JPS6219430A - Manufacture of composite molded body - Google Patents

Abstract

PURPOSE:To reduce the manufacturing man-hours, facilitate the manufacturing work, and at the same time enhance the economical efficiency of a molding tool by a method wherein the peripheral portion of a base layer material is trimmed before the material is taken out of the tool. CONSTITUTION:After the finish of pressing, when necessary, both materials 14 and 17 are cooled down under the state that both forces 2 and 3 are kept on pressingly contacting with each other. On the other hand, at a proper time after or nearly simultaneous with the pressing, fluid pressure cylinders 10 are put into actuation so as to eject cutting blades 8 beyond the tool surface of the top force 3 in order to trim only the base layer material portion located at the peripheral portion A of the top force 3. In this case, only the base layer material 17 is cut off, while the skin material 14 is not cut off. After that, the top force 3 and the bottom force 2 are parted from each other so as to release both the materials bonded with each other from the forces. As for both the taken-out materials 14 and 17, the peripheral portion of the skin material 14 extends itself beyond the peripheral edge of the base layer material 17. Thus, after some part of the extended portion X is trimmed as necessary, the extended portion X is folded back to the base layer material side and secured to the base layer material by means of adhesive, fittings or the like in order to complete a composite molded part 25.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a composite molded article formed by laminating a hard base layer and a soft surface layer.

Composite molded products made by bonding a relatively soft surface layer to a base layer with relatively high rigidity or strength are used as interior materials for vehicles, ships, houses, etc., or exterior materials for various appliances, etc. has been widely used in the past.

Such a composite molded article is generally produced by molding a surface layer material and a base layer material into a predetermined shape using a molding method such as vacuum forming, pressure forming, press molding, etc., and then trimming unnecessary peripheral parts of the molded material. Manufactured by. In this case, if the cut surface is exposed at the periphery of the molded product after trimming, the appearance of the molded product will be seriously damaged. Conventionally, the peripheral part of the surface layer material is folded back toward the base layer material and fixed to the base layer material, thereby covering the cut surface of the molded body and giving the molded body a beautiful appearance.

However, in the past, the surface layer material and base layer material after molding were taken out of the molding device, and then an extension was formed around the periphery of the surface layer material, taking care not to damage the surface side of the surface layer material. In this process, only the base layer material was trimmed, and the work was extremely complicated. The reason why such troublesome work was performed was that if the base layer material and the surface layer material were to be trimmed so that their peripheral edges were aligned, trimming could be done at the same time as the molding while the materials are attached to the molding device. Trimming the base layer material to form an extension in the material is difficult to do at the same time as forming, and must be done after both materials have been removed from the forming equipment. It was based on ideas.

In addition, when the surface material is composed of a skin layer and a thick cushion layer, if the extension of the surface material is folded back to the periphery of the base layer, the ridgeline will become loose and the finish will not be sharp.
Furthermore, the folded peripheral edge becomes thick. For this reason, the cushion layer on the extension part has been peeled off and then folded back.

An object of the present invention is to eliminate the above-mentioned conventional drawbacks and to produce a composite molded article through simple operations. An object of the present invention is to provide a method for manufacturing a composite molded body.

In order to achieve this objective, the method for manufacturing a composite molded article of the present invention is comprised of the combination of the following steps.

1st step: One surface layer material is removed using a lower die in which a large number of vacuum holes are opened on the molding surface and cutting blade relief grooves are formed at the boundary between the effective molding surface area and the non-effective molding surface area of the molding surface. Vacuum form and hold on top of the lower mold.

Second step: Consisting of an effective molding surface area located almost opposite to the effective molding surface area of the lower mold and a peripheral part located outside the area, and slit along the outer periphery of the effective molding surface area. is formed.

The base layer material is press-molded onto the surface layer material held on the lower molding surface by the upper mold, in which the cutting blade is fixed or movably arranged in the slit, and is located in the effective molding surface area. Adhere the base layer material to the surface layer material.

Third step: Immediately before, almost simultaneously with, or after the press forming, a cutting blade is made to protrude from the effective molding surface of the upper mold, and only the peripheral portion of the base layer material located outside the effective molding surface area of the upper mold is cut. .

Fourth step: The nibless-molded molded body consisting of the surface layer material and the base layer material is taken out from the upper and lower molds, and the portion of the surface layer material located outside the effective molding surface area is folded back to the base layer material side and fixed to the base layer material.

Since the method for manufacturing a composite molded article of the present invention is configured as described above, the steps of forming and bonding the first surface layer and the base layer and cutting the base layer material are continuous without damaging the surface of the first surface layer. can be easily implemented. Furthermore, since the extension of the surface material can be made thinner, even if the surface material includes a cushion layer, the folding line can be sharply finished without peeling off the cushion layer of the extension.

dog cover group An advantageous embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 shows a molding apparatus 1 for carrying out the method according to the present invention.
This molding apparatus 1 has a lower mold 2 located on the lower side and an upper mold 3 located on the upper side.

The lower mold 2 has a large number of vacuum holes 4 that open on its molding surface, and the other end of these vacuum holes 4 opens into a cavity 5 formed in the lower region of the lower mold 2. Station 5 is connected via conduit 6 to a vacuum pump (not shown). The molding surface of the lower mold 2 consists of a lower mold effective molding surface area and an ineffective molding surface area a, and a groove C having a U-shaped cross section for cutting blade relief is formed at the boundary between the warp areas a and b. A vacuum hole 4' communicating with the cavity 5 is also opened at the bottom of the groove C.

The molding surface of the upper mold 3 consists of an effective molding surface area B located substantially opposite to the effective molding surface area of the lower mold 2, and an upper mold peripheral portion A located outside this area B. Further, a slit 7 is formed along the outer periphery of the effective molding surface area B, and a cutting blade 8 is arranged in this slit 7 so as to be movable up and down.

The cutting blade 8 is connected to a cylinder rod 11 of a fluid pressure cylinder (for example, a hydraulic cylinder) 10 via a connecting member 9. The connecting member 9 in this example is arranged in a cavity 12 formed in the upper mold so as to be movable up and down.

Instead of a hydraulic cylinder, other drive means may be used, for example an electric motor. The upper mold part located inside the cutting blade 8 and the upper mold part located outside thereof are connected to each other by a connecting part (not shown).

It is natural that this is constructed in one piece.

Note that the cutting blade 8 may be fixed to the slit 7 of the upper mold 3 while protruding from the molding surface of the lower mold 2 and supported immovably with respect to the upper mold.

The molding device i! shown in Figure 1! (2) is generally configured as described above, and an example of its operation will be explained below.

First, the surface layer material 14 constituting the surface layer of the composite molded body to be manufactured is clamped by the clamp frame 13 located outside both molds 2 and 3, and in this state, the surface layer material 14 is placed in the lower mold 2.
1 surface layer material 14 placed above the adjacent heating bag if necessary! (not shown), the surface layer material 14 placed as described above and the lower mold 2 are moved vertically relative to each other, and the surface layer material 14 is lowered as shown by the chain line in FIG. Place on mold 2. Thereafter, the cavity 5 and the vacuum hole 4 of the lower mold 2 are removed by a vacuum pump (not shown).
4' is sucked out, and the surface layer material 14 is vacuum formed as shown in FIG. At this time, the surface layer material portion located above the opening of the groove C of the lower mold 2 is drawn into the groove C, stretched thinly, and tightly adheres to the inner surface of the groove C. Note that the vacuum suction at the bottom of the groove C is separated from the other vacuum holes 4, and the surface layer material located above the opening of the groove C is vacuum-formed later than the other parts, thereby making the surface layer material even thinner in the groove C. It can be pulled inside.

As the surface layer material 14, an appropriate soft material can be used, and this material 14 can be formed in advance into one layer or a plurality of layers. 15 and a cushion layer 16 bonded to the skin layer 15 in advance.

As the skin layer 15, for example, thermoplastic resin sheets such as vinyl chloride resin and thermoplastic elastomer, knitted fabrics, woven fabrics, or non-woven fabrics, carpets, etc., which can be stretched at room temperature or under heat and are shaped, can be advantageously used. As the cushion layer 16, foams such as polyethylene, polypropylene, vinyl chloride resin, and laminates of such foams and urethane foam can be used as appropriate.

In addition, if vacuum forming is performed using the lower mold 2 with an uneven grain pattern engraved on the molding surface, it is possible to transfer the grain pattern to the surface of the surface layer material 14 that has been formed.

Once the surface layer material 14 has been vacuum formed as described above, the base layer material I7, which has been heated in advance as required, is placed between the upper mold 3 and the lower mold 2 as shown in FIGS. 1 and 2. This material 17 is press-molded using the upper mold 3 from above the vacuum-formed surface layer material 4, and the two materials 14 and 17 are bonded to each other (FIG. 3). At this time, the cutting blade 8 occupies a position retracted from the molding surface of the upper mold 3. The periphery of the base layer material 17 that has been press-molded extends to the upper die periphery A outside the cutting blade 8.

In this case, the portion of the base layer material located below the cutting blade 8 is spaced apart from the portion of the surface layer material drawn into the groove C of the lower die.

The above-mentioned base layer material 17 can also be composed of a single layer or a plurality of layers, but since this material 17 constitutes the base layer that supports the rigidity of the composite molded body when the composite molded body is completed, It is advantageous for this material 17 to have a structure of two or more layers to maintain its high rigidity. From this point of view, the base layer material 17 in this example has a three-layer structure consisting of a first outer layer 18, an intermediate layer 19, and a second outer layer 20 that are bonded to each other as shown in FIG.

Further, a large number of small recesses 21 are formed in advance in the intermediate layer 19,
The first outer layer 18 is bonded to cover the openings of these small recesses 21. As a result, the base layer material 1 in this example
A large number of closed hollow chambers 22 defined by the small recesses 21 and the first outer layer 18 are formed in 7 . These hollow chambers 22
Otherwise, the interior space between the first and second outer layers 18.20 is in communication throughout and also communicates with the outside through the periphery of the base layer material. Note that during press molding as described above, either the first outer layer 18 or the second outer layer 20 of the base layer material 17 may be brought into contact with the molding surface of the upper mold 3;
In this example, for convenience of explanation, the first outer layer 18 will be explained as being in contact with the upper molding surface (FIG. 3), and the base layer material 17
The materials constituting each of the layers 18, 19, and 20 include appropriate hard materials, such as thermoplastic synthetic resins such as polypropylene, polyethylene, and vinyl chloride resins, phenolic resins,
Thermosetting resins such as melamine resins, paper materials, wood materials, cross-wire materials of these materials and synthetic resins, or light metals such as aluminum can be used as appropriate (base layer material may be one or two layers, (The same applies when it is configured with four or more layers.)

By the way, the base layer material 17 and the surface layer material 14 are bonded to each other by the above-mentioned press molding, but at that time both materials 1
4. If the materials of the mutually contacting parts of 14.17 are thermoplastic synthetic resins of the same type, before molding the two materials 14.17, they should be heated in advance and bonded by heat by press molding. I can do it. Further, when the materials of the above-mentioned parts are different from each other, it is sufficient to apply an adhesive to at least one of the two materials 14 and 17.
Alternatively, an adhesive film may be pasted on at least one of the surfaces of the two materials 14 and 17 facing each other, or a nonwoven fabric coated with a heat-activated adhesive may be interposed between the two materials 14 and 17 prior to press molding. They can also be bonded together by preheating both materials 14, 17 before molding. Alternatively, both materials 14
．． When the materials of the parts 17 to be bonded to each other are both thermoplastic synthetic resins, a nonwoven fabric formed by mixing approximately equal amounts of fibers of each of these resins is mixed with these materials 14 prior to press molding. .17, heat these materials 14.degree. 17 in advance, and perform press molding in this state to thermally bond both materials 14.degree. 17 through the nonwoven fabric. In this way, both materials 14 can be easily and at low cost.
．． 17 can be advantageously bonded.

Note that when a breathable material is used as the surface material 14, for example, when cloth is used as the skin 15 and urethane foam is used as the cushion body 16,
Since vacuum forming cannot be performed as it is, it is necessary to attach an air-impermeable sheet to this surface layer material 14 in advance. This is exactly the same when the surface layer material is composed of a single layer consisting only of the skin 15 and a breathable material such as cloth is used as the skin. When pasting such a sheet.

If this sheet is pasted to the side of the surface layer material that is in contact with the base layer material, and if a thermoplastic sheet such as an adhesive film is used as this sheet, this sheet also functions as an adhesive means for bonding both materials 14 and 17. is particularly advantageous.

After press forming is completed as described above, both materials 14 and 17 are cooled, if necessary, while maintaining both dies 2 and 3 in the state shown in FIG. 3. This cooling can be performed by flowing a cooling medium through the pipes 23 provided in both molds 2 and 3.

On the other hand, the fluid pressure cylinder 10 is operated at an appropriate time after the press forming or almost simultaneously with the press forming.

The cutting blade 8 is made to protrude from the molding surface of the upper die 3 to trim only the base layer material portion located at the periphery A of the upper die 3 (Fig. 5). In this case, only the body layer material 17 is cut. However, it is important not to cut the surface layer material 14, but in this example, since the base layer material portion and the surface layer material portion that fall below the cutting blade 8 are separated from each other, this requirement can be easily and reliably met. can be satisfied. As the cutting blade 8,
A knife-like blade can be used, or a serrated blade can be used depending on the material of the base layer material. Note that it is also possible to perform press molding in advance with the cutting blade 8 protruding from the molding surface of the upper die 3 and cut the base layer material portion. In this case, cutting may be performed immediately before press forming.

Next, the upper mold 3 and the lower mold 2 are separated from each other, and both materials adhered to each other are taken out from the mold. Both taken out materials 14
．． 17, as shown in FIG. 6, the periphery of the surface layer material is longer than the periphery of the base layer material 17. Therefore, after trimming a part of this extension part X as necessary, fold the extension part X back to the base layer material side and attach it with adhesive or metal fittings etc.
(not shown), the cut surface 24 of the base layer 117 was covered by the extension X of the surface layer 114, as shown in FIG. A beautiful composite molded body 25 is completed. Furthermore, in this example, when the surface layer material is vacuum formed, the peripheral portion thereof is stretched thinly, so that it can be easily folded back to the base layer material side. Not only that, but the appearance after folding can be finished with a sharp appearance.

By the way, when performing the above-mentioned press molding, the base layer material 17
Air enters between the surface layer material 14 and the surface layer material 14, and when both materials 14 and 17 are bonded in this state, the completed composite molded body 2
This may damage the appearance of 5 and cause the base layer 117 and surface layer 114 to separate. In consideration of this point, in this example, a large number of ventilation holes 26 are pre-drilled on the side of the base layer material to be bonded to the first surface layer material 14, that is, on the second outer layer 20 in this example, as shown in FIG. It is set up. In this case, these vent holes 26 are formed in a part of the second outer layer 20 that does not delimit the closed hollow space 22, so that it is true that these vent holes 26 communicate with each other through the interior space of the base layer material 17. It also communicates with the outside of the base layer material through the base layer material.

On the other hand, a through hole 27 is formed in the side wall 3aL of the upper mold 3 as shown in FIG. 3, and the through hole 27 is connected to a vacuum pump (not shown) via a conduit.

In this case, when the upper mold 3 is lowered to the position shown in FIG. The position of the through hole 27 is set so as to be located in the area between the two outer layers 20. Therefore, if the vacuum pump is activated during press molding to suck air from between the outer layers 18 and 20 of the base layer material 17, the base layer material 17 and the surface layer material 14
The air between the two materials 14 and 17 is drawn out through the ventilation hole 26, and the two materials 14 and 17 are reliably brought into close contact with each other without creating any air pockets between them. At that time, if necessary, the air suction by the conduit 6 leading from the lower mold 2 to the vacuum pump is stopped, and if the pressure is set to atmospheric pressure, the surface layer material 14 can be transferred to the base layer material 1.
7 more reliably. In addition, the vacuum pump that forcibly sucks air from the through hole 27 is omitted,
By simply ventilating air through the through holes 27 during press molding, the air between the two materials 17 and 14 can be removed to a certain extent. In this way, a high-quality composite molded body can be produced: ventilation holes 2 formed in the base layer material 17
6 can be formed by an appropriate method, but when a thermoplastic resin is used as the base layer material 17, this material 17
It is advantageous that the ventilation holes 26 can also be formed when creating the .

FIG. 8 shows an example of this. In FIG. 8, 28 is a molding drum having a large number of small recesses 29 on its curved surface, and a large number of vacuum holes 30 are opened on the circumferential surface of this drum 28. 30 communicates with a hollow chamber 31 at the center of the drum,
This hollow chamber 31 is connected to a vacuum pump (not shown). The drum 28 is driven to rotate in the clockwise direction, and at this time, the intermediate layer sheet 19a made of preheated thermoplastic synthetic resin is supplied to the drum 28 as shown by arrow P. When the sheet 19a is wound around the sheet 19a, the sheet 19a is brought into close contact with the drum 28 by the vacuum hole 30 through which air is sucked in by the vacuum pump, and is vacuum-formed, thereby forming a small recess 21 in the sheet 19a. On the other hand, drum 2
A first outer layer sheet 18a made of a thermoplastic synthetic resin which has also been heated in advance is supplied onto the surface of the intermediate layer sheet 19a wrapped around the intermediate layer sheet 19a, and the two sheets 19a and lja are thermally bonded to each other. After the adhered sheets 19a and 18a are separated from the drum 28, a second outer layer sheet 20a made of thermoplastic synthetic resin that has been heated in advance is fed in the direction of arrow Q, and a pair of rotating rollers 31 feed the second outer layer sheet 20a. It is thermally bonded to the sheet 19a.

In this way, the first outer M18, the middle Ja19 and the second
A base layer material 17 consisting of outer MI 20 is produced.

This material 17 then passes between a perforation roller 32 and a presser roller 33, each rotating in the direction of arrow R. At this time, a large number of piercing needles 3 protruding from the circumferential surface of the piercing roller 32
4 by a number of ventilation holes 2 at predetermined positions of the second outside [20]
6 is drilled.

In the above example, the lower mold was used as a vacuum molding mold for the surface layer material, and the upper mold was used as a press molding mold for the base layer material, but conversely, the lower mold could also be used as a press molding mold and the upper mold as a vacuum molding mold. Good things are natural.

Further, in the above embodiments, a 3M structure having a sealed hollow chamber has been described as the base layer material 17, but other base layer materials 17 may be used in the present invention.

Paperboard that can be molded under heat and pressure, synthetic resin sheets, filled synthetic resin sheets, synthetic resin foam sheets, fiber-reinforced synthetic resin sheets, sheet materials made of glass wool or felt impregnated with synthetic resin, and metal plates. be.

Further, as another embodiment of the present invention, the fluid pressure cylinder 10 is operated at an appropriate time after the base layer material 17 and the surface layer material 14 are press-formed, or almost simultaneously with the press-forming, and the cutting blade 8 is cut into the molding surface of the upper die 3. Make it stand out more.

After trimming the base layer material located in the peripheral area A of the upper mold 3, it is also possible to further lower the cutting blade 8 and cut the surface layer material 14 at the bottom of the groove C. In this way, the surface material 14 is trimmed while retaining the extension X corresponding to the depth of the groove C. Therefore, the trimming operation of the surface layer material 14 after removing both materials from the mold can be omitted.

The composite molded product produced by the method according to the present invention has a wide range of uses, including interior materials for vehicles, ships, aircraft, houses, etc. (e.g., vehicle ceiling lining materials, door trims, front seat panels,
Datsushi boards, architectural unit wall materials), furniture,! It can be used as an exterior material for air appliances, etc.

According to the present invention, the periphery of the base layer material is trimmed before it is taken out of the mold, so after the base layer material is taken out of the mold, the material is trimmed using a separately prepared trimming press or the like. In trimming the periphery, the relative number of bevels can be reduced, making it easier to perform one operation, and the economical efficiency of the mold can also be improved.

Further, according to the present invention, since the base layer material and the surface layer material are molded separately, the following secondary effects can also be obtained. Namely.

(1) Compared to the case where the base layer material and the surface layer material are made into an integrated laminate in advance and molded at once, the time for preheating each material and the molding time can be shortened, and the time required for this heating can be reduced. Heat energy can be kept to a minimum.

(2) Since the base layer material and the surface layer material can be heated separately before forming, each material can be heated uniformly over its entirety and at a temperature suitable for each material. In other words, each material can be molded under molding conditions suitable for each material 14.17.

(3) Since the extension of the surface layer material can be made thinner,
Even if the surface layer material includes a cushion layer, the folding ridge line can be sharply finished without loosening without peeling off the cushion layer of the extension, and the thickness of the composite molded body periphery due to folding does not increase. few.

[Brief explanation of drawings]

1 to 3 are cross-sectional views showing the molding process using the molding device, FIG. 4 is a perspective view of the base layer material, and FIG. 5 is a cross-sectional view showing the molding device during trimming. Figure 6 is a perspective view showing the material after it has been removed from the mold;
The figure is a sectional view of the completed composite molded body, and FIG. 8 is an explanatory view showing the manufacturing process of the base layer material. 2...Lower die 3...Upper die 4...Vacuum hole 7...Slit 8...Cutting blade
14...Surface layer material 17...Base layer material
26...Vent hole 114...Surface layer
117...Base layer A...Upper mold periphery B...Upper mold effective molding surface area a...Lower mold ineffective molding surface area. b... Lower mold effective molding surface area C... Groove Figure 2 Figure 3 Figure 4 Figure 5

Claims (1)

[Scope of Claims] A method for producing a composite molded article by laminating a hard base layer material and a soft surface layer material, which comprises the following steps: (b) The surface material is vacuum-evacuated using a lower mold that has a large number of vacuum holes in the molding surface and a cutting blade relief groove formed at the boundary between the effective molding surface area and the non-effective molding surface area of the molding surface. a first step of molding and holding it as it is on the molding surface of the lower mold; (b) an effective molding surface area located substantially opposite to the effective molding surface area of the lower mold; and a peripheral portion located outside the area; A slit is formed along the outer periphery of the effective molding surface area, and a cutting blade is fixedly or vertically movably disposed in the slit. a second step of press-molding on the surface layer material held on top and bonding the base layer material located in the effective molding surface area to the surface layer material; A third step of protruding the cutting blade from the effective molding surface of the mold and cutting the peripheral part of the base layer material located outside the effective molding surface area of the upper mold, (d) from the press-molded surface layer material and base layer material; A fourth step of taking out the molded body from the upper and lower molds, and folding back the surface layer material portion located outside the effective molding surface area to the base layer material side and fixing it to the base layer material.