TWI551452B - Fabrication method of composite layer with different hardness nonwoven fabric - Google Patents
Fabrication method of composite layer with different hardness nonwoven fabric Download PDFInfo
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- TWI551452B TWI551452B TW101122359A TW101122359A TWI551452B TW I551452 B TWI551452 B TW I551452B TW 101122359 A TW101122359 A TW 101122359A TW 101122359 A TW101122359 A TW 101122359A TW I551452 B TWI551452 B TW I551452B
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- woven fabric
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- 239000004745 nonwoven fabric Substances 0.000 title claims description 93
- 238000004519 manufacturing process Methods 0.000 title claims description 67
- 239000002131 composite material Substances 0.000 title claims description 59
- 238000000034 method Methods 0.000 title claims description 37
- 239000000463 material Substances 0.000 claims description 60
- 239000000047 product Substances 0.000 claims description 54
- 239000013067 intermediate product Substances 0.000 claims description 42
- 235000019589 hardness Nutrition 0.000 claims description 32
- 238000010438 heat treatment Methods 0.000 claims description 21
- 230000008569 process Effects 0.000 claims description 13
- 238000000465 moulding Methods 0.000 claims description 11
- 238000001816 cooling Methods 0.000 claims description 7
- 230000004888 barrier function Effects 0.000 claims description 5
- 239000004033 plastic Substances 0.000 claims description 3
- 238000001179 sorption measurement Methods 0.000 claims description 3
- 238000007599 discharging Methods 0.000 claims description 2
- 230000004927 fusion Effects 0.000 claims description 2
- 238000002360 preparation method Methods 0.000 claims 1
- 239000010410 layer Substances 0.000 description 150
- 230000000694 effects Effects 0.000 description 8
- 238000009413 insulation Methods 0.000 description 8
- 238000010521 absorption reaction Methods 0.000 description 6
- 238000007731 hot pressing Methods 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 239000004744 fabric Substances 0.000 description 3
- 239000002356 single layer Substances 0.000 description 3
- 238000003475 lamination Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
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- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
本發明係關於一種具不同硬度不織布複合層產品製造方法，尤指一種不織布複合層產品之硬質層與軟質層係同時在一不等料厚模具內進行一次性熱壓成型之製造方法。 The invention relates to a method for manufacturing a non-woven composite layer product with different hardnesses, in particular to a manufacturing method for a one-time hot press forming of a hard layer and a soft layer of a non-woven composite layer product in a unequal thickness mold.
按，運用不織布成型技術製造出來之不織布產品頗為廣泛運用於日常生活中。其中，有利用單層不織布直接即製造出之產品，也有利用到複合層(至少雙層以上)不織布製造出之產品，例如市售之不織布菜瓜布即區分有單層式產品(常見為綠色)，也有雙層(複合層)式產品(常見一側為綠色、一側為黃色)。又如：座墊、靠墊或睡墊類之產品也常見區分有單層式及複合層式之不同產品者。 According to the non-woven products manufactured by non-woven fabric forming technology, it is widely used in daily life. Among them, there are products that are manufactured directly from a single layer of non-woven fabric, and products that are manufactured by using a composite layer (at least two layers or more) of non-woven fabrics, such as a commercially available non-woven fabric, which is distinguished by a single-layer product (commonly green). There are also double-layer (composite layer) products (green on one side and yellow on the other). Another example: the products of seat cushions, cushions or sleeping mats are also often distinguished by different products of single layer and composite layer.
因為不織布於成型過程中可以藉由調整不同加壓(壓力)及/或加熱(溫度)等控制條件而成型出不同硬度(密度)之不織布，因此利用到複合層不織布去製造產品時，通常就是利用其不同層具有不同硬度之特性，使製造出之整體產品在二側面上各有不同硬度，而能使產品的二側面各有其不同之適用性。例如：複合層式之睡墊可供選擇較硬面或較軟面使用，因此能有多選擇性。另如：為求乘坐舒適及良好之音響效果，因此汽車內裝材料經常被要求必須兼具良好之吸音及隔音效果，以隔絕及吸收外來的中高頻吵雜聲音，以及車輛行駛時本 身所產生的中低頻噪音與共振，若吸音及隔音效果不佳，即難以表現出高級轎車的價值感，因此目前習知之汽車內裝材料皆係由吸音及隔音效果良好之不織布材料採至少雙層以上之複合式層疊方式製成，以符合所要求。而汽車內裝材料除被要求良好之吸音及隔音效果外，有時更被要求必須兼具較佳之接觸性(例如：接觸面必須柔軟)，因此汽車內裝材料若係組裝於與乘員不接觸之部位者(例如鈑金內部)，一般係壓製為硬度相對較高之等厚板材；至於若係組裝於與乘員有接觸之部位者(例如車門內面或車內舖墊)，則一般會將與乘員有接觸之面(部位)製造為接觸性佳(硬度相對較低而能較為柔軟)之態樣，但另側(非接觸側)則仍製造為硬度相對較高之板材狀者。因此可知，習知汽車內裝材料必須製造為不同表面具有不同硬度(密度)之特性。 Because non-woven fabric can be molded into different non-woven fabrics of different hardness (density) by adjusting different pressing (pressure) and/or heating (temperature) control conditions during the molding process, it is usually used when the composite layer is not woven to manufacture products. By utilizing the different hardness characteristics of the different layers, the manufactured whole product has different hardnesses on both sides, and the two sides of the product have different applicability. For example, a composite layer of sleeping pad can be used for a harder or softer surface, so it is more selective. Another example: in order to ride comfort and good sound effects, car interior materials are often required to have good sound absorption and sound insulation, to isolate and absorb the external high-frequency noise, as well as the vehicle when driving The medium and low frequency noise and resonance generated by the body, if the sound absorption and sound insulation effects are not good, it is difficult to express the sense of value of the premium sedan. Therefore, the current automotive interior materials are at least doubled by non-woven materials with good sound absorption and sound insulation. It is made by a composite lamination method above the layer to meet the requirements. In addition to being required to have good sound absorption and sound insulation effects, automotive interior materials are sometimes required to have better contact properties (for example, the contact surface must be soft), so the automotive interior materials are assembled without contact with the occupants. The parts (such as the interior of the sheet metal) are generally pressed into a thick plate of relatively high hardness; if it is assembled in a place that is in contact with the occupant (such as inside the door or in the car), it will generally The contact surface (part) of the occupant is made to have good contact (lower hardness and softer), but the other side (non-contact side) is still made of a plate having a relatively high hardness. Therefore, it is known that conventional automotive interior materials must be manufactured to have different hardness (density) characteristics on different surfaces.
為達成使不織布產品之不同表面具有不同硬度(密度)之要求，本發明人前曾構思對同一素材之不同部位施以不同加熱條件的加熱控制，使不同部位受到不同程度的加熱軟化，然後經過模壓成型，使不同部位形成不同密度之專利案，並以專利名稱「同一素材成型不同密度部位之製造方法」請准中華民國I275469發明專利權及中華人民共和國ZL200610007283.8發明專利權。由該案之專利標的及訴求可知，該案主要係施行於同一素材上之製造方法，惟目前習知之不織布複合層產品很多都是採行先分別成型出不同硬度之不織布材(即為不同素材)，然後再將不同硬度之不織布材藉由層疊接合方式製造完成所預期之不織布複合層產品，故目前習知不織布產品之製造方法明顯與I275469有所不同。 In order to achieve the requirement that the different surfaces of the nonwoven fabric have different hardness (density), the inventors have previously conceived heating control for different heating conditions of different parts of the same material, so that different parts are subjected to different degrees of heating and softening, and then Molding, making patents of different densities in different parts, and patenting the "manufacturing method of different density parts of the same material", please apply for the invention patent of the Republic of China I275469 and the invention patent of ZL200610007283.8 of the People's Republic of China. According to the patent subject and claims of the case, the case is mainly based on the manufacturing method of the same material. However, many of the conventional non-woven composite layer products are made of different non-woven fabrics (that is, different materials). Then, the non-woven composite layer products of different hardnesses are manufactured by lamination bonding, and the manufacturing method of the conventional non-woven fabrics is obviously different from I275469.
茲舉一種習知常見之汽車內裝材料10為例說明目前習知不織布複合層產品之構造組成及製造方法。請參閱第一~二圖所示，分別為習知汽車內裝材料10之構造組成示意圖及製造流程圖。如第一(a)圖所示，汽車內裝材料10由一硬質層11、一中間薄膜12及一軟質層13所組成，最終即將該硬質層11、一中間薄膜12及一軟質層13三者層疊製造為第一(b)圖所示之汽車內裝材料10成品。該硬質層11業界慣稱為cover層，規格為厚度(t)在3~7mm間，重量(w)為1000g/m2左右；該中間薄膜12業界慣稱為Film，係由塑料成型為厚度(t)在50μ左右之薄膜狀阻隔層；該軟質層13業界慣稱為PAD，規格為厚度(t)在20~35mm間，重量(w)為1000g/m2左右。相對之下，該硬質層11為硬度相對較大之層，而該軟質層13則為硬度相對較小之層，故組裝於汽車內裝時，該硬質層11係組裝於乘員不會接觸到之部位，該軟質層13則組裝於乘員會接觸到之部位。 A conventional automobile interior material 10 is taken as an example to illustrate the structural composition and manufacturing method of the conventional non-woven composite layer product. Please refer to the first to second figures, which are respectively a schematic structural diagram and a manufacturing flow chart of the conventional automobile interior material 10. As shown in the first (a) diagram, the automotive interior material 10 is composed of a hard layer 11, an intermediate film 12 and a soft layer 13, and finally the hard layer 11, an intermediate film 12 and a soft layer 13 are three. The laminate is manufactured as a finished product of the automotive interior material 10 shown in the first (b). The hard layer 11 is commonly referred to as a cover layer in the industry, and has a thickness (t) of 3 to 7 mm and a weight (w) of about 1000 g/m 2 . The intermediate film 12 is conventionally called Film and is formed of plastic. (t) A film-like barrier layer of about 50 μ; the soft layer 13 is conventionally referred to as PAD, and has a thickness (t) of 20 to 35 mm and a weight (w) of about 1000 g/m 2 . In contrast, the hard layer 11 is a layer having a relatively large hardness, and the soft layer 13 is a layer having a relatively small hardness. Therefore, when assembled in an automobile interior, the hard layer 11 is assembled in an occupant and is not in contact with the occupant. The soft layer 13 is assembled at a portion where the occupant contacts.
習知將該硬質層11、中間薄膜12及軟質層13三者層疊製造為第一(b)圖所示之汽車內裝材料10產品時之製造方法即如第二圖所示，其步驟如下： The manufacturing method in which the hard layer 11, the intermediate film 12, and the soft layer 13 are laminated to the automobile interior material 10 shown in the first (b) is as shown in the second figure, and the steps are as follows: :
(1).先完成將預備成型出所需規格之硬質層11及軟質層13之第一不織布材11'及第二不織布材13'，同時事先完成該中間薄膜12之製造成型；亦即該不織布材11'、該中間薄膜12及該第二不織布材13'三者皆先行備料。 (1) First, the first non-woven fabric 11' and the second non-woven fabric 13' of the hard layer 11 and the soft layer 13 of the required specifications are prepared, and the intermediate film 12 is formed in advance; that is, the The non-woven fabric 11', the intermediate film 12, and the second non-woven fabric 13' are all prepared in advance.
(2).在一件第一不織布材11'之表面上噴膠，然後與一件中間薄膜12合貼，使成為一件第一中間品14；亦即每一件第一中間品14係由一件第一不織布材11'與一件中間薄膜12藉由噴膠合貼組成。 (2) spraying on the surface of a first non-woven fabric 11', and then bonding with an intermediate film 12 to make it a first intermediate product 14; that is, each of the first intermediate products 14 It consists of a first non-woven fabric 11' and an intermediate film 12 by glue-bonding.
(3).將該第一中間品14經過加熱，加熱溫度在120℃~70℃間，然後置於一等料厚模具15內，將該第一中間品14熱壓成型為一件包含所需規格硬質層11與中間薄膜12之第二中間品16；亦即在完成第二中間品16時，已經完成所需規格之硬質層11，且該中間薄膜12同樣合貼於該硬質層11表面上。 (3) The first intermediate product 14 is heated, heated at a temperature between 120 ° C and 70 ° C, and then placed in a first-thickness mold 15 to thermoform the first intermediate product 14 into a containment chamber. The second intermediate product 16 of the hard layer 11 and the intermediate film 12 is required; that is, when the second intermediate product 16 is completed, the hard layer 11 of the required specification has been completed, and the intermediate film 12 is also bonded to the hard layer 11 On the surface.
(4).接者，將一件第二中間品16置於一不等料厚模具17內，並在該第二中間品16之中間薄膜12表面上噴膠；同時將第二不織布材13'經過加熱，加熱溫度在120℃~70℃間。 (4) The pick-up, a second intermediate product 16 is placed in an unequal thickness mold 17, and the surface of the intermediate film 12 of the second intermediate product 16 is sprayed; and the second non-woven fabric 13 is simultaneously 'After heating, the heating temperature is between 120 ° C and 70 ° C.
(5).將加熱後之第二不織布材13'置於該不等料厚模具17內之第二中間品16上，操作該不等料厚模具17進行熱壓成型，使該第二不織布材13'受壓成型為所需規格之軟質層13，以製造完成一件包含所需規格之硬質層11、中間薄膜12與軟質層13之汽車內裝材料10。 (5) placing the heated second nonwoven fabric 13' on the second intermediate product 16 in the unequal thickness mold 17, and operating the unequal thickness mold 17 to perform hot press forming to make the second nonwoven fabric The material 13' is compression molded into a soft layer 13 of a desired specification to produce an automotive interior material 10 comprising a hard layer 11, a middle film 12 and a soft layer 13 of the desired specifications.
上述係為三層式複合層汽車內裝材料10之構造組成及習知製造方法，其中，該硬質層11主要係具隔音功效，該軟質層13主要係具吸音功效及接觸性佳之作用，該中間薄膜12則係為了提升吸音及隔音效能而設之阻隔層。當汽車內裝材料10是由硬質層11、中間薄膜12與軟質層13三者組成時，提供了較佳之使用功效，但也因其製造過程較為繁雜，相對提升製造本。因此在功效與成本平衡之考量下，習知也有由硬質層11與軟質層13二者組成為雙層式複合層汽車內裝材 料10者，如此則在上述製造方法中，無中間薄膜12、第一中間品14及第二中間品16之存在，而係由等料厚模具15先將經過加熱之第一不織布材11'熱壓成型為所需規格之硬質層11，再由不等料厚模具17將硬質層11及經過加熱之第二不織布材13'膠合及熱壓成型為一件包含所需規格之硬質層11與軟質層13之汽車內裝材料10。 The above-mentioned structure is a three-layer composite layer automobile interior material 10 and a conventional manufacturing method thereof. The hard layer 11 mainly has a sound insulation effect, and the soft layer 13 mainly functions as a sound absorbing function and a good contact property. The intermediate film 12 is a barrier layer for improving sound absorption and sound insulation performance. When the automobile interior material 10 is composed of the hard layer 11, the intermediate film 12 and the soft layer 13, it provides better use efficiency, but also because the manufacturing process is complicated, and the manufacturing cost is relatively improved. Therefore, under the consideration of efficiency and cost balance, it is also known that the hard layer 11 and the soft layer 13 are composed of a double-layer composite layer automobile interior material. In the above manufacturing method, in the above manufacturing method, the intermediate film 12, the first intermediate product 14 and the second intermediate product 16 are not present, and the heated first nonwoven fabric 11' is firstly heated by the equal thickness die 15. The hard layer 11 is formed by hot pressing into a desired size, and the hard layer 11 and the heated second nonwoven fabric 13' are glued and thermoformed into a hard layer 11 of a desired specification by a unequal thickness die 17 The automobile interior material 10 with the soft layer 13.
本發明人專業從事各種不織布產品之設計開發及製造工作，故對於上述習知汽車內裝材料10不論是三層式複合層或雙層式複合層之製造方法頗為熟知。因此在經長時間從事上述習知汽車內裝材料10製造歷練後，發覺習知製造方法中存在著如下缺失： The present inventors are specialized in the design, development, and manufacture of various non-woven fabric products, and thus are well known for the above-described conventional automotive interior materials 10, whether it is a three-layer composite layer or a two-layer composite layer. Therefore, after a long period of experience in manufacturing the above-described conventional automotive interior materials 10, it has been found that the following manufacturing methods have the following drawbacks:
1.該硬質層11係由第一不織布材11'經過等料厚模具15熱壓成型後，才能成為所需規格之硬質層11；而該軟質層13則係由第二不織布材13'經過不等料厚模具17熱壓成型後，才能成為所需規格之軟質層13；因此習知製造方法必須具備有等料厚模具15及不等料厚模具17二種成型模具，且至少必須經過等料厚模具15及不等料厚模具17二道模具成型製程才可以完成，缺一不可。惟如此即造成設備成本之增加及製程之延長，導致製造成本相對提升及產能相對較差。 1. The hard layer 11 is formed by the first nonwoven fabric 11' by hot pressing of the material thick mold 15 to form the hard layer 11 of a desired specification; and the soft layer 13 is passed by the second nonwoven fabric 13'. The hot layer 13 of the desired specification can be formed after the hot-pressing of the thick mold 17; therefore, the conventional manufacturing method must have two molds of the same thickness of the mold 15 and the unequal thickness of the mold 17, and at least must pass The material thick mold 15 and the unequal material thick mold 17 can be completed in two molding processes, which are indispensable. This has resulted in an increase in equipment costs and an extension of the process, resulting in a relatively high manufacturing cost and relatively poor production capacity.
2.該硬質層11係由等料厚模具15先行熱壓成型，然後再置入不等料厚模具17內與第二不織布材13'膠合及接受熱壓成型為所需規格之汽車內裝材料10；惟因該硬質層11在置入不等料厚模具17之前已經定型(若有彎曲則其角度及形狀皆已定型)，因此在不等料厚模具17內之熱壓成型過程主要是要將原為平面狀之第二不織布材13'按照模具內壁曲面(及曲度)推動去和已經定型之硬質層11以相同曲面造 型密貼並膠合，此亦即在不等料厚模具17內之熱壓成型過程中，已定型之硬質層11已經不會改變來迎合第二不識布材13'，而只有第二不織布材13'努力變形來迎合硬質層11；也因此在不等料厚模具17內之熱壓成型過程中，該第二不織布材13'有時會有彎曲度不及(因為曲度較大)，造成與硬質層11間於該處密貼膠合性不佳而產生空心之現象，使得預期之吸、隔音使用功效降低。 2. The hard layer 11 is first hot-pressed by the equal-thickness mold 15, and then placed in the unequal-thickness mold 17 and the second non-woven fabric 13' is glued and subjected to hot press forming into the required specifications. Material 10; however, since the hard layer 11 has been shaped before being placed in the unequal thickness mold 17 (the angle and shape are fixed if bent), the hot press forming process in the unequal thickness mold 17 is mainly It is necessary to push the second non-woven fabric 13' which is originally planar according to the curved surface (and curvature) of the inner wall of the mold and the hard surface 11 which has been shaped to have the same curved surface. The type is closely adhered and glued, that is, during the hot press forming process in the unequal thickness mold 17, the shaped hard layer 11 has not changed to cater to the second unknowing material 13', and only the second non-woven fabric The material 13' is deformed to meet the hard layer 11; therefore, during the hot press forming process in the unequal thickness mold 17, the second non-woven fabric 13' sometimes has a degree of curvature (because the curvature is large). The phenomenon that the hard layer 11 and the hard layer 11 are poorly bonded to each other and the hollow is formed, so that the intended suction and soundproof use efficiency is lowered.
習知不織布複合層產品之製造方法中，在硬質層11與軟質層13間於彎曲處產生空心現象，其實是品質上嚴重之缺失。縱使空心有時不是很大，但因不織布複合層產品在使用時一定會受到震動力或推擠性之壓力，因此使用日久後，即會由空心處開始產生剝離，且剝離現象會越來越大(或快)，因此空心現象絕對是不織布複合層產品的殺手。然在目前因無其他製造方法取代，且在外觀上無法即時分辨出，故一般業者只能以增加不等料厚模具17熱壓成型之時間，期使在第二不織布材13'成型為軟質層13之過程中，其彎曲度能盡量貼近硬質層11，惟受限於硬質層11與軟質層13不同時期成型之先決條件，所以希望空心減少之效果並不佳。然而，增加不等料厚模具17熱壓成型之時間卻又造成製造成本提昇及產能下降。 In the conventional method for manufacturing a non-woven composite layer product, a hollow phenomenon occurs between the hard layer 11 and the soft layer 13 at a bend, which is actually a serious lack of quality. Even if the hollow is not very large, but the non-woven composite layer product will be subjected to the pressure of vibration or pushing when it is used. Therefore, after a long time of use, peeling will start from the hollow, and the peeling phenomenon will come. The bigger (or faster), the hollow phenomenon is definitely the killer of the non-woven composite layer product. However, at present, there is no other manufacturing method, and the appearance cannot be immediately distinguished. Therefore, the general industry can only increase the time of hot pressing of the unequal material mold 17 to make the second non-woven fabric 13' soft. In the process of the layer 13, the curvature can be as close as possible to the hard layer 11, but it is limited by the prerequisites for the formation of the hard layer 11 and the soft layer 13 at different times, so it is desirable that the hollow reduction effect is not good. However, increasing the time for hot press forming of the unequal thickness mold 17 results in an increase in manufacturing cost and a decrease in productivity.
針對上述缺失，本發明人深有所體會，乃積極構思加以克服及改善，在經長時間努力及實際試作後，終有本發明產生。 In view of the above-mentioned deficiencies, the present inventors have deepened their understanding and actively conceived to overcome and improve them. After a long period of hard work and actual trials, the present invention is finally produced.
緣是，本發明之主要目的即在提供一種可以降低設備成本、減省製程、提高產能及品質之具不同硬度不織布複合層產品製造方法。 Therefore, the main object of the present invention is to provide a method for manufacturing a composite fabric of different hardness non-woven fabrics which can reduce equipment cost, reduce process, and improve productivity and quality.
為達致上述目的，本發明即設計一種具不同硬度不織布複合層產品製造方法，不織布複合層產品至少由一硬質層及一軟質層組成，製造該不織布複合層產品之步驟如下：(1).先完成將預備成型出硬質層之第一不織布材，及預備成型出軟質層之第二不織布材；(2).將一件第一不織布材與一件第二不織布材合貼疊置組成為一件中間品；(3).將中間品送入一恆溫烘烤箱內進行加熱，使該第一不織布材及第二不織布材受到充分加熱呈軟化現象，而且合貼之表面藉由熱融而相互接合；及特徵在於：(4).將中間品送出恆溫烘烤箱後，即刻進入一不等料厚模具內進行一次性熱壓成型，使該第一不織布材受壓成型為硬質層，該第二不織布材則受壓成型為軟質層，以製造完成為至少包含硬質層與軟質層之不織布複合層產品。 In order to achieve the above object, the present invention provides a method for manufacturing a non-woven composite layer product having different hardnesses. The non-woven composite layer product is composed of at least a hard layer and a soft layer. The steps for manufacturing the non-woven composite layer product are as follows: (1). Firstly, the first non-woven fabric which is to be formed into a hard layer and the second non-woven fabric which is to be formed into a soft layer are completed; (2) a first non-woven fabric and a second non-woven fabric are laminated and formed. An intermediate product; (3). The intermediate product is sent into a constant temperature baking box for heating, so that the first non-woven fabric material and the second non-woven fabric material are fully heated and softened, and the surface of the attached surface is heated and melted. And being joined to each other; and characterized by: (4). After the intermediate product is sent out of the constant temperature baking box, it is immediately put into a unequal thickness mold for one-time hot press forming, so that the first non-woven fabric is pressed into a hard layer. The second non-woven fabric is compression-molded into a soft layer to be manufactured into a non-woven composite layer product comprising at least a hard layer and a soft layer.
在上述具不同硬度不織布複合層產品製造方法中，該不織布複合層產品更可在該硬質層與該軟質層間介以一中間薄膜，係由塑料成型為厚度在30~75μm間之薄膜狀阻隔層；製造時，即由一件第一不織布材與一件中間薄膜及一件第二不織布材合貼組成為一件中間 品，再依相同步驟成型出包含硬質層、中間薄膜及軟質層之不織布複合層產品。 In the above method for manufacturing a non-woven composite layer product having different hardnesses, the non-woven composite layer product may further form an intermediate film between the hard layer and the soft layer, and is formed of a plastic film into a film-like barrier layer having a thickness of 30 to 75 μm. At the time of manufacture, a piece of the first non-woven fabric is combined with an intermediate film and a second non-woven fabric to form an intermediate portion. In the same step, a non-woven composite layer product comprising a hard layer, an intermediate film and a soft layer is formed.
在上述具不同硬度不織布複合層產品製造方法中，該硬質層規格為厚度2~7mm間，重量600~1200g/m2間，該軟質層規格為厚度1540mm間，重量600~1200g/m2間。 In the above method for manufacturing a composite fabric having different hardness non-woven fabrics, the hard layer has a thickness of 2 to 7 mm and a weight of 600 to 1200 g/m 2 , and the soft layer has a thickness of 1540 mm and a weight of 600 to 1200 g/m 2 .
在上述具不同硬度不織布複合層產品製造方法中，將該中間品送入恆溫烘烤箱內進行加熱之操作，加熱溫度在180±20℃間，每件中間品所受的加熱時至少200(含)秒以上，並可藉由一輸送帶帶動中間品依序進入恆溫烘烤箱內之方式達成；而且將中間品置放於輸送帶上之操作，可藉由一自動夾具採依序夾取置放方式達成。 In the above method for manufacturing a composite fabric having different hardness non-woven fabrics, the intermediate product is sent into a constant temperature baking box for heating, and the heating temperature is between 180±20° C., and each intermediate product is heated by at least 200 ( Including more than two seconds, and can be achieved by a conveyor belt driving the intermediate products into the constant temperature baking box in sequence; and the operation of placing the intermediate products on the conveyor belt can be carried out by an automatic clamp Take the placement method to achieve.
在上述具不同硬度不織布複合層產品製造方法中，藉由輸送帶帶動中間品進入恆溫烘烤箱內進行加熱之操作，可採慢速持續行進方式進行，或採時動時停方式進行。 In the above-mentioned manufacturing method of the non-woven fabric composite layer with different hardness, the operation of driving the intermediate product into the constant temperature baking box by the conveyor belt can be carried out in a slow continuous driving manner, or in a mining time stop mode.
在上述具不同硬度不織布複合層產品製造方法中，中間品送出恆溫烘烤箱後，進入一不等料厚模具之操作，可藉由一自動夾料裝置採依序夾取及定位放料方式達成。 In the above-mentioned manufacturing method of the non-woven fabric composite layer with different hardness, after the intermediate product is sent out of the constant temperature baking box, the operation of entering the unequal thickness die can be sequentially taken and positioned by an automatic clamping device. Achieved.
在上述具不同硬度不織布複合層產品製造方法中，在不等料厚模具之下模具內更設置有真空吸附裝置，可在成型過程中將中間品底面吸附下拉使快速貼合下模具，藉以幫助整體加快成型速度。 In the above method for manufacturing a non-woven composite layer product having different hardnesses, a vacuum adsorption device is further disposed in the mold under the unequal thickness mold, and the bottom surface of the intermediate product is adsorbed and pulled down during the molding process to quickly fit the lower mold, thereby helping The overall speed of molding is accelerated.
在上述具不同硬度不織布複合層產品製造方法中，將成型後之不織布複合層產品自不等料厚模具取出之操作，可藉由一自動夾料裝置採依序夾取置放方式達成。 In the above method for manufacturing a non-woven composite layer product having different hardnesses, the operation of taking out the formed non-woven fabric composite layer product from the undifferentiated material thickness mold can be achieved by an automatic clamping device in a sequential clamping and placing manner.
在上述具不同硬度不織布複合層產品製造方法中，將成型後之不織布複合層產品自不等料厚模具取出後，可進入一冷卻風扇箱進行冷卻定型。 In the above method for manufacturing a non-woven composite layer product having different hardnesses, the formed non-woven fabric composite layer product can be taken out into a cooling fan box for cooling and setting after being taken out of the thick material mold.
10‧‧‧汽車內裝材料 10‧‧‧Automotive interior materials
11‧‧‧硬質層 11‧‧‧hard layer
11’‧‧‧第一不織布材 11’‧‧‧First non-woven fabric
12‧‧‧中間薄膜 12‧‧‧Intermediate film
13’‧‧‧第二不織布材 13’‧‧‧Second non-woven fabric
13‧‧‧軟質層 13‧‧‧Soft layer
14‧‧‧第一中間品 14‧‧‧First Intermediate
15‧‧‧等料厚模具 15‧‧‧Material thick mold
16‧‧‧第二中間品 16‧‧‧Second intermediate
17‧‧‧不等料厚模具 17‧‧‧ Unequal thickness die
20‧‧‧汽車內裝材料 20‧‧‧Automotive interior materials
21‧‧‧硬質層 21‧‧‧ hard layer
21’‧‧‧第一不織布材 21’‧‧‧First non-woven fabric
22‧‧‧中間薄膜 22‧‧‧Intermediate film
23’‧‧‧第二不織布材 23’‧‧‧Second non-woven fabric
23‧‧‧軟質層 23‧‧‧Soft layer
24‧‧‧中間品 24‧‧‧Intermediate goods
27‧‧‧不等料厚模具 27‧‧‧ Unequal thickness die
第一圖係習知例構造分解及組成示意圖。 The first figure is a structural decomposition and composition diagram of a conventional example.
第二圖係習知例製造流程圖。 The second figure is a flow chart of a conventional manufacturing process.
第三圖係本發明實施例構造組成示意圖。 The third figure is a schematic diagram of the constitution of the embodiment of the present invention.
第四圖係本發明實施例製造流程圖。 The fourth figure is a manufacturing flow chart of an embodiment of the present invention.
關於本發明為達致上述目的所採用之技術手段及構造組成，茲舉以下數種較佳可行實施例並配合附圖詳述於后，俾利完全瞭解本發明之特徵所在及功效優點。 With regard to the technical means and structural components of the present invention for achieving the above objects, the following several preferred embodiments are described in detail below with reference to the accompanying drawings, and the advantages and advantages of the present invention are fully understood.
本發明主要係一種用於製造成型出雙面具不同硬度之不織布複合層產品的製造方法，因此可適用於製造任何不織布複合層產品。而為方便做說明，茲舉製造成型一種汽車內裝材料20為本發明之實施例。請參閱第三圖所示，該汽車內裝材料20構造上由一硬質層21、一中間薄膜22及一軟質層23所組成，其中，該硬質層21為cover層，規格為厚度(t)在2~7mm間，重量600~1200g/m2間，係為硬度相對較大之層以具隔音作用，故組裝時位於乘員不會接觸到之部位；該軟質層23為PAD層，規格為厚度(t)在15~40mm間，重量在600~1200g/m2間，係為硬度相對較小而能較為柔軟並具吸音作用之層，故組裝時可 位於乘員會接觸到之部位；該中間薄膜22為Film，係由塑料成型為厚度(t)在30~75μm間之薄膜狀阻隔層，成型時介於硬質層21與軟質層23之間以提升整體之吸音及隔音效能。 The present invention is mainly directed to a method for producing a non-woven composite layer product having a double mask and different hardness, and thus is applicable to the manufacture of any non-woven composite layer product. For convenience of explanation, an automobile interior material 20 is manufactured and molded as an embodiment of the present invention. Referring to the third figure, the automotive interior material 20 is constructed by a hard layer 21, an intermediate film 22, and a soft layer 23, wherein the hard layer 21 is a cover layer and has a thickness (t). Between 2 and 7 mm, the weight is between 600 and 1200 g/m 2 , and the layer with relatively high hardness is soundproof, so it is located at the part where the occupant does not touch during assembly; the soft layer 23 is a PAD layer, and the specification is The thickness (t) is between 15 and 40 mm, and the weight is between 600 and 1200 g/m 2 . It is a layer which is relatively soft and can be soft and has a sound absorbing effect. Therefore, it can be located at a place where the occupant contacts. The intermediate film 22 is a film formed of plastic into a film-like barrier layer having a thickness (t) of 30 to 75 μm, and is formed between the hard layer 21 and the soft layer 23 to improve the overall sound absorption and sound insulation performance.
製造該汽車內裝材料20產品之製造方法如第四圖所示，其步驟如下： The manufacturing method of manufacturing the automobile interior material 20 product is as shown in the fourth figure, and the steps are as follows:
(1).先完成將預備成型出所需規格之硬質層21及軟質層23之第一不織布材21'及第二不織布材23'，同時事先完成該中間薄膜22之製造成型；亦即該不織布材21'、該中間薄膜22及該第二不織布材23'三者皆先行備料。 (1) First, the first non-woven fabric 21' and the second non-woven fabric 23' of the hard layer 21 and the soft layer 23 of the required specifications are prepared, and the intermediate film 22 is formed in advance; that is, the The non-woven fabric 21', the intermediate film 22, and the second non-woven fabric 23' are all prepared in advance.
(2).將一第一不織布材21'、一中間薄膜22及一第二不織布材23'合貼疊置，使該中間薄膜22對齊合貼於該第一不織布材21'與第二不織布材23'中間，共同成為一中間品24；亦即每一中間品24係由一第一不織布材21'與一中間薄膜22及一第二不織布材23'合貼組成。 (2) A first non-woven fabric 21', an intermediate film 22 and a second non-woven fabric 23' are placed on top of each other, and the intermediate film 22 is aligned and attached to the first non-woven fabric 21' and the second non-woven fabric. In the middle of the material 23', together, it becomes an intermediate product 24; that is, each intermediate product 24 is composed of a first non-woven fabric 21' and an intermediate film 22 and a second non-woven fabric 23'.
(3).將該中間品24送入一恆溫烘烤箱內進行加熱，加熱溫度在180±20℃間，加熱時間至少200(含)秒以上，使該第一不織布材21'、中間薄膜22及第二不織布材23'三者受到充分加熱呈軟化現象，而且合貼之表面藉由熱融而相互接合。其中，將該中間品24送入恆溫烘烤箱內進行加熱之操作，可藉由一輸送帶帶動中間品24依序進入恆溫烘烤箱內進行，並可採慢速持續行進方式進行，或採時動時停方式進行。而將中間品24置放於輸送帶上之操作，可採人工依序置放方式達成，或藉由一自動夾具採依序夾取置放方式達成。 (3) The intermediate product 24 is sent to a constant temperature oven for heating, the heating temperature is between 180 ± 20 ° C, and the heating time is at least 200 (inclusive) or more, so that the first non-woven fabric 21', the intermediate film The 22 and the second nonwoven fabric 23' are sufficiently heated to soften, and the surfaces to be joined are joined to each other by heat fusion. Wherein, the intermediate product 24 is sent into the constant temperature baking box for heating, and the intermediate product 24 can be sequentially driven into the constant temperature baking box by a conveyor belt, and can be carried out in a slow continuous manner, or The timing is stopped when the time is taken. The operation of placing the intermediate product 24 on the conveyor belt can be achieved by manual placement, or by an automatic clamp.
(4).中間品24送出恆溫烘烤箱後，即刻進入一不等料厚模具27內進行一次性熱壓成型，使該第一不織布材21'受壓成型為所需規格之硬質層21，該第二不織布材23'則受壓成型為所需規格之軟質層23，以製造完成為一件包含所需規格之硬質層21、中間薄膜22與軟質層23之汽車內裝材料20。其中，中間品24送出恆溫烘烤箱後，進入一不等料厚模具27之操作，可藉由一自動夾料裝置採依序夾取及定位放料方式達成。而在不等料厚模具27之下模具內更設置有真空吸附裝置，可在成型過程中將中間品24底面吸附下拉使快速貼合下模具，藉以幫助整體加快成型速度。 (4) After the intermediate product 24 is sent out of the constant temperature baking box, it is immediately put into a unequal thickness mold 27 for one-time hot press forming, so that the first non-woven fabric 21' is compression-molded into a hard layer 21 of a required specification. The second non-woven fabric 23' is compression-molded into a soft layer 23 of a desired specification to complete the automotive interior material 20 comprising a hard layer 21, an intermediate film 22 and a soft layer 23 of a desired specification. Wherein, after the intermediate product 24 is sent out of the constant temperature baking box, the operation of entering the unequal thickness die 27 can be achieved by an automatic clamping device sequentially picking and positioning and discharging. The vacuum adsorption device is further disposed in the mold below the material thickness mold 27, and the bottom surface of the intermediate product 24 can be pulled down and pulled down to quickly fit the lower mold during the molding process, thereby helping to accelerate the overall molding speed.
(5).將成型後之汽車內裝材料20自不等料厚模具27取出後，即刻進入一冷卻風扇箱進行快速冷卻定型。其中，將成型後之汽車內裝材料20自不等料厚模具27取出之操作，可藉由一自動夾料裝置採依序夾取置放方式達成。 (5). After the formed automobile interior material 20 is taken out from the material thickness mold 27, it is immediately put into a cooling fan box for rapid cooling setting. The operation of taking out the formed automobile interior material 20 from the material-thickness mold 27 can be achieved by an automatic clamping device.
經過上述製造方法之步驟所產生之汽車內裝材料20，有時尚須經過油壓沖剪台進行輪廓邊緣之沖剪修整，使更為符合所需，惟此一步驟僅為輔助性，故不列於本發明之製造方法內。 The automobile interior material 20 produced by the steps of the above manufacturing method has the fashion to be trimmed and trimmed by the oil pressure punching table to make the contour edge more suitable, but this step is only auxiliary, so it is not It is listed in the manufacturing method of the present invention.
上述係為本發明用於製造三層式複合層汽車內裝材料20時所進行步驟之詳述。同樣道理，若汽車內裝材料20在使用功效與製造成本相平衡之考量下，也可以僅由硬質層21與軟質層23二者製造為雙層式複合層汽車內裝材料20，如此則在本發明之製造方法中，無該中間薄膜22之存在，而係由一件第一不織布材21'與一件第二不織布材 23'合貼組成為一件中間品24；然後後續步驟皆相同，最後成型者即為包含所需規格之硬質層21與軟質層23之汽車內裝材料20。 The above is a detailed description of the steps performed in the manufacture of the three-layer composite layer automotive interior material 20. By the same token, if the automobile interior material 20 is balanced between the use efficiency and the manufacturing cost, it is also possible to manufacture the double-layer composite layer automobile interior material 20 only by both the hard layer 21 and the soft layer 23, and thus In the manufacturing method of the present invention, without the presence of the intermediate film 22, a first nonwoven fabric 21' and a second nonwoven fabric are used. The 23' assembly is composed of an intermediate product 24; then the subsequent steps are the same, and the final molded person is the automobile interior material 20 containing the hard layer 21 and the soft layer 23 of the required specifications.
對於本發明所揭示之製造方法，本發明人業於本身所營製造工廠進行無數次之試作，証實製造完成後之產品品質優良，方據以提出專利申請。而將本發明之製造方法與前述習知例相比較，明顯本發明具有下功效： With respect to the manufacturing method disclosed by the present invention, the inventors conducted numerous trials at their own manufacturing plants, and confirmed that the quality of the products after the completion of the manufacture was excellent, and the patent application was filed accordingly. Comparing the manufacturing method of the present invention with the conventional example described above, it is apparent that the present invention has the following effects:
1.因為本發明之製造方法僅須要具備有不等料厚模具27(減省設置等料厚模具)，即可藉以熱壓成型出所需規格之汽車內裝材料20，相對於習知例而言，本發明確實已經減省設備成本、並縮短製程，因此整體而言，本發明之製造成本相對降低，產能則相對提升。 1. Since the manufacturing method of the present invention only needs to have the unequal thickness mold 27 (reducing the thickness of the mold such as the setting), the automobile interior material 20 of the required specifications can be formed by hot pressing, as compared with the conventional example. In view of the above, the present invention has indeed reduced equipment costs and shortened the process, so that the manufacturing cost of the present invention is relatively reduced as a whole, and the production capacity is relatively increased.
2.在本發明中，不論有無該中間薄膜22之存在，該第一不織布材21'與第二不織布材23'二者係合貼後共同接受恆溫烘烤箱之加熱，故二者之軟化程度相同；然後同時進入不等料厚模具27內共同接受熱壓成型為所需規格之汽車內裝材料20；亦即在不等料厚模具27熱壓成型之過程中，該第一不織布材21'與第二不織布材23'二者係共同受到模具內壁曲面(及曲度)推動去成型為硬質層21與軟質層23，因此該第一不織布材21'與第二不織布材23'二者所受到的彎曲(成型)壓力是相同的，所以成型為汽車內裝材料20之硬質層21與軟質層23後，二者間仍係密貼為造型及彎曲度皆相同者，所以在硬質層21與軟質層23間縱為共同彎曲處，也不會產生貼合性不佳之空心現象，本發明製造完成後之產品顯然品質較佳，能完全達成汽車內裝材料20產品所預期之吸、隔音使用功效，並延長使用壽命。 2. In the present invention, regardless of the presence or absence of the intermediate film 22, the first non-woven fabric 21' and the second non-woven fabric 23' are attached together and then subjected to heating by a constant temperature baking box, so the softening of the two The same degree; then simultaneously enter the unequal thickness mold 27 to receive the auto-molding into the required specifications of the automotive interior material 20; that is, in the process of hot-press molding of the unequal thickness mold 27, the first non-woven fabric Both the 21' and the second non-woven fabric 23' are pushed together by the curved surface (and curvature) of the inner wall of the mold to form the hard layer 21 and the soft layer 23, so the first non-woven fabric 21' and the second non-woven fabric 23' The bending (forming) pressures received by the two are the same, so that after forming the hard layer 21 and the soft layer 23 of the automobile interior material 20, the two are still closely attached to each other in shape and curvature, so The longitudinal layer between the hard layer 21 and the soft layer 23 is a common bend, and the hollow phenomenon of poor fit is not produced. The finished product of the present invention is obviously of good quality, and can fully realize the expected product of the automobile interior material 20 Suction, sound insulation, and extended life .
由以上說明可知，本發明所訴求之具不同硬度不織布複合層產品製造方法，主要係將至少由一第一不織布材及一第二不織布材合貼組成之中間品，送入一恆溫烘烤箱內進行加熱，加熱溫度在180±20℃間，加熱時間至少200(含)秒以上，接著進入一不等料厚模具內進行一次性熱壓成型，使完成為一件包含所需規格硬質層與軟質層之不織布複合層產品。當該不織布複合層產品退出不等料厚模具後，則更可進入一冷卻風扇箱進行快速冷卻定型。 It can be seen from the above description that the method for manufacturing a non-woven fabric composite layer product of the present invention is mainly for feeding an intermediate product composed of at least a first non-woven fabric and a second non-woven fabric into a constant temperature baking box. Heating inside, heating temperature between 180±20°C, heating time for at least 200 (inclusive) seconds, and then entering a unequal thickness die for one-time hot press forming, so as to complete a hard layer containing the required specifications Non-woven composite layer product with soft layer. When the non-woven composite layer product exits the unequal thickness mold, it can enter a cooling fan box for rapid cooling and setting.
綜上所述，本發明確可達成預期之發明目的及功效，且所揭露之製造方法不曾見諸昔時，應已具備新穎性及非顯而易知性，爰請依法准予發明專利。惟以上所述者，僅為本發明之較佳可行實施例，並非因此即拘限本發明之範圍，故舉凡運用本發明所為之等效變化，理皆為本發明之專利範圍所含括。 In summary, the present invention can achieve the intended purpose and effect of the invention, and the disclosed manufacturing method has not been seen in the past, should have novelty and non-obviousness, and is required to grant invention patents according to law. However, the above is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and the equivalents of the present invention are all included in the scope of the invention.
20‧‧‧汽車內裝材料 20‧‧‧Automotive interior materials
21’‧‧‧第一不織布材 21’‧‧‧First non-woven fabric
22‧‧‧中間薄膜 22‧‧‧Intermediate film
23’‧‧‧第二不織布材 23’‧‧‧Second non-woven fabric
24‧‧‧中間品 24‧‧‧Intermediate goods
27‧‧‧不等料厚模具 27‧‧‧ Unequal thickness die
Claims (9)
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TW101122359A TWI551452B (en) | 2012-06-22 | 2012-06-22 | Fabrication method of composite layer with different hardness nonwoven fabric |
| MYPI2012003205A MY166392A (en) | 2012-06-22 | 2012-07-13 | Method of manufacturing products with non-woven fabric composite layer of different hardness |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TW101122359A TWI551452B (en) | 2012-06-22 | 2012-06-22 | Fabrication method of composite layer with different hardness nonwoven fabric |
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| TW201400288A TW201400288A (en) | 2014-01-01 |
| TWI551452B true TWI551452B (en) | 2016-10-01 |
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| TW101122359A TWI551452B (en) | 2012-06-22 | 2012-06-22 | Fabrication method of composite layer with different hardness nonwoven fabric |
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| MY (1) | MY166392A (en) |
| TW (1) | TWI551452B (en) |
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| CN104924371B (en) * | 2015-06-24 | 2017-05-17 | 张家港市盛港绿色防火建材有限公司 | Floor composited with wood layer and manufacturing method of floor |
| TWI678283B (en) * | 2018-11-09 | 2019-12-01 | 政鈺機械股份有限公司 | Method for manufacturing anti-collision partition |
| CN112674447A (en) * | 2019-10-17 | 2021-04-20 | 三香科技股份有限公司 | Structure of box body |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040238275A1 (en) * | 2003-05-28 | 2004-12-02 | Hans-Peter Keller | Sound absorbers |
| CN102032419A (en) * | 2009-09-30 | 2011-04-27 | 比亚迪股份有限公司 | Thermal insulation board and preparation method thereof |
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2012
- 2012-06-22 TW TW101122359A patent/TWI551452B/en not_active IP Right Cessation
- 2012-07-13 MY MYPI2012003205A patent/MY166392A/en unknown
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040238275A1 (en) * | 2003-05-28 | 2004-12-02 | Hans-Peter Keller | Sound absorbers |
| CN102032419A (en) * | 2009-09-30 | 2011-04-27 | 比亚迪股份有限公司 | Thermal insulation board and preparation method thereof |
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| TW201400288A (en) | 2014-01-01 |
| MY166392A (en) | 2018-06-25 |
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