JPH0363938B2 - - Google Patents

Description

[Detailed description of the invention] B. Purpose of the invention [Industrial application field] The present invention relates to a method for manufacturing a laminate molded body.

More specifically, the present invention relates to a method for manufacturing a laminate molded article in which the back surface of a predetermined area of a skin material laminated on the outer surface of a substrate is in a non-adhesive, floating state with respect to the substrate surface.

[Conventional technology]

For example, due to the design of a vehicle door trim board, the outer surface of the ground skin of the board body is different from the material, color, and
Many of them are made by partially pasting ornamental skin materials with different patterns (decorative skin part, inner part) in a desired design pattern.

FIG. 3 is an external perspective view of an example of a door trim board having such an ornamental skin part.
A is a door trim dowel body made of a laminated layer of a rigid base 1 and a skin material 2; 3 is an ornament skin portion provided by partially pasting a desired design pattern on the outer surface of the ground skin material 2 of the board body; The ground skin material 2 of the board body is made of woven fabric, knitted fabric, non-woven fabric, carpet, natural leather, synthetic leather, resin sheet material, etc., which is different in material, color, pattern, etc. Such an ornament skin part 3 is applied at the same time as the board main body is molded, or by post-installation processing after the board main body is molded.

The conventional ornament skin part 3 has a configuration in which the entire back surface thereof is completely bonded to the outer surface of the ground skin material 2 of the molded body.

However, in recent years, in vehicle door trim boards and the like, from the viewpoint of the feel and texture of the ornament skin 3, the outer peripheral edge of the ornament skin material is locked to the ground skin material 2 of the board body 1, which is the molded body, but the back side Approximately the entire area of the ornament surface material is provided with a non-adhesive, so-called floating paste form on the two sides of the ground skin material, so that the ornament surface surface consciously expresses fine drape wrinkles, or causes fine wrinkles when touched. I've come to like things.

Conventionally, for such items, as shown in the example in FIG. 4, an ornament skin material 3 is attached to a plate material 4 or a frame member (hereinafter referred to as an ornament core material) formed into an outer shape corresponding to a desired ornament pattern.
, and fold the peripheral edge back to the back side of core material 4.
The folded part is consciously created with decorative drape wrinkles 3a on the surface of the ornamental skin material 3, and is fastened to the core material 4 with adhesive or a locking needle 3b, and the surface material with fine wrinkles 3a or the skin material is loosened. An ornamental skin patch member 5 spread over the eyes is manufactured. The patch member 5 is applied to a predetermined portion of the outer surface of the ground skin material 2 of the molded body A, and the core material 4 is subsequently attached using means such as a locking needle 6, a clip, or an adhesive. In this example, the ground skin material 2 is shown as having a two-layer structure of a decorative skin material 2a and a soft cushion material 2b lined on the back surface thereof.

[Problem that the invention seeks to solve]

However, the above manufacturing method is inefficient, lacks mass productivity, and is expensive because both the production of the ornamental skin material patch 5 and the attachment of the patch 5 to the molded body A are completely manual. Moreover, in order to maintain the quality at a high level without any variation, hot kneading workers are required.

On the other hand, as a modification of the molded body with a floating ornament skin as described above, the surface skin material 2 of the molded body is
As for itself, as shown in Fig. 1e, the back surface of the predetermined range surface area 2d is pasted in a non-adhesive floating state on the surface of the base material to intentionally express the decorative drape wrinkles 2f on the surface material part, or For example, the configuration of a door trim board that causes fine wrinkles when touched is considered to be unique. Conventionally, there is no example of manufacturing a product with such a configuration.

An object of the present invention is to provide an industrial method for efficiently mass-producing the same.

B. Structure of the Invention [Means for Solving Problems] The present invention provides a laminate molding method in which the back surface of a predetermined area of a surface area of a skin material laminated on a substrate is in a non-adhesive, floating state with respect to the substrate surface. In order to obtain the target laminate molded product, the base of the target laminate molded product is molded into a predetermined shape separately from the skin material, and the skin material is molded in a vacuum mold, and the vacuum mold is used to form the skin of the target laminate molded product. A state in which the molding surface area corresponding to the floating surface area of the material is divided by a parting frame and the skin material is vacuum formed in the vacuum mold, and the vacuum molded skin material is held as is in the vacuum mold. Then, the separately molded base material is superimposed on top of the molded base material through an adhesive, and the molded base material and the molded base material are integrated by pressing between the molded base material and the vacuum molded mold using a compression mold. Regardless of the clamping force between the vacuum molding mold and the crimping mold,
Within the parting frame of the vacuum forming mold, the back surface portion of the skin material that is in close vacuum forming contact with the mold surface within the frame and the outer surface portion of the molding base corresponding to the back surface portion do not substantially come into pressure contact with each other. The gist of the present invention is to provide a method for manufacturing a laminate molded product, characterized in that the mold surface level within the parting frame of the vacuum molding mold or the protrusion level of the outer surface corresponding to the part of the molded substrate is set in advance.

[Effect]

When the skin material is vacuum-formed using the vacuum forming mold described above, and the forming substrate is stacked on top of it and the two are laminated and integrated, the back side of the skin material corresponding to the inner area of the parting frame is on the side of the forming substrate when the forming substrate is crimped. does not come into substantial pressure contact with the surface of the material, so that both portions remain loose and substantially non-adhered to each other.

Therefore, it is possible to efficiently obtain a laminate molded product in which the back surface of the predetermined range surface area of the skin material, that is, the range surface area defined by the parting frame, is in a non-adhesive, floating state with respect to the base surface.

〔Example〕

(1) Molded substrate 1 For example, various hard or semi-hard solid or porous fleshy resins, resin felt, polystyrene bead foam, rigid corrugated cardboard structures made of resin or paper, cardboard, hardened plant pieces, etc. , metal plates, etc., are used as raw materials and molded into the desired molded body using a molding method that suits the characteristics of the material, such as vacuum forming, pressure forming, hot press molding, press molding, injection molding, and cast molding. molded into the desired shape as a base body. Also included are molded substrates that are themselves in a laminate configuration.

(2) Ground skin material layer 2 For example, various woven fabrics, knitted fabrics, non-woven fabrics, carpets, soft resin sheets such as vinyl chloride, single layer materials such as natural leather, synthetic leather, etc., or a suitable back-up material on the back side thereof. Materials that can be vacuum formed entirely, such as composite layer materials lined with a cushioning material layer such as soft foam resin such as polypropylene or felt. Highly flexible with bendability and stretch throughout.

(3) Vacuum forming mold Figure 1a shows a cross-sectional view of an example of a vacuum forming mold. 50 is a mold body, 51 is a molding surface, 52 is a vacuum hole opened in each required part of the molding surface, 53 is a vacuum chamber, and 54 is a vacuum pump.

Reference numeral 55 indicates a molding surface region corresponding to the area where the skin material of the target completed molded body is applied in a floating manner, and 56 indicates a parting frame that partitions the molding surface region. Further, in the mold of this example, the molding surface portion 55 is raised and has an uneven surface corresponding to the design fine wrinkles to be displayed on the surface portion of the skin material. The wall thickness of the parting frame 56 can be made as thin as possible.

(4) Manufacturing process a Vacuum forming of the skin material 2 (FIG. 1b) The skin material 2 is vacuum formed using the vacuum mold 50 described above according to a conventional method. In this example, the skin material 2 is a soft vinyl chloride sheet 2 with a thickness of 0.3 mm.
A and a non-breathable cushioning material layer 2b having a thickness of 2 mm and a 25 times foamed polypropylene flexible foam sheet bonded together in advance on the back surface of the cushion material layer 2b. 57 indicates a seal clamp.

b Pressure bonding of the molded base layer 1 (Fig. 1 c and d) The vacuum-formed skin material layer 2 (2a and 2
b) is held in a vacuum mold as it is, and a separately molded base layer 1 is superimposed thereon via an adhesive such as a hot melt type or solvent type to form a pressure bonding mold (press mold). 60, the layer is pressed against the vacuum mold 50 to integrate both layers. The adhesive may be applied in advance to one or both of the mutually opposing surfaces of the molded substrate 1 and the skin material layer 2. In this case, it is better to make the back surface area of the skin material layer and/or the surface area of the base layer corresponding to the floating area of the skin material layer into a non-adhesive surface area. The entire outer surface of the molded substrate 1 may be heated and softened or melted in advance to impart adhesive properties. In this case as well, closeout frame 5
It is preferable that the outer surface portion of the molded substrate corresponding to the inside of the molded substrate is selectively heat-treated so as to be a non-heated portion.

The crimping mold 60 of this example is designed to hold the molded base layer 11 by vacuum suction, and 61 is the molded base layer holding surface of the crimping mold, 62 is a vacuum suction hole, 63 is a vacuum chamber, and 64 is a vacuum pump. show.

The press-bonding process of the molded substrate 1 may be performed simultaneously with the vacuum forming of the skin material layer 2, or may be performed with some delay in operation.

In the above mold clamping process, in the parting frame 56, the back surface of the ground skin material part that is vacuum formed and in close contact with the molding surface 55 in the frame, and the outer surface portion of the molding base corresponding to the back surface are the mold 50. 60
The vacuum molding mold 50
By setting in advance the molding surface level l ₁ (FIG. 1a) in the parting frame 56 or the protrusion level l ₂ (FIG. 1c) of the outer surface corresponding to the part of the molding base 11, the above-mentioned There is substantially no mutual pressure contact between the parts. Therefore, the parting frame 5
Even if adhesive is present on the outer surface area of the molded base 1 or the back surface area of the ground skin material 2 corresponding to the interior of the molded base 1, or even if that surface part is in a heat-softened state and adhesive at that time, the double-sided parts The surface skin material portion defined by the parting frame 56 is not adhered to the outer surface of the molded base and is in a so-called floating state.

c. Opening the mold, taking out the molded object, and processing the ends After the predetermined cooling time has elapsed, the compression mold 60 is pulled up (mold opening), and the molded object is removed from the vacuum forming mold 50. The parting frame 56 on the mold 50 side comes out from within the thickness of the skin material layer 2 of the laminated molded product into which it bites, and the parting frame 56 leaves a groove line 2c.
(FIG. 1e) is the outline dividing line of the skin lifting area 2d.

Next, the unnecessary outer peripheral edge 2e of the skin material layer 2 of the laminated molded product is trimmed c-c, or end treatment is performed such as rolling it onto the back side of the molded base 1 and fixing it with adhesive as shown by the two-dot chain line. and make it a finished product.

Further, by subsequently heating, compressing, kneading, etc. the surface of the skin material in the skin material lifting area 2d, the fine wrinkles can become more natural and the texture can be improved. Also, the area 2
It is also good to fit and lock the molding material 7 along the contour groove line 2c of d to conceal and make up the groove line 2c.

The skin material lifting part 2d can be formed at one or more floating islands within the entire surface area of the skin material as shown in Figure 2a, or at the edge of the molded body as shown in Figure 2b. It can also be formed and provided in such a form.

C. Effects of the Invention In this way, it is possible to efficiently mass-produce a laminate in which the back surface of the desired surface area of the skin material layer is in a so-called floating state with no adhesion to the surface of the base layer. The purpose is well achieved and it is effectively suitable, for example, for manufacturing door trim boards for vehicles.

[Brief explanation of drawings]

Figures 1a to 1e are process explanatory diagrams of the embodiment, Figures 2a and 2b are perspective views showing examples of formation patterns of the skin material lifting part, and Figure 3 is a diagram showing the formation pattern of the ornament skin part. FIG. 4 is an external perspective view of an example of a door trim board for a vehicle, and FIG. 4 is a sectional view showing a conventional example in which an ornament skin portion is provided in a floating form. 1 is a base layer, 2 (2a, 2b) is a skin material layer, 2
d is the surface material layer lifting part, 50 is the vacuum forming mold,
56 is a parting frame, and 60 is a crimp type.

Claims (1)

[Scope of Claims] 1. To obtain a laminate molded product in which the back surface of a predetermined area of the skin material 2 laminated on the base 1 is in a non-adhesive floating state with respect to the base surface, the purpose is to laminate molding. The base body 1 of the body is molded into a predetermined shape separately from the skin material 2, and the skin material 2 is molded into a vacuum mold 5.
0, and the vacuum forming mold 50 is divided by a parting frame 56 into a molding surface area corresponding to the floating surface area of the skin material 2 of the target laminate molded body, and the skin material is molded using the vacuum forming mold. 2 is vacuum-formed, and while the vacuum-formed skin material 2 is held as it is in the vacuum mold 50, the molded substrate 1, which has been molded and manufactured separately, is overlaid and crimped with an adhesive. The molded surface skin material 2 and the molded base 1 are integrated by pressing between them with the vacuum molding mold 50 by the mold 60, and in this case, the vacuum molding mold 50 and the pressure bonding mold 6
Regardless of the mold clamping pressure of 0, within the parting frame 56 of the vacuum forming mold 50, the back surface of the skin material that is in close vacuum forming contact with the mold surface within the frame, and the outer surface of the molding base corresponding to the back surface. The mold surface level in the parting frame of the vacuum forming mold 50 or the protrusion level of the outer surface corresponding to the part of the molding base 1 is set in advance so as not to substantially make pressure contact with the part. A method for producing a featured laminate molded product.