JPH0353096B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to an improved method and apparatus for producing a laminate that can be used as an interior material for automobile doors and the like.

[Conventional technology]

BACKGROUND ART Conventionally, laminates have been widely used as interior materials for automobile doors, in which a cushioning member (skin material) made of a member such as a nonwoven fabric is tightly adhered to a base material called hardboard.

JP-A-53-63461 describes an injection molding method and apparatus for producing this laminate.

To explain the molding method and apparatus according to the reference numerals listed in the publication, the web 3 is supplied from a supply roll at the upper part of an injection mold.

The end portion 6 of this web 3 is gripped by a clamp 7. Due to the weight of the clamp 7, the web 3 is attached to the core 4
and cavity 5 and hangs down vertically. This puts the web 3 in a tensioned state. A second clamp 10 grips the upper part of the web 3. The clamp 7 is energized by the electromagnet 19 in the dead weight 14,
Combined with the dead weight 14, the load applied to the web 3 increases. Move the core 4 of the mold. Clamp 7 and dead weight 14 move upwards, thereby controlling the tension in web 3.

The mold is closed and the plastic material is injected into the web 3 and cooled. After that, the electromagnet 19 is demagnetized to separate the dead weights 14 and 21 from the clamp 7,
The clamp 7 is removed from the web end 6, the elements 10a, 10b of the clamp 10 are placed in the manganese, ready for engagement with the upper part of the next web 3, the web is cut along a line passing through point 26, and the process described above is repeated. This is what happens when you repeat .

However, in this method and apparatus, as described above, after the completion of molding, the clamp 10 is
It is necessary to return each element 10a, 10b to manganese, and in order to clamp it, it is necessary to prepare a large number of clamp elements as described above, and the gap between the mold core and the cavity is separated by the weight of the clamp 7. Since this is a method in which the web 3 is hung down, it has drawbacks such as the inability to determine its position.

[Problem that the invention seeks to solve]

Against this background, an object of the present invention is to provide a novel method for manufacturing a laminate used as an interior material for automobile doors, and an apparatus used therefor.

Another object of the present invention is to provide a method for manufacturing a laminate and an apparatus for manufacturing the same, which do not have the drawbacks of the prior art.

Other objects and novel features of the present invention will become apparent from the entire description of this specification and the accompanying drawings.

[Means for solving problems]

The present invention involves holding a member such as a nonwoven fabric under tension between the core and the cavity of an injection molding mold having a core and a cavity, and injecting an injection molding material between the member and the injection molding material. When manufacturing a laminate comprising a layer, the end of the member is gripped by a movable clamp that is movable by the operation of a cylinder, and the end of the member is passed between the core and the cavity while being gripped, and the injection molding A method for manufacturing a laminate, comprising the steps of: moving to a fixed clamp at the bottom of the mold; grasping the end portion with the fixed clamp; and applying upward tension to the member with a nip roll; and a core and a cavity. A laminate comprising the member and the injection molding material layer by holding a member such as a nonwoven fabric under tension between the core and the cavity of the injection mold and injecting the injection molding material. In an apparatus for manufacturing products, a movable clamp grips the end of a supplied member by actuation of a cylinder, passes the supplied member between the core of the mold and the cavity, and moves it to a fixed clamp position described later; At the lower part of the mold, a fixed clamp is provided with means for grasping the end portion moved by the movable clamp, and a nip roll capable of applying upward tension to the member by rotating the fixed clamp in the opposite direction. The present invention is characterized by a laminate manufacturing apparatus.

〔Example〕

Next, a preferred example of a method for manufacturing a laminate and an apparatus for manufacturing the same according to the present invention will be described based on drawings showing examples thereof.

FIG. 1 is a side view showing a part of the manufacturing apparatus according to the present invention in cross section.

In FIG. 1, reference numeral 1 denotes a supply roll that supplies a member (hereinafter referred to as skin material) 2 such as a nonwoven fabric. The skin material 2 is passed between the rolls 5A and 5B of the nip roll 4 via the guide roll 3, and then between the fixed part 7 and the movable part 8 of the movable clamp 6.

The movable part 8 is configured to move from side to side by the operation of an air cylinder 9 of the movable clamp 6, and by the operation of this air cylinder 9, the movable part 8 is brought into a closed state toward the fixed part 7. Grasp the end 10 of the skin material 2.

At this time, the skin material 2
The end portion 10 is made to protrude by, for example, 30 to 100 mm. In addition, FIG. 1 shows a fixing clamp 1, which will be described later, for the end portion 10.
The state in which it has moved to the 5th position is shown.

The pressure of the air cylinder 9 is, for example, 3 to 7.
Kg/ ^cm2 . The gripping force on the skin material is, for example, 20 to 44 kg.

The movable clamp 6 has an air cylinder 11 at its upper part for lowering the clamp 6.
Attach. By the operation of the air cylinder 11,
The movable clamp 6 is lowered through between the cavity 13 and the core 14 of the injection mold 12 while gripping the skin material 2.

As mentioned above, the end portion 10 of the skin material 2 protrudes from the movable clamp 6. Using this as a grip, the air cylinder 16 of the fixed clamp 15 installed at the bottom of the injection mold 12 is activated, the movable part 17 is brought into the closed state toward the fixed part 18, and the fixed clamp 15 is used to close the skin material 2. Grasp the end 10
grab. At this time, the pressure of the air cylinder 16 is, for example, 3 to 7 kg/cm ² , and the skin material gripping force is, for example, 38 kg/cm 2 .
~88Kg.

After the fixed clamp 15 grips the skin material, the movable part 8 of the movable clamp 6 is opened,
Release the skin material 2.

Next, the movable clamp 6 is raised by actuation of the air cylinder 11 and returned to its home position.

The air pressure in the air cylinder 11 may be the same as in the case of descending described above, but the upward force is due to the weight of the movable clamp 6 (for example, about 20 kg) and the weight of the air cylinder 11 (for example, about 15 kg). For example, it is 3 to 53 kg.

Next, in order to apply tension to the skin material 2, the roll 5A of the nip roll 4 is pressed against the roll 5B side by operating the air cylinder 19.

The nip roll 4 is rotated (reversely rotated) by a torque motor 20 in a manner to pull up the skin material 2.
Reverse rotation is performed for the set time. Furthermore, since it is possible to change the setting time for reverse rotation, the tension setting can be changed. After the set time, the reversely rotating nip roll 4 is stopped and locked. Nituprol 4
The presser foot force is constant.

At this time, the skin material 2 held by the nip roll 4 and the fixing clamp 15 is under a constant tension in the width direction.

Next, in the injection mold 12, the core 14 is moved toward the fixed die plate 21 of the cavity 13.
The moving die plate 22 is advanced. and,
Press the skin material 2 onto the core 14 and
Match (mold clamp) and start injection molding.
During this time, the tension remains constant.

If it is necessary to control the tension depending on the type of skin material 2, for example, the reverse rotation time of the nip roll 4 and the pressing force of the nip roll 4 are controlled.

When the program sequence receives a mold clamping end signal by the injection molding device 12, the movable clamp 6
The air cylinder 9 operates, the movable part 8 enters the closed state, and grips the skin material 2. Moreover, the movable part 17 of the fixed clamp 15 is in an open state, and the skin material 2
Release the terminal unit 10.

Next, the cutter 23 hot-cuts. That is, the heater cutter part 24 of the cutter 23 is heated to a temperature of, for example, 200 to 300°C, and the skin material 2 is heated by operating the air cylinder 25.
Apply the heater cutter part 24 to the hole and hot cut. After cutting, the heater cutter section 24 returns to its original position. The injection molded product is cooled until its shape becomes stable.

Thereafter, the mold is opened, and the laminate (not shown) is removed from the mold 12 with an ejector pin (not shown) and dropped into a product box.

The mold core side 14 is completely opened, and the program sequence receives a mold opening end signal.The skin material 2 is fed out by forward rotation of the nip roll 4, and after being fed out to the gripping length, the skin material 2 is removed by the movable clamp 6. , and automatically performs the same operations as described above, making continuous processing possible. Furthermore, the first
In the figure, 26 is a fixed clamp stabilizer, 27 is a mounting jig, 28 is a chain belt, 29 is a diver,
30 indicates a cover.

Here, when comparing the manufacturing apparatus and manufacturing method according to the present invention with the conventional example described above, there are the following differences.

(1) According to the conventional example, members such as the web are hung down by the weight of the clamp 7, whereas in the present invention, the movable part that is operated by the operation of the air cylinder is closed to the fixed part side. A movable clamp equipped with such a means, which can grasp the member and move (lower) it by actuation of an air cylinder, grasps the member and moves it to a fixed clamp position. .

(2) According to the conventional example, loads such as the clamp 7 and the dead weight 14 are applied to the web to apply downward tension, whereas in the present invention,
After the movable clamp moves to the fixed clamp position,
After the fixed clamp grabs the grip of the member, it releases its grip and returns to its original position. To apply tension to the member, the nip roll is rotated in the opposite direction, and the nip roll and the fixed clamp are connected. The necessary and sufficiently controlled tension is applied in the upward direction between the two ends. In the conventional example, the height of the dead weight 14 with the clamp 7 fixed is controlled by tension by providing play between the bolt 15 and the load 21, but in the present invention, the tension is controlled by the reverse rotation time of the nip roll. We are making adjustments by changing the

(3) According to the conventional example, there is no specific description of the method for cutting the part after cooling the injection molding.
In the present invention, the cutter is provided with a heater cutter portion to hot-cut the member. When hot-cutting, the grip of the fixed clamp is released, the moving clamp grips the member again, and hot-cutting is performed.

(4) According to the conventional method, after the molding is completed, the clamp is returned to the magazine and the clamp is taken out from the manganese to grasp the supplied web again. In other words, the manganese is taken in and out one by one. In contrast, in the present invention, the movable clamp and the stationary clamp each have different functions as described above, and can be fixed at fixed vertical positions of the injection mold.

Next, the injection molding material constituting the member (skin material) and base material used in the present invention will be explained.

A Skin Material Examples of the skin material used in the present invention include nonwoven fabrics, knitted fabrics, woven fabrics, synthetic leathers, natural leathers, foams, sheets, and paper. An appropriate combination of these may be used.

Non-woven, knitted and woven fabrics include natural fibers such as cotton, hemp, wood fibers (natural pulp), silk and wool, as well as glass, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, fluorine-containing polymers (e.g. They are manufactured from synthetic fibers such as vinylidene, polytetrafluoroethylene), nylon (polyamide nylon), polyacrylonitrile, acetalized polyvinyl alcohol, polyurethane, carbon, and polyester (polyethylene terephthalate). In addition, synthetic leather is made of polyvinyl chloride,
It is manufactured from polymers such as acetalized polyvinyl alcohol and polyurethane. Furthermore, natural leather is the leather of animals such as sheep, horses, cows, and pigs. Further, foamed products are obtained by foaming polyurethane, polyethylene, polystyrene, and polyurethane, and the foaming ratio thereof is usually 40 times or less. Furthermore, the sheets are made, for example, from polyethylene, polypropylene, polyester, polyvinyl chloride, polystyrene, acrylonitrile-butadiene-styrene terpolymer (ABC), polyacrylonitrile and polyamide. Moreover, in addition to the paper commonly used as paper, synthetic paper can also be used.

The thickness of these skin materials is generally 0.1 to 10 mm.
, and a thickness of 0.5 to 6 mm is particularly desirable.

(B) Base material Examples of materials used as the base material in the present invention include olefin polymers, specific examples of which include ethylene homopolymers, propylene homopolymers, and random or block polymers of ethylene and propylene. Examples include copolymers and random or block copolymers of ethylene and/or propylene with other α-olefins having at most 12 carbon atoms (copolymerization ratio of α-olefins is at most 20% by weight). Melt index (according to JIS K-6760, measured at a temperature of 190°C and load of 2.16 kg, hereinafter referred to as "MI") or melt flow index (according to JIS K-6758) of these olefin polymers. , measured at a temperature of 230°C and a load of 2.16 kg, hereinafter referred to as "MFI") is preferably 0.01 to 100 g/10 minutes, particularly preferably 0.01 to 80 g/10 minutes. If an olefinic polymer with an MI or MFI of less than 0.001 g/10 min is used, not only will the moldability of the resulting composition be poor, but also the melt-kneading properties described below will be poor, making it difficult to form a homogeneous composition. difficult to obtain. On the other hand, if an olefin polymer with a weight exceeding 100 g/10 minutes is used, the melt-kneading properties and moldability are excellent, but the mechanical properties of the resulting molded product are poor. It also has a low density (0.900
g/cm ² ) to high density (0.980/cm ² ) ethylene homopolymers, propylene homopolymers, random or block copolymers of ethylene and propylene, and random or block copolymers of ethylene or propylene with other α-olefins. Block copolymers are preferred.

Furthermore, the present invention also includes modified polyolefins obtained by graft polymerizing these olefin polymers with a compound having at least one double bond (for example, an unsaturated carboxylic acid or a vinyl silane compound).

These olefin polymers and modified polyolefins may be used alone or in combination of two or more. Two or more of these olefin polymers and modified polyolefins may be used as a resin blend in any proportion.

The methods for producing these olefin polymers and modified polyolefins are well known.

Further, the base material in the present invention may be composed only of the above-mentioned olefinic polymer, but the olefinic polymer may be further supplemented with inorganic fillers (such as talc, glass fiber, etc.) commonly used in the field of synthetic resins or rubber. ) may also be blended.
In this case, the composition ratio of inorganic filler is usually 80% by weight.
or less, particularly preferably 75% by weight or less.

〔Effect of the invention〕

(1) According to the present invention, instead of hanging down members such as webs due to the weight of the clamp as in the conventional example, by closing the movable part operated by the operation of the air cylinder toward the fixed part,
Since the movable clamp is configured to grasp the member and is equipped with such a means and can be moved (lowered) by the operation of an air cylinder, the member is grasped and moved to the fixed clamp position. can be placed in position.

(2) According to the conventional example, there is a complication such as having to take the clamp in and out of the manganese before and after the completion of molding, but in the present invention, the movable clamp is moved up and down by the operation of an air cylinder. That's fine.

The movable clamp of the present invention moves a member to a fixed clamp, and after gripping the member with the fixed clamp, rises and returns to the normal position. This operation is repeatable, and the movement of one movement is repeated. Just prepare a clamp. The movable clamp and the fixed clamp each have different functions and can be fixed at fixed positions above and below the injection mold, so they can be easily attached to many types of injection molding equipment.

(3) According to the present invention, since a hot cut is used when cutting a member, the member can be easily and reliably cut.

(4) According to the present invention, the tension of the member can be easily controlled by adjusting the variation in the reverse rotation time of the nip rolls, the pressing force of the nip rolls, and the like.

[Brief explanation of drawings]

FIG. 1 is a partially sectional side view of the device of the present invention. 1... Supply roll, 2... Member (skin material), 4
...Nitsprol, 6...Movement clamp, 10...
...Member end, 11...Air cylinder, 12...
Injection mold, 13... Cavity, 14... Core, 15... Fixed clamp, 23... Cutter,
24... Heater cutter part.

Claims (1)

[Claims] 1. A member such as a non-woven fabric is held under tension between the core and the cavity of an injection mold having a core and a cavity, and an injection molding material is injected into the member. When manufacturing a laminate having the injection molding material layer, the end of the member is gripped by a movable clamp that is movable by actuation of a cylinder, and the end of the member is passed between the core and the cavity while being gripped, A method for producing a laminate, comprising the steps of moving to a fixed clamp at the bottom of the injection mold, grasping the end portion with the fixed clamp, and applying tension upward to the member with a nip roll. 2. A member such as a nonwoven fabric is held under tension between the core and the cavity of an injection mold having a core and a cavity, and the injection molding material is injected to form the member and the injection molding material layer. In an apparatus for manufacturing a laminate having a cylinder, the supplied member is gripped by the end thereof and passed between the core of the mold and the cavity, and moved to a fixed clamping position as described later. A movable clamp, a fixed clamp provided with a means for grasping the end portion moved by the movable clamp at the lower part of the mold, and a nip roll capable of applying upward tension to the member by reverse rotation thereof. A laminate manufacturing device comprising: