WO2010038314A1 - 積層板及び積層素材の端末処理方法 - Google Patents

積層板及び積層素材の端末処理方法 Download PDF

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Publication number
WO2010038314A1
WO2010038314A1 PCT/JP2008/068076 JP2008068076W WO2010038314A1 WO 2010038314 A1 WO2010038314 A1 WO 2010038314A1 JP 2008068076 W JP2008068076 W JP 2008068076W WO 2010038314 A1 WO2010038314 A1 WO 2010038314A1
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WO
WIPO (PCT)
Prior art keywords
laminated
cover sheet
vertical wall
sheet
wall portion
Prior art date
Application number
PCT/JP2008/068076
Other languages
English (en)
French (fr)
Inventor
高広 長谷川
Original Assignee
盟和産業株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 盟和産業株式会社 filed Critical 盟和産業株式会社
Priority to CN200880131352.3A priority Critical patent/CN102171030B/zh
Priority to PCT/JP2008/068076 priority patent/WO2010038314A1/ja
Publication of WO2010038314A1 publication Critical patent/WO2010038314A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/38—Cutting-out; Stamping-out
    • B26F1/40—Cutting-out; Stamping-out using a press, e.g. of the ram type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B29C65/7844—Holding or clamping means for handling purposes cooperating with specially formed features of at least one of the parts to be joined, e.g. cooperating with holes or ribs of at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/438—Joining sheets for making hollow-walled, channelled structures or multi-tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/725—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs
    • B29C66/7252—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs hollow-walled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/0044—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for shaping edges or extremities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F2210/00—Perforating, punching, cutting-out, stamping-out, severing by means other than cutting of specific products
    • B26F2210/06—Trimming plastic mouldings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7234—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a barrier layer
    • B29C66/72341—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a barrier layer for gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B29C66/83221—Joining or pressing tools reciprocating along one axis cooperating reciprocating tools, each tool reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
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Definitions

  • the present invention relates to a laminated board and a terminal processing method for a laminated material, and relates to a laminated board material used as an interior material of, for example, an automobile, and a laminated material terminal processing method.
  • Resin molded product structures include, for example, a high-rigidity hollow structure and a lightweight, high-rigidity sandwich structure, which are selected according to the required strength, shape, and function.
  • a laminated material having a sandwich structure a structure in which a cover sheet is laminated on one side or both sides of a core sheet having a vertical wall portion, such as a honeycomb core, is known.
  • This laminated material is used as an interior material or exterior material for vehicles or buildings by cutting into a desired contour shape.
  • Patent Document 1 the shape of the laminated material is restricted in the process for improving the appearance of the end, and the mold becomes complicated and the cost increases.
  • Patent Document 2 a technique that improves the degree of freedom of shape without any restrictions.
  • Patent Document 2 a pair of cover sheets are laminated through a core sheet having a vertical wall portion to form a laminated material, and further formed by bonding a nonwoven fabric on the surface of the laminated material.
  • the peripheral part of the laminated material with the skin material (peripheral part of the laminated material) is heated and softened.
  • the floor board can be die-cut from the laminated material with the skin material simply by pressing the cutting blade of the punching die against the heat-softened peripheral edge and bringing one cover sheet into contact with the other cover sheet and welding. it can. JP 2001-18308 A JP 2008-143384 A
  • the present invention improves the appearance of the end portion while maintaining the degree of freedom of shape, and does not cause peeling of the skin material after molding or does not open the welded portion of the end portion, and improves the rigidity of the end portion. It is an object of the present invention to provide a laminated board and a terminal treatment method for a laminated material.
  • the present invention relates to a laminated board.
  • This laminated plate is a laminated material formed by laminating a thermoplastic resin sheet having a vertical wall portion and a cover sheet made of a thermoplastic resin and a skin material on one side of the thermoplastic sheet having the vertical wall portion.
  • a predetermined range of the vertical wall portion in at least a part of the outer peripheral end portion of the laminated material is melted and crushed to the cover sheet side and the skin material side, and has a weld portion welded substantially flush with the cover sheet,
  • the said welding part is shape
  • the present invention relates to a laminated board.
  • a cover sheet made of a thermoplastic resin is laminated on both sides of a thermoplastic resin sheet having a vertical wall portion and a thermoplastic sheet having the vertical wall portion, and a skin material is provided on the cover sheet on at least one side.
  • a skin material is provided on the cover sheet on at least one side.
  • the predetermined range has a welded portion melted and crushed to the cover sheet on one side and the skin material side on the one side, and welded substantially flush with the cover sheet on the one side, and the welded portion Is formed into a predetermined shape on the cover sheet side on the other side of the thermoplastic resin sheet having the vertical wall portion.
  • the laminate according to claim 1 or 2 wherein the laminate is used for automobile interior materials, particularly ceiling materials, side door trim panels, back door trim panels, luggage side trim panels, and seat back boards. Board.
  • the present invention relates to a terminal processing method for a laminated material.
  • This terminal treatment method includes a thermoplastic resin sheet having a vertical wall portion, and a terminal treatment of a laminated material formed by laminating a cover sheet made of a thermoplastic resin and a skin material on one side of the thermoplastic sheet having the vertical wall portion.
  • a predetermined range of the vertical wall portion in at least a part of the outer peripheral end portion of the laminated material is melted and crushed using a hot blade block to the cover sheet side and the skin material side, so that the surface substantially faces the cover sheet.
  • a second step is used to form a predetermined shape and cooled to the other side of the thermoplastic resin sheet having the vertical wall portion where the cover sheet is not laminated.
  • the present invention relates to a terminal processing method for a laminated material.
  • a cover sheet made of a thermoplastic resin is laminated on both sides of a thermoplastic resin sheet having a vertical wall portion and a thermoplastic sheet having the vertical wall portion, and the cover sheet on at least one side is covered with a skin.
  • the cover material on the other side where the skin material is laminated or not laminated at least at a part of the outer peripheral end of the laminated material and the vertical wall portion are included.
  • thermoplastic resin sheet is melted and crushed using a hot blade block to the cover sheet on one side and the skin material side on the one side, and welded substantially flush with the cover sheet on the one side.
  • a first step of forming a welded portion, and the welded portion is press-formed into a predetermined shape toward the cover sheet side of the other side of the thermoplastic resin sheet having the vertical wall portion. Made from the second step of retirement.
  • the present invention it is possible to improve the appearance of the end portion while maintaining the degree of freedom of the shape and to improve the rigidity of the end portion without causing peeling of the skin material or opening of the welded portion of the end portion after molding. It is possible to provide a laminated plate and a terminal treatment method for a laminated material.
  • FIG. 1 is a perspective view showing a back door trim panel (laminate board) 19 according to the present embodiment
  • FIG. 2 is an exploded perspective view showing the structure of a laminated material 1d with a skin material constituting the back door trim panel 19
  • FIG. 3 is a cross-sectional view of a laminated material 1 constituting the door trim panel 19.
  • FIG. 2 and 3 are displayed upside down.
  • FIGS. 2 (a) and 3 (a) show the structure of the laminated material 1d with a skin material made of the laminated material 1 having a three-layer structure and the back door trim panel 19, and FIGS. 2 (b) and 3 (b). ) Shows the structure of the laminated material 1d with the skin material made of the laminated material 1 having the two-layer structure and the back door trim panel 19.
  • FIGS. 2A and 3A will be exemplified.
  • the back door trim panel 19 is formed by subjecting the end portion of the laminated material 1d with the skin material in which the nonwoven fabric 5 is bonded to the laminated material 1 to the end.
  • the back door trim panel 19 includes a laminated material 1 made of thermoplastic resin, and a skin portion in which a lower surface (second cover sheet 4) of the laminated material 1 is covered with a nonwoven fabric 5.
  • the end portion (design shape end portion 6d) of the laminated material 1d with the skin material is subjected to terminal processing.
  • it has a clip hole 7 through which the resin clip is inserted when the resin clip is fastened to the vehicle body.
  • the laminated material 1 constituting the back door trim panel 19 will be described.
  • the laminated material 1 includes a core sheet 2 having a concavo-convex shape having a plurality of columnar embossed portions 2 a and having a vertical wall portion 2 b (corresponding to the vertical wall portion 21 in FIG. 3)
  • a plate-like cover sheet 3 which is welded to the core sheet 2 and the back surface of the laminated material 1 is formed;
  • a plate-like cover sheet 4 which is welded to the core sheet 2 and the surface of the laminated material 1 is formed;
  • the laminated material 1 has a structure in which a pair of first and second cover sheets 3 and 4 are laminated via a core sheet 2 having a vertical wall portion 2b.
  • the core sheet 2 and the first and second cover sheets 3 and 4 are each formed of a non-breathable polypropylene resin (thermoplastic resin).
  • a laminated material 1 d with a skin material is formed by bonding a nonwoven fabric (skin material) 5 to the surface of the cover sheet 4.
  • This laminated material 1d with a skin material is formed into a desired shape by trim processing described later. Then, in the trim processing, terminal processing as shown in region A of FIG. 3 is performed, and the back door trim panel 19 is formed.
  • the second cover sheet 4 is curved toward the direction of the first cover sheet 3 (upward in the drawing) at the end portion (design-shaped end portion 6d) shown in the region A of FIG. ing.
  • the first cover sheet 3 is once bent toward the direction of the second cover sheet 4 (downward in the drawing), and is bent upward integrally with the shape of the second cover sheet 4 in the middle.
  • the core sheet 2 arrange
  • the 1st and 2nd cover sheets 3 and 4 and the core sheet 2 are heated and crushed and welded by the terminal process mentioned later.
  • FIG. 4 is a process diagram for specifically explaining the operation flow of the heating and crushing process in the first process.
  • the cross-sectional shapes of the hot blade receiving block 50 and the hot blade block 60 for processing the end portion 6 of the laminated material with a skin material 1d are shown.
  • a reference pin 53 is provided at a predetermined position on the upper surface 51 of the hot blade receiving block 50.
  • the clip hole 7 is formed at a predetermined position so that the reference pin 53 can be inserted. Positioning is performed by the reference pin 53 and the clip hole 7.
  • the clip hole 7 is used as a resin clip mounting hole for mounting to a vehicle body or the like when the back door trim panel 19 is molded as a finished product.
  • the upper surface 51 is configured to be one step lower than the upper surface 54 of the outer region that is not covered by the laminated material 1d with the skin material when the laminated material 1d with the skin material is placed.
  • the position of the end portion 6 where the laminated material 1 d with the covering material is heated and crushed when the hot blade block 60 is processed is referred to as a pressure receiving portion 52.
  • the hot blade block 60 is arranged such that the upper side of the hot blade block 60 does not press a portion other than the end portion 6 to be crushed of the laminated material 1d with the skin material so as to be a space. Is configured.
  • the lower surface of the hot blade block 60 is formed with a lower surface 64 facing the outer region that is one step lower in the hot blade receiving block 50 so as to protrude downward one step downward.
  • the convexly formed portion is fitted to the lower portion of the pressure receiving portion 52, and the upper surface 54 and the lower surface 64 of the portion do not come into contact with each other. It has become.
  • the pressure receiving portion 52 is pressed by a predetermined width so that the end portion 6 can be crushed together with the pressure receiving portion 52 described above at the position of the end portion 6 where the laminated material with skin material 1d is heated and crushed.
  • a surface 62 is formed, and a slope 63 extending obliquely upward is formed from the inner end of the pressing surface 62 toward the inside.
  • the slope 63 presses and heats a portion protruding from a flat portion (a welding portion 6a described later) to some extent in the process of heating and crushing the end portion 6 of the laminated material 1d with the covering material with the pressing surface 62. By doing so, it is made into a shape that can be easily molded in the cooling step, which is a subsequent step.
  • the operator inserts the reference material 53 into the clip hole 7 and places the laminated material 1 d with the covering material on the upper surface 51 of the hot blade receiving block 50.
  • the hot blade block 60 is lowered, and the pressing surface 62 of the hot blade block 60 is laminated with the skin material on the press receiving portion 52 as shown in FIG. 4C.
  • the end 6 of the material 1d is crushed while being heated.
  • the portion crushed by the pressing surface 62 of the end portion 6 is referred to as a welded portion 6a.
  • the portion inside from the crushed end portion 6 is pressed while being heated by the inclined surface 63, and an inclined surface is formed in a sectional view along the inclined surface 63. This sloped portion is referred to as an end inclined portion 6b.
  • FIG. 5 is a process diagram for specifically explaining the operation flow of the processing cooling process in the second process.
  • the cross-sectional shapes of the cooling press lower die 70 and the cooling press upper die 80 in the second step are shown by paying attention to the portion where the end portion 6 of the laminated material with skin material 1d is processed and cooled.
  • a predetermined depth specifically, the thickness of the back door trim panel 19 is matched to the shape of the back door trim panel 19 shown in FIG. 1 and FIG.
  • a design formation surface 73 formed continuously from the formation surface 72 in a predetermined design shape, here a curved shape, in accordance with the shape of the end portion of the back door trim panel 19. is doing.
  • a reference pin 74 is formed on the forming surface 72 so as to protrude upward at a position corresponding to the clip hole 7 of the laminated material 1d with the skin material, similarly to the reference pin 53 of the hot blade receiving block 50.
  • the reference pin 74 is formed up to a position higher than the upper surface 71.
  • a design forming protrusion 82 having a shape matching the shape of the design forming surface 73 is formed on the lower surface 81 facing the design forming surface 73 of the cooling press lower mold 70. Further, a reference pin relief hole 83 is formed so that the reference pin 74 can be inserted so that the reference pin 74 does not hit the lower surface 81 when the upper die 80 of the cooling press is lowered to the position of the lower die 70 of the cooling press. .
  • FIG. 5B shows a state in which the laminated material 1d with the skin material is placed on the upper surface 71 of the lower mold 70 of the cooling press.
  • the laminated material 1d with the skin material has the upper surface 71 on the welding portion 6a.
  • the laminated material 1d with the skin material is placed on the upper surface 71 with the reference pin 74 being slightly inserted into the clip hole 7 of the laminated material 1d with the skin material.
  • the laminated material 1d with the skin material is not in contact with the surface 72 or the design forming surface 73. More specifically, the outer portion of the welded portion 6 a is in contact with the upper surface 71, and the inner portion of the welded portion 6 a is in a state separated from the design forming surface 73.
  • the inner part of the welded portion 6a of the laminated material 1d with the skin material and the end inclined portion 6b are crushed by the design forming surface 73 of the cooling press lower die 70 and the design forming protrusion 82 of the cooling press upper die 80.
  • This shape portion is called the design shape end portion 6d
  • the portion sandwiched between the upper surface 71 of the cooling press lower die 70 and the lower surface 81 of the cooling press upper die 80 is called the end trim portion 6c.
  • the reference pin 74 is inserted into the reference pin relief hole 83.
  • type 80 raises and the press molding and cooling process of the laminated material 1d with a skin material are complete
  • FIG. 6 schematically shows the configuration and operation flow of the trim unit 90 that performs the trimming process (third process).
  • the trim unit 90 includes a trim lower block 91 and a trim upper block 92.
  • a reference pin 94 is formed on the upper surface 91a of the trim lower block 91 at a predetermined position so as to be able to be inserted into the clip hole 7 of the laminated material 1d with the skin material in order to position the laminated material 1d with the skin material.
  • a trim blade 93 is formed at a predetermined position of the trim lower block 91.
  • the trim blade 93 is arranged so that the front end of the trim blade 93 is located at the boundary between the end trim portion 6c and the design shape end 6d when the laminated material 1d with the skin material is positioned and placed. Has been.
  • the trim upper block 92 is formed with a trim blade receiving portion 95 protruding downward at a position facing the trim blade 93.
  • the trim upper block 92 is lowered, and the trim blade 93 and the trim blade receiving portion 95 cause the end trim portion 6c and the design shape end portion 6d of the laminated material 1d with the skin material to The edge trim 6c is removed from the laminated material 1d with the skin material, and the back door trim panel 19 is completed.
  • the end portion (design shape end portion 6d) of the back door trim panel 19 can be formed into a desired curved press shape, so that the degree of freedom in shape is improved. Moreover, since the design-shaped end portion 6d is formed by being crushed, its rigidity can be improved. In addition, since the degree of freedom of the shape of the design shape end portion 6d is improved as described above, the design shape end portion 6d is more strongly curved, and a bent portion is formed at the intermediate portion of the design shape end portion 6d. It is also possible to adopt a shape that can further improve.
  • the nonwoven fabric 5 is more strongly bonded to the cover sheet 4 by the anchor effect, so that the nonwoven fabric 5 may be peeled off or the end portion 6 (designed shape end portion 6d). Can be prevented from opening. Further, since trim is performed after the laminated material 1d with skin material is molded and cooled, burrs caused by the molten resin are not formed in the trim portion.
  • a laminated material made of polypropylene resin is used, but a laminated material made of thermoplastic resin may be used.
  • the nonwoven fabric is used as a skin material, you may use another fabric, a leather skin, etc.
  • the laminated material 1d with the skin material which bonded the nonwoven fabric 5 on the surface of the laminated material 1 is used, what laminated the nonwoven fabric on the both surfaces of the laminated material 1 may be used.
  • the core sheet 2 in which the column-shaped embossed part 2a was formed is used, not only this but the edge part 6 of the laminated material 1d with a skin material can be heated and crushed.
  • seat part 2 can use various sheets, such as a straw type core, a honeycomb type core, and a foamed resin core.
  • the three-layer structure of the first and second cover sheets 3 and 4 and the core sheet 2 has been illustrated as the laminated material 1, the present invention is not limited to this, and is illustrated in FIGS. 2B and 3B. As shown, there may be a two-layer structure of the second cover sheet 4 and the core sheet 2 without the first cover sheet 3.
  • the 1st process, the 2nd process, and the 3rd process were illustrated as another apparatus, naturally each process is equipped in the same apparatus, and the laminated material 1d with a skin material is moved and installed. You may shape

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Forests & Forestry (AREA)
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  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

　端部の見栄えを向上させるとともに形状自由度を向上させることのできる積層板および積層素材の端末処理方法を実現する技術を提供する。 　図５に示すように、冷却プレス上型８０が下降すると、意匠形成突部８２が表皮材付積層素材１ｄの溶着部６ａの内側の一部及び端部傾斜部６ｂを下方向に押圧する。また、表皮材付積層素材１ｄの加工処理されない部分は、下面８１の形成面７２まで押し込まれる。そして、表皮材付積層素材１ｄの溶着部６ａの内側の一部及び端部傾斜部６ｂは、冷却プレス下型７０の意匠形成面７３と冷却プレス上型８０の意匠形成突部８２により押しつぶされて所望の形状にプレス成形される。

Description

積層板及び積層素材の端末処理方法
　本発明は、積層板及び積層素材の端末処理方法に係り、例えば自動車等の内装材として用いられる積層板材及び積層素材の端末処理方法に関する。
　自動車においては、トランクルームのパネルやドアトリム等の内装材に樹脂成形品が以前より使用されている。そして、近年では、樹脂成形品の特徴の「軽量」及び「複雑な形状に対応可能」という二つの特徴から、一層着目されるようになっている。
　樹脂成形品の構造には例えば高剛性の中空構造や、軽量高剛性のサンドイッチ構造などがあり、必要とされる強度や形状、機能に応じて選択されている。
　従来、サンドイッチ構造の積層素材として、例えばハニカムコアのように、縦壁部を有するコアシートの片面又は両面にカバーシートを積層した構造のものが知られている。この積層素材は、所望の輪郭形状に切断することで、車両用や建築用の内装材や外装材などとして用いられている。
　しかしながら、この種の積層素材は、縦壁部を有するコアシートを含んで厚くなり、単に端部を切断しただけでは端部の切断された部分が見えてしまう事から見栄えが悪くなってしまうおそれがあった。そこで、切断した端部に端末処理を施して、端部の見栄えを向上させた積層板が提案されている（例えば、特許文献１）。この特許文献１に開示の技術では、積層素材の端部に熱刃を押し当てて積層素材を加熱しながら押し潰して折曲部を形成し、当該折曲部を上側に折り曲げて積層素材の側部に融着させた積層板が開示されている。
　また、特許文献１に開示の技術では、端部の見栄えをよくするための処理において積層素材の形状に制約が生じることや、金型が複雑になりコストが増加してしまう事から、そのような制約の無い形状自由度を向上させた技術も提案されている（特許文献２参照）。この特許文献２に開示の技術では、一対のカバーシートを縦壁部を有するコアシートを介して積層して積層素材を形成し、さらにその積層素材の表面上に不織布を接合して形成された表皮材付積層素材の周縁部（積層素材の周縁部）を加熱軟化している。さらに加熱軟化させた周縁部に抜き型の切断刃を押し当てて、一方のカバーシートを他方のカバーシートに接触させて溶着するだけで、表皮材付積層素材からフロアボードを型抜きすることができる。
特開２００１－１８３０８号公報 特開２００８－１４３３８４号公報
　しかしながら、複雑な曲線形状を有する積層素材に端末処理を施す際に、かかる特許文献１に開示の方法を用いた場合、複雑な曲線形状をした部分では折り曲げた折曲部に大きな皺が発生してしまうため、当該折曲部を積層素材の側端部にうまく接触させることができなかった。すなわち、上記端末処理方法では、積層素材の形状に制約が生じるという課題があった。
　特許文献２に開示の技術では、積層素材の形状の制約は実用的な範囲において解消されたものの、近年の需用者の高まる要望に応えるには、さらに改良が必要になってきており、別の技術が求められるようになってきた。例えば、端部の剛性の向上、端部溶着部分の口開き防止、表皮材の剥離防止、端部トリム部分のバリ処理などが、従来以上に求められるようになってきた。
　そこで、本発明は、形状自由度を保ちながら端部の見栄えを向上させるとともに成形後に表皮材の剥離が起きたり端部の溶着部分が口開きすることなく、かつ、端部の剛性を向上することのできる積層板および積層素材の端末処理方法を提供することを目的とする。
　本発明は積層板に関する。この積層板は、縦壁部を有する熱可塑性樹脂シートと当該縦壁部を有する熱可塑性シートの一方の側に熱可塑性樹脂からなるカバーシートと表皮材とを積層してなる積層素材において、当該積層素材の外周端部の少なくとも一部分において前記縦壁部の所定範囲が、前記カバーシート側および前記表皮材側へ溶融押し潰され、前記カバーシートと略面一に溶着した溶着部を有し、かつ当該溶着部が前記縦壁部を有する熱可塑性樹脂シートの前記カバーシートを積層していない他方の側へ所定形状に成形されている。
　本発明は積層板に関する。この積層板は、縦壁部を有する熱可塑性樹脂シートと当該縦壁部を有する熱可塑性シートの両方の側に熱可塑性樹脂からなるカバーシートが積層され、少なくとも一方の側のカバーシートに表皮材を積層してなる積層素材において、当該積層素材の外周端部の少なくとも一部分において前記表皮材が積層された若しくは積層されていない他方の側のカバーシートと前記縦壁部を有する熱可塑性樹脂シートの所定範囲が、前記一方の側のカバーシートおよび前記一方の側の表皮材側へ溶融押し潰され、前記一方の側のカバーシートと略面一に溶着した溶着部を有し、かつ当該溶着部が前記縦壁部を有する熱可塑性樹脂シートの前記他方の側のカバーシート側へ所定形状に成形されている。
　また、前記積層板は自動車内装材、特に天井材、サイドドアトリムパネル、バックドアトリムパネル、ラゲージサイドトリムパネル、シートバックボードに使用されることを特徴とする請求項１又は請求項２に記載の積層板。
　本発明は、積層素材の端末処理方法に関する。この端末処理方法は、縦壁部を有する熱可塑性樹脂シートと当該縦壁部を有する熱可塑性シートの一方の側に熱可塑性樹脂からなるカバーシートと表皮材を積層してなる積層素材の端末処理方法において、当該積層素材の外周端部の少なくとも一部分において前記縦壁部の所定範囲を、前記カバーシート側および前記表皮材側へ熱刃ブロックを用いて溶融押し潰して、前記カバーシートへ略面一に溶着して溶着部を形成する第一の工程と、当該溶着部が前記縦壁部を有する熱可塑性樹脂シートの前記カバーシートを積層していない他方の側へ所定形状にプレス成形され冷却する第二の工程と、からなる。
　本発明は、積層素材の端末処理方法に関する。この端末処理方法は、縦壁部を有する熱可塑性樹脂シートと当該縦壁部を有する熱可塑性シートの両方の側に熱可塑性樹脂からなるカバーシートが積層され、少なくとも一方の側のカバーシートに表皮材を積層してなる積層素材の端末処理方法において、当該積層素材の外周端部の少なくとも一部分において前記表皮材が積層された若しくは積層されていない他方の側のカバーシートと前記縦壁部を有する熱可塑性樹脂シートの所定範囲が、前記一方の側のカバーシートおよび前記一方の側の表皮材側へ熱刃ブロックを用いて溶融押し潰して、前記一方の側のカバーシートと略面一に溶着して溶着部を形成する第一の工程と、当該溶着部が前記縦壁部を有する熱可塑性樹脂シートの前記他方の側のカバーシート側へ所定形状にプレス成形され冷却する第二の工程からなる。
　本発明によると、形状自由度を保ちながら端部の見栄えを向上させるとともに成形後に表皮材の剥離が起きたり端部の溶着部分が口開きすることなく、かつ、端部の剛性を向上することのできる積層板および積層素材の端末処理方法を提供することができる。
実施形態に係る、積層板を示す斜視図である。 実施形態に係る、積層板を構成する表皮材付き積層素材の構造を示す分解斜視図である。 実施形態に係る、積層板の端部に着目した断面図である。 実施形態に係る、第一の工程の構成および動作フローを模式的に示した図である。 実施形態に係る、第二の工程の構成および動作フローを模式的に示した図である。 実施形態に係る、第三の工程（トリム工程）の構成および動作フローを模式的に示した図である。
符号の説明
１　積層素材
１ｄ　表皮材付積層素材
２　コアシート
３　第１のカバーシート
４　第２のカバーシート
５　不織布
６　端部
６ａ　溶着部
６ｂ　端部傾斜部
６ｃ　端部トリム部
６ｄ　意匠形状端部
１９　バックドアトリムパネル（積層板）
５０　熱刃受けブロック
５２　押圧受け部
６０　熱刃ブロック
６２　押圧面
６３　斜面
７０　冷却プレス下型
７２　形成面
７３　意匠形成面
８０　冷却プレス上型
８２　意匠形成突部
９０　トリムユニット
９１　トリム下ブロック
９２　トリム上ブロック
　次に、本発明を実施するための最良の形態（以下、単に「実施形態」という）を、図面を参照して具体的に説明する。以下に説明する実施形態では、自動車の内装部品、具体的に、自動車のバックドアに取り付けられるバックドアトリムパネルとして使用される樹脂成形品（積層板）について説明する。図１は、本実施形態にかかるバックドアトリムパネル（積層板）１９を示す斜視図、図２はバックドアトリムパネル１９を構成する表皮材付積層素材１ｄの構造を示す分解斜視図、図３はバックドアトリムパネル１９を構成する積層素材１の断面図である。なお、図２と図３とは上下が逆に表示している。また、図２（ａ）及び図３（ａ）は、３層構造の積層素材１からなる表皮材付積層素材１ｄとバックドアトリムパネル１９の構造を示し、図２（ｂ）及び図３（ｂ）は２層構造の積層素材１からなる表皮材付積層素材１ｄとバックドアトリムパネル１９の構造を示している。以下では、図２（ａ）及び図３（ａ）の３層構造について例示する。
　バックドアトリムパネル１９は、積層素材１に不織布５が貼り合わされた表皮材付積層素材１ｄの端部に端末処理を施すことで形成される。例えば図３に示すように、バックドアトリムパネル１９は、熱可塑性樹脂製の積層素材１と、積層素材１の下側の面（第２のカバーシート４）を不織布５で被覆した表皮部とを備え、図３の領域Ａに示すように表皮材付積層素材１ｄの端部（意匠形状端部６ｄ）が端末処理されている。また、車体に樹脂クリップ留めする際に樹脂クリップが挿通されるクリップ穴７を有している。
　まず、バックドアトリムパネル１９の構成する積層素材１について説明する。積層素材１は、図２に示すように、多数の円柱状のエンボス部２ａが形成され縦壁部２ｂ（図３の縦壁部２１に相当する）を有する断面凹凸状のコアシート２と、当該コアシート２に溶着され、積層素材１の裏面が形成される板状のカバーシート３と、当該コアシート２に溶着され、積層素材１の表面が形成される板状のカバーシート４と、を備えている。すなわち、積層素材１は、一対の第１及び第２のカバーシート３，４を縦壁部２ｂを有するコアシート２を介して積層した構造をしている。そして、本実施形態では、コアシート２および第１及び第２のカバーシート３，４は、それぞれ非通気性のポリプロピレン樹脂（熱可塑性樹脂）で形成されている。
　さらに、カバーシート４の表面に不織布（表皮材）５を接合することで表皮材付積層素材１ｄが形成されている。この表皮材付積層素材１ｄが、後述するトリム処理により、所望の形状に形成される。そして、そのトリム処理において、図３の領域Ａに示すような端末処理が施され、バックドアトリムパネル１９が形成される。
　具体的には、図３の領域Ａに示す端部（意匠形状端部６ｄ）において、第２のカバーシート４は、第１のカバーシート３の方向（図示では上方向）に向けて湾曲している。また、第１のカバーシート３は、一旦第２のカバーシート４の方向（図示では下方向）に向けて湾曲し、途中で、第２のカバーシート４の形状と一体となり上方に湾曲している。そして第１及び第２のカバーシート３，４の間に配置されているコアシート２は、第１及び第２のカバーシート３，４に挟まれて湾曲している。そして、第１及び第２のカバーシート３，４及びコアシート２は、後述する端末処理によって加熱及び押しつぶされて、溶着している。
　つぎに、第一の工程による表皮材付積層素材１ｄの端末の加熱及び押しつぶし処理について具体的に説明する。図４は第一の工程による加熱及び押しつぶし処理の動作フローについて具体的に説明するための工程図である。ここでは、表皮材付積層素材１ｄの端部６を加工するための熱刃受けブロック５０及び熱刃ブロック６０の断面形状に着目して示している。
　熱刃受けブロック５０の上面５１には、所定の位置に基準ピン５３が設けられている。一方、表皮材付積層素材１ｄには、その基準ピン５３が挿入可能に所定の位置にクリップ穴７が形成されている。この基準ピン５３とクリップ穴７により、位置決めがなされる。このクリップ穴７は、完成品としてバックドアトリムパネル１９が成形された時に、車体等に取り付けるための樹脂クリップ取付用穴として利用される。また、本実施形態では、上面５１は、表皮材付積層素材１ｄが載せられたときに、表皮材付積層素材１ｄに覆われない外側領域の上面５４は、一段低く構成されている。また、上面５１において、熱刃ブロック６０が加工したときに被覆材付積層素材１ｄの加熱及び押しつぶしされる端部６の位置を押圧受け部５２と呼ぶ。また、熱刃ブロック６０が下降した状態で熱刃ブロック６０が表皮材付積層素材１ｄの押しつぶす端部６以外の部分を押圧しないように、その部分の上側が空間になるように熱刃ブロック６０が構成されている。
　また、熱刃ブロック６０の下側の面は、熱刃受けブロック５０において一段低くなっている外側の領域に対向する下面６４が、下側に一段下方向に突出して形成されており、熱刃ブロック６０が最も下降した状態で、その凸状に形成された部分は、押圧受け部５２の一段低くなっている部分に嵌合し、また、その部分の上面５４及び下面６４が当接しないようになっている。そして、表皮材付積層素材１ｄの加熱及び押しつぶしされる端部６の位置に、上述した押圧受け部５２とともに前記の端部６を押しつぶすことができるように、押圧受け部５２が所定幅だけ押圧面６２が形成されている、そして、押圧面６２の内側の端部から内側に向かって、斜め上方向に延びる斜面６３が形成されている。この斜面６３は、押圧面６２で被覆材付積層素材１ｄの端部６を加熱及び押しつぶす処理において、押しつぶされて平面状になる部分（後述の溶着部６ａ）からはみ出した部分をある程度押圧し加熱することで、後工程である冷却工程における成形がしやすい形状にする。
　作業者は、図４（ａ）の状態の時に、クリップ穴７に基準ピン５３を挿通させて被覆材付積層素材１ｄを熱刃受けブロック５０の上面５１に載せる。
　そして、図４（ｂ）に示す状態になり、熱刃ブロック６０が降下し、図４（ｃ）に示すように、熱刃ブロック６０の押圧面６２が押圧受け部５２上の表皮材付積層素材１ｄの端部６を加熱しつつ押しつぶす。ここで端部６の押圧面６２により押しつぶされた部分を溶着部６ａと呼ぶ。また、押しつぶされた端部６から内側の部分は、斜面６３により加熱されつつ押圧され、斜面６３に沿った断面視で斜面が形成される。この斜面形状の部分を端部傾斜部６ｂと呼ぶ。
　被覆材付積層素材１ｄの端部６の加熱及び押しつぶし処理が終了すると、図４（ｄ）に示すように、熱刃ブロック６０が上昇し、表皮材付積層素材１ｄの加熱及び押しつぶし処理が終了する。
　つぎに、第二の工程による表皮材付積層素材１ｄの端部６の加工冷却処理について説明する。図５は第二の工程による加工冷却処理の動作フローについて具体的に説明するための工程図である。ここでは、第二の工程の冷却プレス下型７０及び冷却プレス上型８０の断面形状について、表皮材付積層素材１ｄの端部６を加工冷却処理する部分に着目して示している。
　図５（ａ）に示すように、冷却プレス下型７０の図１及び図３に示したバックドアトリムパネル１９の形状に合わせて、所定深さ、具体的には、バックドアトリムパネル１９の厚さだけ低く形成された形成面７２と、バックドアトリムパネル１９の端部の形状に合わせて所定の意匠形状、ここでは湾曲した形状に形成面７２から連続して形成された意匠形成面７３とを有している。さらに、形成面７２には、表皮材付積層素材１ｄのクリップ穴７に対応する位置に基準ピン７４が、熱刃受けブロック５０の基準ピン５３と同様に上方向に突出して形成されている。この基準ピン７４は、上面７１より高い位置まで形成されている。
　また、冷却プレス上型８０は、冷却プレス下型７０の意匠形成面７３に対向する下面８１に意匠形成面７３の形状に合わせた形状の意匠形成突部８２が形成されている。また、冷却プレス上型８０が冷却プレス下型７０の位置まで下降したときに、基準ピン７４が下面８１にぶつからないように、基準ピン７４が挿通可能に基準ピン逃げ穴８３が形成されている。
　図５（ｂ）は、表皮材付積層素材１ｄが冷却プレス下型７０の上面７１に載せられた状態を示しており、この状態では、表皮材付積層素材１ｄは、溶着部６ａが上面７１に当接した状態で、また基準ピン７４が表皮材付積層素材１ｄのクリップ穴７に僅かに挿入されたで状態で表皮材付積層素材１ｄが上面７１に載っており、この状態では、形成面７２や意匠形成面７３には表皮材付積層素材１ｄは当接していない。より具体的には、溶着部６ａの外側部分が上面７１に当接し、溶着部６ａの内側部分が意匠形成面７３から離れた状態になっている。
　つづいて、図５（ｃ）に示すように、冷却プレス上型８０が下降して、冷却プレス上型８０の下面８１が冷却プレス下型７０の上面７１にほぼ当接する位置まで下降すると、意匠形成突部８２が表皮材付積層素材１ｄの溶着部６ａの内側の一部及び端部傾斜部６ｂを下方向に押圧する。また、表皮材付積層素材１ｄの加工処理されない部分は、下面８１の形成面７２まで押し込まれる。そして、表皮材付積層素材１ｄの溶着部６ａの内側の一部及び端部傾斜部６ｂは、冷却プレス下型７０の意匠形成面７３と冷却プレス上型８０の意匠形成突部８２により押しつぶされて、図３の領域Ａで示したような所望の湾曲した曲面形状に成形される。この形状部分を意匠形状端部６ｄと呼び、また、冷却プレス下型７０の上面７１と冷却プレス上型８０の下面８１とにより挟まれた部分を端部トリム部６ｃと呼ぶ。また、このとき、基準ピン７４は、基準ピン逃げ穴８３に挿入されている。
　そして、図５（ｄ）に示すように、冷却プレス上型８０が上昇し、表皮材付積層素材1ｄのプレス成形及び冷却処理が終了する。
　図６は、トリム工程（第三の工程）を行うトリムユニット９０の構成及び動作フローを模式的に示したものである。図６（ａ）に示すように、トリムユニット９０は、トリム下ブロック９１とトリム上ブロック９２とを備えて構成されている。トリム下ブロック９１の上面９１ａには所定の位置に、表皮材付積層素材１ｄの位置決めのために、表皮材付積層素材１ｄのクリップ穴７に挿通可能に基準ピン９４が形成されている。また、トリム下ブロック９１の所定の位置にトリム刃９３が形成されている。このトリム刃９３は、表皮材付積層素材１ｄが、位置決めされて載せられたときに、トリム刃９３の先端が端部トリム部６ｃと意匠形状端部６ｄの境界部分に位置するように、配置されている。
　トリム上ブロック９２には、トリム刃９３の対向する位置にトリム刃受け部９５が下側に向かって突出して形成されている。
　そして、図６（ｂ）に示すように、トリム上ブロック９２が下降し、トリム刃９３とトリム刃受け部９５により、表皮材付積層素材１ｄの端部トリム部６ｃと意匠形状端部６ｄとの境界部分が切り込まれ、端部トリム部６ｃが表皮材付積層素材１ｄから除去されバックドアトリムパネル１９が完成する。
　以上の本実施形態によれば、バックドアトリムパネル１９の端部（意匠形状端部６ｄ）は所望の湾曲したプレス形状に成形できるので、形状の自由度が向上する。また、意匠形状端部６ｄが押しつぶされて形成されていることから、その剛性を向上させることができる。また、上述のように意匠形状端部６ｄの形状の自由度が向上することから、意匠形状端部６ｄをより強く湾曲させる、意匠形状端部６ｄの中間部に折り曲げ部分を形成する等、剛性をより一層向上させることができる形状を採用することもできる。さらに、溶着部６ａが加熱されながら押しつぶされる過程で、不織布５はより強くカバーシート４とアンカー効果により接合されるので、不織布５が剥離してしまったり、端部６（意匠形状端部６ｄ）が口開きしてしまうことを防止することができる。また、表皮材付積層素材1ｄを成形冷却した後にトリムを行うことから、トリム部分に溶融樹脂に起因するバリが形成される事が無い。
　以上、本発明にかかる積層板の好適な実施形態について説明したが、本発明は上記実施形態に限ることなく要旨を逸脱しない範囲で種々の実施形態を採用することができる。
　例えば、上記実施形態においては、ポリプロピレン樹脂製の積層素材を使用しているが、熱可塑性樹脂製の積層素材であればよい。また、表皮材として不織布を用いているが、他のファブリックやレザー表皮等を用いてもよい。また、本実施形態では、積層素材１の表面に不織布５を貼り合わせた表皮材付積層素材１ｄを用いているが、積層素材１の表裏両面に不織布を貼り合わせたものを用いてもよい。また、本実施形態では、円柱状のエンボス部２ａが形成されたコアシート２を用いているが、これに限らず、表皮材付積層素材１ｄの端部６を加熱して押しつぶすことが可能であれば、コアシート２の部分がストロータイプコア、ハニカムタイプコア、発泡樹脂コア等、種々のシートを用いることができる。また、積層素材１として、第１及び第２のカバーシート３、４及びコアシート２の３層構造について例示したが、これに限る趣旨ではなく、図２（ｂ）及び図３（ｂ）に示したように、第１のカバーシート３がない、第２のカバーシート４及びコアシート２の２層構造であってもよい。また、第一の工程、第二の工程、及び第三の工程（トリムユニット９０）を別装置として例示したが、当然に各工程を同一装置内に備え、表皮材付積層素材１ｄを移動設置させながら連続的に成形してもよい。

Claims (5)

  1. 　縦壁部を有する熱可塑性樹脂シートと当該縦壁部を有する熱可塑性シートの一方の側に熱可塑性樹脂からなるカバーシートと表皮材とを積層してなる積層素材において、
    　当該積層素材の外周端部の少なくとも一部分において前記縦壁部の所定範囲が、前記カバーシート側および前記表皮材側へ溶融押し潰され、前記カバーシートと略面一に溶着した溶着部を有し、かつ当該溶着部が前記縦壁部を有する熱可塑性樹脂シートの前記カバーシートを積層していない他方の側へ所定形状に成形されていることを特徴とする積層板。
  2. 　縦壁部を有する熱可塑性樹脂シートと当該縦壁部を有する熱可塑性シートの両方の側に熱可塑性樹脂からなるカバーシートが積層され、少なくとも一方の側のカバーシートに表皮材を積層してなる積層素材において、
    　当該積層素材の外周端部の少なくとも一部分において前記表皮材が積層された若しくは積層されていない他方の側のカバーシートと前記縦壁部を有する熱可塑性樹脂シートの所定範囲が、前記一方の側のカバーシートおよび前記一方の側の表皮材側へ溶融押し潰され、前記一方の側のカバーシートと略面一に溶着した溶着部を有し、かつ当該溶着部が前記縦壁部を有する熱可塑性樹脂シートの前記他方の側のカバーシート側へ所定形状に成形されていることを特徴とする積層板。
  3. 　前記積層板は自動車内装材、特に天井材、サイドドアトリムパネル、バックドアトリムパネル、ラゲージサイドトリムパネル、シートバックボードに使用されることを特徴とする請求項１又は請求項２に記載の積層板。
  4. 　縦壁部を有する熱可塑性樹脂シートと当該縦壁部を有する熱可塑性シートの一方の側に熱可塑性樹脂からなるカバーシートと表皮材を積層してなる積層素材の端末処理方法において、
    　当該積層素材の外周端部の少なくとも一部分において前記縦壁部の所定範囲を、前記カバーシート側および前記表皮材側へ熱刃ブロックを用いて溶融押し潰して、前記カバーシートへ略面一に溶着して溶着部を形成する第一の工程と、
    　当該溶着部が前記縦壁部を有する熱可塑性樹脂シートの前記カバーシートを積層していない他方の側へ所定形状にプレス成形され冷却する第二の工程と、
    　からなることを特徴とする積層素材の端末処理方法。
  5. 　縦壁部を有する熱可塑性樹脂シートと当該縦壁部を有する熱可塑性シートの両方の側に熱可塑性樹脂からなるカバーシートが積層され、少なくとも一方の側のカバーシートに表皮材を積層してなる積層素材の端末処理方法において、
    　当該積層素材の外周端部の少なくとも一部分において前記表皮材が積層された若しくは積層されていない他方の側のカバーシートと前記縦壁部を有する熱可塑性樹脂シートの所定範囲が、前記一方の側のカバーシートおよび前記一方の側の表皮材側へ熱刃ブロックを用いて溶融押し潰して、前記一方の側のカバーシートと略面一に溶着して溶着部を形成する第一の工程と、
    　当該溶着部が前記縦壁部を有する熱可塑性樹脂シートの前記他方の側のカバーシート側へ所定形状にプレス成形され冷却する第二の工程と、
    　からなることを特徴とする積層素材の端末処理方法。　
PCT/JP2008/068076 2008-10-03 2008-10-03 積層板及び積層素材の端末処理方法 WO2010038314A1 (ja)

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JP2012187993A (ja) * 2011-03-10 2012-10-04 Meiwa Ind Co Ltd 車両用内装部品
JP2013240966A (ja) * 2012-05-22 2013-12-05 Gifu Plast Ind Co Ltd 中空構造体の製造方法、製造装置及び端面封止構造
JP2015071275A (ja) * 2013-10-04 2015-04-16 盟和産業株式会社 車両用内装部材および車両用内装部材の端末処理方法
JP2016175269A (ja) * 2015-03-19 2016-10-06 トヨタ自動車東日本株式会社 樹脂成形品及び樹脂成形品の装着構造
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CN110126245A (zh) * 2018-02-02 2019-08-16 广州金发碳纤维新材料发展有限公司 一种热塑性蜂窝板的折弯装置及其折弯方法
EP3991948A1 (en) * 2020-11-02 2022-05-04 Pratt & Whitney Canada Corp. Sandwich-structured panels and method of manufacture

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JP2012187993A (ja) * 2011-03-10 2012-10-04 Meiwa Ind Co Ltd 車両用内装部品
JP2013240966A (ja) * 2012-05-22 2013-12-05 Gifu Plast Ind Co Ltd 中空構造体の製造方法、製造装置及び端面封止構造
JP2015071275A (ja) * 2013-10-04 2015-04-16 盟和産業株式会社 車両用内装部材および車両用内装部材の端末処理方法
JP2016175269A (ja) * 2015-03-19 2016-10-06 トヨタ自動車東日本株式会社 樹脂成形品及び樹脂成形品の装着構造
WO2019004285A1 (ja) * 2017-06-27 2019-01-03 岐阜プラスチック工業 株式会社 板材
CN110126245A (zh) * 2018-02-02 2019-08-16 广州金发碳纤维新材料发展有限公司 一种热塑性蜂窝板的折弯装置及其折弯方法
EP3991948A1 (en) * 2020-11-02 2022-05-04 Pratt & Whitney Canada Corp. Sandwich-structured panels and method of manufacture

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