside the molds. In addition to the above-mentioned molds 5 and 6, as an auxiliary mold 7, the base layer 1 of the objective composite molded product A is
A mold that substantially matches the overall shape and thickness of both the intermediate material layer 2 and the skin material layer 3, excluding the molding shape and thickness after vacuum forming of the intermediate material layer 2 and the vacuum forming of the skin material layer 3, which will be described later. A mold corresponding to the combined shape and thickness of the subsequent molding shape and thickness is adjusted.

The first mold 5 has a vacuum forming function by opening a large number of vacuum holes 52 in its molding surface 51 or by making the thick material in the region of the molding surface 51 a continuous porous body.

53 is a vacuum chamber formed inside the mold 5;
The vacuum holes 52 mentioned above are in communication with each other.

54 is a vacuum vibrator that communicates the chamber 53 with a vacuum pump (not shown), and 55 is a cooling water vibrator embedded within the thickness of the mold 5.

The second mold 6 has a foamable resin bead injection vibrator 62 opened on its molding surface 61, and has a large number of steam ejection holes 63.
is left open. Reference numeral 64 denotes a steam introduction chamber formed inside the mold 6, and each of the steam ejection holes 63 described above communicates with this chamber 64.

Reference numerals 65 and 66 designate a steam introduction vibe connected to the chamber 64 and the same exhaust vibe, and 67 and 68 designate a cooling water introduction vibe and the same exhaust vibe connected to the chamber 64.

Further, a plurality of elongated air venting vibes 8 are provided, penetrating from the back side of the mold 6 to the molding surface 61 side, so that they can move forward and backward freely. In this example, the base of each vibrator 8 is fixed to a common advancing/retracting plate 81, and the plate 81 is moved forward/backward by a drive mechanism (not shown), so that all the vibrators are moved forward/backward. Each vibrator 8 is connected to a vacuum pump (not shown). 13 is a sealing packing between each vibrator 8 and the mold side advance/retreat hole.

In addition, the mutually opposing surfaces 511 and 611 of the two molds 5 and 6 around the effective molding surface areas 51 and 61 are made of a sheet material that will become the intermediate material layer 2 between the two molds 5 and 6, as will be described later. When the mold is clamped with the sheet material forming the skin layer 3 interposed, the sheet material portions 2'' and 3'' (Fig. 6) interposed between the mold facing surfaces 511 and 611 are pressed together. The mold structure is such that a gap space 9 (FIG. 6) is created between the mold facing surfaces 511 and 611 so that the mold is not damaged.

In the illustrated example, the surface 611 on the side of the mold 6 is formed as an inclined surface, and the surface 511
- A tapered gap space 9 is formed between 611. 2. The mold facing surfaces 511 and 61
1 are provided with a compressed air jet hole 56 and a vacuum suction hole 69, respectively. Next, the manufacturing process will be explained step by step. I 1st step (modeling of base layer 1, Figures 2 and 3) 3 ((
1) The auxiliary mold 7 is placed on the molding surface 51 of the first mold 5 in the open state.
Insert.

This fitting of the mold 7 can be easily automated using a robot mechanism (not shown) or the like. Also, the mold 7 is held against the first mold 5 by, for example, magnetic adsorption, or by hooking claws 3! This can be easily and stably carried out by appropriate means such as. (
2) The first mold 5 with the auxiliary mold 7 set therein and the second mold 6 are clamped together.

Due to this mold clamping, the inner surface 714C of the auxiliary mold 7 (
A cavity having a spatial shape approximately corresponding to the shape and thickness of the base layer 1 of the target composite molded body A is formed between the effective molding surface 61 of the second mold (the surface opposite to the mold 5 side) and the effective molding surface 61 of the second mold. . (3
) By moving the plate 81 forward, each venting vibrator 8 is advanced inward of the mold, and its tip end enters the cavity from the molding surface 61 of the second mold 6'', and furthermore, the tip end is inserted into the auxiliary mold. It enters each vibrator tip receiving recess 72 formed in advance on the surface 71 of the mold 7 and moves forward until it hits the end.

:4) Introduce expandable resin beads 1'' such as expandable polystyrene beads into the cavity from the resin bead injection vibe 62 to fill the cavity with the beads 1''.

5) Steam (or hot air may be used) is introduced into the chamber 64 in the second mold 6 from the vibrator 65. As a result, the steam is injected into the filled cavity of the beads 1'' through each steam injection hole 63, and the individual filled beads 1'' are thermally foamed by the heat of the steam, and the whole becomes a mass due to the foaming pressure and heat. A resin bead foam molded body, that is, a base layer 1 having a predetermined shape is formed.
In this case, since the base layer 1 to be molded is relatively thick, introducing steam only from one side of the second mold molding surface 61 will result in insufficient foaming of the beads 1'' in the vicinity of the auxiliary mold surface 71. If there is a risk, connect the steam introducing vibrator 57 to the chamber 53 of the first mold 5, make the auxiliary mold 7 a porous structure, or provide a large number of ventilation holes 73 to improve ventilation. The steam introduced from the vibrator 57 into the chamber 53 is transferred to each vacuum hole 52 of the first molding surface 51 (the thick material in the region of the molding surface 51 is made of a continuous porous material to provide a vacuum forming function). Steam may also be introduced into the cavity from the surface 71 side of the auxiliary mold 7 through the porous flesh of the auxiliary mold 7 or the ventilation holes 73.

Alternatively, the steam is introduced from the 61 molding surfaces of the second mold, and the steam in the cavity is transferred to the auxiliary mold 7 by setting the steam exhaust vibrator 58 connected to the chamber 53 of the first mold 5 to a steam exhaust state.
Porous flesh or ventilation holes 73 - Vacuum holes 5 of the first mold 5
2 or porous flesh→chamber 53→vibrator 58 path to create a suction state, thereby making the steam inside the cavity actively flow from the second mold molding surface 61 side toward the surface 71 of the auxiliary mold 7. It's okay.

In the above case, the effective molding surface 71 outer peripheral portion 74 of the auxiliary mold 7
It is allowed to have no ventilation.

In addition, each venting vibrator 8 is also used as a steam blowing vibrator,
It is also effective to introduce steam into the cavity through each of the vibes 8, in addition to introducing steam from the steam jet holes 63 of the molding surface 61.

That is, in the state shown in FIG. 3, a horizontal hole 82 is provided in the tube wall of each vibrator 8 located in the cavity, and a horizontal hole 83 is provided in the tube wall of each vibrator 8 located in the chamber 64. , the steam introduced into the chamber 64 is passed through the horizontal hole 8 of each vibrator 8.
3→Inside each vibrator 8→Introduced into the cavity through the horizontal hole 82 at the tip of each vibrator 8.

(6) After complete foaming of the beads inside the cavity,
Stopping steam introduction → Chambers 64, 53 by vibrators 66, 58
Elimination of residual steam inside → Cooling water is introduced into the chamber 64 by the vibrator 67 and cooling water is introduced into the vibrator 55, thereby cooling the molds 5, 6, 7 and the molded body 1 inside to a predetermined mold opening temperature. do.

■Second process (Vacuum forming of intermediate material layer 2 and skin material layer 3, Figures 4 and 5) (1) When the temperature of the mold and internal molded body has dropped to the predetermined mold opening temperature, internal molded body 1 is held on the molding surface 61 of the second mold 6, and the mold is opened.

The molded body 1, that is, the molded base layer 1, is held on the second mold 6 side by inserting the tip of the elongated air venting vibe 8 into the thickness of the molded base layer 1 (C). This keeps it stable. 1st
The auxiliary mold 7 fitted onto the molding surface 51 of the mold 5 is removed and removed. The removal of this auxiliary mold 7 can also be automated using a robot machine or the like, similar to the above-mentioned fitting. (
2) During this opening process, or after opening the mold, each elongated air venting vibrator 8 is moved slightly backward until the tip of each vibrator is flush with the outer surface of the molding base layer 1 and the road surface.

(3) Place the skin material layer sheet 3 and the intermediate material layer sheet 2 between the first and second molds 5 and 6 in the opened state, with the skin material layer sheet 3 on the first mold 5 side. Introduce.

In this case, the sheet 3 for the skin material layer is made of a material that exhibits elongation at room temperature or when heated and has breathability, such as a fabric or
Knitted fabrics, nonwoven fabrics, felt, etc. are used, and those that exhibit elongation when heated are heat-treated in advance and introduced between the molds 5 and 6. Further, the sheet 2 for the intermediate material layer is also heated and softened in advance before being introduced. The introduction of both sheets 3 and 2 is carried out by sequentially feeding out each long sheet on a roll using a feed mechanism (not shown), passing through a heating station (not shown) on the way, and guiding it between the molds 5 and 6. It can be done automatically. Further, a suitable adhesive layer 31 (for example, sheet 3,
A heat-activated adhesive that is activated by the heat of the preheating treatment in step 2) is applied and formed.

Then, the first mold 5 is heated to the chamber 53 by the vacuum vibrator 54.
The outside air is sucked through the openings of the vacuum holes 52 of the molding surface 51 by eliminating the air inside, and the sheet 3 for the skin material layer and the sheet 2 for the intermediate material layer are superimposed on the molding surface 51. Apply.

As a result, vacuum forming force acts on the intermediate material layer sheet 2 through the breathable skin material layer sheet 3, and the skin material layer sheet 3
and the intermediate material layer sheet 2 are simultaneously molded along the molding surface 51, and the opposing surfaces of the effective molding area of the molded sheets 3 and 2 are bonded to each other due to the adhesion force of both sheets 3 and 2 based on this molding. They are integrated through the agent layer 31. Reference numeral 10 indicates a seat clamp for the intermediate material layer, 102 indicates a seat clamp for the skin material layer, and 103 indicates a common clamp for both sheets, including a clamp 101 that holds the sheet 2 for the intermediate material layer and a clamp 102 that holds the sheet 3 for the skin material layer. The two sheets 2 and 3 are placed close to each other and placed on top of each other, and the two sheets 2 and 3 are clamped by the common clamp 103 and applied to the first mold 5 to perform vacuum forming of both the sheets 2 and 3. .

The sheet 3 for the skin material layer has high air permeability, and as a result, excessive outside air is sucked in from the periphery of the sheet 3 through the breathable layer of the sheet during the vacuum forming, resulting in the sheet 3 passing through the sheet 3 for the intermediate material layer. If the vacuum suction force acting on the sheet 2 is weakened and the sheets 2 and 3 cannot be sufficiently vacuum formed, temporarily tighten the sheet 3 for the skin layer and the sheet 2 for the intermediate layer together to remove the periphery of the sheet 3. The lamp configuration may be such that it blocks the inflow of outside air from the outside.

11 is a clamp 10 that is activated after vacuum forming sheets 2 and 3.
1.10.

This is a cutting device for separating the vacuum formed part and the subsequent sheet part between the clamp 103 and the clamp 103. ■Third process (
Lamination of base layer 1 and intermediate material layer 2 (Figures 5 and 6) (1) Composite vacuum-formed product of second mold 6 holding the above-mentioned modeling base layer 1, skin material layer 3 and intermediate material layer 2 The first mold 5 holding the mold is re-clamped.

This re-clamping is carried out in a state in which outside air is sucked from the air venting vibe 8 of the second mold 6. As a result, the air that would be trapped between the base layer 1 and the intermediate material layer 2 during the mold clamping process is actively vented, and finally the base layer 1 and the intermediate material layer are separated from each other in their effective molding area. The two layers 1 and 2 are in close contact with each other without causing any local air pockets, and are pressed against each other by the mold clamping force; Transform into a Yoso body. Further, the effective molding areas of the skin material layer 3 and the intermediate material layer 2 are also pressed by this mold clamping force, and the bonding by the adhesive layer 31 is strengthened. Adhesive layer 21 for bonding base layer 1 and intermediate material layer 2
In advance, the skin material layer 3 and the intermediate material layer 2 are placed on the surface on the intermediate material layer 2 side.
In the same way as in the case of bonding, a heat-activated adhesive layer or the like is applied or formed on one or both of the facing surfaces of the base layer 1 and the intermediate material layer 2 before re-clamping. You can apply adhesive by spraying etc. (2) Immediately after the molds 1 and 2 are clamped, the holes 56 and 69 are opened in the opposing surfaces 511 and 611 of both molds around the effective molding surface areas 51 and 61, respectively. Air is blown out from. In addition, the hole 69 is placed in a state where outside air is sucked.

Then, the intermediate material layer sheet portion 2'' around the outside of the effective molding area receives pressing force from compressed air through the thickness of the breathable skin material layer sheet portion 3'', and the back surface thereof receives a hole 6.
9, it is separated from the back surface of the skin material layer sheet portion 3'' around the outside of the effective molding area and is suctioned and held by the mold surface 611, as shown in FIG.

The purpose of separating the sheet portions 2'' and 3'' is to facilitate the removal of the unnecessary intermediate material layer portion 2'' during edge processing of the molded product, as will be described later. It also works effectively and appropriately for processing the outer periphery of the effective molding area between molded products in the case of molding multiple molded products.However, in this case, the compressed air blowing mechanism of the five molds is unnecessary.Also, the sheet portion 2'' mentioned above is not required. Separation from seat part 3'' is done using clamp 10.
1 in the direction of the second mold 6 using a moving mechanism (not shown).

Furthermore, even if no active separation mechanism is provided for sheet portions 2'' and 3'' as described above, there will be an active contact pressing force on the sheet portions 2'' and 3'' during vacuum forming of sheets 2 and 3. does not work, and also when re-clamping the molds 5 and 6, the mold structure creates a gap 9 between the mold facing surfaces 511 and 611 of the portions so that the sheet portions 3'' and 2'' are not pressed as described above. Therefore, although both 3'' and 2'' are in contact with each other via the adhesive layer 31, the bonded state is extremely weak and they cannot be easily separated from each other immediately after the molded body is demolded. I am in a position to do so.

(3) The actions of venting air from the vibrator 8, blowing air from the hole 56, and sucking air from the hole 69 are stopped. The vibrator 8 is moved backward and its tip is retreated from inside the molded object into the mold 6. Open the mold and take out the composite molded body. Clamps 101 and 102 are removed before or after opening the mold. ■Fourth step (Edge finishing treatment of molded product, Figures 7 and 8) The removed molded product has a base layer 1, intermediate material layer 2,
The three parts of the skin material layer 3 are integrally joined, and the intermediate material layer part 2'' and the skin material layer part 3'' on the outer periphery thereof are of a form separated from each other.

Alternatively, as described above, the portions 2'' and 3'' are in a weakly bonded state that can be easily separated from each other. In this case, both parts are then separated. Therefore, the intermediate material layer portion 2'' around the outside of the effective molding area is removed by cutting 12-12 (FIG. 7) along the periphery of the base layer 1.

In this case, the base of the intermediate material layer portion 2'' is the skin material layer portion 3''.
Even if it is adhered to the root part through the adhesive 31, 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''. I can do it. The skin material portion 3'' is left as it is or trimmed leaving only the extension width 1 necessary for commercialization.Then, the extended skin material portion 3'' around the molded body is trimmed.
The final product A is obtained by folding this back to the back side of the base body 1 as shown in FIG. 8 (=dashed line in FIG. 1) and fixing it to the back face of the base body with an adhesive or a suitable fastener.

Alternatively, if edge treatment by folding back the skin material layer portion 3'' is not required, both the skin material layer portion 3'' and the intermediate material layer portion 2'' around the outside of the effective molding area of the molded body may be folded over the base layer 1. Final product A (with trimming along the outer periphery)
(solid line in Figure 1).

In the embodiments described above, the base layer 1 is formed by a resin bead foam molding method, but it may also be formed by a resin injection molding method or a pressure molding method.

Figure 9 shows an example in which the base layer 1 is formed by the injection molding method, and the mold configuration in this case is the second mold in comparison with the examples in Figures 2 to 6. Change the resin bead injection vibrator 62 in 6 to a molten resin injection or pressure feeding pipe 62'', no need for steam introduction system in the 2nd and 1st molds 6 and 5 (steam introduction/discharge vibrator 65, 66, 57, 58) , steam vent 63
), the second mold 6 is cooled by a cooling water vibrator 70 within the mold wall thickness.
The difference is that the chamber 64 and cooling water introduction/exhaust system vibrators 67 and 68 are not required, and the auxiliary mold 7 does not have to be porous. Composite molded body A
The manufacturing procedure is the same as that of the above-mentioned embodiment except that the base layer 1 is formed by pouring or pumping the resin.

Note that during injection or pressure molding of molten resin, the tip of each venting vibe 8 in the mold cavity enters and fits into the recess 72 on the surface of the auxiliary mold 7, and the tip opening is held in a closed state. Therefore, the molten resin introduced into the cavity does not enter into the vibrator 8 through the tip opening.

As described above, according to the method of the present invention, the following effects are obtained, the intended purpose is well achieved, and the method is effective and suitable as a method for producing this type of composite molded article.

(a) The base layer 1 is formed into a predetermined shape by a resin bead foam molding method, a resin injection molding method, or a pressure molding method, and the intermediate material layer 2 and the skin material layer 3 are formed into a predetermined shape by vacuum forming. Because it is a method that combines and integrates three layers, it is better than the method in which three layers are laminated together and then formed into the desired shape.
Even if the product has a complex uneven shape, it is possible to obtain a molded product with no so-called ambiguity in the molded shape, sharp highlights, and even details as per the predetermined design.

(b) Since the skin material layer 3 and the intermediate material layer 2 are overlaid and molded on the same molding surface 51, no lifting occurs between them, and in the process of laminating the intermediate material layer 2 and the base layer 1. Since the air between the two layers is actively vented, there is no air pocket between the two layers, and a high quality product in which the three layers are closely bonded can be obtained. Furthermore, since there is no air pocket between each layer, surface defects due to air expansion do not appear when heated by solar heat or other heating causes during use, and surface quality at high temperatures is also guaranteed.

(C) The series of steps 1 to 3 mentioned above can be continuously automated, and unlike the molding of a three-layer laminated board, the vacuum forming of only the skin material layer 3 and the intermediate material layer 2 can be performed easily and quickly. In addition, since the base layer 1 can be easily shaped, the entire structure can be manufactured quickly and efficiently.

(d) Since the intermediate material layer portion 2'' and the skin material layer portion 3'' around the outside of the effective molded area can be molded products that are separated from each other or can be easily separated from each other, the intermediate material Removal of the layer portion 2'' is extremely easy, so that the end face 4 of the molded part
It is possible to easily and efficiently obtain a molded article with a good-looking and beautiful edge finish, which is concealed and covered by folding the extension piece 3'' of the skin material layer 3.

(e) Since the base layer 1 is formed by resin bead foam molding and resin injection molding by pressure molding, there is no so-called trimming loss, and the intermediate material layer portion 2'' removed by trimming is
and the skin material layer portion 3″ are each separated separately, so they can be recovered and reused (for example, melted and reused as the intermediate material layer/
It can be used as a raw material for the skin layer), reducing material costs and saving resources without any waste.

[Brief explanation of the drawing]

Figure 1 is a vertical cross-sectional view of an example of a composite molded product (a car door trim board), Figure 2 is a vertical cross-sectional view of a mold, and Figure 3 is a partial view of the mold in a state where the base layer is being formed. 4 is a vertical sectional view of a part of the state in which the intermediate material layer sheet and the skin material layer sheet are introduced between the molds that have been opened after forming the base layer, and FIG. Fig. 6 is a vertical cross-sectional view of a part of the mold in the re-clamping process after vacuum forming, Fig. 6 is a longitudinal cross-sectional view of a part of the mold after the mold has been clamped, and Fig. 7 is a longitudinal cross-sectional view of a part of the molded product taken out after opening the mold. FIG. 8 is a cross-sectional view of the mold after edge treatment, and FIG. 9 is a longitudinal cross-sectional view of a part of the mold after forming a base layer by resin injection molding. 5 and 6 are first and second molding dies, 7 is an auxiliary mold, A is a composite molded body, 1 is a base layer, 2 is an intermediate material layer, and 3 is a skin material layer.

Claims (1)

[Claims] 1. In obtaining a composite molded product consisting of a base layer 1, an intermediate material layer 2, and a skin material layer 3 laminated in sequence, when the mold is clamped, there is a layer between the opposing effective molding surfaces 51 and 61. A first mold 5 for molding the front side of the composite molded body, which is configured with a cavity having a spatial shape corresponding to the overall shape and thickness of the composite molded body, and a second mold 6 for molding the back side of the composite molded body, and an auxiliary mold 7 having a shape and thickness corresponding to the overall combined shape and thickness of the intermediate material layer 2 and skin material layer 3 of the desired composite molded body, and forming the molding surface of the first mold 5. Reference numeral 51 is provided with a vacuum forming function, and the foamable resin bead introduction hole 62 in the second mold 6 is a resin injection or pressure feeding hole 6.
2' is opened, and a small-diameter vent pipe 8 is provided so that it can move freely forward and backward from the molding surface 61, and when both molds 5 and 6 are clamped together, both sides of the outer periphery of the effective molding surface area of both molds are opened. A mold structure is adopted in which a gap 9 is created between the mold opposing surfaces 51_1 and 61_1 so that the intermediate material layer portion 2' and the skin material layer portion 3' interposed therebetween are not pressed against each other, and the molding surface of the first mold 5 is The auxiliary mold 7 is fitted to the auxiliary mold 7 to clamp the first and second molds 5 and 6, and the vent pipe 8 on the second mold 6 side is moved forward to insert the tip of each pipe into the auxiliary mold 7. The molding surfaces 61 and 71 of the second mold 6 and the auxiliary mold 7
The base layer 1 is shaped by introducing and filling the foamable resin beads 1' into the cavity formed between them and foaming them, or by injecting or pumping the molten resin. Open both molds 5 and 6 by holding them on the mold 6 side, remove the auxiliary mold 7 from the first mold 5, and remove the auxiliary mold 7 from the first mold 5.
Using the molding surface 51 of the mold 5, the sheet 2 for the intermediate material layer is layered with the sheet 3 for the surface material layer, which is air permeable and exhibits elongation at room temperature or by heating, on the surface side thereof, and the sheet 3 for the surface material layer is combined with the sheet 3 for the skin material layer. While vacuum forming, both molding layers 3 and 2 are integrated by an adhesive layer 3_1 interposed between both sheets 3 and 2 in advance, and then a second mold 6 holding the above-mentioned modeling base layer 1 and a skin material are formed. The first mold 5 holding the integral vacuum molded product of the layer 3 and the intermediate material layer 2 is re-clamped, and at this time, the air vent pipe 8 is put into the air suction state between the base layer 1 and the intermediate material layer 2. The base layer 1 and the intermediate material layer 2 are formed by clamping the mold while removing air from the base layer 1 and intermediate material layer 2.
and an adhesive layer 2_1 in which both layers 1 and 2 are interposed in advance between the two layers by fitting and pressing them together in the effective molding area.
A method for producing a composite molded article, characterized by: 2 A compressed air jet hole 56 and a vacuum suction hole 69 are opened in the opposing surfaces 51_1 and 61_1 of the first and second molds 5 and 6 around the outside of the effective molding surface area, respectively, and the molds 5 and 6 are opened. When the mold is re-tightened, the above-mentioned holes are respectively put into air ejection and air suction states to move the intermediate material layer portion 2' around the outside of the effective molding area to the surface 61_1 side around the outside of the effective molding surface area of the second mold 6. Both 2' and 3' are biased and separated from the skin material layer portion 3'.
2. A method for producing a composite molded article according to claim 1, wherein the two are actively kept separated from each other. 3 After re-clamping the molds 5 and 6, the molds are opened and the intermediate material layer 2 of the composite molded body taken out is trimmed with the material portion 2' around the outer area of the effective molded part, and the effective molded part of the skin material layer 3 is removed. Fold back the material portion 3' around the outside of the area and fix it to the back side of the base layer 1, or trim both the material parts 2' and 3' around the outside of the effective molding area for the intermediate material layer 2 and the skin material layer 3. 2. The method for producing a composite molded article according to claim 1, wherein the composite molded article is removed by removing the composite molded article.