JPH091572A - Manufacture of laminate - Google Patents

Abstract

PURPOSE: To provide an apparatus for manufacturing a not peeling laminate of a base material and a skin material during a manufacturing step in the apparatus capable of covering the outer periphery of the base material and the end face of an opening by winding the extended part of the skin material. CONSTITUTION: A laminate is molded by pressing a molten resin 11 melt to become a base material and a skin material 12 between both molds 40 and 41. Resin flow preventive members 44, 45 are energized in the direction of the upper mold 41 by springs 51, 52, brought into contact with the mold 41 via the material 12 in the pressing step of both the molds 40, 41, and at the step of separating the molds 40, 41 after the pressing is finished, they are held at the position at the time of completing the pressing by locking members 46, 47. The material 12 is cut by cutters 44a, 45a during the pressing step, and the extensions covering the end faces of the base material are formed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for manufacturing a laminate used for a vehicle door trim, a vehicle interior material, an indoor interior material, a vehicle seat exterior material, and the like.

[0002]

2. Description of the Related Art As a laminate used for the above-mentioned applications, there is known one in which a base material made of a resin material molded into a predetermined shape is coated with a resin layer. An example of such a laminated body is an automobile door trim in which a sheet-shaped skin material is adhered to a resin base material formed in a door trim shape with an adhesive. Depending on the type of the door trim, a pocket or a There is an opening where you can attach accessories such as speakers.

In order to manufacture a door trim having such a structure, first, as shown in FIG. 13 (a), a base material 91 having a predetermined shape is set on a lower mold 100 of a vacuum forming mold, and the surface thereof is set. A sheet-shaped skin material 92 having a predetermined design pattern is formed on the base material 91 and pressed between the upper mold 101 and the lower mold 100 to form a base material with an adhesive. The material 91 and the skin material 92 are bonded and integrated,
The bonded body shown in FIG. 13B is formed. After the two members 91 and 92 have been integrated in this way, as shown in FIG. 13 (c), the outer periphery of the skin material 92 is cut so as to form a protruding portion 92a slightly protruding from the base material 91. Further, the base material 91 and the skin material 92 are cut at the same time so that the opening A for assembling the pocket is formed.

Subsequently, as shown in FIG. 13 (d), the end surface 91a of the base material 91 is rolled up by the protruding portion 92a of the outer periphery of the skin material 92 to be adhered.
The end surface 91b of the opening A is covered with another member such as the garnish 93 so as not to be exposed. In this way, the door trim is formed so that the end portion of the skin material 92 and the end surfaces 91a and 91b of the base material 91 cannot be seen from the outside.

Alternatively, as shown in FIG. 14 (a), the opening portion A is first formed in a state where the base material 91 is a single body, and then the base material 91 is placed in a lower mold as shown in FIG. 14 (b). 100, and a skin material 92 similar to the above is placed on the base material 91 and pressed between the upper mold 101 and the lower mold 100 to integrally bond the base material 91 and the skin material 92. Figure 1
A joined body as shown in FIG. 4 (c) is formed, and the outer peripheral portion of the skin material 92 and the opening A are protruding portions 92a, 92b.
To be cut off. Then, as shown in FIG. 14D, the end faces 91a, 91 of the outer periphery of the base material 91 and the inner periphery of the opening A are formed.
The protruding portions 92a and 92b of the skin material 92 are wound around and adhered to b, so that the ends of the skin material 92 and the base material 9 are adhered.
The door trim is formed so that the end faces 91a and 91b of the first unit are not visible from the outside.

[0006]

In the conventional door trim manufacturing method described above, the base material 91 which is integrally bonded to the skin material 92 must be formed in advance in the shape of the door trim. Separate equipment and steps for molding 91 are required. Further, in order to perform the peripheral edge processing, the protruding portion 92 of the skin material 92 is
A step of forming a to an appropriate length, and a step of bonding the protruding portion 92a so as to cover the end surface 91a of the base material 91 are required. Further, in order to form the opening A for assembling the pocket of the door trim, the step of cutting the skin material 92 and the base material 91, the step of fitting the garnish 93,
Alternatively, a step of forming the protruding portion 92b similar to the processing of the end portion of the outer periphery and the end surface 91 of the protruding portion 92b.
There is also a problem in that a step of performing an adhesive treatment so as to cover b is required to be performed, and a series of manufacturing devices and a number of manufacturing steps at the time of manufacturing a door trim are increased and are complicated.

[0007]

SUMMARY OF THE INVENTION Therefore, the present invention has been made to solve the above-mentioned problems, and the base material and the skin material can be integrated without preforming the base material into a shape such as a door trim in advance. An object of the present invention is to provide an apparatus for manufacturing a laminated body such as a door trim capable of covering the outer periphery of a base material or the end surface of an opening by winding a protruding portion of a skin material.

[0008]

The apparatus for producing a laminate of the present invention, which is configured to achieve the above-mentioned object, comprises a base material side molding die provided with a molding surface conforming to the shape of the back surface of the base material. And a skin material side molding die provided with a molding surface conforming to the shape of the surface of the skin material, and a supply means for supplying the molten resin material serving as the base material between the both molding dies. By molding the mold and molding the skin material and the molten resin material supplied to the back surface side of the skin material between the two molding dies and curing the molten resin material, one of the base materials is formed. An apparatus for producing a laminate in which a side surface is entirely covered with the skin material and an end surface of the base material can be covered by winding a protruding portion of the skin material, the feature being the base material side molding. Mounted on the molding surface of the mold so that it can move back and forth toward the molding mold on the surface material side. A resin flow blocking member that abuts a predetermined portion of the skin material to prevent the molten resin-based material from flowing to the predetermined portion during polymerization of both molds, and adjusts the advance / retreat position of the resin flow blocking member. The position adjusting means and the resin flow-preventing member abut on the skin material at the predetermined position from the middle of the polymerization of the both molds in the polymerization process of the both molds to the complete polymerization of the both molds. And in the separation process of the two molds after the two molds are completely polymerized, the skin material and the molten resin-based material are in a position where they are maintained in the shape at the time of polymerization of both molds. And a control means for controlling the position adjusting means so that the resin flow blocking member is held.

In the first embodiment of the laminated body manufacturing apparatus thus constructed, the first drive means connected to the resin flow blocking member is used as the position adjusting means.
Moreover, a first control means for controlling the first drive means can be adopted as the control means.

In the second embodiment of the laminated body manufacturing apparatus configured as described above, a member biased toward the skin material side forming die is adopted as the resin flow blocking member, and A locking member capable of holding the resin flow blocking member at the position where the two molds are superposed by locking the position adjusting means against the biasing force of the resin flow blocking member and locking the resin flow blocking member. A second drive means for driving the stopper member, and further, as the control means, in the polymerization process of the both molds, the locking is performed from the middle of the molding of the both molds until the two molds are completely polymerized. When the resin flow blocking member is unlocked by the member and the molding dies are completely polymerized between the molding dies, the resin flow blocking member is positioned at the time of polymerization of the molding dies. To keep the above The controlling said second drive means so as to perform locking of the resin flow blocking member by member 2
Control means may be employed.

Further, in the third embodiment of the laminated body manufacturing apparatus configured as described above, a member biased toward the skin material side molding die is adopted as the resin flow blocking member, and A pressing member for mounting the position adjusting means at a position facing the resin flow blocking member on the molding surface of the skin material side molding die so as to be able to move forward and backward toward the base material side molding die and for pressing the resin flow blocking member. A third driving means for moving the pressing member forward and backward, and further as the control means, in the polymerization process of the both molds, from the middle of the molding of the both molds until the both molds are completely polymerized. In the separation process of the two molds after releasing the pressing of the resin flow blocking member by the above and completely polymerizing the two molds, the skin material and the molten resin-based material are both molded. Wherein by the pressing member to retain the resin flow blocking member to the position to be maintained in the polymerization at a shape so as to perform pressing of the resin flow blocking member 3
Third control means for controlling the driving means can be adopted.

In the laminated body manufacturing apparatus configured as described above, the flow of the molten resin material is applied to at least one of the resin flow blocking member and the skin material side molding die facing the resin flow blocking member. Is cut off and the molten resin-based material is cured, and then the skin material is cut at the time of polymerization of both the molds at a position apart from the end surface of the base material in the extension direction of the base material by a predetermined distance. It is preferable that a cutting portion is provided so that the protruding portion of the skin material for coating the end surface of the base material can be formed simultaneously with the polymerization of both molds.

[0013]

When a laminated body is manufactured by using the laminated body manufacturing apparatus of the present invention having the above-described structure, first, the skin material set between both molds and the skin material Both molds are brought close to each other in order to press the molten resin material as the base material supplied by the supply means on the back surface side. During the process of bringing the two molds close to each other until the two molds are completely polymerized, the control means controls the position adjusting means to cover the resin flow blocking member assembled on the molding surface of the base material mold with the skin. The material is brought into contact with a predetermined portion of the material so that the molten resin material does not flow to the predetermined portion. Therefore, if the resin flow blocking member that contacts the skin material is not provided in this way, the molten resin-based material also flows to a predetermined portion of the skin material during the polymerization step, and the skin material at the predetermined location A burr made of a resin-based material that forms the base material is formed on the back surface of the base material. However, in the present invention, since the resin flow-preventing member is provided, the molten resin-based material does not flow to a predetermined location. No burr is formed. In this way, the molten resin-based material is spread between the two molding dies over the entire surface of the skin material excluding predetermined portions to form a laminate.

In the process of separating the two molding dies after the laminated body is molded as described above, the control means controls the position adjusting means to be the same as when the two molding dies overlap the resin flow inhibiting member. The position is maintained so that the skin material and the molten resin material are maintained in a positional relationship. Therefore, when the resin flow blocking member is not held in the position for maintaining the skin material and the molten resin material in the same positional relationship as when the two molds were polymerized, that is, the resin flow blocking member was used to If the resin flow prevention member pushes through the skin material at a predetermined position when it penetrates and protrudes, the skin material and the base material may be peeled off, but in the present invention, the skin material and the molten resin system are used. Since the resin flow inhibiting member is held at a position where the material does not prevent the positional relationship between the two molds from being maintained during polymerization, peeling between the skin material and the base material does not occur.

The laminated body thus manufactured is then subjected to a step of cutting a predetermined portion of the skin material to form a protruding portion,
By performing the step of winding the protruding portion and covering the end surface of the base material, a post-treatment is performed so that the end portion of the skin material does not protrude and the end surface of the base material is not exposed.

As described above, according to the manufacturing apparatus of the present invention, the base material and the skin material can be integrated without preforming the base material, and the outer periphery of the base material and the end surface of the opening are covered with the skin material. It is possible to easily manufacture a laminated body that can be coated by winding the protruding portion.

In the first aspect of the present invention, the position of the resin flow blocking member is adjusted by controlling the first drive means connected to the resin flow blocking member by the first control means.

In the second aspect of the present invention, a member urged toward the molding material side molding die is used as the resin flow blocking member, and the position of the resin flow blocking member is adjusted by the member. Is performed by using a locking member that locks the resin flow blocking member against the urging force of the resin. This locking member is driven by the second drive means under the control of the second control means, so that during the polymerization process of both molds, the resin is kept from the middle of both molds being polymerized until both molds are completely polymerized. The resin flow blocking member is held at the position where both molds are polymerized so that the locking with the flow blocking member is released, and in the separation process of both molds after the two molds are completely polymerized. Therefore, it is positioned so as to engage with the resin flow blocking member.

In the third aspect of the present invention, a member urged toward the skin material side molding die is adopted as the resin flow prevention member, and the position adjustment of the resin flow prevention member is performed on the skin material side molding die. This is performed by pressing the resin flow blocking member with a pressing member that is assembled in a position facing the resin flow blocking member on the molding surface so as to be able to move forward and backward toward the base material side mold. This pressing member advances and retreats by being driven by the third drive means under the control of the third control means, and during the polymerization process of both molds, from the middle of both molds to the complete polymerization of both molds. Is so as to release the pressing of the resin flow blocking member, and in the separation process of the two molds after the two molds are completely polymerized, the skin material and the molten resin-based material are The resin flow blocking member is positioned so as to press the resin flow blocking member so as to hold the resin flow blocking member in a position where the shape is maintained.

In the laminated body manufacturing apparatus thus constructed, the flow of the molten resin material is blocked by at least one of the resin flow blocking member and the skin material side mold facing the resin flow blocking member. After the molten resin material is cured, a cutting portion is provided to cut the skin material at the time of polymerization of both molds at a position apart from the end surface of the base material in the extension direction of the base material by a predetermined distance. If it is applied, it is possible to form the protruding portion of the skin material for coating the end surface of the base material at the same time as polymerization of both molds, and post-treatment (treatment to cover the end surface of the base material by rolling in the protruding portion of the skin material ) Can be further simplified.

[0021]

EXAMPLES As examples of the laminated body manufacturing apparatus of the present invention, laminated body manufacturing apparatuses (first to third embodiments) capable of manufacturing a vehicle door trim by a post-treatment are adopted. The device will be described with reference to the drawings.

The laminated body manufactured by the manufacturing apparatus of this embodiment is a laminated body 10a for manufacturing an automobile door trim 10 as shown in FIGS. 1 and 2. The door trim 10 is composed of a polypropylene resin base material 11 formed in the shape of a door trim, and a polypropylene resin skin material 12 which covers the front surface of the base material 11 entirely. A part of the skin material 12 is decorated with an ornament 13. This door trim 10
There is an opening 10h at the position where the back part of the pocket penetrates.
Are perforated.

A manufacturing apparatus of the first embodiment used for manufacturing the laminated body 10a for manufacturing a door trim having the above-described structure is shown in FIGS. 3 to 5, and the apparatus is the same as that of the back surface of the door trim. A lower die 20 (corresponding to the base material side molding die of the present invention) having a molding surface 20a conforming to the shape, and an upper die 21 (having a molding surface 21a conforming to the shape of the surface of the door trim) It corresponds to the skin material side molding die of the invention.)
And a pouring device 22 (corresponding to the supplying means of the present invention) for supplying the molten resin 11melt as the base material to the molding surface 20a through the resin passage 20b formed inside the lower mold 20. The resin passage 20b is surrounded by the passage 20
The heater 23 is arranged so that the molten resin 11melt passing through the inside of b is not cooled and hardened.

Resin flow blocking members 24 and 25 are attached to the outer periphery of the molding surface 20a of the lower mold 20 and the respective portions corresponding to the openings for mounting the pockets so as to be able to advance and retract toward the upper mold 21. . These resin flow blocking members 24 and 25 are connected to the interlocking member 28 via connecting rods 26 and 27, respectively, and the drive mechanism (29:
The advance / retreat position is changed by the operation (corresponding to the first driving means of the present invention). Then, the operation of the drive mechanism 29, the upper mold 21, the injection device 22, and the supply mechanism (not shown) for the skin material 12 is controlled by the control circuit (30: corresponding to the first control means of the present invention). It should be noted that, as will be described in detail later, on the upper surfaces of the resin flow blocking members 24 and 25, the skin material 12 is cut when the molding dies 20 and 21 are polymerized, and the end surfaces 11a and 11b of the base material 11 are cut. Cutting portion 2 for forming protruding portions 12a, 12b for covering
4a and 25a are provided.

In manufacturing the laminated body 10a for manufacturing a door trim by using the manufacturing apparatus of the first embodiment, first, the temperature of both molds 20 and 21 is maintained at about 50 to 60 ° C., and the control circuit 30 is used. Drives the drive mechanism 29, and as shown in FIG.
Of the polypropylene resin in a sheet shape between the two molding dies 20, 21 by driving the skin material supply mechanism (not shown) sufficiently.
Is further provided, and the injection device 22 is controlled to supply the polypropylene resin 11melt in a molten state (180 ° C. to 200 ° C.) to the molding surface 20 a of the lower mold 20.

Next, the control circuit 30 controls the upper mold 21 to approach the lower mold 20, and the resin flow blocking members 24, 25.
Is brought into contact with the molding surface 21a of the upper mold 21 through the skin material 12. In this contact state, the cutting portions 24a and 25a provided on the upper surface of the resin flow blocking member 24 cut the skin material 12. Subsequently, the control circuit 30 causes the upper die 21 and the drive mechanism 29 to
By controlling the upper mold 21 and the resin flow blocking member 2
4, 25 are integrally lowered, and the molten polypropylene resin 11melt is spread between the lower mold 20 and the entire back surface of the skin material 12. At this time, the respective flows of the molten polypropylene resin 11melt toward the outer peripheral portion of the door trim and the opening portion 10h for mounting the pocket are changed by the resin flow blocking member 2
Completely blocked by 4,25. Then, as shown in FIG. 4, until the upper mold 21 is completely polymerized with the lower mold 20, the upper mold 2
When the resin flow blocking members 24 and 25 are simultaneously in contact with 1 and descended, the molten polypropylene resin 1 spread out.
1melt is welded to the polypropylene resin of the skin material 12 and cured as it is to form a laminated body 10a for manufacturing the door trim 10.

In this way, the resin flow blocking member 24,
If 25 is not provided, the molten polypropylene resin 11melt flows over the molding surface 20a of the lower mold 20 to the outer peripheral portion of the door trim 10 and the opening 10h during the polymerization process, and between the skin material 12 and the lower mold 20. Burrs made of polypropylene resin forming the base material 11 are formed, but since the apparatus of the first embodiment is provided with the resin flow blocking members 24 and 25, the molten polypropylene resin 11melt forms an outer peripheral portion and an opening 10h. No burr is formed and no such burr is formed. Further, since the resin flow blocking members 24 and 25 of the manufacturing apparatus of the first embodiment are provided with the cut portions 24a and 25a, the resin flow blocking members 24 and 25 are formed on the skin material 1.
When the upper mold 21 is abutted through the cutting part 24a,
The protrusion portion 25 cuts the skin material 12 and thus easily covers the end surfaces 11a and 11b of the base material 11.
a and 12b can be formed. Thus, it is not necessary to perform the molding step of the base material which is indispensable in the conventional manufacturing apparatus, and the outer peripheral end surface 11a of the base material and the end surface 11b of the opening are bonded to the conventional base material with the skin material. A step of cutting the base material and the skin material, which are necessary in the integrated manufacturing method (see FIG. 13), to form an opening, and cutting the outer peripheral edge of the skin material so as to slightly protrude from the base material (FIG. 13 (b)), and a garnish is attached to cover the end surfaces of the base material and the skin material of the door trim opening, or the end portion of the base material at the protruding portion of the skin material to cover the outer peripheral end surface of the base material. Can be covered with the skin material 12 without performing the step of covering so as to wrap (see FIG. 13D).

Next, the control circuit 30 raises the upper mold 21 in order to remove the laminated body 10a molded between the molding dies 20 and 21 as described above from the molding dies 20 and 21. At this time, the laminated body 10a is still held by the lower mold 20. In this case, the bonding strength (difficulty of peeling) between the molten polypropylene resin 11melt forming the base material 11 and the molding surface 20a of the lower mold 20 is better than the molding surface 2 of the skin material 12 and the upper mold 21.
This is because it is larger than the bonding strength with 1a. This upper mold 2
1, the control circuit 30 controls the resin flow blocking member 24,
The drive mechanism 29 is not moved in order to hold 25 at the position where both molds 20 and 21 are superposed. The molded laminate 10a is removed from the lower mold 20 after the base material 11 is completely cooled and hardened.

Therefore, since the skin material 12 is not pushed up by the rise of the resin flow blocking members 24 and 25 before the base material 11 is completely cured, the skin material 12 is not peeled off from the base material 11, Uniform skin 12
It is possible to manufacture a good-looking laminated body 10a in which the base material 11 and the base material 11 are joined.

FIG. 6 (a) shows a laminate 10a manufactured in this way, which is subjected to a post-treatment as shown in FIG. 6 (b), that is, an outer peripheral end surface 11a of the substrate 11. The end surface 11b of the opening is formed on the protruding portion 12 of the skin material 12, respectively.
The door trim 10 shown in FIG. 1 and FIG. 2 can be manufactured by rolling in a and 12b and performing a covering process.

Next, the door trim 10 shown in FIG. 1 and FIG.
The manufacturing apparatus of the second embodiment used for manufacturing the laminated body 10a for manufacturing is shown in FIGS.
The apparatus includes a lower mold 40 (corresponding to the base material side molding mold of the present invention) having a molding surface 40a formed to match the shape of the back surface of the door trim, and a molding surface 41a adapted to the shape of the surface of the door trim. The molten resin 11melt, which is a base material, is supplied to the molding surface 40a through the upper mold 41 (corresponding to the skin material side molding mold of the present invention) in which is formed and the resin passage 40b formed inside the lower mold 40. Injection device 42 (corresponding to the supply means of the present invention). In addition, the molten resin 11 passing through the inside of the resin passage 40b is surrounded by the resin passage 40b.
A heater 43 is arranged so that the melt does not cool and harden.

Resin flow blocking members 44 and 45 are attached to the upper die 41 by springs 51 and 52 at the outer peripheral portion of the molding surface 40a of the lower die 40 and at the respective locations corresponding to the openings for mounting the pockets. It is assembled and assembled. These resin flow blocking members 44, 4
Locking recesses 44b and 45b are provided on the side walls of the locking member 5, respectively, and locking parts 46a and 47a of the locking members 46 and 47 are provided.
Is configured so that it can be locked in these locking recesses 44b, 45b to counter the upward biasing force of the resin flow blocking members 44, 45. The lower portions of the locking members 46, 47 are connected to the interlocking member 48, and the locking members 46, 4 are operated by the operation of the driving mechanism (49: corresponding to the second driving means of the present invention).
The position of 7 changes. Then, the operation of the drive mechanism 49, the upper mold 41, the injection device 42, and the supply mechanism (not shown) for the skin material 12 is controlled by a control circuit (50: corresponding to the second control means of the present invention). As will be described later in detail, the upper surface of the resin flow blocking members 44 and 45 is covered with the skin material 1 when the molding dies 40 and 41 are polymerized.
Cutting portions 44a and 45a are provided for cutting out 2 and forming protruding portions 12a and 12b for covering the end surfaces 11a and 11b of the base material 11.

In manufacturing the laminated body 10a for manufacturing a door trim by using the manufacturing apparatus of the second embodiment, first, the temperature of both molding dies 40 and 41 is maintained at about 50 to 60 ° C., and the control circuit 50 is used. 7 drives the drive mechanism 49 to place the locking portions 46a, 47a of the locking members 46, 47 in positions where they are disengaged from the locking recesses 44b, 45b of the resin flow blocking members 44, 45, as shown in FIG. . As a result, the resin flow blocking members 44, 45 are connected to the springs 51, 52.
Due to the urging force of, the molding surface 40a is sufficiently projected.
Further, the control circuit 50 drives a skin material supply mechanism (not shown) to dispose the skin material 12 formed of polypropylene resin into a sheet shape between the two molding dies 40 and 41, and controls the injection device 42. The polypropylene resin 11melt is supplied to the molding surface 40a of the lower mold 40 in a molten state (180 ° C. to 200 ° C.).

Next, the control circuit 50 controls the upper mold 41 to approach the lower mold 40, and the resin flow blocking members 44, 45 are controlled.
Is brought into contact with the molding surface 41a of the upper mold 41 through the skin material 12. Further, as the control circuit 50 lowers the upper mold 41, the resin flow blocking members 24 and 25 are moved to the springs 51 and 52.
Press down while descending. At this time, the flow of the molten polypropylene resin 11melt toward the outer peripheral portion of the door trim and the opening 10h for mounting the pocket is blocked by the resin flow blocking members 44 and 45, respectively.
When 1 is lowered to the completely polymerized state shown in FIG. 8, the molten polypropylene resin 11melt is spread over the entire back surface of the skin material 12. And at the same time, the skin material 12
Cutting part 44 provided on the upper surface of the resin flow blocking member 44
a, 45a is cut by the end surface 11a of the base material 11,
Protruding portions 12a and 12b for covering 11b are formed. Expanded molten polypropylene resin 11me
lt is welded to the polypropylene resin of the skin material 12 and cured as it is to form a laminated body 10a for manufacturing the door trim 10.

In this way, the resin flow blocking member 44,
If 45 is not provided, the molten polypropylene resin 11melt flows over the molding surface 40a of the lower mold 40 to the outer peripheral portion of the door trim 10 and the opening 10h during the polymerization process, and between the skin material 12 and the lower mold 20. Burrs made of polypropylene resin forming the base material 11 are formed. However, since the apparatus of the second embodiment is provided with the resin flow blocking members 44 and 45, the molten polypropylene resin 11melt forms the outer peripheral portion and the opening 10h. No burr is formed and no such burr is formed. Further, since the resin flow blocking members 44, 45 of the manufacturing apparatus of the second embodiment are provided with the cut portions 44a, 45a, the resin flow blocking members 44, 45 are formed on the skin material 1.
The cutting portions 44a and 45a cut the skin material 12 until the molding dies 40 and 41 are completely overlapped with each other by contacting the upper die 41 via 2 and easily cover the end surfaces 11a and 11b of the base material 11. It is possible to form the protruding portions 12a and 12b for doing so. Thus, it is not necessary to perform the molding step of the base material which is indispensable in the conventional manufacturing apparatus, and the outer peripheral end surface 11a of the base material and the end surface 11b of the opening are bonded to the conventional base material with the skin material. A step of cutting the base material and the skin material, which are necessary in the integrated manufacturing method (see FIG. 13), to form an opening, and cutting the outer peripheral edge of the skin material so as to slightly protrude from the base material (FIG. 13 (b)),
And a step of attaching a garnish to cover the end surface of the base material and the skin material of the door trim opening, or covering the end portion of the base material with the protruding portion of the skin material to cover the outer peripheral end surface of the base material. It can be covered with the skin material 12 without performing (see FIG. 13D).

Both molds 40 and 41 as described above
In the completely superposed state, the control circuit 50 controls the drive mechanism 49 to engage the locking portions 46a, 47a of the locking members 46, 47 with the locking recesses 44b, 45b of the resin flow blocking members 44, 45. After holding the positions of the resin flow blocking members 44 and 45 in this way, as shown in FIG. 9, the laminated body 10a molded between the molding dies 40 and 41 is formed into the molding dies 4 and 4.
The control circuit 50 raises the upper mold 41 in order to remove it from 0, 41. At this time, the laminated body 10a is still held by the lower mold 40. In this case, the bonding strength (difficulty of peeling) between the molten polypropylene resin 11melt that constitutes the base material 11 and the molding surface 40a of the lower mold 40 is better than the skin material 12 and the upper mold 4.
This is because it is larger than the peeling resistance from the first molding surface 41a. The molded laminate 10a is removed from the lower mold 40 after the base material 11 is completely cooled and hardened.

Therefore, since the skin material 12 is not pushed up by the rise of the resin flow blocking members 44 and 45 before the base material 11 is completely cured, the skin material 12 is not peeled off from the base material 11, Uniform skin 12
It is possible to manufacture a good-looking laminated body 10a in which the base material 11 and the base material 11 are joined. Laminate 10 produced in this way
a becomes the door trim 10 shown in FIGS. 1 and 2 by performing the above-mentioned post-treatment shown in FIG.

Next, the door trim 10 shown in FIG. 1 and FIG.
The manufacturing apparatus of the third embodiment used for manufacturing the laminated body 10a for manufacturing the same is shown in FIGS. 10 to 12, and the apparatus has a molding surface 60a adapted to the shape of the back surface of the door trim. And a lower mold 60 (corresponding to the base material side molding mold of the present invention) formed with the upper mold 61 (a skin material side molding mold of the present invention) having a molding surface 61a that matches the shape of the surface of the door trim. ), And an injection device 62 (corresponding to a supply means of the present invention) for supplying the molten resin 11melt as a base material to the molding surface 60a through the resin passage 60b formed inside the lower mold 60. Is equipped with. The resin passage 60
A heater 63 is arranged around b so that the molten resin 11melt passing through the inside of the passage 60b is not cooled and hardened.

Resin flow blocking members 64 and 65 are attached to the upper mold 61 by springs 71 and 72 at the outer peripheral portion of the molding surface 60a of the lower mold 60 and at the respective positions corresponding to the openings for mounting the pockets. It is assembled and assembled. On the other hand, pressing members 66 and 67 are attached to the molding surface 61a of the upper die 61 at positions facing the resin flow blocking members 64 and 65, respectively, so as to be able to move forward and backward toward the lower die 60. These pressing members 6
The upper portions of 6, 67 are connected to the interlocking member 68, and the forward / backward positions of the pressing members 66, 67 are changed by the operation of the drive mechanism (69: equivalent to the third drive means of the present invention), so that the push-back members are in the advanced state. The resin flow blocking members 64 and 65 are pressed to counter the upward biasing force of the resin flow blocking members 64 and 65. The operation of the drive mechanism 69, the upper die 61, the injection device 62, and the supply mechanism (not shown) for the skin material 12 is controlled by a control circuit (70: corresponding to the third control means of the present invention). As will be described in detail later, on the upper surfaces of the resin flow blocking members 64 and 65, the skin material 12 is cut when the molding dies 60 and 61 are polymerized, and the end surfaces 11a and 11b of the base material 11 are cut. Cutting portion 6 for forming protruding portions 12a, 12b for covering
4a and 65a are provided.

In manufacturing the laminated body 10a for manufacturing a door trim by using the manufacturing apparatus of the third embodiment, first, the temperature of both molding dies 60 and 61 is maintained at about 50 to 60 ° C., and the control circuit 70 is also used. Drives the driving mechanism 69 to sufficiently retract the pressing members 66 and 67 into the upper mold 61 as shown in FIG. As a result, the resin flow blocking members 64 and 65 are sufficiently projected from the molding surface 60a by the biasing force of the springs 71 and 72. Further, the control circuit 70 drives a skin material supplying mechanism (not shown) to dispose the skin material 12 formed of polypropylene resin into a sheet shape between the two molding dies 60 and 61, and the injection device 62.
Is controlled to supply the polypropylene resin 11melt in a molten state (180 ° C. to 200 ° C.) to the molding surface 60a of the lower mold 60.

Next, the control circuit 70 controls the upper mold 61 to approach the lower mold 60, and the resin flow blocking members 64 and 65 are provided.
Is brought into contact with the molding surface 61a of the upper die 61 via the skin material 12. Further, as the control circuit 70 lowers the upper die 61, the resin flow blocking members 64 and 65 are moved to the springs 71 and 72.
Press down while descending. At this time, the flow of the molten polypropylene resin 11melt toward the outer peripheral portion of the door trim and the opening 10h for mounting the pocket is blocked by the resin flow blocking members 64 and 65, respectively.
When 1 is lowered to the completely polymerized state shown in FIG. 11, the molten polypropylene resin 11melt is spread over the entire back surface of the skin material 12. And at the same time, the skin material 12
Is the cutting portion 6 provided on the upper surface of the resin flow blocking member 64.
End surface 11 of base material 11 cut by 4a, 65a
Overhanging portions 12a and 12b for covering a and 11b
To form Expanded molten polypropylene resin 1
1melt is welded to the polypropylene resin of the skin material 12 and cured as it is to form a laminated body 10a for manufacturing the door trim 10.

In this way, the resin flow blocking member 64,
If 65 is not provided, the molten polypropylene resin 11melt flows over the molding surface 60a of the lower mold 60 to the outer peripheral portion of the door trim 10 and the opening 10h during the polymerization process, and between the skin material 12 and the lower mold 60. A burr made of polypropylene resin forming the base material 11 is formed, but since the apparatus of the third embodiment is provided with the resin flow blocking members 64 and 65, the molten polypropylene resin 11melt forms an outer peripheral portion and an opening 10h. No burr is formed and no such burr is formed. Further, since the resin flow blocking members 64 and 65 of the manufacturing apparatus of the third embodiment are provided with the cut portions 64a and 65a, the resin flow blocking members 64 and 65 are formed on the skin material 1.
The cutting portions 64a and 65a cut the skin material 12 until the molding dies 60 and 61 are completely overlapped with each other by contacting the upper die 61 via 2 to easily cover the end surfaces 11a and 11b of the base material 11. It is possible to form the protruding portions 12a and 12b for doing so. Thus, it is not necessary to perform the molding step of the base material which is indispensable in the conventional manufacturing apparatus, and the outer peripheral end surface 11a of the base material and the end surface 11b of the opening are bonded to the conventional base material with the skin material. A step of cutting the base material and the skin material, which are necessary in the integrated manufacturing method (see FIG. 13), to form an opening, and cutting the outer peripheral edge of the skin material so as to slightly protrude from the base material (FIG. 13 (b)),
And a step of attaching a garnish to cover the end surface of the base material and the skin material of the door trim opening, or covering the end portion of the base material with the protruding portion of the skin material to cover the outer peripheral end surface of the base material. It can be covered with the skin material 12 without performing (see FIG. 13D).

Next, in order to remove the laminated body 10a molded between the molding dies 60 and 61 as described above from the molding dies 60 and 61, as shown in FIG.
At the same time as 0 raises the upper die 61, the driving mechanism 69 is controlled to advance the pressing members 66 and 67 from the molding surface 61a of the upper die 61, and from the molding surface 60a of the lower die 60 of the resin flow blocking members 64 and 65. Pressing member 6 so as not to change the advance position of
The resin flow blocking members 64, 65 are pressed against the plates 6, 67. At this time, the laminated body 10a is still held by the lower mold 60. This is because the bonding strength (difficulty of peeling) between the molten polypropylene resin 11melt forming the base material 11 and the molding surface 60a of the lower mold 60 is more difficult than the peeling strength between the skin material 12 and the molding surface 61a of the upper mold 61. Is also large.
Then, the formed laminated body 10 a is removed from the lower mold 60 after the base material 11 is completely cooled and hardened.

Therefore, since the skin material 12 is not pushed up by the rise of the resin flow blocking members 64 and 65 before the base material 11 is completely cured, the skin material 12 is not peeled off from the base material 11, Uniform skin 12
It is possible to manufacture a good-looking laminated body 10a in which the base material 11 and the base material 11 are joined. Laminate 10 produced in this way
a becomes the door trim 10 shown in FIGS. 1 and 2 by performing the above-mentioned post-treatment shown in FIG.

In the manufacturing apparatus of the first to third embodiments, the resin passages 20b, 40b, 60b are used as the supply means for supplying the molten resin 12melt to the molding surfaces 20a, 40a, 60a of the lower molds 20, 40, 60. The injection device 22, 42, 62 for injecting the molten resin 12melt into the lower mold 2 is used.
A discharge device for directly discharging the molten resin 12melt onto the molding surfaces 20a, 40a, 60a of 0, 40, 60 may be adopted.

Further, in the manufacturing apparatus of the above-mentioned first to third embodiments, the resin flow blocking members 24, 25, 44, 45, 64,
On the upper surface of 65, the cut portions 24a, 25a, 44 of the skin material 12
Since the a, 45a, 64a, and 65a are provided, the skin material 12 is cut through the polymerization process and the protruding portions 12a and 12 that cover the end surfaces 11a and 11b of the base material 11 are cut off.
b is an apparatus for manufacturing a pre-formed laminated body 10a, but as another embodiment of the present invention, a skin flow material is cut by using a resin flow blocking member having no cut portion of the skin material. It may be a manufacturing apparatus for manufacturing a laminated body which is not formed. In this case, the skin material 12 may be cut in a subsequent step to form the protruding portions 12a and 12b.

Although polypropylene resin is used as the base material 11 in the description of manufacturing the door trim by the manufacturing apparatuses of the first to third embodiments, a thermoplastic resin such as ABS resin may be used. In addition, such a thermoplastic resin may be mainly used, and a reinforcing agent, a conductive agent for antistatic, etc. may be appropriately added and used.

Further, in the description when manufacturing the door trim using the manufacturing apparatus of the above-mentioned first to third embodiments, the skin material 12 is used.
Polypropylene resin was used as the olefin resin, but other olefin resins such as vinyl chloride, polyethylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic acid polymer, polyamide resin, A
You may use thermoplastic resin, such as SA resin, individually or in mixture of 2 or more types. Further, a gloss-imparting agent that imparts gloss to the skin material, a flame retardant, or the like can be added as appropriate in consideration of the appearance and performance of the finished product.

[Brief description of the drawings]

FIG. 1 is a perspective view of a door trim manufactured by a laminated body manufacturing apparatus according to the present invention.

FIG. 2 is a vertical sectional view taken along line 2-2 in FIG.

FIG. 3 is a cross-sectional view of a manufacturing apparatus for a laminated body for manufacturing a door trim according to the first embodiment of the present invention, and is a diagram for explaining one step in manufacturing a laminated body using the same apparatus.

FIG. 4 is a cross-sectional view of a manufacturing apparatus for a laminated body for manufacturing a door trim according to the first embodiment of the present invention, which is for explaining one step following FIG. 3 in manufacturing a laminated body using the same apparatus. It is a figure.

FIG. 5 is a cross-sectional view of a manufacturing apparatus for a laminated body for manufacturing a door trim according to the first embodiment of the present invention, for explaining one step following FIG. 4 in manufacturing a laminated body using the same apparatus. It is a figure.

FIG. 6A is a cross-sectional view of the door trim manufacturing laminate manufactured by the manufacturing apparatus according to the first embodiment of the present invention, and FIG. 6B is the post-treatment process of the door trim manufacturing laminate. It is a sectional view for explaining.

FIG. 7 is a cross-sectional view of a manufacturing apparatus for a laminated body for manufacturing a door trim according to the second embodiment of the present invention, and is a diagram for explaining one step in manufacturing a laminated body using the same apparatus.

FIG. 8 is a cross-sectional view of an apparatus for manufacturing a laminated body for manufacturing a door trim according to a second embodiment of the present invention, which is for explaining one step following FIG. 7 in manufacturing a laminated body using the same apparatus. It is a figure.

FIG. 9 is a cross-sectional view of a manufacturing apparatus for a laminated body for manufacturing a door trim according to a second embodiment of the present invention, for explaining one step following FIG. 8 when manufacturing a laminated body using the same apparatus. It is a figure.

FIG. 10 is a cross-sectional view of a device for manufacturing a laminated body for manufacturing a door trim according to a third embodiment of the present invention, and is a diagram for explaining one step in manufacturing a laminated body using the same device.

FIG. 11 is a cross-sectional view of a manufacturing apparatus for a laminated body for manufacturing a door trim according to a third embodiment of the present invention, which is for explaining one step following FIG. 10 in manufacturing a laminated body using the same apparatus. It is a figure.

FIG. 12 is a cross-sectional view of a device for manufacturing a laminated body for manufacturing a door trim according to a third embodiment of the present invention, which is for explaining one step following FIG. 11 in manufacturing a laminated body using the same device. It is a figure.

13 (a), (b), (c) and (d) are process drawings for explaining a method for manufacturing a door trim using a conventional door trim manufacturing apparatus.

14 (a), (b), (c) and (d) are shown in FIG.
FIG. 7 is a process drawing for explaining a method for manufacturing a conventional door trim different from that of FIG.

[Explanation of symbols]

10 ... Door trim, 10h ... Opening part, 11 ... Base material, 11
melt ... Molten resin, 11a, 11b ... End face, 12 ... Skin material, 12a, 12b ... Protruding portion, 20, 40, 60 ...
Lower mold 21, 41, 61 ... Upper mold, 20a, 21a, 40
a, 41a, 60a, 61a ... Molding surface, 22, 42, 6
2 ... injection device, 24, 25, 44, 45, 64, 65 ...
Resin flow blocking member, 24a, 25a, 44a, 45a,
64a, 65a ... Cutting part, 28, 48, 68 ... Interlocking member, 29, 49, 69 ... Driving mechanism, 30, 50, 70 ...
Control circuit, 44b, 45b ... locking recess, 46, 47 ... locking member, 66, 67 ... pressing member, 51, 52, 71, 7
2 ... Spring.

Claims (5)

[Claims] 1. A base material side molding die having a molding surface conforming to the shape of the back surface of the base material, and a skin material side molding die having a molding surface conforming to the shape of the surface material of the skin material. The molten resin-based material serving as the base material is supplied between the molding dies, and the molding dies are polymerized to be supplied between the molding dies and the skin material and the back surface side of the skin material. By molding the molten resin-based material and curing the molten resin-based material, one side surface of the base material is entirely covered with the skin material, and the end surface of the base material is a protruding portion of the skin material. An apparatus for manufacturing a laminate capable of being covered by winding, wherein the manufacturing apparatus is assembled on the molding surface of the base material side molding die so as to be able to advance and retreat toward the skin material side molding die. The molten resin material is brought into contact with a predetermined portion of the skin material during polymerization. A resin flow blocking member for preventing the resin from flowing to the predetermined place, a position adjusting means for adjusting the advancing / retreating position of the resin flow blocking member, and during the polymerization process of the both molds, the two molds are polymerized during the polymerization. Until the two molds are completely polymerized, the resin flow blocking member is brought into contact with the skin material at the predetermined location, and in the separation process of the two molds after the two molds are completely polymerized. A control means for controlling the position adjusting means is provided so that the resin flow blocking member is held at a position where the skin material and the molten resin material are maintained in the shapes of the two molding dies during polymerization. An apparatus for manufacturing a laminated body, characterized in that 2. The position adjusting means is a first drive means connected to the resin flow blocking member, and the control means is a first control means for controlling the first drive means. The manufacturing apparatus of the laminated body according to claim 1. 3. The resin flow blocking member is a member biased toward the skin material side mold, and the position adjusting means resists the biasing force of the resin flow blocking member to prevent the resin flow blocking member. The resin flow blocking member can be locked by the member to hold the resin flow blocking member at the position where the two molds are superposed, and the second driving means for driving the locking member. During the polymerization process of the mold, the resin flow blocking member is unlocked by the locking member and the mold between the molds is completely polymerized until the molds are completely polymerized. In the separation process of the two molding dies after the polymerization, the resin flow blocking member is locked by the locking member so as to hold the resin flow blocking member in the position where the two molding dies are stacked. To the second
The laminated body manufacturing apparatus according to claim 1, which is second control means for controlling the driving means. 4. The resin flow blocking member is a member biased toward the skin material side molding die, and the position adjusting means is provided on the resin flow blocking member on the molding surface of the skin material side molding die. It comprises a pressing member that is installed at an opposing position so as to be able to advance and retreat toward the base material side mold and that presses the resin flow blocking member, and a third drive means that moves the pressing member forward and backward, and the control means includes both of the above. In the polymerization process of the molding die, from the middle of the polymerization of both the molding dies to the complete polymerization of both the molding dies, the pressing of the resin flow inhibiting member by the pressing member is released and the molding between the two molding dies is completely polymerized. The pressing member for holding the resin flow blocking member at a position where the skin material and the molten resin-based material are maintained in the shape at the time of polymerization of the two molds in the process of separating the two molds after To 2. The laminated body manufacturing apparatus according to claim 1, further comprising third control means for controlling the third driving means so as to press the resin flow blocking member. 5. The flow of the molten resin-based material is blocked by at least one of the resin material flow-inhibiting member and the molding material-side mold facing the resin flow-inhibiting member, and the molten resin-based material is cured. 7. A cutting portion for cutting the skin material at the time of polymerization of both molds is provided at a position apart from the end surface of the base material in the extension direction of the base material by a predetermined distance. The manufacturing apparatus of the laminated body as described in any one of 1-4.