JPS6021864B2 - Manufacturing method of composite molded body - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a composite molded body consisting of a laminated structure of a substrate layer 1, a cushion layer 2, and a skin layer 3, in which the peripheral edge of the molded body is finished in an attractive and beautiful manner. The purpose is to efficiently manufacture products.

For example, composite molded products having the above-mentioned layer structure are generally used for vehicle interior parts such as door trim boards, front seat panels, ceiling lining boards, and dashboards.
In addition, composite molded products with the above-mentioned layer structure are often used for various interior materials for buildings, furniture, exterior parts of electrical appliances, etc. The general manufacturing method is to prepare each constituent layer 1, 2, and 3 in advance.
A laminated flat plate obtained by laminating these together is used as a material, and is formed into a desired three-dimensional shape by an appropriate forming method such as vacuum forming, pressure forming, hot press forming, or press forming. At the same time as the molding, or after demolding, unnecessary material around the molded object (edge around the molded object) is cut and removed (trimming process).
do. Although some products are made into final products after this process, the laminated surfaces of the constituent layers 1, 2, and 3 are exposed on the cut end surface 4 at the periphery of the molded product, making it unsightly. Because the skin layer 3 and cushion layer 2 are likely to peel off from the cut end surface, depending on the type of material, after the trimming process around the molded product, an edge finishing process is applied to hide the trimmed end surface to produce the final product. Specifically, as shown in Fig. 1a, a separately manufactured molding material 5 is attached to the green area around the trimmed molded body to hide the IJ trimming end face 4 and finish the edges to produce the final product. However, the processing of the molding material requires materials and labor, resulting in high costs.

Furthermore, the molded body is surrounded by a frame-like frame when the molding material 5 is attached, which is not a desirable form in many cases. Therefore, if such a green finishing form is not preferred, the composite sheet material (hereinafter referred to as cushion layer 20 and skin layer 3) consisting of the substrate layer 1, which is the constituent layer of the composite molded product, the cushion layer material and the skin layer material
), each material is separately molded, the substrate layer 1 is formed into a molded body with a desired external shape, the cushion layer 20 and the skin layer 3 are formed into a molded body with an external shape slightly larger than the required external shape, The two molded bodies are overlapped and bonded together, and the extra extended portion 6 around the molded body of the cushion layer 20 and the skin layer 3 is rolled onto the back side of the substrate layer 1 as shown in Fig. 1b. The method is to fix the edges with adhesive or the like and finish the edges.

In this way, by extending the peripheral edges of the cushion layer 2 and the skin layer 3 of the molded body 6, wrapping the extended portions around the back side of the substrate layer 1, and performing the edge treatment, the end face of the molded body will be in line with the surface of the molded body. The problem of using the molding material 5 is eliminated, and an attractive green finish is obtained.

However, in cases where the thickness of the cushion layer 2 is designed to be relatively thick in order to improve the feel of the molded product, the cross-sectional shape of the winding cannot be sharp due to the thickness, and the thickness may be too thick. There is a problem with the edge finish.

In such a case, before the wrapping process, the cushion layer 2 is removed from the back surface of the skin layer 3 of the extra extension part 6 of the skin layer 3, and the skin layer 3 is removed as shown in FIG. 1c.
However, it is difficult to peel off the cushion layer 2 quickly and neatly, and this is not practical. In addition, in the case of a molded product whose outer periphery is greatly bent, wrinkles tend to occur near the rolled-up part when the rolling process is performed due to the bending, so it is necessary to roll the molded product uniformly around the entire circumference. It takes considerable skill and effort to do so.

In addition, in cases where the surface of the skin layer 3 has a pattern, the pattern on the surface of the skin layer near the outer periphery of the molded body may be stretched due to the tensile force associated with the above-mentioned rolling process, causing pattern distortion. be. The present invention, like the latter, extends the periphery of the cushion layer 2 and the skin layer 3, and the extended portion 6 is wrapped around the back side of the substrate layer 1 to produce a green-finished composite material molded body. However, it is an object of the present invention to provide a method for efficiently manufacturing a molded article whose peripheral edge portion is finished in an attractive and beautiful manner without causing the above-mentioned problems. That is, the substrate layer is manufactured as a single substrate layer molded body by molding the substrate layer material into the required external shape, and the cushion layer and the skin layer are manufactured by extending a composite sheet material of the cushion layer material and the skin layer material extra around the required external shape. It is manufactured as a composite sheet material molded body with a material part added, and the above two molded bodies are bonded and integrated with each other by iron polymerization using female and male molds. In the polymerization state, the excess extension material around the cushion layer and skin layer composite sheet material molded product is heated and softened, and the part of the mold corresponding to the excess extension material of the mold on the pressing side of the substrate layer molded product is heated and softened. The material is stretched into a thin layer by vacuum force, compressed air force, or vacuum/compressed air force within the inner hollowed out portion formed in the area, and the thin stretched material portion covers the outer circumferential surface of the substrate layer and the back surface of the substrate layer near its end surface. The gist of the present invention is a method for manufacturing a composite molded body characterized by the following.

This will be explained in detail below.

In Fig. 2, 10' is a composite sheet in which the cushion layer material 2 and the skin layer material 3 of the constituent layers of the composite material molded body, ie, the substrate layer 1, the cushion layer 2, and the skin layer 3, are laminated together in advance. A vacuum forming mold that molds the material into the required shape, 11
12 is a vacuum hole opened at various places on the molding surface, and 13 is a communication path connecting each vacuum hole to a vacuum pump 14. Reference numeral 15 denotes an extended molding surface region formed around the effective molding surface region for molding the composite sheet materials 2 and 3 into a desired shape on the molding surface and continuous with the effective molding surface region; Vacuum holes 16 are closed at various locations, and the vacuum holes are shut off to the vacuum pump 14 via communication passages 17 and valves 18.

19 are the vacuum hole 16 of the extended molding surface area 15 and the vacuum pump 1
This is the valve of the tube 19 20', which is an air release tube provided by branching the communication path between the vacuum hole 16 and the valve 18 for the communication path 17 connecting the vacuum hole 16 and the valve 18.

The entire composite sheet materials 2 and 3 of the cushion layer material and the skin layer material are heated and softened, and the surface on the skin layer material side is molded into a molding surface 11.
It is placed on the side and placed over the mold 10, and the vacuum pump 14 is driven.

As a result, each vacuum hole 12 of the molding surface 11 enters a vacuum suction state. In this case, the valve 20 is closed, the valve 18 is opened, and each vacuum hole 16 in the extended molding surface area 15 of the mold is also brought into a vacuum suction state. As a result, the composite sheet materials 2 and 3 of the cushion layer material and the skin layer material are formed on the mold forming surface 1 including the extension forming surface 15.
Composite molded bodies 2, 3 of cushion layer material + skin layer material with an extra material portion 6 that adheres closely to the entire body of 1 and extends around the periphery.
is obtained. Reference numeral 21 denotes a clamp that holds the periphery of the composite sheet materials 2 and 3, which are the materials to be formed.

The cushion layer material 2 is, for example, a European foam sheet made of thermoplastic resin such as polyethylene, polypropylene, or polyvinyl chloride, and the skin layer material 3 is, for example, polyvinyl chloride or TPE.
Similarly, soft solid fleshy sheets of thermoplastic resin, cloth that can be stretched by heating, etc., are used.

When the skin layer material 3 is a thermoplastic resin sheet,
If the current uneven pattern is formed on the molding surface 11 of the mold 10, the uneven pattern corresponding to the pattern on the molding surface can be clearly and beautifully provided on the surface at the same time as the material is vacuum formed.

Composite sheet material 2 of the above cushion layer material 10 skin material layer,
Thereafter, the pump 14 continues to drive the molded article No. 3 to keep it in close contact with the molding surface 11 of the mold 10.

Reference numeral 22 denotes a press mold which is disposed above the vacuum forming mold 10 so as to be able to move vertically, and the substrate layer molded product 1 is bonded and held on the lower surface 23 of the press mold 22, which is manufactured separately, and moved downward. The effective molding areas of the molded bodies 2 and 3 of the cushion layer + skin layer held on the side of the vacuum mold 10 are iron-coupled and an appropriate pressing force is applied to form layers 2 and 1 in advance. It serves to integrate the parts through a mounting agent layer 7 formed on the surface of the parts.

The substrate layer molded body 1 is made of various hard/semi-hard solid or porous resins, resin felt, polystyrene bead foam,
Rigid cardboard structures made of resin, paper, etc., cardboard, hardened plant material, metal plates, etc. are used as raw materials, and these are vacuum formed.
It is possible to use products molded using a molding method that matches the characteristics of the material, such as air pressure molding, hot press molding, press molding, injection molding, or cast molding. It is molded to have a surface shape that exactly matches the two surfaces of the cushion layers of the molded bodies 2 and 3, a predetermined wall thickness, and a predetermined external shape.

The substrate layer molded body 1 iron-bonded to the lower surface of the press die 22 is held by mechanical holding means such as hooks provided on the press die side.
This can be done by means such as vacuum suction, magnetic force, or temporary adhesion with an adhesive such as double-sided adhesive tape.

The lowering of the press die 22 lowers the substrate layer molded body 1 held on the lower surface.
are the cushion layer 10 and the skin layer molded product 2 on the vacuum forming mold 10 side,
3 and descends a little further, and when a suitable pressing force for adhesion is applied between layer 1 and layer 2, the lower surface of the overhanging flange 24 around the press die forms a cushion layer + skin layer molded product. 2
.

A large inward gouge 25 is formed on the side periphery of the press mold 22, and vacuum holes 27 are closed at various locations on the gouge surface 26.
The vacuum hole is connected to the vacuum pump 14 via a connecting path 28 and a valve 29, and the valve 29 is normally kept closed. Then, in the state shown in FIG. 2, that is, the composite sheet materials 2 and 3 of the cushion layer material and the skin layer material are vacuum formed using the vacuum forming mold 10, and the molded bodies 2 and 3 are placed in the mold 11.
With the press mold 22 holding the substrate layer molded product 1 on its lower surface, the lower surface of the outer metal part 24 firmly pinches the outer peripheral edge 6'' of the molded products 2 and 3, and presses the press mold 22 into a vacuum forming mold. Layer 1 and Layer 2 are lowered until they are received by the top surface of the surrounding convex edge.
and are bonded together by pressure through the adhesive layer 7 interposed in advance, the extended molding surface of the vacuum molding mold is closed by closing the valve 18 on the vacuum molding mold 10 side and opening the valve 20. The vacuum suction action of the vacuum holes 16 that close to the region 15 is stopped, and each vacuum hole 16 is exposed to the atmosphere via the communication path 17→the same 19→valve 20 by the valve 20. Next, the valve 29 on the press mold 22 side
open.

Then, each vacuum hole 27 opened in the side circumferential hollowed surface 26 of the press die 22 enters a vacuum suction state, and the hollowed out part 25 becomes a negative pressure, and the negative pressure causes the extended forming surface 1 of the vacuum forming die 10
The extended extra material portion 6 of the cushion layer + skin layer molded bodies 2 and 3 corresponding to the 5 regions is the hollowed out portion 25 on the side periphery of the press die 22.
is stretched inward and pulled in, and finally the third
As shown in the figure, the excess material portion 6 is the end surface of the substrate layer 1, the outer edge of the back surface of the substrate layer 1, and the gouged surface 26 on the side periphery of the press mold 22.
It is then stretched thin and vacuum formed 6'.
Extended vacuum forming mold hollowed out part 2 of the above-mentioned excess material part 6
The stretched thickness of the portion 6 can be freely set by appropriately designing the size of the portion 5 in relation to the thickness of the cushion layer material 20 and the thickness of the skin layer material 3.

Further, the stretching vacuum forming of the portion 6 is carried out while the cushion layer material 20 and the skin layer material 3 are maintained in a thermally softened state. Alternatively, a heating means 30 such as a heating pipe or a heating wire is installed within the thickness of the mold in the area of the extended molding surface 15 to maintain the material portion 6 in a thermally softened state. Alternatively, a hot air outlet (not shown in the figure) may be provided in the hollowed out surface 26 around the side of the press mold 22 to form the hollowed out part 2.
Hot air is blown into the material portion 5 to make the material portion 6 into a thermally soft IQ state. After the vacuum forming process of the material portion 6, the molded bodies 1, 2, 3 are cooled by passing cooling water into the cooling pipes (not shown) installed in the molds 10, 22, the vacuum pump 14 is stopped, and the mold 10, 22 are opened and the molded bodies 1, 2, 3 are taken out.

In this case, the material portion 6' that is in close contact with the side circumferential hollowed surface 26 of the press die 22 is thin and has a rough texture, so the hollowed out portion 25
It can be removed more easily. FIG. 4 shows a cross section of the end of the molded body taken out, and shows the end surface of the substrate layer molded body 1 and the back surface of the substrate layer 1, with the excess material portion 6 in FIG. It covers the outer edge and is continuous with the extra stretch.

Therefore, the extra stretched portion is trimmed away at the C-C line position. The thin covering portions 6' on the end surfaces of the substrate layer 1 and the outer edges of the back surface of the substrate layer 1 are made by applying an adhesive layer to the cushion layer material surface of the excess material portion 6 in FIG. If formed, it can be integrally attached to the substrate layer 1 side at the same time as the vacuum forming of the portion 6.

An adhesive may be applied to the back surface of the thin covering portion 6' remaining after trimming and removal of the excess stretched portion at the C-C line position, or to the surface portion of the substrate layer covered by the thin covering portion 6', and the thin covering portion 6' may be bonded together. In this case, since the thin covering portion 6' has already been formed in the direction of wrapping around the end of the substrate, adhesion along the outer periphery of the substrate layer can be easily and beautifully performed. The gouged surface 26 on the side periphery of the press die and the lower surface of the flange 24 are treated with non-adhesive material such as fluororesin to form a thin molding material portion 6' and a clamping material portion 6 continuous thereto.
'' to the mold surface (particularly when the cushion layer surface has an adhesive layer, adhesion between the adhesive layer and the golden part 24 of the press mold) is prevented.Excess material portion 6
In the case where hot air is blown into the hollowed out portion 26 as an auxiliary heating softening means, if there is a risk that the hot air heat may cause softening or thermal deformation at the edge of the substrate layer 1, causing a problem, please prepare the edge surface of the substrate beforehand. The excess material part 6 is stretched and vacuum formed with a thin heat shielding member covering the part, and after taking out the molded body, the heat shielding member is removed, and the excess material part 6 is stretched at the C-C line position. The thin covering portion 6' remaining after trimming may be bonded to the substrate layer 1 side.

In this case, the thin covering portion 6' has already been formed in the winding direction of the end face of the substrate layer, so the operation is easy. Trimming and removal of excess stretched material may be performed as shown in Figure 4C.
It is also possible to carry out the masking at the line '-C' so that only the end face of the substrate layer 1 is covered by the thin coating 6'.

Stretching of the excess material portion 6 is performed using the vacuum hole 1 on the mold 10 side.
Pressure forming where air is ejected from 6, vacuum hole 1 on the mold 10 side
Air is blown out from the vacuum hole 27 on the mold 22 side.
The molding may be carried out by a combination of compressed air and vacuum forming in an air suction state.

As described above, the present invention consists of a laminated layer of a substrate layer 1, a cushion layer 2, and a skin layer 3, and the peripheral green extension part 6 of the cushion layer 2 and skin layer 3 is
In order to obtain a green-finished composite material molded body by wrapping the material on the back side of the substrate layer, the cushion layer 20 and the peripheral green extension 6 of the skin layer 3 are heated and softened, and then the back side of the substrate layer is heated and softened. Since the outer periphery of the substrate layer is coated and concealed by the stretched thinned portion 6' of the stretched portion in the winding direction, the edges of the molded product have the edge finish form of each of the examples shown in FIGS. 1a to 1c. It is beautifully finished without causing any defects.

Moreover, since the edge finishing can be performed simultaneously with the molding of the molded body, mass production can be carried out efficiently.

[Brief explanation of the drawing]

Figures 1a, b, and c are cross-sectional views of various green finish examples, respectively;
Figure 2 is a cross-sectional view of the molded body of the cushion layer material + skin layer material in which the substrate layer molded body is press-bonded, and Figure 3 is the end of the molded body about the excess extension material of the cushion layer + skin layer. FIG. 4 is a sectional view of the end of the molded product taken out from the mold. 1 is a substrate layer, 2 is a cushion layer, 3 is a skin layer, 6 is an extra extension material portion of the cushion layer + skin layer, 6' is a stretched thin-walled portion thereof, 10 is a vacuum mold, and 22 is a press mold. Figure 1 Figure 2 Ticket a Mizojuku Figure 4

Claims (1)

[Claims] 1 Consists of a laminate of a substrate layer 1, a cushion layer 2, and a skin layer 3, and the peripheral extensions of the cushion layer 2 and skin layer 3 are thinned6.
In order to obtain a composite material molded body in which the edges are finished by rolling the substrate layer 1 onto the back side of the substrate layer 1, the substrate layer 1 is produced as a single molded body of the substrate layer by molding the substrate layer material into the desired external shape,
The cushion layer 2 and the skin layer 3 are manufactured by manufacturing a composite sheet material of the cushion layer material and the skin layer material as a composite sheet material molded body in which an extra extension material portion is added around the required external shape, and the above two molded bodies are The female and male molds are fitted and polymerized to bond and integrate with each other, and in the state of fitting and polymerization between the female and male molds of the two molded bodies, the cushion layer 2 and the skin layer 3 are formed.
The extra extended material portion at the periphery of the composite sheet material molded body is heated and softened, and a vacuum force is applied to the inside hollowed out portion 25 formed in the mold portion corresponding to the extra extended material portion of the mold 22 on the substrate layer molded body pressing side. Or, a method for manufacturing a composite molded article, which comprises stretching and forming the composite molded article into a thin layer using pneumatic force or vacuum/pressure pneumatic force, and covering the outer circumferential end surface of the substrate layer and the back surface of the substrate layer in the vicinity of the end surface with the thin stretched material portion. .