JPH02281925A - Manufacture of laminated molding - Google Patents

Abstract

PURPOSE:To hinder extension of stretching to be caused by a deformation of the title moldings to the next sphere by a notched part even if a deep drawn part is in existence on a molded form, by a method wherein a boundary part between a moldings sphere part of a laminated sheet and a sphere part adjoining to the moldings sphere part is notched by leaving the both sides of the sphere part behind and extending over a part of the whole of a skin material. CONSTITUTION:A laminated sheet 19 is notched by a cutter. The notch is provided on a crossing line meeting at about right angles with a longitudinal direction of the laminated sheet 19 and preferably on the whole of a skin material by penetrating through the laminated sheet 19 by leaving behind both sides on projected parts 18a of a resin part 18. Since there is also a part where stretching is little in accordance with a form of moldings in this notched part 23, notching on neither the skin material 16 extending over the whole width nor a part where the stretching due to a deformation is little is required always. With this construction, extension of the stretching of the resin part to the next sphere can be hindered.

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention relates to a method for manufacturing an 85-layer molded product, and more particularly, to a method for manufacturing a laminate molded product in which, for example, interior parts of an automobile are continuously molded from laminated sheets. Regarding the method.

(Prior art) Conventionally, a laminated molded product made by laminating a fiber sheet to a filter resin material and used as an interior part of an automobile, for example, was manufactured by Japanese Patent Publication No. 62-1.
It was formed by the method disclosed in Japanese Patent No. 9286.

Briefly, the method for forming a laminate molded product disclosed in the above-mentioned publication is as shown in FIG. The resin sheet 3 is extruded into a resin sheet 3 in a highly heat-softened state, and fiber sheets 4 of a predetermined shape are placed on top of the resin sheet 3 at predetermined intervals.
In this process, the product is continuously supplied to a vacuum-pressure forming device 7, and after being formed into a predetermined shape by the vacuum-pressure forming device 7, it is punched out by a shape-cutting press M8 after a predetermined cooling time to form a product. there were.

(Division DI to be solved by the invention) However, in the conventional method of forming a laminate molded product as described above, individual fiber sheets 4 are placed at intervals on a continuously supplied resin sheet 3. Since each wAn sheet 4 is placed on the vacuum-pressure forming apparatus 7,
There was a problem in that positioning was difficult, resulting in poor work efficiency.

In addition, in the conventional forming method, each 1! ! When each fiber sheet 4 is molded into a predetermined shape in the vacuum-pressure forming device t7, depending on the shape (for example, depending on the shape with a deep drawing part), the resin sheet 3 around the fiber sheet 4 is stretched. The mutual spacing between the fiber sheets 4 must be kept quite large, and this, together with the above-mentioned problem, has caused the problem that the productivity is very poor even though it is called a continuous molding method.

The object of the present invention is to eliminate such conventional f! This was done in order to solve the problems in the method of forming 1 m molded products, and the purpose is to provide a method for manufacturing 811 molded products with extremely high production efficiency.

(Means for Solving the Problems) The method for manufacturing a laminate molded product according to the present invention involves layering a belt-shaped thermoplastic resin in a highly heat-softened state on a continuously supplied belt-shaped stretchable skin material, and mutually bonding the resin with a pressure roller. It is fixed to form a continuous laminated sheet, and in the laminated sheet, both sides are left in the transverse direction of the laminated sheet at the boundary between the areas necessary for one molding, and the width of the skin material is The method is characterized in that a cut is made in a part or all of the direction, and then the one-time molding region of the laminated sheet is entered into a thermoforming machine to form a molded product in a predetermined shape.

(Function) According to the method for manufacturing a laminate molded product of the present invention, a thermoplastic resin in a highly heat-softened state is extruded from a device such as a continuous extrusion molding machine to the strip-shaped stretchable skin material that is continuously supplied. They are layered in a strip wider than the material, and are bonded together using a pressure roller to continuously form sheets. In this laminated sheet, a cut is made in the boundary between the areas required for one molded product in a direction transverse to the laminated sheet, leaving both sides thereof and extending to part or all of the skin material.

Next, one molded product region of the laminate sheet is introduced into a thermoforming machine, and in this molding machine, one molded product region of the laminate sheet is formed into a molded product having a predetermined shape. Due to the deformation of the area, the resin part of the area is stretched and tends to extend to the next area. However, since a cut is made between them, the extension of the resin part is prevented from spreading to the next area by the cut, and is processed within that area.

(Example) Hereinafter, the method for manufacturing a laminate molded product of the present invention will be described in more detail with reference to an example.

FIG. 1 shows a device M10 used in a method for manufacturing a laminate molded product according to an embodiment of the present invention. This device 10 is
It includes a continuous extrusion molding machine 12 installed so as to be able to reciprocate back and forth on a rail 11. This continuous extrusion molding machine 12 has a pair of upper and lower pressure rollers 13a, 13 which are cooled by circulating cooling water or the like at its front end (rightward in FIG. 1).
A conveyor line 14 is formed by a conveyor 15, etc., and is substantially horizontal and extends forward with a reference position between the rollers 13a and 13b.

For example, a stretchable sheet-like skin material 16 made of woven fabric, non-woven fabric, etc. (here, "stretchable" refers to a material that can be expanded and deformed to match the shape of the mold during subsequent thermoforming. The roll 17 wound with
This skin material 16 is pulled out from the roll 17 and placed with its surface facing downward on the rollers 13a,
13b, and is fed on the conveyance line 14.

At this time, just before the skin material 16 is introduced between the rollers 13a and 13b, the molten thermoplastic resin 18 continuously extruded from the extrusion molding machine 12 is placed on the back surface of the skin material, which is the upper surface thereof. Usually, as shown in FIG. 2, the molten thermoplastic resin 18 is placed on the molten thermoplastic resin 18 to have a width greater than the width of the skin material 16 and with its central axis substantially aligned with that of the skin material 16. Therefore, the molten thermoplastic resin 18 protrudes outward from both sides of the skin material 16 almost uniformly.

Then, this molten thermoplastic resin 18 is transferred to an extrusion molding machine 12.
Immediately the roller 13 is asked to come out from the surface and be placed on the skin material 16.
It is introduced together with the skin material 16 between a and 13b, and the two are pressed together to form an 8ff layer sheet 19. In this way, the laminated sheet 19 is continuously formed and fed on the conveyance line 14. Directly above this conveyance line 14, a heating device 20 having a size corresponding to the area required for one molding of the laminated sheet 19 is arranged. When molding the laminated sheet 19, this heating device 20 is used to
It is made up of a combination of multiple heaters so that the heating temperature can be controlled locally according to the molded shape.

In this case, the resin portions on both sides of the laminated sheet 19 that protrude from the skin material 16 (hereinafter simply referred to as protruding portions 18a) are clamped by a clamping device during the molding process described later, and as a result, these portions are particularly stretched. A heating plate is arranged so that this protruding portion 18a can also be reheated.

Reheated by heating device 20! iI layer sheet 19
As shown in FIG. 3, the molded product region enters the ripening mold 8!21 installed at the end of the conveyance line 14 by the overall conveyance movement of the sheet 19. The illustrated thermoforming machine 21 is constructed by arranging a vacuum mold 21a above and a pressure mold 21b below. The thermoforming device 21 is not limited to the one shown in the drawings, but may be any other device such as a vacuum type device only, a device provided with an assist plug, or the like. In the illustrated apparatus, the resin portion of the laminated sheet 19 faces the vacuum mold 21a, and the skin material 16 faces the compressed air mold 21b. In this way, the skin material 16
The reason why the skin material 16 is made to face the air pressure mold 21b is to prevent the hair from falling when the skin material 16 is made of, for example, woven fabric or non-woven fabric due to the skin material 16 coming into close contact with the mold.

When the molding area of the laminated sheet 19 for one batch enters the vacuum mold 21a and the pressure mold 21brIR of the thermoforming machine (vacuum pressure molding machine) 21 as shown in FIG. As described above, a clamping device (not shown) clamps the edges of the resin portion 18a protruding from both sides of the skin material 16, and holds and fixes both sides of the molded product region.

At this time, a cut is made at the boundary between the next molded product area in the laminated sheet 19 that is located directly below the heating device 20 and is being reheated.

That is, before the entrance of the vacuum pressure forming machine 21,
In other words, a cutter 22 is provided at the end of the conveyance line 14, and the cutter 22 cuts the powder into the laminated sheet 1.
A notch is made at 9.

This cut is made in the laminated sheet 1 as shown in FIG.
The 8I layer sheet 19 is provided on a transverse line substantially orthogonal to the longitudinal direction of the skin material 1G, and preferably covers the entire (full width) of the skin material 1G, leaving both sides of the protruding portion 18a of the resin portion 18.
It is installed through the

Such a notch is shown at 23 in FIG.

The notches 23 extend as the resin part is stretched due to the deformation that occurs when the molded product area in the laminated sheet 19 is molded into a desired shape by the thermoforming machine 21, and the next molded product area attempts to deform. This is to prevent

Therefore, depending on the shape of the molded product, there are some parts where this elongation is small, so it is not necessary to form the entire width of the skin material 16, and there is no need to make cuts in parts where the elongation due to deformation is particularly small. Therefore, the cut portions 23 may be provided intermittently in the transverse direction of the laminated sheet 19.

After that, the vacuum mold 21a of the thermoforming machine 21 is lowered, and the pressure mold 21b is raised, and they are brought into contact with the molded product area of the lamination rate 19, and the inside of the vacuum mold 21a is vacuum-suctioned, and at the same time, the pressure mold 21b is moved into the pressure mold 21b. Pressurized air is introduced to bring the molded product region into close contact with the inner surface of the vacuum mold 21a, as shown in FIG. 5, and mold it into a desired shape. Also during this molding, the next molded product region is reheated by the heating device 20.

The molded product area of the laminated sheet 19 is vacuum-pressure formed 8jlI
Cut section 23 made by the cutter 22 after entering the cutter 21
The laminated sheet 19 must be stopped during the formation of the molded article by the thermoforming machine 21 and the simultaneous reheating of the next molded article area. That is, it is necessary to feed the laminated sheet 19 intermittently. However, the extrusion of the molten resin from the extruder 12 is continuous with the delivery of the skin material 16 from the roll 17.

Therefore, after the molded product area of the ¥*rs sheet 19 enters the thermoforming machine 21, the entire 12 is extruded and moved on the rail 11 at the same speed as the skin material 16 as shown in FIG. Move at speed and retreat.

Therefore, while the extrusion molding machine 12 is retracting, the WIR sheet 19 on the conveyance line 14 is substantially stopped, and the above-described processing is performed during that time.

When the molding of the molded product area in the laminated sheet 19 is completed in this way, the extrusion molding machine 1
2 is advanced at a speed faster than the feeding speed of the skin material 16 and stopped at the original position.

As a result, the laminated sheet 19 is sent again, and the thermoforming [21
The molded product region formed into a molded product comes out of the outlet of the molding machine 21, and the boundary with the next molded product region (the part where the notch 23 was formed in the previous process) is cut by the cutter 24. The laminated sheet 19 is separated from the completed molded product 25 by cutting. This operation is then repeated.

In the above-mentioned embodiments, the thermoplastic resin used in the method for producing the laminate molded product includes polyolefin resins such as polypropylene and polyethylene, and styrene resins such as polystyrene and ABS, which can be made into a sheet form by ordinary extrusion molding. Examples include thermoplastic resins. Further, the resin sheet disposed on the skin material 16 may be a foam sheet obtained by mixing a foaming agent or a multilayer sheet obtained by multilayer extrusion.

Further, in this embodiment, the skin material 16 was turned over and the resin was placed on the back side facing upward, but it is also possible to place the skin material 16 on top and the resin sheet on the bottom and press them together. . In that case, the heating device 20 is arranged below the conveyance line 14, and the vacuum mold 21a and the pressure mold 21b of the vacuum pressure forming machine 21 are vertically reversed.

(Effects of the Invention) As explained above, according to the method for manufacturing a laminated molded product in the present invention, both sides of the laminated sheet are left at the boundary between the molded product area and the adjacent strategic area, and By making a cut that covers part or all of the skin material, even if there is a deep drawing part in the shape, the cut part will prevent the elongation caused by this deformation from spreading to the next area. There is no need to widen the distance between the regions, and since the skin material is continuously supplied, positioning in the thermoforming machine is easy, and the productivity of laminated molded products of desired shapes is significantly improved.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram schematically showing the configuration of a manufacturing apparatus for carrying out a method for manufacturing a laminated molded product according to an embodiment of the present invention, and FIG. 2 is an enlarged view of the vicinity of the polishing roller in the apparatus shown in FIG. 1. And show it! FIG. 3 is a top view of sheet II, and FIG. 3 is a structural explanatory diagram similar to FIG. Figure 4 is a plan view showing a laminated sheet in which notches are formed at the boundaries between regions of one molded product before the vacuum-pressure forming machine, and Figures 5 and 6 show how the laminated sheet is formed as desired in the vacuum-pressure forming machine. A structural explanatory diagram similar to FIG. 1 showing the state in which the product is formed into a shape and the state in which the molded finished product is separated from the laminated sheet, and FIG. 7 schematically shows a conventional laminated molded product forming apparatus. It is a configuration explanatory diagram. DESCRIPTION OF SYMBOLS 10... Laminate molded product manufacturing device, 12... Continuous extrusion molding machine, 13a, 13b... Polishing roller, 14...
...Conveyance line, 16...Skin material, 18...Resin part, 19...Laminated sheet, 20...Heating device, 21...
...Vacuum pressure forming machine, 22...Cutter patent applicant Kumi Kasei Co., Ltd. (,:t-

Claims (1)

[Claims] (1) A strip of thermoplastic resin in a highly heat-softened state is layered on a continuously supplied strip of stretchable skin material, and is bonded to each other by a pressure roller to form a laminated sheet, and the laminated sheet is molded once. making a cut in the boundary between the areas required for the laminated sheet in a direction transverse to the laminated sheet, leaving both sides thereof and extending partially or entirely in the width direction of the skin material; 1. A method for manufacturing a laminate molded product, which comprises: entering a molding area into a thermoforming machine to form a molded product having a predetermined shape.