JPH0242353B2 - - Google Patents
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- Publication number
- JPH0242353B2 JPH0242353B2 JP60169210A JP16921085A JPH0242353B2 JP H0242353 B2 JPH0242353 B2 JP H0242353B2 JP 60169210 A JP60169210 A JP 60169210A JP 16921085 A JP16921085 A JP 16921085A JP H0242353 B2 JPH0242353 B2 JP H0242353B2
- Authority
- JP
- Japan
- Prior art keywords
- material layer
- skin material
- mold
- molding
- molded
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Description
【発明の詳細な説明】
イ 発明の目的
〔産業上の利用分野〕
本発明は基体材料層と表皮材料層との複合（積
層）成形体の製造方法に関する。DETAILED DESCRIPTION OF THE INVENTION A. Object of the Invention [Industrial Field of Application] The present invention relates to a method for manufacturing a composite (laminated) molded product comprising a base material layer and a skin material layer.
例えば、車両用の各種内装・外装部品（ドアト
リムボード・フロントシートパネル・天井内張り
板・ダツシユボード等）、建築用各種内装部材、
家具、電気機器外装（化粧）容器などには、第８
図ａ乃至ｄのように基体材料層Ａと表皮材料層Ｂ
との複合成形体製品が多用されている。
For example, various interior and exterior parts for vehicles (door trim boards, front seat panels, ceiling lining boards, dart boards, etc.), various interior parts for construction,
No. 8 is applied to furniture, electrical equipment exterior (cosmetic) containers, etc.
As shown in figures a to d, the base material layer A and the skin material layer B
Composite molded products are often used.
基体材料層Ａは例えば、硬質又は半硬質で、充
実又はポーラス肉質の各種の樹脂・ゴム質材料、
或はこれらと炭酸カルシウム・タルク・パルプ粉
砕紙・木粉等との混合材料、レジンフエルト、ポ
リスチレン等の樹脂ビーズ発泡体、樹脂製・紙製
等の段ボール構造板、金属板、草木片凝結材等
の、単一材質材料或は２以上の所望材質材料の組
合せ複合層材料である。 The base material layer A is, for example, a hard or semi-hard, solid or porous resin/rubber material,
Alternatively, mixed materials of these with calcium carbonate, talc, pulp-pulverized paper, wood powder, etc., resin felt, resin bead foams such as polystyrene, corrugated cardboard structural boards made of resin or paper, metal plates, plant debris condensation materials. It is a single material material or a composite layer material combining two or more desired materials.
表皮材料層Ｂは例えば、硬質又は半硬質で、充
実又はポーラス肉質の各種の樹脂シート（塩化ビ
ニル、Ｔ・Ｐ・Ｅ等）・ゴム質材料、伸び性を有
する布帛類（織布・編布・不織布・カーペツト
等）、天然又は合成皮革等の、単一材質材料或は
２以上の所望材料の組合せ複合材料である。第８
図の各表皮材料層Ｂは上記のような材料を外面材
料層b1としその裏面に適当厚さの軟質或は半軟質
クツシヨン材料層b2、例えば塩化ビニル・ポリエ
チレン・ポリプロピレン・ウレタンフオーム等の
軟質発泡シート、不織布、フエルト等を貼合せて
なる複合材料である。 The skin material layer B is made of, for example, hard or semi-hard, solid or porous resin sheets (vinyl chloride, T, P, E, etc.), rubber materials, stretchable fabrics (woven fabrics, knitted fabrics, etc.).・Non-woven fabric, carpet, etc.), natural or synthetic leather, etc., or a single material or a composite material combining two or more desired materials. 8th
Each skin material layer B in the figure has an outer surface material layer b 1 made of the above-mentioned material, and a soft or semi-soft cushion material layer b 2 of an appropriate thickness on the back surface, such as vinyl chloride, polyethylene, polypropylene, urethane foam, etc. It is a composite material made by laminating soft foam sheets, nonwoven fabrics, felt, etc.
上記のような複合成形体製品は、一般には基体
材料層Ａと表皮材料層Ｂを予め積層貼合せ処理し
た積層平板或は積層シート状材料を素材にして、
それを成形型を用いた適宜のシートフオーミング
手法、例えば真空成形法・圧空成形法・真空圧空
成形法・プレス成形法等により所要の製品形状に
１個取り或は多数個取りで成形処理する。そして
その成形と同時に或は脱型後に成形体の有効成形
部分囲りの非有効成形材料部分（不要材料部分）
をトリミング処理ｔ−ｔ（第８図ａ）する。上記
トリミング処理ｔ−ｔだけにどどめた製品もある
が、この場合は複合成形体のトリミング端面に各
構成材料層b1・b2・Ａの積層横断面が露呈してお
り、外観体裁が悪いこと、この端面部から構成材
料層b1・b2がめくれて剥離を生じ易いこと等か
ら、トリミング端面の隠蔽を必要とするものにつ
いては従来一般に第８図ａの２点鎖線示のように
複合成形体の周縁に別生産のモール材ｍ（縁飾り）
を取付け処理して縁仕上げしている。しかもモー
ル材ｍによる縁処理品はそれだけコスト高のもの
となるし、又成形体の縁がモール材ｍで額縁的に
縁取られ違和感がある等のことから形態として好
まれない場合も少なくない。 The above-mentioned composite molded product is generally made of a laminated flat plate or laminated sheet material in which a base material layer A and a skin material layer B are laminated and laminated in advance.
It is then molded into the desired product shape by an appropriate sheet forming method using a mold, such as a vacuum forming method, a pressure forming method, a vacuum pressure forming method, a press molding method, etc., either in one piece or in multiple pieces. . At the same time as the molding or after demolding, the ineffective molding material part (unnecessary material part) surrounding the effective molding part of the molded object
is subjected to trimming processing t (FIG. 8a). There are products that are only subjected to the above trimming process t-t, but in this case, the laminated cross section of each constituent material layer b 1 , b 2 , and A is exposed on the trimmed end surface of the composite molded body, and the external appearance is affected. Unfortunately, the constituent material layers b 1 and b 2 tend to turn over and peel off from this end face, so for those that require concealment of the trimmed end face, conventionally, the method shown by the two-dot chain line in Fig. 8a is generally used. Separately produced molding material m (edge decoration) is placed around the periphery of the composite molded body.
are attached and finished with edges. Moreover, edge-treated products made of molding material m are correspondingly expensive, and the edges of the molded body are often framed with molding material m, giving an unnatural feeling, so that they are often not preferred as a form.
このような場合その縁処理形態としては第８図
ｂのように、複合成形体の表皮材料層Ｂについて
その周縁を裏側の基体材料層Ａの周縁よりも延長
B1しその延長材料層部分B1を基体材料層Ａの裏
面側へ折返して接着剤や止め金具等で止めた形態
のものとするが違和感がなく自然で外観体裁のよ
い美麗な縁仕上げ状態となる。又モール材２を必
要としない分コストの低減を図ることができる。
而して本出願人はそのような縁処理（端末処理）
形態の複合成形体の製造手法について既に数多く
の有効な手法の提案を行つている。例えば、特公
昭59−6229号・同59−6230号・同59−31934号・
同60−1193号・同60−21864号、特開昭56−
111645号・同56−154040号・同56−157329号・同
57−137156号・同58−29633号・同59−29162号・
同59−136255号・同59−165620号・同60−48349
号・同60−48350号、同61−193824号・同61−
213151号・同61−2208228号等。 In such a case, the edge treatment form is to extend the periphery of the skin material layer B of the composite molded body beyond the periphery of the base material layer A on the back side, as shown in Figure 8b.
B 1 and its extended material layer portion B 1 is folded back to the back side of the base material layer A and fixed with adhesive or fasteners, etc., with a beautiful edge finish that looks natural and has a good appearance. becomes. Further, since the molding material 2 is not required, costs can be reduced.
Therefore, the applicant has decided to carry out such edge processing (terminal processing).
A number of effective methods have already been proposed for manufacturing composite molded bodies of different shapes. For example, Special Publication No. 59-6229, No. 59-6230, No. 59-31934,
No. 60-1193, No. 60-21864, JP-A-56-
No. 111645, No. 56-154040, No. 56-157329, No. 56-154040, No. 56-157329, No.
No. 57-137156, No. 58-29633, No. 59-29162,
No. 59-136255, No. 59-165620, No. 60-48349
No. 60-48350, No. 61-193824, 61-
No. 213151, No. 61-2208228, etc.
しかし、上記第８図ｂのように表皮材料層Ｂの
延長材料層部分B1の幅寸法を十分にとり、それ
を基体材料層Ａの裏面側に折返して止め処理する
のではなく、第８図ｃのように基体材料層Ａの外
周端面を表皮材料層Ｂの細幅延長材料層部分B1
で隠蔽処理する、或は第８図ｄのように表皮材料
層Ｂの外周縁部をわずかに内向きに折返した縁処
理形態で足りる、或はそのような縁処理形態によ
ることを要求される場合も多い。
However, instead of taking a sufficient width dimension of the extension material layer portion B1 of the skin material layer B and folding it back to the back side of the base material layer A and fixing it as shown in FIG. 8b above, As shown in c, the outer peripheral end face of the base material layer A is extended to a narrow width of the skin material layer B.
It is sufficient or required that the outer peripheral edge of the skin material layer B is turned inward slightly as shown in Fig. 8(d). There are many cases.
上記第８図ｃの縁処理形態のものは表皮材料層
Ｂの延長材料層部分B1の幅寸法を基体層Ａの外
周端面についてそれを隠蔽するに足る細幅にトリ
ミング処理し、その細幅延長材料層部分B1を基
体層Ａの外周端面に折返して接着剤等で止め処置
すれば製造可能であるが、延長材料層部分B1が
細幅であるから第８図ｂのように幅広の延長材料
層部分B1を基体層Ａの裏面側へ折返して止め処
理する場合に比べて実際上格段に手間を要し、非
能率的で量生産は難しい。第８図ｄの縁処理形態
のもの更に難しい。 In the case of the edge treatment form shown in FIG . It is possible to manufacture the extended material layer portion B 1 by folding it over the outer peripheral end surface of the base layer A and fixing it with adhesive, etc. However, since the extended material layer portion B 1 is narrow, it may be wide as shown in Fig. 8b. Compared to the case where the extended material layer portion B1 is folded back to the back side of the base layer A and fixed, it actually requires much more effort, is inefficient, and is difficult to mass-produce. The edge treatment configuration shown in FIG. 8d is even more difficult.
本発明は上述の第８図ｃや同ｄのような縁処理
形態の複合成形体につき、それを合理的・能率的
に量産することができる手法を提供することを目
的とする。 An object of the present invention is to provide a method that can rationally and efficiently mass-produce composite molded bodies having the edge treatment configurations as shown in FIGS. 8c and 8d above.
ロ 発明の構成
〔問題を解決するための手段〕
本発明は、
基体材料層Ａと表皮材料層Ｂからなる複合成形
体を得るに当り、
目的複合成形体の表皮材料層Ｂ側の面を造形す
る成形型１にシート状表皮材料についての真空成
形機能或は圧空成形機能或は真空圧空成形機能を
具備させ、且つ該成形型の有効成形面領域１０の
周縁部に成形キヤビテイ内方に内向きに張り出さ
せて可撓性の或は可動の突縁部材１６を配設し、
該突縁部材の成形キヤビテイ内方への張り出し寸
法Ｗは造形基体材料層Ａの外周端面の幅寸法或は
表皮材料層Ｂの厚さ寸法に略対応した或はそれ以
下の適当寸法に設定し、
上記成形型１によりシート状表皮材料を真空成
形或は圧空成形或は真空圧空成形してそのまま該
成形面に保持させ、
上記成形型１に保持されている成形表皮材料層
Ｂの有効成形領域部の裏面側に基体材料層Ａを造
形被着させて、造形基体材料層Ａの外面及び外周
端面部を表皮材料層Ｂで被覆した形態の、或は造
形基体材料層Ａの外面を被覆した表皮材料層Ｂの
有効成形領域部周縁の材料層部分を内向きに折返
し成形した形態の複合成形体を製造し、
脱型後、該複合成形体の成形表皮材料層Ｂの有
効成形領域部外周囲の不要材料部分B′をトリミ
ング処理ｔ−ｔする、
ことを特徴とする複合成形体の製造方法を要旨
とする。B. Structure of the Invention [Means for Solving the Problems] In obtaining a composite molded article consisting of a base material layer A and a skin material layer B, the present invention provides the following steps: The mold 1 is equipped with a vacuum forming function, a pressure-pressure forming function, or a vacuum-pressure forming function for sheet-like skin material, and the periphery of the effective molding surface area 10 of the mold is provided with an inward direction toward the inside of the molding cavity. A flexible or movable flange member 16 is arranged to protrude from the
The projecting dimension W of the projecting edge member inward from the molding cavity is set to an appropriate dimension approximately corresponding to or less than the width dimension of the outer peripheral end surface of the modeling base material layer A or the thickness dimension of the skin material layer B. , Vacuum forming, pressure forming, or vacuum pressure forming a sheet-like skin material using the mold 1 and holding it as it is on the molding surface, and forming an effective molding area of the molded skin material layer B held in the mold 1. The base material layer A is shaped and adhered to the back side of the part, and the outer surface and the outer peripheral end surface of the shaped base material layer A are covered with the skin material layer B, or the outer surface of the shaped base material layer A is covered. A composite molded body is manufactured by folding the material layer portion around the effective molding area of the skin material layer B inwardly, and after demolding, the outside of the effective molding area of the molded skin material layer B of the composite molded body is manufactured. The gist of the present invention is a method for manufacturing a composite molded body, which is characterized in that the surrounding unnecessary material portion B' is trimmed.
即ち、成形型１として上記したような突縁部材
１６を具備させたものを用い、該成形型１により
先ず表皮材料層Ｂとなるシート状表皮材料を真空
成形或は圧空成形或は真空圧空成形して成形表皮
材料層Ｂをそのまま成形型面に保持させ、その保
持成形表皮材料層Ｂの有効成形領域部の裏面側に
基体材料層Ａを造形被着させることにより、成形
型の上記突縁部材１６の存在により、脱型して得
られる複合成形体は造形基体材料層Ａの外面及び
外周端面部が表皮材料層Ｂで被覆された形態のも
の、或は造形基体材料層Ａの外面を被覆した表皮
材料層Ｂの有効成形領域部周縁の材料層部分が内
向きに折返し成形された形態のものとなる。成形
型１の突縁部材１６部分は型のアンダカツト部と
なるが、その突縁部材１６は可撓性の或は可動の
部材としてあるので、複合成形体の脱型は支障な
く、容易になされる。而して脱型後の複合成形体
の成形表皮材料層Ｂにつきその有効成形領域部外
周囲の不要材料部分B′（第４，７図）をトリミン
グ処理ｔ−ｔすることにより、第８図ｃ或はｄの
ような縁処理形態の複合成形体を容易に量産的に
製造することができるものである。
That is, a mold 1 equipped with the above-mentioned flange member 16 is used, and the sheet-like skin material that will become the skin material layer B is first vacuum-formed, pressure-formed, or vacuum-pressure-formed using the mold 1. By holding the molded skin material layer B as it is on the surface of the mold, and forming and depositing the base material layer A on the back side of the effective molding area of the retained molded skin material layer B, the above-mentioned ridge of the mold is Due to the presence of the member 16, the composite molded product obtained by demolding is one in which the outer surface and the outer peripheral end surface of the modeling base material layer A are covered with the skin material layer B, or the outer surface of the modeling base material layer A is covered with the skin material layer B. The material layer portion at the periphery of the effective molding area of the covered skin material layer B is folded inward. The flange member 16 portion of the mold 1 becomes the undercut portion of the mold, but since the flange member 16 is a flexible or movable member, demolding of the composite molded product can be easily done without any trouble. Ru. Then, by trimming the unnecessary material portion B' (FIGS. 4 and 7) around the outside of the effective molding area of the molded skin material layer B of the composite molded body after demolding, the shape shown in FIG. It is possible to easily mass-produce a composite molded body having an edge-treated form such as c or d.
実施例 １（第１〜５図）
本例は基体材料層Ａを樹脂の射出成形により造
形するようにしたものである。
Example 1 (Figures 1 to 5) In this example, the base material layer A is formed by injection molding of resin.
１及び２は互いに型締めしたとき対向成形面１
０，２０間に目的複合成形体の全体形状に略一致
したキヤビテイＣ（第１図２点鎖線示）が形成さ
れる、複合成形体の表皮材料層Ｂ側の面を造形す
る第１成形型（本例では可動型）と、基体材料層
Ａ側の面を造形する第２成形型（本例では固定
型）である。 1 and 2 are opposed molding surfaces 1 when the molds are clamped together.
A first mold for shaping the surface of the composite molded body on the skin material layer B side, in which a cavity C (shown by a two-dot chain line in FIG. 1) is formed between 0. (a movable mold in this example), and a second mold (a fixed mold in this example) for shaping the surface on the side of the base material layer A.
第１成形型１において、１１は成形面１０に数
多開口させた真空小孔であり、それ等の真空小孔
は型内の真空室１２に連通している。真空室１２
には真空ポンプ１４に通じる真空パイプ１３を接
続してあり、真空ポンプ１４の作動により各真空
小孔１１が真空吸引状態となり、型１は真空成形
型として機能する。１５は型１の肉厚内に埋設し
た型冷却用冷媒導入パイプである。 In the first mold 1, numeral 11 is a large number of small vacuum holes opened in the molding surface 10, and these small vacuum holes communicate with a vacuum chamber 12 inside the mold. Vacuum chamber 12
A vacuum pipe 13 leading to a vacuum pump 14 is connected to the mold 1, and the operation of the vacuum pump 14 brings each vacuum hole 11 into a vacuum suction state, and the mold 1 functions as a vacuum molding mold. Reference numeral 15 denotes a refrigerant introduction pipe for mold cooling, which is buried within the thickness of the mold 1.
１６は該成形型１の有効成形面領域１０の周縁
部に型キヤビテイ内方に張り出させて配設した、
それ自体適度に可撓性の或は可動の突縁部材であ
る。該突縁部材１６の型キヤビテイ内方への張り
出し寸法Ｗは造形される基体材料層Ａの外周端面
の幅寸法、或は表皮材料層Ｂの厚さ寸法に略対応
した或はそれ以下の適当寸法に設定してある。 16 is disposed at the periphery of the effective molding surface area 10 of the mold 1 so as to protrude inward from the mold cavity.
As such, it is a suitably flexible or movable flange member. The projecting dimension W of the projecting edge member 16 inward from the mold cavity is an appropriate value approximately corresponding to or smaller than the width dimension of the outer peripheral end surface of the base material layer A to be modeled or the thickness dimension of the skin material layer B. The dimensions are set.
上記の突縁部材１６は具体的には適度の可撓弾
性を有する耐熱ゴム部材（本例はその例）、第５
ａのように金属ばね板部材、同図ｂのようにヒン
ジ１７を中心に起倒回動自由の剛性板部材、同図
ｃのようにある温度以上に加熱されることにより
２点鎖線示のようにキヤビテイ内方から外方へま
くれ上り変形し、冷却されると実線示のように型
キヤビテイ内方に張り出した状態に戻り変形する
形状記憶合金板等で構成することができる。１８
ａ，１８ｂは突縁部材１６としての形状記憶合金
板の加熱用ヒータ、及び冷却用冷媒導入パイプ、
１８ｃは断熱板である。 Specifically, the above-mentioned projecting edge member 16 is a heat-resistant rubber member (this example is an example) having appropriate flexibility and elasticity, and a fifth
As shown in figure a, a metal spring plate member, as shown in figure b, a rigid plate member that can be raised and rotated freely around the hinge 17; It can be made of a shape memory alloy plate or the like that curls up from the inside of the mold cavity to the outside and deforms when cooled, returning to the state of protruding inside the mold cavity as shown by the solid line. 18
a, 18b are a heater for heating a shape memory alloy plate as a flange member 16, and a refrigerant introduction pipe for cooling;
18c is a heat insulating board.
第２成形型２において、２１は成形面２０に開
口させた基体材料層Ａ用の溶融樹脂射出孔部、２
２は型肉厚内に埋設した型冷却用冷媒導入パイプ
である。 In the second mold 2, 21 is a molten resin injection hole portion for the base material layer A opened in the molding surface 20;
Reference numeral 2 denotes a refrigerant introduction pipe for cooling the mold, which is buried within the thickness of the mold.
尚、溶融樹脂射出機本体、エジエクタ機構、型
固定支持・型移動機構等は図に省略した。 The main body of the molten resin injection machine, ejector mechanism, mold fixing support/mold moving mechanism, etc. are omitted from the figure.
(1) 表皮材料層Ｂの成形
第１及び第２成形型１，２を型開きした状態
において第１成形型１によりシート状表皮材料
を常法によつて真空成形し、そのまま成形型面
に保持させた状態にする。第２図はその状態を
示す部分拡同図である。１９はシート状表皮材
料の取り枠或はシートクランプを示す。(1) Forming of the skin material layer B With the first and second molds 1 and 2 opened, a sheet-like skin material is vacuum-formed using the first mold 1 in a conventional manner, and then directly applied to the surface of the mold. Leave it in a retained state. FIG. 2 is a partially enlarged view showing this state. Reference numeral 19 indicates a frame or a sheet clamp for the sheet-like skin material.
本例で使用のシート状表皮材料は、外面材料
層b1と、その裏面に積層したクツシヨン材料層
b2と、更にその裏面に積層した耐熱耐圧用樹脂
シート層b3との３層構成のものである。 The sheet-like skin material used in this example consists of an outer material layer b1 and a cushion material layer laminated on the back side of the outer material layer b1.
It has a three-layer structure consisting of b 2 and a heat-resistant and pressure-resistant resin sheet layer b 3 laminated on the back side thereof.
耐熱耐圧用樹脂シート層b3は、本例の場合基
体材料層Ａを溶融樹脂の射出成形で造形する関
係上、その射出溶融樹脂の熱と圧力でクツシヨ
ン材料層b2が溶融して或は射出溶融樹脂が浸入
して充実肉質化したり、へたりを生じたりしな
いようにクツシヨン材料層b2を保護する目的で
設けたものである。 In this example, the heat-resistant and pressure-resistant resin sheet layer b 3 is formed by molding the base material layer A by injection molding of molten resin, so the cushion material layer b 2 is melted by the heat and pressure of the injected molten resin. This is provided for the purpose of protecting the cushion material layer b2 from infiltration of the injected molten resin, causing it to become thick and thick or sag.
更にそのシート層b3の裏面に必要に応じて基
体材料層Ａとの接合を強化する接着剤層を予め
形成しておいてもよく、或は表皮材料の真空成
形処理後、成形型１面に保持されている成形表
皮材料層Ｂの有効成形領域部の裏面に必要に応
じて接着剤をスプレー等して施してもよい。 Furthermore, an adhesive layer may be formed in advance on the back surface of the sheet layer b3 to strengthen the bond with the base material layer A, if necessary, or after the vacuum forming process of the skin material, one side of the mold If necessary, an adhesive may be applied by spraying on the back side of the effective molding area of the molded skin material layer B held in the molded skin material layer B.
b4は上記成形表皮材料層Ｂを保持した第１成
形型１を第１成形型２に型締めしたとき第２成
形型２側の溶融樹脂射出孔部２１と対向対面す
る成形表皮材料層の裏面部分に貼着したアルミ
ニウムホイル片等の耐熱耐圧片である。 b 4 is a portion of the molded skin material layer that faces the molten resin injection hole 21 on the second mold 2 side when the first mold 1 holding the molded skin material layer B is clamped to the first mold 2. It is a heat-resistant and pressure-resistant piece such as a piece of aluminum foil attached to the back side.
溶融樹脂射出孔部２１は対向対面する成形表
皮材料層の裏面部分は溶融樹脂の射出がなされ
たとき射出樹脂の圧力と熱を一番強く受け、そ
の結果その部分のクツシヨン材料層b2部分に局
部的に溶融やへたり等を生じるおそれがある。
上記のように耐熱耐圧片b4を予め添着しておく
ことにより射出処理樹脂によるクツシヨン材料
層b2の局部的処理等を防止することができる。
この耐熱耐圧片b4の添着は表皮材料の真空成形
後に手作業で或はロボツト装置にて自動的に行
つてもよいし、真空成形前に表皮材料の所要裏
面部分に予め貼着するようにしてもよい。 When the molten resin is injected, the back side of the molded skin material layer that faces the molten resin injection hole 21 receives the pressure and heat of the injected resin most strongly, and as a result, the cushion material layer b 2 in that area receives the pressure and heat of the injected resin most strongly. There is a risk of local melting or settling.
By attaching the heat-resistant and pressure-resistant piece b4 in advance as described above, it is possible to prevent the cushion material layer b2 from being locally processed by the injection-processed resin.
The heat-resistant and pressure-resistant piece b 4 may be attached manually or automatically using a robot device after vacuum forming the skin material, or it may be attached to the required back side of the skin material in advance before vacuum forming. It's okay.
第１成形型１の有効成形面１０に予めしぼ等
の所望の凹凸模様を刻設しておくことにより表
皮材料層Ｂの外面に該材料真空成形と同時に上
記凹凸模様を転写付与することができる。 By carving a desired uneven pattern such as grains in advance on the effective molding surface 10 of the first mold 1, it is possible to transfer and impart the uneven pattern to the outer surface of the skin material layer B at the same time as vacuum forming the material. .
表皮材料の第１成形型１による成形は真空成
形の他、圧空成形、或は真空圧空成形で行つて
もよい。 In addition to vacuum forming, the skin material may be formed by pressure forming or vacuum pressure forming.
表皮材料自体が通気性で真空成形・圧空成
形・真空圧空成形が困難或は不能であつても、
例えばその材料の裏面側に伸張柔軟性の非通気
性のゴム膜シート等を重ね合せて成形操作する
ことにより支障なく成形処理できる。 Even if the skin material itself is breathable and vacuum forming, pressure forming, or vacuum pressure forming is difficult or impossible,
For example, by superposing a stretchable, non-breathable rubber membrane sheet or the like on the back side of the material and performing the molding operation, the molding process can be carried out without any problem.
(2) 基体材料層Ａの造形
上記成形表皮材料層Ｂを保持させた第１成形
型１を第２成形型２に対して型締めし、第１成
形型１側に保持されている成形表皮材料層Ｂの
有効成形領域部の裏面と第２成形型２の成形面
２０間のキヤビテイ内に第１成形型２側の射出
孔部２１から基体材料層用の溶融樹脂を射出注
入する。これにより成形表皮材料層Ｂの有効成
形領域部の裏面側に基体材料層Ａが造形されて
一体に被着状態となる（第３図）。(2) Shaping of the base material layer A The first mold 1 holding the molded skin material layer B is clamped to the second mold 2, and the molded skin held on the first mold 1 side The molten resin for the base material layer is injected into the cavity between the back surface of the effective molding area of the material layer B and the molding surface 20 of the second mold 2 from the injection hole 21 on the first mold 2 side. As a result, the base material layer A is formed on the back side of the effective molding area of the molded skin material layer B and is integrally adhered (FIG. 3).
次いで、型１，２の各冷媒導入パイプ１５，
２２で型１，２及び内部の製造複合成形体の冷
却を行う。 Next, each refrigerant introduction pipe 15 of types 1 and 2,
At step 22, the molds 1 and 2 and the manufactured composite molded body inside are cooled.
(3) 脱型
所定の冷却硬化時間が経過したら第１及び第
２成形型１，２の型開きを行う。キヤビテイ内
の基体材料層・表皮材料層からなる複合成形体
は第１成形型１側に保持されて型開きにされ
る。(3) Mold removal After the predetermined cooling and hardening time has elapsed, the first and second molds 1 and 2 are opened. The composite molded body consisting of the base material layer and the skin material layer in the cavity is held on the first mold 1 side and opened.
而して該第１成形型１から製造された複合成
形体を脱型する。該成形型の突縁部材１６部分
は型のアンダカツト部となるが、その突縁部材
１６はそれ自体可撓性の、或は可動の部材であ
ること、張り出し寸法Ｗが比較的小さいことか
ら複合成形体の脱型は支障なく、容易に行うこ
とができる。脱型補助のために型成形面の各真
空小孔１１から空気を噴出状態にすることも有
効である。 The composite molded body produced from the first mold 1 is then demolded. The flange member 16 portion of the mold becomes the undercut portion of the mold, but since the flange member 16 itself is a flexible or movable member and the overhang dimension W is relatively small, it is a composite material. The molded body can be easily demolded without any problems. It is also effective to blow out air from each vacuum hole 11 on the molding surface to assist in demolding.
突縁部材１６を第５図ｃのように形状記憶合
金で構成した場合は、上記型開き後にヒータ１
８ａで該突縁部材１６を加熱状態にすることに
より該突縁部材１６が２点鎖線示のように型キ
ヤビテイ内方から外方へまくれ上り状態に変形
することにより型内の複合成形体は容易に脱型
される。脱型後は冷却用冷媒導入パイプ１８ｂ
により冷却することにより上記まくれ上り変形
した突縁部材１６は再び元の実線示の張り出し
状態に復元する。 When the projecting edge member 16 is made of a shape memory alloy as shown in FIG. 5c, the heater 1 is
By heating the flange member 16 at step 8a, the flange member 16 is deformed into a state where it curls up from the inside of the mold cavity to the outside as shown by the two-dot chain line, and the composite molded body in the mold is heated. Easily demolded. After demolding, the cooling refrigerant introduction pipe 18b
By cooling, the raised and deformed projecting edge member 16 returns to its original extended state as shown by the solid line.
(4) 縁処理
脱型して得られる複合成形体は第４図示のよ
うに、造形基体材料層Ａの外面及び外周端面部
が表皮材料層Ｂで被覆された形体のもの、或は
造形基体材料層Ａの外面を被覆した表皮材料層
Ｂの有効成形領域部用縁の材料層部分に内向き
に折返し成形された形態のもので、更に成形表
皮材料層Ｂの有効成形領域部外周に不要材料部
分B′が存在している。(4) Edge treatment As shown in Figure 4, the composite molded product obtained by demolding is one in which the outer surface and the outer peripheral end surface of the molded base material layer A are covered with the skin material layer B, or the molded base material is This is a form in which the outer surface of the skin material layer B, which covers the outer surface of the material layer A, is folded inward at the edge of the material layer for the effective molding area, and is further unnecessary on the outer periphery of the effective molding area of the molded skin material layer B. Material portion B′ is present.
そこで該複合成形体の成形表皮材料層Ｂにつ
き、上記表皮材料層Ｂの基体材料層端面部被覆
部分或は内向き折返し成形部分を含む表皮材料
層有効成形領域部よりも外方の不要材料部分
B′をトリミング処理ｔ−ｔすることにより第
８図ｃのような縁処理形態の目的複合成形体が
得られる。 Therefore, regarding the molded skin material layer B of the composite molded article, the unnecessary material portion outside the skin material layer effective molding area including the base material layer end face covering portion of the skin material layer B or the inwardly folded molded portion is removed.
By subjecting B' to a trimming process t-t, a desired composite molded body having an edge-treated form as shown in FIG. 8c is obtained.
実施例 ２（第６，７図）
本例は基体材料層Ａを熱発泡性樹脂ビーズの発
泡モールド成形により造形することにしたもので
ある。Example 2 (FIGS. 6 and 7) In this example, the base material layer A was formed by foam molding of heat-expandable resin beads.
第１成形型１は前記実施例１の第１成形型１と
同様の構成のものである。 The first mold 1 has the same structure as the first mold 1 of the first embodiment.
第２成形型２はその成形面２０の略中央面部に
熱発泡性樹脂ビーズ（熱発泡性ポリスチレンビー
ズ等）の注入口２３を開口させてある。又成形面
２０には数多の蒸気噴出用小孔２４を開口させて
ある。２５は該型内に配設した蒸気及び冷媒導入
室であり、上記の各蒸気噴出用小孔２４は該室２
５に連通している。２６，２７は該室２５に接続
した蒸気パイプ及び冷媒導入パイプ、２８はドレ
ン・冷媒排出パイプである。 The second mold 2 has an injection port 23 for heat-expandable resin beads (thermally-expandable polystyrene beads, etc.) opened approximately at the center of its molding surface 20 . Also, a large number of small holes 24 for blowing out steam are opened in the molding surface 20. Reference numeral 25 is a steam and refrigerant introducing chamber arranged in the mold, and each of the above-mentioned steam jetting small holes 24 is connected to the chamber 2.
It is connected to 5. 26 and 27 are steam pipes and refrigerant introduction pipes connected to the chamber 25, and 28 is a drain/refrigerant discharge pipe.
(1) 表皮材料層Ｂの成形 前記実施例１の(1)と同様の要領で行う。(1) Molding of skin material layer B This is carried out in the same manner as (1) of Example 1 above.
(2) 基体材料層Ａの造形
成形表皮材料層Ｂを保持した第１成形型１を
第２成形型２に対して型締めし、第１成形型１
側に保持されている成形表皮材料層Ｂの有効成
形領域部の裏面と第２成形型２の成形面２０間
のキヤビテイ内に第２成形型２側の樹脂ビーズ
注入口２３から基体材料層用の熱発泡性樹脂ビ
ーズを十分に注入充填する。(2) Molding of the base material layer A The first mold 1 holding the molded skin material layer B is clamped to the second mold 2, and the first mold 1
A resin bead injection port 23 on the second mold 2 side is inserted into the cavity between the back surface of the effective molding area of the molded skin material layer B held on the side and the molding surface 20 of the second mold 2 for the base material layer. The heat-expandable resin beads are sufficiently injected and filled.
次いで蒸気パイプ２６から室２５内に蒸気を
導入する。そうすると室２５内の導入蒸気が各
小孔２４から上記樹脂ビーズ充填キヤビテイ内
に噴入し、キヤビテイ内の充填樹脂ビーズが熱
発泡して全体に一体の樹脂ビーズ発泡成形体化
して造形基体材料層Ａとして成形表皮材料層Ｂ
の有効成形領域部の裏面側に一体に被着状態と
なる。 Steam is then introduced into the chamber 25 from the steam pipe 26. Then, the introduced steam in the chamber 25 is injected into the resin bead-filled cavity from each small hole 24, and the resin beads filled in the cavity are thermally foamed to form an integral resin bead foamed molded body, forming a modeling base material layer. Molded skin material layer B as A
It is integrally attached to the back side of the effective molding area.
次いで第１成形型１の冷媒導入パイプ１５、
第２成形型２の室２５内への冷媒導入により型
１，２及び内部の製造複合成形体の冷却を行
う。 Next, the refrigerant introduction pipe 15 of the first mold 1,
By introducing a coolant into the chamber 25 of the second mold 2, the molds 1 and 2 and the manufactured composite molded body inside are cooled.
(3) 脱型 前記実施例１の(3)と同様の要領で行う。(3) Demoulding This is carried out in the same manner as (3) of Example 1 above.
(4) 縁処理（第７図）
前記実施例１と同様の要領で行うことにより
第８図ｄのような縁処理形態の目的複合成形体
が得られる。(4) Edge treatment (FIG. 7) By carrying out the same procedure as in Example 1, a desired composite molded body having an edge treatment configuration as shown in FIG. 8d can be obtained.
尚、基体材料層Ａの造形は実施例１の樹脂射
出成形、実施例２の樹脂ビーズの発泡モールド
成形の他に、樹脂のモールドプレス成形、注型
成形、ウレタン樹脂等の発泡成形で行うことが
できる。 In addition to the resin injection molding in Example 1 and the resin bead foam molding in Example 2, the base material layer A should be formed by resin mold press molding, cast molding, and foam molding of urethane resin, etc. Can be done.
ハ 発明の効果
以上のように本発明方法によれば、第８図ｃの
ように基体材料層Ａの外周端面を表皮材料層Ｂで
被覆隠蔽した形態、或は第８図ｄのように表皮材
料層Ｂの外周縁部をわずかに内向きに折返した縁
処理形態の複合成形体を合理的・能率的に量産す
ることができる。C. Effects of the Invention As described above, according to the method of the present invention, the outer peripheral end face of the base material layer A is covered and concealed with the skin material layer B as shown in FIG. 8c, or the skin material layer is hidden as shown in FIG. It is possible to rationally and efficiently mass-produce an edge-treated composite molded body in which the outer peripheral edge of the material layer B is slightly folded inward.
第１図は第１実施例における第１及び第２成形
型の難開き状態の概略の縦断面図、第２図は第１
成形型で表皮材料を真空成形した状態の一部分の
拡大縦断面図、第３図は型締めして基体材料層を
射出造形した状態の同上図、第４図は脱型した、
トリミング処理前の複合成形体の一部の断面図、
第５図ａ乃至同図ｃは突縁部材の各種の構成形態
例の断面図、第６図は樹脂ビーズで基体材料層を
造形した状態の型開き前の第１及び第２成形の縦
断面図、第７図は脱型した、トリミング処理前の
複合成形体の一部の断面図、第８図ａ乃至同図ｄ
は各種の縁処理形態例の断面図。
１，２は第１及び第２の成形型、Ａは基体材料
層、Ｂは表皮材料層。
FIG. 1 is a schematic vertical cross-sectional view of the first and second molds in a difficult-to-open state in the first embodiment, and FIG.
An enlarged vertical cross-sectional view of a part of the skin material vacuum-formed with the mold, FIG. 3 is the same view with the mold clamped and the base material layer injection-molded, and FIG. 4 is the mold removed.
A cross-sectional view of a part of the composite molded body before trimming processing,
Figures 5a to 5c are cross-sectional views of various configuration examples of the flange member, and Figure 6 is a longitudinal cross-section of the first and second moldings before opening the mold in a state where the base material layer is molded with resin beads. Figures 7 and 7 are cross-sectional views of a part of the composite molded body that has been removed from the mold and before trimming, and Figures 8a to 8d are
FIG. 2 is a cross-sectional view of various edge treatment embodiments. 1 and 2 are first and second molds, A is a base material layer, and B is a skin material layer.
Claims (1)
形体を得るに当り、 目的複合成形体の表皮材料層Ｂ側の面を造形す
る成形型１にシート状表皮材料についての真空成
形機能或は圧空成形機能或は真空圧空成形機能を
具備させ、且つ該成形型の有効成形面領域１０の
周縁部に成形キヤビテイ内方に内向きに張り出さ
せて可撓性の或は可動の突縁部材１６を配設し、
該突縁部材の成形キヤビテイ内方への張り出し寸
法Ｗは造形基体材料層Ａの外周端面の幅寸法或は
表皮材料層Ｂの厚さ寸法に略対応した或はそれ以
下の適当寸法に設定し、 上記成形型１によりシート状表皮材料を真空成
形或は圧空成形或は真空圧空成形してそのまま該
成形面に保持させ、 上記成形型１に保持されている成形表皮材料層
Ｂの有効成形領域部の裏面側に基体材料層Ａを造
形被着させて、造形基体材料層Ａの外面及び外周
端面部を表皮材料層Ｂで被覆した形態の、或は造
形基体材料層Ａの外面を被覆した表皮材料層Ｂの
有効成形領域部周縁の材料層部分を内向きに折返
し成形した形態の複合成形体を製造し、 脱型後、該複合成形体の成形表皮材料層Ｂの有
効成形領域部外周囲の不要材料部分B′をトリミ
ング処理ｔ−ｔする、 ことを特徴とする複合成形体の製造方法。 ２ 成形型１に保持させた成形表皮材料層Ｂの有
効成形領域部の裏面側に対する基体材料層Ａの造
形は、樹脂の射出成形、モールドプレス成形、注
型成形、熱発泡性樹脂ビーズのモールド成形、ウ
レタン樹脂等の発泡成形等で行う、特許請求の範
囲第１項に記載の複合成形体の製造方法。 ３ シート状表皮材料の裏面に予め接着剤層を設
け、或はシート状表皮材料の成形型１による成形
処理後に成形表皮材料層Ｂの有効成形領域部の裏
面に接着剤を付与し、該接着剤層を介して造形基
体材料層Ａと成形表皮材料層Ｂとを一体化させ
る、特許請求の範囲第１項に記載の複合成形体の
製造方法。 ４ 表皮材料層Ｂは単層材料、或は２種以上の材
質材料の複合層材料である、特許請求の範囲第１
項に記載の複合成形体の製造方法。[Scope of Claims] 1. In obtaining a composite molded body consisting of a base material layer A and a skin material layer B, a sheet-like skin material is placed in a mold 1 for shaping the surface of the target composite molded body on the skin material layer B side. The mold is equipped with a vacuum forming function, a pressure forming function, or a vacuum pressure forming function, and a flexible or is provided with a movable flange member 16,
The projecting dimension W of the projecting edge member inward from the molding cavity is set to an appropriate dimension approximately corresponding to or less than the width dimension of the outer peripheral end surface of the modeling base material layer A or the thickness dimension of the skin material layer B. , Vacuum forming, pressure forming, or vacuum pressure forming a sheet-like skin material using the mold 1 and holding it as it is on the molding surface, and forming an effective molding area of the molded skin material layer B held in the mold 1. The base material layer A is shaped and adhered to the back side of the part, and the outer surface and the outer peripheral end surface of the shaped base material layer A are covered with the skin material layer B, or the outer surface of the shaped base material layer A is covered. A composite molded body is manufactured by folding the material layer portion around the effective molding area of the skin material layer B inwardly, and after demolding, the outside of the effective molding area of the molded skin material layer B of the composite molded body is manufactured. A method for manufacturing a composite molded article, comprising: trimming a surrounding unnecessary material portion B'. 2. The base material layer A can be formed on the back side of the effective molding area of the molded skin material layer B held in the mold 1 by resin injection molding, mold press molding, cast molding, or thermofoamable resin bead molding. A method for producing a composite molded article according to claim 1, which is carried out by molding, foam molding of urethane resin, or the like. 3. An adhesive layer is provided in advance on the back surface of the sheet-like skin material, or an adhesive is applied to the back surface of the effective molding area of the molded skin material layer B after the sheet-like skin material is molded with the mold 1, and the adhesive is applied to the back surface of the effective molding area of the molded skin material layer B. The method for producing a composite molded article according to claim 1, wherein the molded substrate material layer A and the molded skin material layer B are integrated via a compound layer. 4 The skin material layer B is a single layer material or a composite layer material of two or more types of materials, Claim 1
A method for producing a composite molded article as described in 2.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP60169210A JPS6228246A (en) | 1985-07-31 | 1985-07-31 | Manufacture of composite molded shape |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP60169210A JPS6228246A (en) | 1985-07-31 | 1985-07-31 | Manufacture of composite molded shape |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS6228246A JPS6228246A (en) | 1987-02-06 |
| JPH0242353B2 true JPH0242353B2 (en) | 1990-09-21 |
Family
ID=15882241
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP60169210A Granted JPS6228246A (en) | 1985-07-31 | 1985-07-31 | Manufacture of composite molded shape |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS6228246A (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS63162220A (en) * | 1986-12-25 | 1988-07-05 | Toyota Tekko Kk | Manufacture of laminate object |
| JPH0798342B2 (en) * | 1988-01-06 | 1995-10-25 | 大日本印刷株式会社 | Manufacturing method for painted products |
-
1985
- 1985-07-31 JP JP60169210A patent/JPS6228246A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPS6228246A (en) | 1987-02-06 |
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