JPH11240092A - Laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate not having possibility of generating a cavity in a skin material even if the skin material is formed from TPO(olefinic thermoplastic elastomer) suitable for recycling. SOLUTION: An instrument panel 1 consists of a base material 10 having through-holes 10a for evacuation, a barrier layer 13 applied to the upper surface of the base material 10 in the state closing the through-holes 10a, a foamed layer 14 applied to the barrier layer 13 and the skin material 15 applied to the foamed layer 14. Further, the barrier layer 13 is a sheet having a modulus value higher than that of the skin material 15. There is no axiety such that the barrier layer is depressed toward the through-holes even if the through-holes are evacuated. Since the foamed layer is separated from the through-holes by the barrier layer, the foamed layer is not depressed toward the through-holes. As a result, even if the skin material is formed from relatively soft material quality, a depression is not generated in the skin material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminate in which a sheet is closely adhered to a substrate by evacuation.

[0002]

2. Description of the Related Art FIG. 7 is a sectional view of a main part of a conventional instrument panel of a vehicle. Instrument panel 1
Reference numeral 00 denotes a panel arranged in front of a driver's seat of a vehicle for arranging instruments and operation switches. The panel is formed of an injection-molded base material 101, a skin material 103, and a foam layer 104 (polypropylene foam). After preparing the formed sheet 102 and applying the primer 105a to the back surface of the sheet 102 and applying the adhesive 105b to the surface of the base material 101, the sheet 102 is put on the base material 101 while being stretched by being pulled and stretched by right and left clamps. , Through hole 101a of substrate 101
Is evacuated as indicated by an arrow to adhere the sheet 102 to the substrate 101.

The material of the base material 101 is polypropylene (hereinafter referred to as “PP”), the material of the skin material 103 is polyvinyl chloride (hereinafter referred to as “PVC”), and the material of the foam layer 104 is P
Although P is a typical example, an olefin-based thermoplastic elastomer (hereinafter, referred to as “TPO”) attracts attention as a material of the skin material 103 because it is suitable for recycling.

[0004]

By the way, the skin material 10
No. 3 has a portion which greatly expands due to the uneven shape of the base material 101 and a portion which expands slightly. Then, the skin material 103 becomes thinner in a portion where the elongation of the skin material 103 is large. on the other hand,
TPO is a softer material than PVC, so
When a vacuum is drawn through the base material 01a, a thin portion of the skin material 103 covering the base material 101 is sucked into the through hole 101a, and a concave portion 102a is generated on the surface of the skin material 103. For this reason,
The quality of the laminate may be degraded.

[0005] Therefore, an object of the present invention is to provide a technique in which even if a skin material is formed of TPO suitable for recycling, there is no possibility that a dent will occur in the skin material.

[0006]

In order to achieve the above object, a first aspect of the present invention is to provide a base material having a through hole or a groove for vacuum evacuation, and a base material in a state where the through hole or the groove is closed. A barrier layer overlaid on one side, a foam layer over the barrier layer, and a skin material over the foam layer, wherein the barrier layer is a sheet having a higher modulus than the skin material. . The “modulus value” is an elastic modulus (modu
lus of elasticity), that is, a value obtained by dividing the stress applied to the material within the elastic limit by the strain generated in the material, and the larger the value, the more difficult it is to deform.

In view of the above, a configuration is adopted in which the through holes or grooves of the base material are closed with a barrier layer having a higher modulus than the skin material.
When the through holes or grooves are evacuated and the barrier layer is brought into close contact with the substrate, there is no fear that the barrier layer will be recessed toward the through holes or grooves. In addition, since the barrier layer plays the role of a wall and can be separated from the through holes or grooves, there is no fear that the foam layer is dented to the through holes or grooves. As a result, even if the skin material is formed of a relatively soft material, there is no fear that the skin material will be dented.

[0008]

Embodiments of the present invention will be described below with reference to the accompanying drawings. The drawings should be viewed in the direction of reference numerals. FIG. 1 is a front view of a laminate (an example of an instrument panel of a vehicle) according to the present invention. In addition,
In the description, “left” and “right” are as illustrated. The instrument panel 1 as a laminated body is a panel arranged in front of a driver's seat of a vehicle to arrange instruments and operation switches, and is opened on the right side for mounting instruments and operation switches. An opening 2 is provided for opening a tray, an opening 3 is provided for mounting a tray, an opening 4 is provided below the opening 3 for mounting a glove box, and an opening 5 is provided on the left side of the opening 4 for mounting a defroster. It is a thing.

FIG. 2 is a perspective view (schematic diagram) of the instrument panel according to the present invention, and shows the instrument panel 1.
Is a base material 10 injection-molded into a substantially U shape, and the base material 10
The sheet 12 adhered to the surface of the base material 10 and the sheet 1
It is composed of a primer 17a and an adhesive layer 17b for adhering the base material 10 and the sheet 12 to be provided between the two. Each component will be described in detail with reference to FIG.

FIG. 3 is a sectional view of the laminate according to the present invention. The base material 10 is formed by injection molding PP, and is a member having a through hole 10a for evacuation. Sheet 1
2 is a barrier layer 13 covering the upper surface of the base material 10 in a state of closing the through hole 10a, and a foam layer 14 covering the barrier layer 13.
And a skin material 15 covered on the foam layer 14.

[0011] Barrier layer 13 is a layer of PP-made or the like having a high modulus value than the skin material 15 is obtained by setting the modulus value in the range of 3.0kg / cm ² ~5.0kg / cm ² . If the pressure is lower than 3.0 kg / cm ² , the barrier layer 13 may be dented to the side of the through hole 10a by evacuating the through hole 10a.
If it is higher than m ² , the deep drawability will be poor.

The foam layer 14 is a PP foam (polypropylene foam). The skin material 15 is a layer made of TPO, and is a sheet member that is substantially non-permeable, that is, contains a small amount of ventilation. The modulus of the skin material 15 is in the range of 0.02 kg / cm ^{2 to} 2.0 kg / cm ² . This is because, since the barrier layer 13 is provided, even if the skin material 15 is softened, there is no fear that the surface of the skin material 15 will be dented. As a result, even if the skin material 15 is formed of TPO suitable for recycling, there is no fear that the quality of the instrument panel 1 will be deteriorated.

Next, a method for manufacturing the above-described laminate will be described. FIGS. 4A and 4B are first explanatory views of the method for manufacturing a laminate according to the present invention. In (a), the barrier layer 1
3. A three-layer sheet 12 is formed from the foam layer 14 and the skin material 15, and a primer 17a is applied to the back surface of the sheet 12.

In (b), the substrate 10 is placed on the mold 20 of the vacuuming device, and the adhesive 17b is applied to the substrate 10.
Next, the left and right ends of the sheet 12 are clamped by left and right clamps 25 and 26.
To support the sheet 12 in a stretched state. After heating and softening the sheet 12 in this state,
Lower the left and right clamps 25 and 26 as indicated by arrows.

FIGS. 5A and 5B are second explanatory views of the method for manufacturing a laminate according to the present invention, and FIG. 5B is an enlarged view of a portion b of FIG. In (a), the left and right clamps 25,
26, the center of the sheet 12 is first placed on the upper surface of the base material 10 and the base material 10 is stretched while the sheet 12 is being stretched.
Cover both sides. In this state, by driving the vacuum pump 21 to open the stop valve 22, the through holes 20a and 10a of the vacuum pumping die 20 are evacuated as indicated by arrows.

In FIG. 2B, the sheet 12 adheres to the substrate 10 with the primer 17a and the adhesive 17b, and the through-hole 10a of the substrate 10 is closed by the barrier layer 13. Barrier layer 1
The modulus value of 3.0 is higher than the skin material 15 by 3.0 kg / c.
m ^{2 to} 5.0 kg / cm ² , so that
There is no fear that the barrier layer 13 will be depressed toward the through hole 10a even if the pressure of 0a is evacuated. The pores 1 are formed by the barrier layer 13 through the foam layer 14.
Since the foam layer 14 can be separated from 0a, there is no fear that the foam layer 14 will be dented. For this reason, there is no danger that the skin material 15 covering the foam layer 14 will be dented. Therefore, even if the skin material 15 is formed with TPO suitable for recycling, there is no fear that the quality of the instrument panel 1 is deteriorated.

FIGS. 6A and 6B are cross-sectional views of a laminate according to the present invention. FIG. 6A shows a conventional laminate 100 as a “comparative example”, and FIG. The laminate 1 is shown as “Example”. (A) shows that a base material 101 is injection-molded with PP, and a TPO skin material 103 is formed on the base material 101.
And sheet 10 formed in two layers with foam layer 104 made of PP
2 is covered. Since the material of the skin material 103 is made of TPO suitable for recycling, it is softer than a skin material made of PVC. For this reason, when the through-hole 101a is evacuated as shown by the arrow, the foam layer 104 becomes the through-hole 1 as shown by the arrow.
01a, and the concave portion 102 is formed on the surface of the skin material 103.
a may occur.

(B) Injection molding the base material 10 with PP,
The base material 10 is covered with a sheet 12 formed of three layers of a skin material 15 made of TPO, a foam layer 14 made of PP, and a barrier layer 13 made of PP. The modulus values of the skin material 15 in a range of ^{0.02kg / cm 2 ~2.0kg / cm 2} , the barrier layer 13 high modulus value than the skin material 15 (of 3.0kg / cm ² ~5.0kg / cm ² Range).

The modulus of the barrier layer 13 is determined by
The through holes 10a of the base material 10 are set to be higher by the barrier layer 13.
, The barrier layer 13 does not have to be depressed toward the through hole 10a even if the through hole 10a is evacuated as shown by the arrow. Since the foam layer 14 can be separated from the holes 10 a by the barrier layer 13, no depression occurs in the foam layer 14. For this reason, there is no fear that dents will occur in the skin material 15 covered on the foam layer 14, and the skin material 1 is made of TPO suitable for recycling.
Even if 5 is formed, there is no fear that the quality of the instrument panel 1 is deteriorated.

In the above embodiment, the material of the base material 10 is PP,
Although the instrument panel 1 in which the material of the barrier layer 13 is PP, the material of the foam layer 14 is PP, and the material of the skin material 15 is TPO has been described, the base material 10, the barrier layer 13, the foam layer 14, and the skin material The material of 15 is not limited to this.

In the above embodiment, the laminated body is described as the instrument panel 1. However, the laminated body according to the present invention is not limited to the instrument panel 1, but can be applied to other parts.

In the above-described embodiment, the description has been made of the content in which the base 10 is provided with the through hole 10a and the through hole 10a is evacuated. However, the base 10 is provided with a groove instead of the through hole 10a, and this groove is formed. The same effect can be obtained by vacuuming.

In the above-described embodiment, the description has been given of the case where the primer 17a is applied to the back surface of the sheet 12, but instead of applying the primer 17a, the sheet 1 is subjected to corona treatment.
2 may be surface-treated.

[0024]

According to the present invention, the following effects are exhibited by the above configuration. Claim 1 has a configuration in which the through holes or grooves of the base material are closed with a barrier layer having a higher modulus value than the skin material. Therefore, when the through holes or grooves are evacuated and the barrier layer adheres to the base material, the barrier layer is closed. However, there is no fear that the hole is recessed on the through hole side or the groove side. In addition, since the barrier layer plays the role of a wall and can be separated from the through holes or grooves, there is no fear that the foam layer is dented to the through holes or grooves. For this reason, even if the skin material is formed of a relatively soft material, there is no fear that the skin material will be dented. As a result, even if the material of the skin material is made of TPO suitable for recycling, no dent is generated, so that the product can be maintained at high quality.

[Brief description of the drawings]

FIG. 1 is a front view of a laminate (an example of an instrument panel of a vehicle) according to the present invention.

FIG. 2 is a perspective view (schematic diagram) of an instrument panel according to the present invention.

FIG. 3 is a sectional view of a laminate according to the present invention.

FIG. 4 is a first explanatory view of a method for manufacturing a laminate according to the present invention.

FIG. 5 is a second explanatory view of the method for manufacturing a laminate according to the present invention.

FIG. 6 is a cross-sectional view of a laminate according to the present invention.

FIG. 7 is a sectional view of a main part of an instrument panel of a conventional vehicle.

[Explanation of symbols]

1 ... laminated body (instrument panel), 10 ... substrate,
10a: through hole, 13: barrier layer, 14: foam layer, 15:
Skin material.

 ────────────────────────────────────────────────── ─── Continued on the front page (72) Inventor Junichi Saita 1-10-1, Shinsayama, Sayama City, Saitama Prefecture Honda Engineering Co., Ltd.

Claims (1)

[Claims] 1. A base material having a through hole or a groove for evacuation, a barrier layer covering one surface of the base material in a state in which the through hole or the groove is closed, and a foam layer covering the barrier layer. A laminate comprising a skin material covered by the foam layer, wherein the barrier layer is a sheet having a higher modulus than the skin material.