JPS63134225A - Bonding of different kinds of skin material and device therefor - Google Patents

Abstract

PURPOSE:To carry out efficiently cutting without deviation of lap margin of each sheet and bonding the same by mounting a cutting blade with an adjustable cutting edge on a specific section of a bonding electrode plate and moving said blade up and down in the processes before and after bonding. CONSTITUTION:A polyvinyl chloride sheet 7 of 0.8 mm thickness as a skin material is set on a low electrode plate 1 of a welder. Then, an upper electrode plate 2 is lowered down and prefixed sites are cut off. At that time, the cutting blade is set at a position higher than the face of a lower weld bar 3. Next, after the upper electrode plate 2 is lifted up, a nonrigid polyvinyl chloride resin sheet 8 is set. Subsequently, the upper electrode plate 2 is lowered and the prefixed sites are fused. At that time, the cutting blade is set at the same level as the lower weld bar face or lower. By said arrangement, deviation of lap margin is not generated to eliminate defective bondings.

Description

Detailed Description of the Invention (Industrial Application Field) The present invention relates to a method for joining different skin materials, and is mainly applied to transportation vehicles such as automobiles, railway vehicles, aircraft, and ships, other household items, bags, and clothing. The present invention relates to a method and apparatus suitable for producing skin materials for various interiors, exteriors, and clothing that have excellent decorative appearance and are used in various products.

(Prior art) Recently, there has been a demand for interior-oriented designs that are luxurious and have a good texture for the appearance of interior materials such as interior materials such as automotive instrument panel pads (hereinafter abbreviated as instrument pads) and door trims. As a result, there is a demand for the decorative surface not only to be made of a single material, but also to use a composite skin material, for example, a combination of vinyl chloride skin material and 77 bricks.

Conventionally used methods for making these composite skin materials include sewing thermoplastic synthetic resin sheets such as vinyl chloride sheets and 77 bricks, flocking short fibers onto the surface of the vinyl chloride skin material, or using chloride. The joint ends of the vinyl sheet and the 77 bricks are joined by the skin folding method, or the 7 bricks lined with the vinyl chloride sheet are adhered to the surface of the vinyl chloride skin material using an adhesive, or weld welding is used. has been used.

However, the methods for manufacturing composite skin materials according to the above-mentioned conventional techniques each have various problems, and solutions to these problems have been sought. A skin material made by joining a thermoplastic synthetic resin sheet and another skin material by sewing requires a lot of man-hours and exposes perforations, which is undesirable in terms of appearance.In addition, this skin material requires molded products by integrally foaming urethane. When doing so, there was a drawback that the foaming liquid leaked out due to the foaming pressure.

The problem with the method of flocking short fibers onto the surface of the skin material is that there is a lack of freedom in design. In addition, with skin materials joined by the skin folding method, injection fluid tends to leak from the joint during urethane foaming, and it is difficult to apply the skin folding method to join three-dimensional parts.
There were design limitations. Traditionally, the method of attaching 7-Applications to the surface of the skin material with an adhesive is a labor-intensive process, and the adhesive tends to seep into the edges of the 7A-Applications, resulting in stains (also, the method of attaching 7A-Applications to the surface of the skin material with an adhesive is difficult). The surface material used had the disadvantage that the 7-ply prick portion rose on the surface of the finished product, spoiling its decorative appearance.

- A method of welding the periphery of the 7-ply with a welder by stacking the 7-ply with a force field vinyl sheet backed with an adhesive on the vinyl chloride skin material does not require the use of solvents and takes a short time. This method has many advantages, such as being able to complete the welding immediately, resulting in high productivity and low cost.However, with this method, it is necessary to closely match the overlap between the upper weld bar and the planned welding area around the 77 brick. Often, the overlap margins are misaligned, which spoils the appearance.

For the purpose of solving these problems, for example, Japanese Patent Application Laid-Open No. 58-17565
0 describes a method for manufacturing automotive interior materials such as door trims that have surface layers made of different materials, but this method requires a lower mold that is divided into two parts W4, and Although it is possible to obtain a horizontal pattern, it is not possible to obtain a more complicated decorative horizontal pattern, and there are serious drawbacks such as low productivity and high cost.

Furthermore, JP-A-59-101324 describes a method for manufacturing skin materials with partially different materials by slush molding, but this method requires molds and holding jigs depending on the width. It is difficult to obtain complex decorative horizontal patterns, and productivity is also low.

Furthermore, JP-A-60-2320 describes a method for producing a skin material with a multicolored surface by an injection method using a masking material, but it is also difficult to obtain complex decorative horizontal patterns with this method. , productivity is low.

In addition, Japanese Utility Model Publication No. 61-34104 describes a weld mold suitable for setting the cut skin material in the lower weld mold, and then laminating different skin materials and performing high-frequency welding. In this case, a trimming die is required to cut the skin material in advance, which increases the number of man-hours and reduces productivity.

Furthermore, in the molding of door trims for automobile interiors, a method is used in which a skin sheet, an ornament, and a core material are laminated in this order, and high-frequency welding and fusing are performed simultaneously using a mold with a cutting blade fixed to a weld bar. However, in this case, it is not possible to set the cut conditions and weld conditions for the skin sheet separately, so if the ornament is made of polyvinyl chloride, due to the high frequency current from the cutting blade tip,
The border line on the ornament side may melt, resulting in a poor appearance. On the other hand, in order to reduce damage to the ornament base material, weakening the welding conditions or lowering the height of the cutting blade will prevent the cutting of the outer sheet. become insufficient or
The weld strength between the skin sheet and the ornament may become weak.

(Problems to be Solved by the Invention) An object of the present invention is to provide a method and apparatus for manufacturing a composite skin material that has an excellent appearance without shifting the welding overlap between different skin materials.

Another object of the present invention is to provide a method and apparatus for manufacturing a composite skin material having excellent bonding strength with fewer man-hours.

(Means for Solving the Problems) The present invention involves lowering the upper electrode plate and cutting the first skin material on the lower electrode plate of the welder under pressure using a cutting blade attached to the lower weld bar. The cutting edge height of the cutting blade is set to be the same as or lower than the height of the lower weld bar, and the first skin material and the second skin material laminated on the skin are pressure welded using the upper weld bar. How to cut and join different skin materials and its implementation! Regarding LC placement.

Hereinafter, the present invention will be explained with reference to the drawings. For example, as shown in FIG. 1, the apparatus of the present invention is a joining apparatus for joining different skin materials having an upper electrode plate attached with an upper weld bar and a lower electrode plate attached with a lower weld bar. Adjust the height of the cutting edge! A cutting blade that can be adjusted is provided for cutting.

Here, FIGS. 1A, 1B, and 1C are schematic diagrams illustrating a welding process by high-frequency welding as an embodiment of the present invention. As shown in Figure 1 (A) (lower electrode plate (1)
The first skin material (7) is set on top, and then the upper electrode plate (2) is lowered to cut a predetermined portion. In this case, the cutting blade is set at a position higher than the surface of the lower weld bar (3). PIIJ1 diagram (
B) shows the state in which the upper electrode plate (2) is raised and the second skin material (8) is set. FIG. 1(C) shows a state in which the upper electrode plate (2) has been lowered and predetermined portions have been welded. In this case, set the cutting blade at the same height as the surface of the lower weld bar or at a lower position.

In this way, by lowering the cutting blade during welding, the influence of the high frequency current from the tip of the cutting blade on the second skin material can be prevented. For example, if the second skin material is a soft polyvinyl chloride sheet, the portion in contact with the cutting blade will melt, forming grooves and discoloring, which can be prevented.

In addition, by setting the cutting blade height sufficiently high and cutting the IJ41 skin material reliably, it becomes easy to remove the first skin material that covers the surface of the second skin material after welding. . This - is advantageous when the thickness of the first skin material is greater than that of a conventional skin.

As a mechanism for adjusting the height g of the cutting blade in the present invention, a wedge mechanism, a cam mechanism, a jack mechanism, and others can be used as appropriate. A schematic diagram of these mechanisms is shown in FIG.

Figure 2 (A) shows a mechanism that moves the movable lower electrode plate (1') up and down to change the cutting blade length.

FIG. 2(B) shows a mechanism for changing the height of the cutting blade by moving the taper pin in and out.

In Figure 2 (C), a cam is placed at the bottom of the cutting blade, and the height of the cutting blade can be adjusted by rotating the cam! This shows the mechanism for adjusting.

Figure 2 (D) shows a mechanism for changing the height of the cutting blade by inserting a jack into the lower part of the cutting blade.

In the present invention, the welding method can be appropriately selected from heat pressing, high frequency welding, ultrasonic welding, etc. depending on the combination of the first R skin material and the second skin material.

In the case of a high-frequency welder, the first and second skin materials are polyvinyl chloride, polyvinylidene chloride, polyethylene, polypropylene, polyamide, polyurethane, poly7 cetal, polycarbonate, polytetrafluoroethylene, polystyrene, polyester, polycellulose. A thermoplastic sheet with high dielectric loss, such as acetate, is preferred. Moreover, if an ultrasonic welder is used, it can be applied to all thermoplastic plastics. In this case, a tool horn is used as the upper die and a pedestal is used as the lower die. *
Even if one of the first or second skin materials is not a thermoplastic such as 7-enol-formalin resin, resorcinol resin, lily-7 resin, melamine resin, epoxy resin, 7-lan resin, or silicone resin, the net-like If the structure allows easy penetration of molten PVC, the picture surface material can be bonded. Furthermore, either the first or second skin material is made of natural fibers or recycled fibers such as rayon.
Even if it is made of plastic or a blend of these and other chemical fibers, it has relatively high air permeability, and if it has a thermoplastic sheet laminated on the back side, it can be bonded to the picture surface material.

(Effects of the Invention) The method of the present invention eliminates process defects caused by misalignment of overlapping allowances, which have conventionally been a problem when welding different skin materials, and also solves problems such as crushing of the boundary between different skin materials. Furthermore, cutting and welding can be performed using the same mold, reducing the number of man-hours and making it possible to stably manufacture products with decorative beauty. *The method of the present invention is also advantageous for welding sheets with large variations in thickness.

(Example) A detailed explanation will be given below with reference to examples.

Example 1 A polyvinyl chloride sheet with a thickness of 0.8 mm was used as the first skin material, and this was placed on the lower electrode plate of a welder as shown in Figure 3 (A), and the upper electrode plate was It was lowered and cut using a cutting blade attached to the lower weld bar. The dimensions of the lower weld mold used at this time were f
In the lS5 diagram, h=1, Omm, α=30”, W
=2 wheels m, w=1. Frequency 2 with a pressure of 5 kg/es+" using the upper weld bar.
Cutting was performed by applying electricity at 7.12 MHz + output of 1.5 kW for 1 second.

Next, a second skin foamed polyvinyl chloride sheet is laminated,
After lowering the upper cueld bar, set the cutting blade low as shown in Figure (B) on page 143 and apply a pressure of 10
kg/c ugly 2. Both skins were joined by high frequency welding under conditions of an output of 3 kW and a welding time of 3 seconds.

Example 2 As the first skin material, a non-foamed polyvinyl chloride sheet with a thickness of 0.3+u+ and a sheet with a thickness of 1. Using a skin layered with 10x foamed polyvinyl chloride sheets of Omm, the skin was set in a lower weld mold, a polyester moquette skin was laminated at a predetermined location, and then the density was 0.05 g/cI113 and the thickness was 2. A polyurethane cushion pad material of 511I11 and a hardboard for the core material were laminated, and the lowermost skin was cut by melting as shown in FIG. 4(A). The dimensions of the lower weld mold used at this time were the same as in Example 1, but the height h of the cutting blade was adjusted to 1.5 mm.

In addition, the welding conditions are 6 pressure applied by the upper weld bar.
kg/am', frequency 27.12 MHz, output 2
kW.

Cutting was performed by applying electricity for 1 second. Under these conditions, the moquette skin is welded to the uncut primary layer in the state shown in FIG. 4(A) by lowering the cutting blade and in the state shown in FIG. 4(B). The conditions at this time are pressurizing force 10 kg/em", output 3
kW, and WA was 4.5 seconds when energized.

[Brief explanation of the drawing]

Fig. 1 is a schematic diagram illustrating a weld welding process as an embodiment of the present invention, Fig. 2 is a schematic diagram showing a height adjustment mechanism of the cut blade of the present invention, and Fig. 3 is a schematic diagram illustrating the height adjustment mechanism of the cut blade of the present invention. A schematic diagram showing a state in which the material is cut and a state in which the first and second skin materials are welded together. FIG. A schematic diagram showing a state in which the second skin material, core material, and cushion material are welded together, and FIG. 5 is an explanatory diagram showing an example of a lower felt bar provided with a cutting blade. (The above) Applicant: Toyo Rubber Industries Co., Ltd. Agent: Patent attorney 1) Iwao Mura No. 1
Figure 2 Figure 3 (A) Figure 4 (Japanese) Figure 5 12 Core material

Claims (3)

[Claims] (1) After lowering the upper electrode plate and cutting the first skin material on the lower electrode plate of the welder with the cutting blade attached to the lower weld bar, the height of the tip of the cutting blade is adjusted to the lower weld bar. of different skin materials, the first skin material and the second skin material laminated on the skin are pressure welded using an upper weld bar. Joining method. (2) The joining method according to claim 1, wherein the skin material is cut using a high frequency current during the cutting. (3) Upper electrode plate with upper weld bar attached;
A joining device for joining different skin materials having a lower electrode plate attached with a lower weld bar, characterized in that the lower weld bar is provided with a cutting blade that can adjust the height of the cutting edge. Device.