JP4198533B2 - Mold and method for producing laminated molded body - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a mold for laminate molding in which a plurality of layers are integrated at the same time as molding and a method for producing a laminate molded body.
[0002]
[Prior art]
A molded body in which a skin material is laminated and integrated on a surface of a base material including a wood material is used as an interior material of a vehicle or a building. In such a method for producing a molded body, a skin material formed in a sheet shape in advance is placed in a mold for molding the base material, and the base material and the skin material are integrated simultaneously with the molding of the base material. There is a way. In this method, air may remain between the skin material and the base material at the time of clamping, and in this case, the molded body may swell and become defective. Therefore, in order to vent the gas between the skin material and the base material, for example, a molding die of a type in which the base material is injected as a molten resin in a state where the skin material is installed in the mold, the back surface of the skin material, That is, there is disclosed one in which a groove communicating with the cavity and the outside is provided on the peripheral surface of a mold on the side provided with a gate for injecting a molten resin (see, for example, Patent Document 1). According to this mold, the gas pushed to the periphery of the mold as the resin is filled in the cavity is discharged to the outside through the groove.
[0003]
[Patent Document 1]
Patent No. 3400020 [0004]
[Problems to be solved by the invention]
However, the base material is not limited to an injectable molten resin, and there are materials that include fillers such as fibers and materials that cannot sufficiently reduce viscosity even by heating. When using these materials, prior to simultaneous molding with the skin material, after preforming into a mat shape, a board shape, etc., it is placed in a mold and press-molded in a predetermined temperature region together with the skin material. Therefore, in this method, since the base material is located in the peripheral portion of the mold from the beginning, the gas positioned between the skin material and the base material cannot be removed with the mold having the above-described configuration. .
[0005]
Therefore, an object of the present invention is to provide a molding die that can be molded simultaneously using the base material and the sheet member in various states while venting the gas between the base material and the sheet member.
Another object of the present invention is to provide a method for producing a laminated molded body that simultaneously molds while removing the gas between the base material and the skin material using the base material and the sheet member in various states. To do.
[0006]
[Means for Solving the Problems]
In order to solve the above problems, the present invention is a method for producing a laminated molded body, comprising a sheet member between a pair of molds for pressure molding, and an intermediate material having a space through which gas can flow, The base material is arranged in this order, and when the mold is clamped, the sheet member is stretched by partially pressing the tension member along the outer periphery of the molding part from the surface opposite to the intermediate member of the sheet member. Provided is a method for producing a laminated molded body characterized by being provided.
In this method, when the sheet member, the intermediate material, and the base material are sandwiched between the tension member and the mold on the base material side, the gas between the sheet member and the base material is passed through the intermediate material. Thus, it can be discharged out of the molding space from between the sheet member portion where the tension member is not in contact with the base material. Therefore, it is possible to manufacture a laminated molded body while suppressing wrinkles and sagging of the sheet member and at the same time suppressing occurrence of gas bulging in the sheet member.
Further, in the present invention, a sheet member provided with an intermediate material having a space through which gas can be circulated on the side in contact with the base material, a mold forming a pair of molds, and one of the molds forming the pair, Provided between molds that have a tensile portion that protrudes from the abutting surface and extends along the outer periphery of the cavity surface, and a gas vent that is formed in a concave shape extending from the cavity surface to the outside of the abutting surface so as to cut off the tensile portion. A state in which the base material is arranged between the sheet member and the other mold while maintaining the tension in contact with the one mold having the preparation step and the tension member and the gas venting portion. The manufacturing method of a molded object provided with the shaping | molding process of clamp | tightening a shaping | molding die and shape | molding and carrying out lamination | stacking integration is provided.
The pair of molds used in this method is provided with a tension part and a gas vent part in one mold, and the sheet is clamped by the tension part so that the sheet member is in contact with this one mold. Generation of wrinkles can be suppressed by maintaining the member in a stretched state. At this time, since the degassing portion is not pressed against the sheet, the gas between the sheet member and the base material can be extracted from the portion corresponding to the degassing portion through the space through which the gas of the intermediate material can flow. Therefore, in the method of laminating and integrating at the same time as the molding, it is possible to satisfactorily produce a laminated molded body while suppressing the occurrence of wrinkles and gas expansion of the sheet member. Further, by using the sheet member integrally provided with the intermediate material as in the present invention, the intermediate material can be easily held in a stretched state.
In addition, a sheet-like material having a predetermined shape is used as the base material, and in the forming step, the sheet member is wrinkled or gasified by press forming with a forming die that forms a pair of the base member and the base material. It is possible to produce a board-shaped laminated molded body having various shapes by pressing while suppressing swelling. In particular, by using a base material that is formed in a solid state in advance, it is possible to satisfactorily avoid filling the space in which the gas of the intermediate material can flow with the base material, and to maintain a good gas flow path. Can be molded.
[0007]
Further, in the present invention, there is provided a molding die for producing a laminated molded body composed of a plurality of layers having an intermediate material having a space through which gas can flow, wherein one of the paired mold and the paired mold is butt-matched. There is provided a mold having a tension part protruding from the surface and extending along the outer periphery of the cavity surface, and a gas vent part formed in a concave shape extending from the cavity surface to the outside of the abutting surface so as to cut off the tension part.
In this mold, the tension portion protruding from the cavity surface can contact the sheet member before contacting the cavity surface during mold clamping, and can be provided in a state where the sheet member is stretched. On the other hand, the degassing part is concave as compared to the tension part and extends from the cavity surface to the outside of the butt surface, so even when the sheet member is stretched by the tension part, It is possible to provide a space in which the tension applied to the sheet member is small and gas can flow. Accordingly, when another molding raw material (for example, a base material) is formed between the mold on the side not provided with the tension portion and the sheet member, the gas stays between the other molding raw material and the sheet member. Can be discharged to the outside through the gas venting portion from between the sheet member corresponding to the gas venting portion and the base material during the mold clamping operation. Therefore, it is a mold capable of forming a laminated molded body by reducing molding defects such as gas expansion and wrinkles. In this mold, by providing a tensile portion at least on the protruding portion on the outer periphery of the cavity, the sheet member is satisfactorily stretched more reliably by suppressing sagging and wrinkles of the sheet member even when the gas venting portion is provided. Can be maintained in a state.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, one Embodiment of the molded object which can be shape | molded by the manufacturing method of the shaping | molding die of this invention and a laminated molded object is shown. FIG. 1 shows an interior door 1 of a building, which is formed of a frame member (not shown) and a laminated molded body 10 that covers the entire surface of the frame member.
As shown in FIG. 2, the laminated molded body 10 of the present embodiment has a three-layer structure including a base material 12, an intermediate material 14, and a surface material 16 in this order. The base material 12 is formed by bonding a wood material, specifically a wood fiber material, using a thermoplastic resin as a binder. The base material 12 can be formed of various materials that can be formed by injection molding or press molding, such as a mixed material of various resin materials, chips, fibers, or the like and a binder that binds these.
[0009]
In the present embodiment, the intermediate material 14 is a non-woven fabric, and is formed of fibers of thermoplastic resin such as polyester or polyolefin, such as a mixed fiber of polyethylene terephthalate (PET) and polyethylene (PE). The intermediate material 14 is a structure which can distribute | circulate gas, and can specifically select a nonwoven fabric and a continuous foam type foaming material. Moreover, the intermediate material 14 can be comprised from the material which provides a softness | flexibility to the surface of a molded object, or improves the adhesiveness with an adjacent other layer.
[0010]
The surface material 16 is a material that forms the surface of the laminated molded body 10, and is formed from sheet-like materials having various appearances and designs. For example, in the present embodiment, it is made of polypropylene having a woodgrain color and a texture pattern. As the surface material 16, a material provided with flocking or raising, a material provided with various colors and patterns, or a material provided with a three-dimensional uneven shape such as a texture pattern can be used. . Moreover, as a material, it can select from the various materials which have the property (for example, heat resistance) which can endure the molding conditions at the time of manufacture, ie, the formation process of the manufacturing method mentioned later.
[0011]
Next, a method for manufacturing the laminated molded body 10 using the mold 30 according to an embodiment of the present invention will be described.
First, the mold 30 will be described in detail with reference to FIGS. The mold 30 includes molds 31 and 41 that form a pair. The paired molds 31 and 41 are formed of a known core mold and cavity mold. Further, as shown in FIG. 5, the paired molds 31 and 41 are known in the same manner as the apparatus that stacks and integrates at the same time as molding, and keeps the sheet member 18 held between the molds 31 and 41 in a stretched state. A clamp 37 can be attached. In addition, although the type | molds 31 and 41 which comprise the pair of this embodiment are well-known type | molds for a press, the type | mold for injection press molding can also be used, for example.
[0012]
Of the molds 31 and 41 forming a pair, the mold 31 on the side that comes into contact with the sheet member 18 when the laminated molded body 10 is molded is provided with a tension part 51 and a gas vent part 52.
As shown in FIG. 4, the pulling portion 51 is a portion provided so as to protrude from the abutting surface 34 along the outer periphery of the cavity surface 32. A plurality of tension portions 51 of the present embodiment are provided at predetermined intervals along the outer peripheral surface. Specifically, as shown in FIGS. 5 and 6, the block is formed by a block having a rectangular cross section, and is fixed to the butting surface 34 by a bolt (not shown). The pulling portion 51 preferably includes a corner portion that is continuous with the cavity surface 32 and protrudes so as to be in pressure contact with the sheet member 18. When the corner portion is provided, the sheet member 18 can be more reliably maintained in a stretched state. In the mold 31 shown in FIG. 4, a right-angled corner portion of the block continuous to the outer periphery of the cavity surface 32 is formed in a corner portion 51 a to which the sheet member 18 can be pressed. In addition, when the tension portion 51 is preferably provided in a portion protruding from the other portion in the outer peripheral shape of the cavity surface 32, the sheet member 18 can be maintained in a well-stretched state. In the present embodiment, as shown in FIG. 4, tension portions 51 b are provided so as to surround each corner portion of the rectangular cavity surface 32.
[0013]
The gas vent 52 is a concave portion extending from the cavity surface 32 to the outside of the abutting surface 34 so as to cut off the pulling portion 51. In the mold 31 of FIG. 4, the tension portion 51 is formed by a block fixed to the butting surface 34, and the gas venting portion 52 is formed by the butting surface 34 having no block and the wall surface of the block. The degassing part 52 can be provided in various parts according to the molding shape. In the present embodiment, the pulling portions 51 and the gas venting portions 52 are provided so as to be alternately arranged at equal intervals.
[0014]
Note that the shape of the gas vent 52 is not limited to a form having a groove-like space having a rectangular cross section as in the present embodiment, and a plurality of groove-like spaces having a fan-like cross-section and a plurality of elongated slit-like spaces are provided. The form is not particularly limited. The gas vent part 52 is a shape part that is not pressed when the sheet member 18 is pressed into contact with at least the tension part 51. Therefore, it may have a shape that protrudes from the butting surface 34 and does not protrude from the tension portion 5. For example, a frame body that covers the entire abutting surface 34 may be provided, a portion having a higher protruding amount than the abutting surface 34 may be formed in the pulling portion, and a portion having a lower protruding amount may be provided as the degassing portion. Alternatively, it is also possible to provide a concavity and convexity directly on the abutting surface 34 of the mold 31 and form a convex part in the tension part and a concave part in the gas vent part.
[0015]
Next, a method for manufacturing the laminated molded body 10 using the mold 30 will be described.
First, as shown in FIG. 3, a base material 20 and a sheet member 18 are prepared.
The base material 20 is a plate-like material that can be satisfactorily placed between the dies 31 and 41 and can be formed into a desired shape by press molding. As the base material 20, various thermoplastic resin materials and materials including thermosetting resin materials that are cross-linked by heating can be selected. In addition, these materials may be used as binders, and various materials formed into chips, flakes, fibers, granules, etc., for example, plastics, rubber, metals, ceramics, glass, woody materials, etc. good. Preferably, a material containing a wood material, particularly a wood fiber material and a thermoplastic resin material as a binder, can be selected. In this case, as the binder, for example, polyolefin such as polypropylene (PP), polyester such as polyethylene terephthalate (PET), and polylactic acid can be preferably used.
[0016]
The base material 20 shown in FIG. 3 is a preform, and a web is formed by uniformly mixing a kenaf fiber material and a PP fiber material, and after tightening by needle punching or the like, the temperature is higher than the softening temperature of PP. It was obtained by pressing at such a temperature that it can be molded later. The base material 20 has a stable shape and good handling properties. Since the base material 20 is only required to be molded by the molding die 30, for example, it may be a plate-like material having a mat-like flexibility obtained by fastening the web by needle punching or the like, or a plate-like block made only of a resin material. good.
In the case of manufacturing by injection press molding, the base material is a known material that can be injected and is supplied to the cavity in a molten or softened state.
[0017]
A known so-called skin material can be used for the sheet member 18. For example, a thermoplastic resin sheet formed by a stretching roll or the like can be used. As shown in FIG. 3, the sheet member 18 of the present embodiment has a PP surface material 16 and an intermediate material 14 made of a nonwoven fabric in which PET fibers and PP fibers are mixed, integrated by lamination. It is a so-called skin material. This corresponds to the sheet member provided with the intermediate material in the present specification.
[0018]
(Preparation process)
First, the sheet member 18 is sandwiched and held so as to be stretched on the clamp 37. Next, the sheet member 18 held by the clamp 37 is disposed between the mold 31 and the mold 41. Thereby, the sheet | seat member 18 can be arrange | positioned in the state stretched between the type | molds 31 and 41 which make a pair. The sheet member 18 may be heated in advance with a heater, an oven, or the like.
[0019]
(Molding process)
In the present embodiment in which press molding is performed, the base material 20 is disposed between the pair of dies 31 and 41. In the present embodiment, pressure molding is performed at a temperature equal to or higher than a temperature at which PP as a binder softens. The heating may be a hot press that heats the paired molds 31 and 41 to a predetermined temperature, but preferably the base material 20 is heated and cold pressed before molding.
[0020]
As shown in FIG. 5, the base material 20 is disposed on the side of the mold 41 that does not include the pulling part 51 and the gas venting part 52 and is clamped. When the mold 31 and the mold 41 begin to overlap due to the mold clamping, first, the outer peripheral end 42a of the cavity surface 42 of the mold 41 and the tension portion 51 (corner portion 51a) of the mold 31 approach each other. At this time, the sheet member 18 is in a state of being more tightly pressed against the tension portion 51. Further, the sheet member 18 and the base material 20 are sandwiched between the tension part 51 and the cavity surface 42, and the base material 20 and the outer peripheral end 42 a of the cavity surface 42 and the corner part 51 a of the tension part 51 are sandwiched. The sheet member 18 is strongly sandwiched and brought into a crimped state. The appearance at this time is shown in FIG.
[0021]
When the molds 31 and 41 start to overlap as much as in FIG. 6, a gap is formed between the outer peripheral end 42 a of the cavity surface 42 of the mold 41 and the gas vent part 52 in the part of the gas vent part 52 as shown in FIG. 7. The tension applied to the sheet member 18 is small, and no pressure is applied between the sheet member 18 and the base material 20 or a smaller pressure is applied. For this reason, the gas staying between the sheet member 18 and the base material 20 escapes toward the gas vent 52 where the pressure bonding pressure between the sheet member 18 and the base material 20 is relatively small, and the gas is released. It is discharged from the portion 52 to the outside. In the present embodiment, in particular, since the sheet member 18 includes the intermediate material 14 through which the gas can circulate on the contact surface with the base material 20, the space through which the gas circulates can be more stably secured by the intermediate material 14. Thus, the gas can be extracted well.
[0022]
Thereafter, the molds 31 and 41 are further clamped and pressed to a position where mold clamping is completed as shown in FIG. 8 with a predetermined pressure, thereby forming the base material 20 and the sheet member 18. In this molding process, the thermoplastic resin softened by the heat of the base material 20 and the intermediate material 14 softened by the heating of the sheet member 18 or the heat transfer from the base material 20 are used for molding. Can be welded well. Therefore, after the mold clamping, the laminated molded body 10 in which the sheet member 18 and the base material 12 are integrated at the same time as the molding is obtained by holding the pressurized state for a predetermined time and then opening and cooling the mold. Can do.
[0023]
In this manufacturing method, by using the molding die 30 provided with the tension portion 51 and the gas venting portion 52 along the outer periphery of the cavity surface 32 of the die 31 on the side in contact with the sheet member 18, the same operation as in the prior art is performed. The gas between the sheet member 18 and the base material 20 can be extracted from the degassing portion 52 while performing the mold clamping and molding while maintaining the tension of the sheet member 18. Therefore, it is possible to manufacture the laminated molded body 10 while suppressing the occurrence of both gas expansion and wrinkles in the sheet member 18. In particular, by arranging the intermediate material 14 through which gas can flow between the sheet member 18 and the base material 20, the base material 20 and the sheet member 18 between the tension portion 51 and the mold 41 side. Even when the gas is sandwiched between the base material 20 and the sheet member 18, the intermediate material 14 can ensure a good gas circulation space in the gas vent 52 where the pressure applied to the base material 20 and the sheet member 18 is smaller. Therefore, it is possible to remove the gas more securely and integrate the layers, and it is possible to obtain the laminated molded body 10 having a good appearance.
[0024]
In addition, this invention is not limited to the said embodiment.
The mold in which the tension part 51 and the gas vent part 52 are provided is the side in direct contact with the sheet member, and is not limited to the cavity mold, but may be a core mold. In the case of an injection press mold, it is a mold on the side not provided with a gate for molten resin injection.
Moreover, the tension | pulling part 51 and the gas vent part 52 are not limited to the form integrated with a shaping | molding die, You may be made into the tension member formed separately from the type | mold. (That is, the mold of this embodiment can also be referred to as a mold in which a tension member is integrated.) For example, the tension member is a portion where the tension portion 51 of the mold 31 shown in FIG. 5 is provided. It can be set as the part by the side of the tension | pulling part 51 cut | disconnected by the line m extended in an up-down direction in the figure. The tension member formed separately from the mold can be applied to a conventional mold. In this case, the tension member may be fixed to one of the molds, or may be fixedly provided at a position where it can be pressed against the sheet member 18 when the mold is clamped.
Further, the intermediate material is not limited to the case where the intermediate material is integrated with the sheet member, and may be integrated in advance on the base material side formed on the plate-like material, or may be separated. You may arrange | position between the sheet | seat member of the stretched state, and a base material.
In addition, it is a matter of course that a desired form of a single layer body or a multilayer body can be selected for both the base material and the sheet member.
[0025]
【The invention's effect】
In the present invention, by using a base material and a sheet member in various states, by providing a mold that can be simultaneously molded while venting a gas between the base material and the sheet member, or in various states By providing a method for producing a laminated molded body that simultaneously molds while removing the gas between the base material and the skin material using the base material and sheet member in a state, the laminated molded body is formed using the sheet member. It is possible to produce a laminated molded body while suppressing wrinkles and gas bulging on the sheet member during production.
[Brief description of the drawings]
FIG. 1 is a perspective view of a door provided with an interior material that is an embodiment of a laminated molded body manufactured by a method for manufacturing a laminated molded body according to the present invention.
FIG. 2 is an enlarged partial cross-sectional view of the interior material of the door of FIG.
FIG. 3 is a plan view showing a base material and a skin material prepared in the method for producing a laminated molded body according to the present invention.
FIG. 4 is a perspective view showing an embodiment of a laminated mold according to the present invention.
5 is a cross-sectional view showing a state in which the base material and the skin material shown in FIG. 3 are set in the lamination mold shown in FIG.
6 is a cross-sectional view of a tension portion when the laminated mold shown in FIG. 4 is clamped. FIG.
7 is a cross-sectional view of a gas vent portion when the laminated mold of FIG. 4 is clamped.
8 is a cross-sectional view showing a state where molding is completed after the mold clamping of the laminated mold of FIG. 4 is completed.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Interior door 10 Laminated molded body 12 Base material 14 Intermediate material 16 Surface material 18 Sheet member 20 Base material 30 Molding die 31, 41 Mold 32, 42 Cavity surface 34 Butting surface 37 Clamp 51, 51b Tensile part 51a Corner part 52 Gas Unplug part

Claims (3)

A sheet member provided with an intermediate material having a space through which gas can flow on the side in contact with the base material is a mold that forms a pair of molds, and protrudes from one end of the pair into a cavity projecting from a butting surface A preparation step provided between a mold having a tension part extending along the outer periphery of the surface and a gas vent part formed in a concave shape extending from the cavity surface to the outside of the butt surface so as to cut off the tension part;
Maintaining the sheet member in a stretched state in contact with one mold having the tension part and the gas vent part, and forming a molding die in a state in which the base material is arranged between the sheet member and the other mold A molding process that molds and laminates and molds together
A method for producing a laminated molded body. The laminated molded article according to claim 1, wherein a plate-like material having a predetermined shape is used as the base material, and in the forming step, the sheet member and the base material are press-molded with a pair of forming dies . Production method. A mold for producing a laminated molded body composed of a plurality of layers,
A pair of molds,
A tensile portion protruding from one abutting surface of the pair of molds and extending along the outer periphery of the cavity surface;
A degassing portion formed in a concave shape extending from the cavity surface to the outside of the butt surface so as to cut off the pulling portion;
A mold.

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