JPH0342229A - Preparation of interior material made of photo-setting resin - Google Patents

Abstract

PURPOSE:To enhance the adhesion of a photo-setting resin sheet to a mold and to accelerate photo-setting molding by laminating a skin material and the photo-setting resin sheet to the surface of a mold provided with a large number of fine piercing holes in this order to suck both of them under vacuum and simultaneously supplying compressed air into a chamber. CONSTITUTION:A skin material 8 such as a nonwoven fabric, a fabric or a raised knitted fabric and a photo-setting resin sheet 4 composed of an unsaturated polyester resin are laminated to the surface of a vacuum mold 1 in this order and the periphery of the photo-setting resin sheet 4 is pressed by the chamber 2 and the mold 1 is evacuated from the vacuum suction holes 3 thereof while compressed air 6 is supplied to the chamber 2 from a compressed air supply port 6. By pressing the periphery of the photo-setting resin sheet 4 by the chamber 2, vacuum suction can be well performed and even the shapes of the fine parts of the vacuum mold 1 can be taken. By this method, the photo-setting resin sheet 4 is firmly and closely bonded to the surface of the vacuum mold 1. Subsequently, the surface of the photo-setting resin sheet 4 is irradiated with light by the irradiation apparatus 7 provided in the chamber 2 to be cured and molded in a desired shape. After the completion of curing, a molded product is taken out by demolding.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing a photocurable resin interior material used for molded ceiling interior materials, door trims, etc. of automobiles.

[Prior Art] Conventionally, there have been the following methods for manufacturing interior materials using photocurable resin sheets.

A photocurable resin sheet was attached to the surface of the mold to conform to the shape of the mold, and then cured and molded by irradiation with light.

At this time, since the photocurable resin sheet applied to the mold conforms to the mold shape only by its own weight, there was a problem that it did not fit tightly to the mold surface.

In order to solve this problem, the photocurable resin sheet on the surface of the mold is pressed with a transparent synthetic resin mold such as polycarbonate or methmethyl acrylate, and while maintaining the mold shape, light is applied from above the synthetic resin mold. The curable resin sheet was cured and molded by irradiating it with light.

[Problems to be Solved by the Invention] However, the method of pressing a photocurable resin sheet with a highly transparent synthetic resin mold to conform to the mold surface shape has a disadvantage in accelerating the curing of the photocurable resin sheet. Ta. In other words, even though the synthetic resin mold is highly transparent, there is a synthetic resin mold between the irradiation device and the photocurable resin sheet, so some light is absorbed by the synthetic resin mold, making it difficult to use. There was a problem in that a high irradiation efficiency could not be obtained, which hindered the promotion of curing.

An object of the present invention is to overcome the above-mentioned problems and provide a method for manufacturing a photocurable resin interior material that can enhance the adhesion of a photocurable resin sheet to a mold and promote photocurable molding.

[Means to solve the problem]

The means of the present invention for solving the problem is to laminate a skin material and a photocurable resin sheet in this order on the surface of an air-permeable porous mold or a mold provided with a large number of minute through-holes, and then install an irradiation device inside. The periphery of the photocurable resin sheet is held in a chamber equipped with a chamber to hold the surface shape of the mold, and compressed air is supplied to the inside of the chamber and vacuum is sucked from the minute through-holes to compress the photocurable resin sheet. was brought into close contact with the surface of the mold, and the photocurable resin sheet was irradiated with the irradiation device to cure and mold the photocurable resin sheet and integrate it with the skin material.

[For production]

A skin material and a photocurable resin sheet are laminated in this order on a mold surface with a large number of minute through holes, and vacuum suction is performed.
At the same time, compressed air is supplied inside the chamber, so
The adhesion of the photocurable resin sheet to the mold surface is extremely excellent, and shape accuracy is significantly improved and formability is high.

Moreover, since the irradiation device is provided inside the chamber that presses the photocurable resin sheet, the light is directly irradiated onto the surface of the photocurable resin sheet. Therefore, the class 14 efficiency is excellent and photocuring molding can be significantly accelerated.

Furthermore, since the photocurable resin sheet has viscosity before curing, by laminating the skin material, it becomes possible to bond the sheets simultaneously with curing, thereby eliminating the need for an adhesive.

〔Example〕

An example in which the present invention is embodied in a method for manufacturing a photocurable resin interior material used for automobile interior materials is shown in FIGS. 1 and 2.
This will be explained with a diagram.

To explain the mold used in the present invention, the air-permeable porous mold can be made by bonding and solidifying metal powder with a thermosetting resin. Further, as the mold, there are wooden molds, synthetic resin molds such as epoxy resin molds, and metal molds made of highly durable aluminum ξ, and the surfaces of these molds are provided with a large number of minute through-holes 3. In the embodiment of the present invention, minute through holes 3 are formed on the mold surface.
An example using a vacuum forming mold l having a large number of molds will be explained.

As shown in the cross-sectional view in FIG. 2, the mold used in the manufacturing method of the present invention includes a vacuum forming mold 1 provided with a large number of minute through holes 3, and a metal mold holding the outer periphery of the vacuum forming mold 1. It consists of a chamber 2. A large number of minute through-holes 3 are provided on the surface of the vacuum forming mold l so that a photocurable resin sheet 4 is placed on the mold surface and the photocurable resin sheet 4 is brought into close contact with the mold surface by vacuum suction. There is. On the other hand, the chamber 2 has a shape that follows the periphery of the mold surface of the vacuum molding mold 1. A compressed air supply port 5 is formed in the chamber 2, and by supplying compressed air from the compressed air supply port 5, the photocurable resin sheet 4 can be brought into close contact with the surface of the vacuum mold 1. Furthermore, an irradiation device 7 such as a halogen lamp or a mercury lamp is provided inside the chamber 2 so as to irradiate the surface of the vacuum mold 1.

During molding, as shown in FIG. 1, a skin material 8 such as nonwoven fabric, woven fabric, or raised knit and a photocurable resin sheet 4 made of unsaturated polyester resin are laminated in this order on the surface of the vacuum mold 1. Then, as shown in FIG. 2, the periphery of the photocurable resin sheet 4 is pressed down in the chamber 2, vacuum suction is applied through the vacuum suction hole 3 of the mold 1, and compressed air is supplied through the compressed air supply port 5. By pressing the periphery of the photocurable resin sheet 4 with the chamber 2, vacuum suction can be performed well and even the detailed shape of the vacuum mold 1 can be picked up. Thereby, the photocurable resin sheet 4 firmly adheres to the surface of the vacuum mold 1.

Next, the four sides of the photocurable resin sheet are irradiated for about 20 to 30 seconds using an irradiation device 7 provided inside the chamber 2 to harden and mold them into a desired shape. Once curing is complete, the film is shaped and the molded product is taken out. If necessary, wrap the skin material 8 around the back side to complete the process.

〔Effect of the invention〕

The present invention has the following effects.

(1) A skin material and a photocurable resin sheet are laminated in this order on the surface of a 9-breathable porous mold or a mold with many minute through-holes, and vacuum suction is applied from the vacuum mold and compressed air is supplied from the chamber. supplying. That is, by using vacuum suction and compressed air in combination, the adhesion of the photocurable resin sheet to the surface of the vacuum molding mold is improved, so that the molding property is extremely high and it is possible to sufficiently handle complex shapes.

(2) Since the irradiation device is provided inside the chamber that presses the photocurable resin sheet, the light directly hits the photocurable resin sheet, resulting in good irradiation efficiency.

Therefore, the photocuring speed is increased and productivity is improved.

[Brief explanation of drawings]

FIG. 1 and FIG. 2 are process schematic diagrams of the manufacturing method of the present invention. ■...Vacuum mold, 2...Chamber...Minute through hole,...Photocurable resin sheet,...Compressed air supply port, 6...Compressed air,...Irradiation device, 8...Skin material.

Claims (1)

[Claims] A skin material and a photocurable resin sheet are laminated in this order on the surface of a breathable porous mold or a mold with a large number of minute through holes, and then the photocurable resin sheet is heated in a chamber equipped with an irradiation device inside. The mold surface shape is held by pressing the periphery, and compressed air is supplied to the inside of the chamber and vacuum suction is applied from the minute through-holes to bring the photocurable resin sheet into close contact with the mold surface, and the irradiation device is used to A method for producing an interior material made of a photocurable resin, in which the photocurable resin sheet is cured and molded by irradiating the photocurable resin sheet, and is integrated with a skin material.