JPS6059867B2 - Method for manufacturing a laminate molded product - Google Patents

Description

[Detailed description of the invention] The present invention relates to a method for manufacturing a laminate molded body.

For example, interior materials such as vehicle door trim boards, dashboards, front seat panels, and ceiling lining boards generally require two, three, or more layers, such as a board layer + cushioning material layer, a board layer, a cushioning material layer, and a skin material layer. Using a thermoformable laminated flat plate made by bonding layers together and integrating them in advance, it is formed into a predetermined three-dimensional shape using a thermoforming method using a mold such as vacuum forming, pressure forming, or heat press molding. Manufactured by molding.

However, this manufacturing method has the following problems. (a
) The molded product is trimmed to remove unnecessary and ineffective molding material that continues around the effective molding area (molded product part) at the same time as molding or after demolding. The amount of trimming waste is large, and the percentage of trimming waste may reach 50% or more due to the shape of the molded product, the material used, etc.

However, since the waste material is a composite of layers of different materials, it is almost impossible to recycle it as a raw material by remelting it or the like, and in most cases it is disposed of as is. Therefore, the utilization rate of materials is poor and costs are high, and it is also unsatisfactory from the viewpoints of industrial waste issues, resource conservation, etc. (b) for thermoforming;
When heating and softening a laminated flat plate, which is a raw material plate, it is important to note that the constituent layers of the laminated flat plate often have greatly different thermal properties, and that the thickness of the laminated plate is generally thicker as a result of lamination of each constituent layer. Due to the fact that each component layer softens slightly. A high degree of skill is required to properly soften the entire laminate while taking a sufficient amount of time, and the processing time is relatively long, resulting in poor efficiency.

The fourth objective of the present invention is to provide a rational manufacturing method for this type of laminated molded product free from the above-mentioned problems. In this method, a laminated molded product having a desired layer configuration is finally obtained by individually molding and laminating the layer materials for each constituent layer.

Hereinafter, a case in which a laminate molded product having a two-layer structure is obtained will be specifically explained in the order of the steps.

For convenience, the outer layer of the two-layer laminated molded product is called the first layer,
The inner layer is called the second layer. Both the first and second layer materials are thermoformable sheet or plate materials.

For example, the first layer material may be thermoplastic resin or thermoplastic rubber (
T. P. E) soft solid or foamed fleshy materials, woven fabrics, knitted fabrics, non-woven fabrics, carpets, etc. that have heat elongation. There are also products that actually have a composite layer structure, such as those laminated with a thin thermoplastic resin or rubber layer, cloth that can be stretched by heating, etc. as a skin layer on the outer surface of a thermoplastic resin or foamed material. example. In this case, it is treated as a single first layer material. The second layer material is, for example, a hard or semi-rigid solid or foamed material such as thermoplastic resin or rubber, or a thermoplastic material such as a foam material such as urethane, a felt-like fibrous material, a paper material, a glass fiber material, etc. It is a thermoformable cured plate impregnated with or mixed with a binder such as a resin liquid, a thermosetting resin liquid, or a resin powder such as polyethylene or polypropylene. A Molding of the first layer material (Fig. 1) Using a mold with a molding surface that corresponds to the external shape of the desired laminate molded product, the first layer material is subjected to vacuum forming, pressure forming, heat press forming, etc. Molding is carried out in a conventional manner using an appropriate thermoforming method.

The example in FIG. 1 shows the case of vacuum forming.

10 is a vacuum forming mold, 11 is the effective molding area of the mold,
12 is an extra surface area on the outer peripheral surface of the area, 13 is a number of vacuum suction holes opened in each part of the effective molding surface 11, 14 is a vacuum pump, and 1 is a vacuum molded area following the molding surface 11. The first layer of material, 15, indicates a sealing clamp that held the periphery of the material.

By carving a desired uneven pattern such as a grain pattern on the molding surface 11, the first layer material 1 has a solid fleshy texture or a dense foamed fleshy texture, or such a fleshy texture is laminated as a skin material layer. When the material 1 is molded, an uneven pattern corresponding to the uneven pattern on the molding surface can be clearly transferred and formed on the outer surface of the material at the same time as the material 1 is molded.

In addition, if the first layer material 1 is breathable, it is impossible or difficult to perform vacuum forming when it is as it is, such as breathable foamed fleshy material, cloth or carpet, or combination of cloth or carpet with breathable foamed fleshy material. Bonded materials, single-layer materials or bonded materials that have been physically or chemically treated to form numerous through holes for the purpose of sound absorption or design (for example, vinyl chloride sheet and polyurethane foam or polyethylene foam) Even if it is a bonding material), a thin heat-resistant airtight film such as a silicone rubber film with a high elongation rate is applied to the back side of the heat-softened material 1 (the side opposite to the side facing the molding surface 11). By applying the material 1 as a forming auxiliary material 1 and performing a vacuum or pressure forming operation on the material 1, the airtight membrane acts as a ventilation barrier layer for the material 1, and vacuum forming or pressure forming of the material 1 can be achieved without any trouble. .

After molding the material 1, the airtight film, which is a molding aid, is removed.
B Molding and lamination of the second layer material (Figs. 2 to 7) (1) The molded first layer material 1 is held as it is on the molding surface of the mold 10 without being demolded, and the molding material 1 is On top of mold 10
A heat-resistant rigid frame board having a planar external shape substantially the same as the planar external shape of the mold 10, and having a surface portion corresponding to the effective molding surface area 11 of the mold 10 as a hollowed out hole 161 having a shape substantially matching the external shape of the area 11. 16 is placed so that the frame plate 16 shields the non-effective molding material 11 surface on the outer peripheral surface of the effective molding material region of the molding material 1. (2) In the case of a molded body in which the ineffective molded portion is three-dimensional, the frame plate 16 is not a flat plate but a molded molded plate having irregularities.

Further, a second layer material 2 is placed thereon, and the periphery of the material 2 is pressed airtightly against the upper surface of the frame plate 16 with a clamp frame 17. (3) Air in the space S between the first layer material 1 and the second layer material 2 is evacuated to bring the space into a negative pressure state.

As this exhaust means, this example uses a frame plate 1 as shown in Figure 3.4.
6 is made of an air-permeable porous fleshy material (for example, a porous metal plate made by a metal spraying method), and putty or the like is applied to the top, bottom, and outer edges of the porous fleshy frame except for the inner edge 162 to form a blinding layer. 163, and an air suction cylindrical fitting 164 is attached to the outer peripheral surface of the frame plate 16 at one location or at appropriate intervals at several locations with tip openings communicating with the porous flesh of the frame plate 16. By connecting the vacuum vibrator 165 to the air suction state, the air in the space S is transferred from the inner circumferential end surface 162 of the frame plate 16 to the frame plate 16.
The suction is shown along the path of porous flesh → cylindrical metal fitting 164 → vibrator 165. Vacuum pipe 1
Since the mold 10 is vacuum molded in this example, the vacuum suction path 141 (FIG. 2) of the mold is branched, and the branched path is connected to the cylindrical metal fitting 164 as a vacuum vibrator 165. 166 is an on-off valve provided in the middle of the vacuum vibrator 165.

The frame plate 16 is made of a resin with good heat deformation resistance and has a porous wall, or is a solid wall with a through hole for air suction extending from the outer peripheral end surface of the frame to the inner peripheral end surface of the frame. etc. If the frame is made of resin, it is best to apply a heat-shielding paint to its outer surface. Due to the increase in negative pressure in the space S due to this evacuation, the second layer material 2 may be bent inward to the mold 10 depending on the degree of rigidity of the second layer material 2, but this is not a problem.

(4) The heating device 18 is positioned above the second layer material 2 to heat the material 2 as a whole.

As the material 2 is heated and softened, the material is drawn into the cavity of the mold 10 by the negative pressure in the space S, and finally the molded first layer material 1 held on the molding surface 11 of the mold 10 is heated and softened. It is closely bonded to the back surface of the effective molding material area following the shape of the back surface (dashed line in FIG. 2). When joining the first layer material 1 and the second layer material 2, if both materials 1 and 2 have good thermal fusion properties, the 2 sides of the heat-softened materials will stick to the back side of the material 1. By doing so, they can be well fused and integrated with each other without the intervention of an adhesive.

Even if materials 1 and 2 have poor thermal adhesion, a suitable adhesive such as a heat-activated adhesive (hot-melt adhesive) is coated on one or both of the joint surfaces of materials 1 and 2 in advance. Alternatively, in the case of an olefin resin, the two materials 1 and 2 can be firmly joined and integrated by performing a discharge activation treatment on the joining surfaces in advance. In addition, if it is desired to form a part in the effective molding area where the first layer material 1 and the second layer material 2 are not integrally joined, the first layer material 1 may be molded. A mold release agent 12 (FIG. 1) may be applied in advance to a required area on the back surface of the material 1.

In the case of deep drawing, the heating device 18 is also moved downward to follow the lower edge of the second layer material 2, which is drawn into the mold 10 as it is heated and softened, as shown in Figure 5. It is possible to take measures to uniformize the heat softening state of each part. The removal of air from the space S in item (3) above and the heating softening of the second layer material 2 in item (4) may be performed in parallel.

Alternatively, the air in the space S may be removed by covering the first molded layer material 1 on which the frame plate 16 is placed with the second layer material 2 which has been subjected to heat softening treatment as a whole in advance. If the second layer material 2 is heated and softened in a state where the air in the space S is removed and the space S is made into a substantially vacuum state as in the process of the above example, the material 2 on the space S side will be thermally insulated. There is an advantage that the heating efficiency of the material 2 is increased because of the state. Even if the second layer material 1 is breathable and cannot be air-formed or is difficult to form under pressure, it may be thin and stretchy, such as a silicone rubber film, as explained in the molding of the first layer material 1 in Section A above. The material can be vacuum-formed or pressure-formed by, for example, using a heat-resistant airtight membrane with a high heat-resistance ratio as a molding aid.

Vacuum forming of the second layer material 2 onto one side of the first layer material
During the bonding process, when the vacuum drawing of the second layer material 2 has progressed to a certain extent, a vacuum suction frame may be formed locally between the first layer material 1 and the second layer material 2 due to the molding shape, etc. Board 16
In the case where there is a risk of creating an independent sealed air retention space that does not communicate with the air, resulting in a portion where the second layer material 2 is not vacuum-formed and bonded to the first layer material 1 side, as shown in Fig. 6. It is preferable to heat soften and vacuum form the second layer material 2 in the following manner. That is, the first layer material 1 has already been molded, the molded product is held as it is on the molding surface, and the second layer material 2 is placed on the mold 10 on which the frame plate 16 is placed, and then the material is 2 is heated by a heat source element 191 such as a nichrome wire heater or steam vibrator on the top surface, and many on the bottom surface! Lower the heating plate 19 with the vacuum suction holes 192 opened so that the periphery of the material 2 is airtightly sandwiched between the upper surface of the frame plate 16 and the lower surface of the heating plate 19, and The upper surface of the material 2 is held in close contact with the entire surface by the vacuum suction force of each vacuum suction hole 192, and the material 2 is heated and softened.

Then, the heat-softened material 2 is held as it is on the lower surface of the heating plate 19 by vacuum suction, and the air in the space S between the first layer material 1 and the second layer material 2 is removed as much as possible. to bring the space S into a substantially vacuum state. Thereafter, the vacuum suction holding of the layer material 2 in the second heat-softened state on the lower surface of the heating plate 19 is released. Then, the material 2 is molded into mold 1 by the vacuum force of space S.
0, the first layer material 1 is instantly and strongly drawn inward.
The effective molding material area is tightly bonded to the entire back surface without creating any air pockets. The second layer material 2, which has been heated and softened in a separate process, may be adsorbed and kept warm by the heating plate 19, and then molded according to the above procedure.ノ The above heating plate 1
When the vacuum suction and holding of the second layer material 2 from the lower surface of the material 2 is released, if air or warm air is actively blown out from each vacuum suction hole 192 at the same time as the vacuum suction is released, the pressure forming force can be further applied to the material 2. This results in more effective shaping of the material 2.

In FIG. 6, 193 is a vacuum suction vibrator connected to the vacuum suction chamber of the heating plate 19, and the other end is connected to the vacuum suction path 141 of the vacuum mold 10 via the valve 19. Reference numeral 195 indicates an atmosphere release or pressurized air introduction vibe branched from the vacuum suction vibe 193, and 196 an opening/closing valve for the branch vibe.

FIG. 7 shows a second layer material 2 in which a foam material such as urethane, a felt-like fibrous material, a paper material, a glass fiber material, etc. is coated with a thermoplastic resin, a thermosetting resin liquid, a foamable resin sol such as vinyl chloride, etc. A shapeable hardenable plate impregnated with a binder component liquid of a desired concentration and squeezed appropriately, or a shapeable hardenable plate mixed with resin powder such as polyethylene or polypropylene as a binder component is used, and this is heated. This shows an example of molding using the breath method.

That is, the first layer material 1 has already been molded, the molded product is held as it is on the molding surface, and the second layer material 2 is heat-treated on top of the mold 10 on which the frame plate 16 is placed. The hardenable board is covered and its peripheral edge is pressed onto the upper surface of the frame board 16 with a clamp 17.

In this case, if necessary, the material 2 is pressed while adjusting the pressing force so that it can be molded by slipping. Next, the heated convex mold 20 for a press above the material 2 is lowered and the material 2 is pushed into the mold 10 to form the back surface shape against the back surface of the preferred molding material region of the first layer material 1. The second layer material 2 is then pressed and tightly bonded. 201 is a mold heating heating element embedded in the convex mold 20.

In the second layer material 2 that has been press-molded, the binder component resin is gelled by the heating for the above-mentioned molding, and becomes hardened by subsequent cooling.

Alternatively, it is thermally cured into a hardened state. In addition, the first layer material 1 and the second layer material 2 are bonded and integrated by using the binder component resin of the second layer material 2 as an adhesive, or by bonding both materials 1 and 2 in advance.
It is strengthened by an adhesive layer such as a heat-activated adhesive applied to one or both of the two joining surfaces. Second layer material 2
is non-breathable/difficult to breathe, the first and second layer materials 1
・The air in the space S between 2 is vented to prevent air pockets from forming. C Demolding and trimming of the molded product (Figures 8 to 10) (1) After sequentially molding and laminating the materials 1 and 2 of the second layer shown in Figure 1 above, the molded product is cooled to a predetermined demolding temperature. Remove from the mold.

In the demolded laminate molded product, the first and second layer materials 1 and 2 are integrally joined to each other in the effective molding material region, and the first and second layer materials in the ineffective molding material region around that region are joined together. Layer material part 1
1 and 12 are separated from each other with a frame plate 16 interposed therebetween (FIG. 8). (2) Remove the frame plate 16. If either of the layer materials 1 and 2 is soft, the frame plate 16 can be easily removed by turning over the frame plate surface covering portion of that layer. Double layer material 1
- If both of the frame plates 2 are hard, the frame plate 16 can be easily extracted and removed by configuring it into several types of parts as indicated by the dividing line a in Fig. 3. In order to prevent the layer materials 1 and 2 (11 and 21) from sticking to the surface of the frame plate 16, making it difficult to remove the frame plate 16, the frame plate 16 is It is best to apply a mold release agent such as silicone oil or silicone grease to the surface before use.

Alternatively, the frame board material may not be bonded to layer materials 1 and 2, or may have weak bonding properties, such as silicone rubber, fluororesin, polypropylene resin, or glass fiber mat material impregnated with such resins. do. (3) Trim and remove the ineffective molding material portions 11 and 21 around the outside of the effective molding material area of the molded product (FIG. 9).

The waste materials discharged by this trimming are in a form in which the constituent layer materials 11 and 21 are separated from each other.

Note that even if both materials 11 and 21 are connected in a partially adhesive state on the cut end surface side, they can be easily separated by pulling both material portions 1121. Therefore, by collecting the trimming waste material by sorting it into materials 11 and 21, if these materials 11 and 21 are made of a single material, they can be remelted to form the first layer material 1 or the second layer material. It can be effectively reused as a raw material for producing material 2. For example, even if the material 11 is a two-layer laminated material of a skin layer and a backing layer made of different resins, if the skin layer is thin and the backing layer is thick and the resin content ratios are greatly different, then both materials may be used. In many cases, there is no problem in melting them together and reusing them as backing layer materials.
For example, even if the material 11 is cloth or carpet, if the material is thermoplastic and essentially simple, it can be remelted and reused as a raw material. In addition, the ineffective molding material parts 11 and 21 are trimmed as shown in FIG. 10, with the part 21 being trimmed along the outer circumferential surface of the effective molding area of the molded product, and the part 11 being trimmed one or two times around it. By trimming the outer periphery of the molded product to a moderately large outer shape, and folding the extra extended material portion 1″1 back to the back side of the molded product, that is, to the free surface side of layer 2, and fixing it by means such as adhesive, the outer circumference of the molded product has a trimmed cut end surface of the material 1″1. It is also possible to easily obtain a product with a neatly finished edge that is concealed by one fold.

For the sake of convenience, the manufacturing of a laminate molded product having a substantially two-layer structure has been explained above as an example, but in the case of a laminate molded product having a three-layer structure or more, the second layer material 2 is used for the first layer material 1. In the same way as for forming and laminating, the frame plate is used to prevent the ineffective molding material areas from joining each other, and the constituent layer materials from the third layer onwards are sequentially formed and laminated to form the desired multi-layer structure. A laminated molded product is obtained.

As described above, in the production of a laminated molded product, the present invention uses each constituent layer material in the ineffective molding material region phase of each layer material. A method in which mutual bonding is prevented by using a frame plate, and the space between the constituent layer materials is vented using an air venting function provided in the frame plate, or the materials are sequentially formed and laminated while being vented. Therefore, it has the following major advantages, and the intended purpose can be easily achieved.

The waste materials discharged from the noise trimming process are those in which the constituent layer materials are separated from each other, or even if they are partially adhesively connected, they can be easily separated by pulling. By sorting and collecting the materials for each separation layer, they can be reused as raw materials for each constituent layer, reducing product costs, conserving resources, and reducing the problem of industrial waste.

Since the heat-softening treatment of the material for molding is performed for each individual layer material, the process is much easier than when heat-softening a thick composite plate made by laminating different constituent layer materials together in advance. It also takes less time and is efficient. (c) It is also possible to easily produce a material with an attractive edge finish as shown in FIG. 10.

2. Continuous molding is also possible by using long raw fabrics as materials for each constituent layer.

(e) The constituent layer materials in the effective molding material area are bonded well to each other without forming air pockets between them, and products without quality defects due to the presence of air pockets can be manufactured efficiently with high yield.

[Brief explanation of the drawing]

Figure 1 is a cross-sectional view of the mold after vacuum forming the first layer material, and Figure 2 shows the second layer material placed on top of the mold via a frame plate and heat treated. Figure 3 is a plan view of an example of a frame plate, Figure 4 is an enlarged cross-sectional view along the line ■-■ in Figure 3, and Figure 5 is a heating device following the drawing of material for deep drawing. Figure 6 is a cross-sectional view of the second layer material being heated and softened by suctioning and holding the material on the heating plate surface, and Figure 7 is a cross-sectional view of the second layer material being lowered by suction. Figure 8 is a cross-sectional view of the material being molded with a heat press, and the mold is removed.
An enlarged cross-sectional view of a part of the molded product before removing the frame plate, Figure 9 is an enlarged cross-sectional view of a part of the molded product showing a state in which unnecessary material parts have been trimmed, and Figure 10 is an enlarged cross-sectional view of a part of the molded product showing a state in which unnecessary material parts have been trimmed. An enlarged cross-sectional view of a part of the molded product that has been finished with an attractive edge finish.

Claims (1)

[Claims] 1 a Step of thermoforming the first constituent layer material 1 into a desired shape using a mold 10 such as vacuum forming, pressure forming, or hot press molding; b The molded first constituent layer; The material 1 is held as it is on the molding surface, and the first constituent layer material 1 is placed on top of it.
The second component layer material 2 is placed over the ineffective molding material region of the first component layer material 1 through the frame plate 16 that covers the free surface, and between the effective molding material region of the first component layer material 1 and the second component layer material 2. The air in the space S is vented by the venting function provided in the frame plate 16, or while the air is vented, the second constituent layer material 2 is formed using the already molded first constituent layer material 1 as a mold. A step of laminating and integrating the second constituent layer material 2 on the free surface of the effective molding material area of the first constituent layer material 1 by thermoforming, c. If there is a third or more constituent layer, the structure thereof. A step of sequentially laminating and integrating the constituent layer materials from the third layer on by repeating the same operation as the above step b for the layer materials, d demolding the laminate molded body and removing the ineffective molding material area of the molded body a step of removing the frame plate 16 interposed between the constituent layer materials, e.
A method for producing a laminated molded body, comprising the step of trimming and removing an ineffective molding material region of the molded body. 2. In step b, the space S is evacuated through the porous flesh of the frame plate 16 or through vent holes opened in the inner circumferential end surface of the frame plate 16. Method for manufacturing a laminate molded product. In step 3b, the second constituent layer material 2, which has been placed over the molded first constituent layer material 1 via the frame plate 16, is heated and softened for thermoforming treatment on the free surface of the material 2. A heating plate 19 having a vacuum suction and holding function is brought into contact with the material, and the material is suctioned and held on the entire surface of the heating plate, and the space S between the first and second constituent layer materials 1 and 2 is Claim 1, wherein the vacuum suction and holding of the heat-softened second component layer material to the heating plate surface is released in a state where the space S is made substantially vacuum by sufficiently exhausting the air. A method for producing a laminate molded product as described in . 4. The method for manufacturing a laminate molded body according to claim 3, which comprises releasing the vacuum suction and holding of the second constituent layer material 2 onto the heating platen surface, and subsequently blowing air out from the vacuum suction holes 19 onto the heating platen surface. . 5 The second constituent layer material 2 is a foam material such as urethane,
Thermoplastic resin liquid for felt-like fibrous materials, glass fiber materials, etc.
A rectangular curable plate impregnated with a binder component liquid of a desired concentration such as a thermosetting resin liquid or a foamable resin sol liquid such as vinyl chloride, and squeezed appropriately, or polyethylene as a binder component.
Claim 1, which is a rectangular curable plate mixed with resin powder such as polypropylene, which is laminated and integrated with a molded first constituent layer material by heat pressing or royal molding. The method for manufacturing the laminate molded product described above.