JPS635268B2 - - Google Patents

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention is directed to a sheet-shaped cover material and a laminate mainly composed of a core material made of flexible polyurethane foam, which are joined together and a predetermined floating material is bonded together. The present invention relates to an apparatus for forming into an extruded shape.

(Prior art) For example, as a novel method for molding a predetermined raised shape on a sheet material in which a foamed plastic such as polyurethane foam is integrally bonded to a cover material such as cloth, The invention described in Publication No. 1184 has been proposed.

The method of this invention includes: (a) a cover material of synthetic resin film or woven fabric;
A thin layer of anhydrous polyurethane foam-generating material is applied to one or both of the contact surfaces with the core material of a flexible polyurethane foam sheet having a considerable thickness, and (b) the anhydrous polyurethane foam-generating material causes a foaming reaction. (c) bringing the cover material and core material into contact with each other over the entire area; (d) introducing a sufficient amount of moisture into the coating surface to (a) applying sufficient heat to cure the foam-generating material; and (b) applying sufficient pressure to create the desired embossed pattern when pressed through a predetermined mold. It consists of each step of (d), or (b) a cover material of synthetic resin film or woven fabric;
One or both of the contact surfaces of a flexible polyurethane foam sheet having a considerable thickness with the core material, and one or both of the contact surfaces of the core material with a backing material such as a synthetic resin film, woven fabric, or plywood. (b) introducing a sufficient amount of moisture to the coated surface to cause the anhydrous polyurethane foam forming material to cause a foaming reaction; and (c) applying the anhydrous polyurethane foam forming material to the coating surface. and (d)(a) sufficient heat to cure the polyurethane foam-forming material from both exterior surfaces of the cover and backing; and b) Sufficient pressure to create the desired embossed pattern by pressing with a predetermined die from the external surface of said covering material or from both the external surfaces of said covering material and backing material; This is a method for producing a laminated cloth, which consists of the following steps (a) to (d):

By the way, when implementing these methods on an actual product, specifically, the following work steps are taken.

Application of polyurethane foam-generating material to the laminated material Application of moisture Setting of the laminate in a mold Heat forming Of these, a known press device is usually used for heat forming, but this type of product is formed into a wide sheet. This required a large press plate that could cover a wide press area. However, using a large press machine not only increases the size of the equipment and is uneconomical, but above all, this process requires setting the laminate into a mold beforehand, so it is difficult to use a mold. This had a major drawback in that there was no flexibility in the work when placing the laminated material on the plate. At the same time, this was a major problem in terms of production efficiency, as it was not possible to automate this type of molding process or to put it on a production line.

(Problems to be Solved by the Invention) In view of this situation, the present inventors have conducted various studies and found that when molding this type of embossed shape, it is difficult to use a large press such as a press plate. It has been found that, rather than applying pressure, it is sufficient if the spacing of the upper or lower mold relative to the stack is kept constant in a predetermined position. In this case, there is no need to use a large press plate, and some kind of clamping mechanism sufficient to maintain a predetermined spacing is sufficient. The invention disclosed herein is proposed based on this idea.

The main purpose of this invention is to
Firstly, the degree of freedom of work in this type of molding process can be expanded and the density can be greatly increased. Secondly, the molding process can be automated or integrated into a production line, which is an advantage in terms of production efficiency. The third point is economic efficiency regarding equipment, power consumption, product cost, etc.

(Means for Solving the Problems) That is, the apparatus for forming a laminate into an embossed shape according to the present invention includes a laminate mainly composed of a sheet-like cover material and a core material made of flexible polyurethane foam. It is a device that forms a predetermined embossed shape while joining them together, and opens and closes a machine base and an upper mold that has a heat source inside and a predetermined mold on the bottom side through a pivot joint with the machine base. an upper mold device; a locking device for fixing the upper mold to the machine base in a closed state; and a lower mold device for moving the lower mold having a heat source inside and a predetermined mold on the upper surface up and down along the machine base. It is characterized by consisting of.

(Example) The present invention will be described in detail below based on the attached drawings. Fig. 1 is a side view of a molding apparatus according to the invention, Fig. 2 is a plan view thereof, and Fig. 3 is a setting state of a laminate. FIG. 4 is an enlarged sectional view of a mold portion showing a molding state, and FIG. 5 is a partial sectional view showing an example of a molded product.

The apparatus 1 according to the present invention is composed of a machine base 10, an upper mold device 20, a lock device 30, and a lower mold device 40.

The machine stand 10 is a frame fixed on a base such as a turntable, and the upper mold 21 is pivotably supported at the upper part so that it can be freely opened and closed, and the lower mold 41 is mounted on the lower part so that it can move up and down. It is something that will be done.

The upper mold device 20 includes an upper mold 21 having a mold 21a that imparts a predetermined shape to a laminate, and a mechanism that opens and closes the upper mold 21 in an arc shape via a pivot shaft 23 pivotally supported on the machine base 10. It is equipped with

The upper mold 21 has a heat insulating plate 21 on the lower surface side of the substrate 22.
c, a hot plate 21b, and a mold 21a are integrally constructed in this order, and are pivotally supported on the side columns 11, 11 of the machine base via a pivot shaft 23 at the rear of the base plate 22. The upper hot plate 21b has a built-in steam pipe so as to be heated by steam, and is connected to a flexible connecting pipe 4a. In addition, the mold 21a may have a smooth plate shape when forming an embossed shape only on one surface of the laminate (see the sectional view in FIG. 4).

The upper mold 21 is opened and closed by the following mechanism. That is, gears 2 are provided at both rear ends of the substrate 22 of the upper die 21.
5, 25 are provided, and the side columns 11, 11 of the machine base 10
The upper die 21 is configured to open and close in an arc shape from a pivot shaft 23 by the vertical movement of a rack 26 connected to a piston of a cylinder device 27 attached to the upper die. Reference numerals 26a and 26a in the figure are guide rollers of the rack 26.

Note that it is preferable from the viewpoint of work safety to provide a mechanism for fixing the upper mold 21 when the upper mold 21 is in an open state. In the embodiment, an arm 16 is pivotally attached to a pole 14 at the rear of the machine base 10, and a locking pin 28 of an upper mold 21 is engaged with the arm 16. When closing the upper mold 21, the piston of the cylinder device 15 rises and the arm 16
to release the engagement with the locking pin 28 of the upper die 21.

Next, the locking device 30 will be explained. This locking device 30 fixes and holds the upper mold 21 on the machine base 10 in a closed state, and prevents mold runout or mold deviation when the lower mold 41, which will be described later, is raised. This is to prevent This lock device 30 may have a structure in which a piston 32 of a cylinder device 31 fixed to the machine base 10 fits into a recess 33 provided in a part of the upper mold 21 as shown in the figure, In the case of the embodiment in which a rack 26 and a gear 25 are provided, it is preferable that the locking is done at the front part of the upper mold.

Next, the lower mold device 40 will be explained. The lower die device 40 is a die 41a that gives a predetermined shape to the laminate.
It consists of a lower mold 41 having a shape and a mechanism for moving the lower mold 41 up and down.

The lower mold 41 has substantially the same structure as the upper mold 21, and includes a heat insulating plate 41c, a hot plate 41b, and a mold 41a integrally provided on the upper part of the substrate 42. However, the mold 41a in the lower mold 41 of the embodiment is made of a plywood board 41a'' with mold blades 41a' protruding from it for molding the laminate into an embossed shape (see the sectional view in FIG. 4).The hot plate 41b is It is heated by steam similarly to that of the upper mold 21. Reference numeral 4a in the figure is a connecting pipe.

The mechanism for moving the lower mold 41 up and down is cylinder devices 45, 45. The reason why the lower mold 41 moves up and down is to facilitate the opening and closing (arc movement) of the upper mold 21 and to prevent the surface of the laminated material from shifting, which may occur when the upper mold 21 is opened and closed. That is, when the difference in the unevenness of the mold 21a of the upper mold 21 is large, and if the lower mold 41 is in a fixed position, the convex part of the mold descends in an arc shape while contacting the surface of the laminate. If the surface of the laminate is a sheet-like material such as cloth, wrinkles will occur and a beautiful finish cannot be expected. Therefore, the arc movement of the upper mold 21 is performed in a completely free space, and when the upper mold 21 is in a horizontally closed position, the lower mold 4
If 1 were allowed to rise horizontally, such concerns would be resolved.

(Operation) FIG. 5 is a partial sectional view showing an example of a molded product produced by the above molding apparatus. This molded product 60 mainly consists of a sheet-like cover material 61 and a core material 65 made of flexible polyurethane foam, etc., and the cover material 61 and the core material 65 are integrally bonded with an adhesive. A recess 69 that forms a raised shape
In this case, the cover material 61 and the core material 65 are compressed, impregnated with an adhesive and cured, and bonded and shaped as one body.

The operation of the apparatus of the present invention will be explained below using this molded article 60 as an example. First, the laminate 60A constituting the molded product 60 is set in the apparatus of the present invention. In this setting process, the upper mold 21
is opened upward in an arc shape, and the lower mold 4
1 is in the lowered position by the cylinder device 45,
A free space for large operations is formed above the lower die 41. Then, as shown in FIG. 3, the laminate 60A is set on the lower mold 41, and the laminate 60A is prepared in advance by a sheet-like cover material 61 and a core material 65 made of flexible polyurethane foam. An anhydrous polyurethane foam generating material 63 is applied as an adhesive to a predetermined surface of the laminate, and water and water are applied to the other surface of the laminate or other surfaces of the laminate so that moisture can be introduced thereto. It is coated with the necessary curing accelerator.

When the setting process of the laminate is completed, the upper mold 2 is
Arm 16 that fixed 1 on its back side
is actuated by the cylinder device 15 to release the engagement of the upper die 21 with the latching pin 28. At the same time, the cylinder device 27 of the upper die device 20 operates to release the rack 26.
, and close the upper mold 21 downward.

When the upper mold 21 is completely closed horizontally, the cylinder device 31 of the locking device 30 is activated to fix the upper mold 21 at a predetermined position on the machine base 10.

When the upper mold 21 is completely fixed by the locking device 30, the cylinder device 45 of the lower mold device 40 is operated to raise the lower mold 41 to the molding position.

This starts the thermoforming process. Upper mold 2
1 is fixed by a locking device 30, and the lower die 41 is operatively fixed by a cylinder device 45, and both are held at a predetermined distance, and the laminate 60A is pressed as shown in FIG. Sufficient pressure is applied to create the shape. In addition, each mold 21a,
41a connects the connecting pipe 4a to the hot plates 21b and 4.
1b to provide sufficient heat to cure the polyurethane foam forming material. Due to this pressure and heat, moisture is introduced into the anhydrous polyurethane foam material and a foaming reaction begins, causing the cover material 61 and the core material 6 to
5 are joined together by their adhesive action. At the same time, in the vicinity of the mold blade 21a', the cover material 6
1 and the core material 65 are compressed, and the foaming component of the anhydrous polyurethane foam material is impregnated and hardened, and the molded product is bonded and shaped to form the recess 69 of the molded product. During this time, a timer is operating to measure the molding time, and when the molding time expires, the lower mold 41 is first lowered in the reverse order to that described above. The lock device 30 of the upper mold 21 is released,
The upper mold 21 is opened by the cylinder device 27. Then, attach the arm 1 to the latch pin 28 on the back side again.
6 is engaged and fixed to the machine stand, the molded product is taken out, and the laminated material for the next molding operation is set.

These steps can be configured to be performed on a turntable or the like, for example.

(Effects) As illustrated and explained above, according to the present invention,
Since it does not use a heavy press like in the past, it can be placed on a turntable, etc., and the process can be made into a line, greatly contributing to the automation of this process.

Another great effect of this invention is that since the upper mold is configured to open and close, a large free space is formed above the lower mold, making it easier to work and allowing for higher density work. Molded products having this kind of raised shape are required to be more aesthetically pleasing, and wrinkles or the like on the cover material should not be tolerated. Therefore, the fact that the setting process of laminated materials can be carried out easily and with high density has a great advantage in terms of work efficiency.

[Brief explanation of the drawing]

Fig. 1 is a side view of a molding apparatus according to the present invention, Fig. 2 is a plan view thereof, Fig. 3 is an enlarged front cross-sectional view of the main parts of the apparatus showing the setting state of laminated materials, and Fig. 4 is a sectional view of the forming apparatus according to the present invention. FIG. 5 is an enlarged cross-sectional view of a molding die portion showing a molding state, and FIG. 5 is a partial cross-sectional view showing an example of a molded product. 1... Molding device, 10... Machine stand, 16... Arm, 20... Upper mold device, 21... Upper mold, 25...
Gear, 26...Rack, 27...Cylinder device,
30...Lock device, 31...Cylinder device, 4
0... Lower mold device, 41... Lower mold, 45... Cylinder device, 60... Molded product, 60A... Laminate, 6
DESCRIPTION OF SYMBOLS 1... Cover material, 63... Anhydrous polyurethane foam generating material, 65... Core material, 69... Molded product recess.

Claims (1)

[Scope of Claims] 1. An apparatus for integrally joining a sheet-like cover material and a laminate mainly composed of a core material made of flexible foamed polyurethane and forming it into a predetermined raised shape, ) a machine base; (b) an upper mold device that opens and closes an upper mold having a heat source inside and a predetermined mold on the lower surface side via a pivot joint with the machine base; and (c) an upper mold device that closes the upper mold. (d) a lower mold device that has a heat source inside and a predetermined mold on the upper surface side and moves the lower mold up and down along the machine base; A device that molds the body into an embossed shape.