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CN101200125A - 层压板及层压板的末端处理方法 - Google Patents

层压板及层压板的末端处理方法 Download PDF

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Publication number
CN101200125A
CN101200125A CNA2007100069153A CN200710006915A CN101200125A CN 101200125 A CN101200125 A CN 101200125A CN A2007100069153 A CNA2007100069153 A CN A2007100069153A CN 200710006915 A CN200710006915 A CN 200710006915A CN 101200125 A CN101200125 A CN 101200125A
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CN
China
Prior art keywords
laminated
plate
peripheral portion
pair
covering
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Granted
Application number
CNA2007100069153A
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English (en)
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CN101200125B (zh
Inventor
长谷川高广
能登伸也
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Meiwa Corp
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Meiwa Corp
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Publication of CN101200125A publication Critical patent/CN101200125A/zh
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
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    • B29B13/02—Conditioning or physical treatment of the material to be shaped by heating
    • B29B13/023—Half-products, e.g. films, plates
    • B29B13/024—Hollow bodies, e.g. tubes or profiles
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
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    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
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    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R5/00—Compartments within vehicle body primarily intended or sufficiently spacious for trunks, suit-cases, or the like
    • B60R5/04—Compartments within vehicle body primarily intended or sufficiently spacious for trunks, suit-cases, or the like arranged at rear of vehicle
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • Y10T156/1054—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing and simultaneously bonding [e.g., cut-seaming]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

本发明目的在于得到一种能够提高端部的美观度并提高形状自由度的层压板及层压板的末端处理方法。层压板(19)的制造方法具有：用支撑部件(9)支撑通过纵壁部(2b)层压一对板状部件(3、4)的热塑性树脂制的层压坯料(1)，以使该层压坯料(1)的周边部(1a)露出，将热风吹到上述周边部(1a)上使该周边部(1a)加热软化的第一工序；以及，将冲模(17)的切断刀(17a)与上述加热软化了的周边部(1a)接触并将上述一对板状部件(3、4)的一方的板状部件(4)向另一方的板状部件(3)推压，使上述一对板状部件(3、4)彼此接触而熔合在一起，并且使层压板(19)从上述层压坯料(1)脱模的第二工序。

Description

层压板及层压板的末端处理方法
技术领域
本发明涉及层压板及层压板的末端处理方法。
背景技术
以往，作为层压板，公知的是例如蜂窝芯子那样具备层压具有纵壁部的芯板的构造。该层压板通过切断成所希望的轮廓形状，作为车辆用或建筑用的内装材料或外装材料等使用。
然而，这种层压板包含具有纵壁部的芯板而厚度大，因此若仅切断端部则存在端部的外观变差的问题。
因此，提出对切断的端部进行末端处理而提高端部的美观度的层压板的方案(例如专利文献1：日本特开2001-18308号公报)。
在该专利文献1中公开的层压板是，将热刀与层压板的端部接触，在加热层压板的同时压碎层压板而形成折弯部，并将该折弯部向上侧折弯而使其与层压板的侧部熔接在一起。
然而，当在对具有复杂的曲线形状的层压板进行末端处理时使用了这种方法的场合，由于在形成复杂的曲线形状的部分中折弯的折弯部上产生大的褶皱，因此不能使该折弯部很好地接触层压板的侧端部。即，上述末端处理方法存在对层压板的形状产生限制的问题。
发明内容
因此，本发明目的在于得到一种能够提高端部的美观度并提高形状自由度的层压板及层压板的末端处理方法。
本发明第一方案的层压板的末端处理方法的特征是，具有以下工序：用支撑部件支撑通过纵壁部层压一对板状部件的热塑性树脂制的层压坯料，以使该层压坯料的周边部露出，将热风吹到上述周边部上使该周边部加热软化的第一工序；以及，使冲模的切断刀与上述加热软化了的周边部接触并将上述一对板状部件的一方的板状部件向另一方的板状部件推压，使上述一对板状部件彼此接触并熔合在一起，并且使层压板从上述层压坯料脱模的第二工序。
本发明第二方案的层压板的末端处理方法是在第一方案中，其特征是，上述支撑部件是绝热件。
本发明第三方案的层压板的末端处理方法是在第一或第二方案中，其特征是，在上述层压坯料的外面贴合有包覆材料。
本发明第四方案的层压板，具备具有纵壁部和通过该纵壁部层压的一对板部的热塑性树脂制的主体部，其特征是，上述一对板部中一方的板部的端部向另一方的板部的端部弯曲的形成并熔敷在该另一方的板部上。
本发明第五方案的层压板是在第四方案中，其特征是，形成有包覆上述主体部的外面的包覆部。
本发明具有以下效果。
根据第一方案的发明，由于加热软化通过纵壁部层压一对板状部件的层压坯料的周边部，使冲模的切断刀与该加热软化了的周边部接触，只是在使层压坯料的一方的板状部件与另一方的板状部件接触而熔合在一起后，就可以使层压板从层压坯料脱模，因此可以将进行了末端处理的状态的层压板做成复杂的形状，能够提高层压板的形状自由度。
根据第二方案的发明，当加热软化层压坯料的周边部时，通过用绝热件支撑该层压坯料的加热软化了的周边部以外的区域，从而能够抑制层压坯料的加热软化了的周边部以外的区域被加热。其结果，能够抑制由热引起的层压坯料的加热软化了的周边部以外的区域的线膨胀，能够抑制形成层压板时产生变形。
根据第三方案的发明，通过使用在外面贴合了包覆材料的带包覆材料的层压坯料来形成层压板，能够提高该层压板的外观设计性。
根据第四方案的发明，由于一对板部中一方的板部的端部向另一方的板部的端部弯曲地形成并熔敷在该另一方的板部上，因此可以将层压板的末端精加工得很美观。
根据第五方案的发明，由于在主体部的外面上形成有包覆该外面的包覆部，因此能够提高层压板的外观设计性。
附图说明
图1是表示本发明的一实施方式的贴合了无纺布的层压坯料的立体图。
图2是表示本发明的一实施方式的贴合了无纺布的层压坯料的构造的分解立体图。
图3是表示本发明的一实施方式的贴合了无纺布的层压坯料的剖视图。
图4是表示将本发明的一实施方式的贴合了无纺布的层压坯料放置在加热装置上的状态的分解立体图。
图5是表示将本发明的一实施方式的贴合了无纺布的层压坯料放置在加热装置上的状态的剖视图。
图6是表示将本发明的一实施方式的贴合了无纺布的层压坯料放置在承载台上的状态的分解立体图。
图7是表示将本发明的一实施方式的贴合了无纺布的层压坯料放置在承载台上的状态的剖视图。
图8是表示是本发明的一实施方式的贴合了无纺布的层压坯料脱模的状态的剖视图。
图9是本发明的一实施方式的层压板的剖视图。
图中：
1-层压坯料；1a-带包覆材料的层压坯料1d的周边部(层压坯料的周边部)；1b-表面(外面)；2b-纵壁部(纵壁)；3-盖板(另一方的板状部件)；4-盖板(一方的板状部件)；5-无纺布(包覆材料)；9-绝热件(支撑部件)；17-冲模；17a-切断刀；19-底板(层压板)；20-主体部；21-纵壁部；22-背面侧板部(另一方的板部)；22a-端部；23-表面侧板部(一方的板部)；23a-端部；24-包覆部。
具体实施方式
以下，参照附图详细说明本发明的实施方式。在这里，作为层压板举例说明敷设在汽车的行李箱中的底板。
图1是表示本实施方式的贴合了无纺布的层压坯料的立体图，图2是表示贴合了无纺布的层压坯料的构造的分解立体图，图3是贴合了无纺布的层压坯料的剖视图，图4是表示将贴合了无纺布的层压坯料放置在加热装置上的状态的分解立体图，图5是表示将贴合了无纺布的层压坯料放置在加热装置上的状态的剖视图，图6是表示将贴合了无纺布的层压坯料放置在承载台上的状态的分解立体图，图7是表示将贴合了无纺布的层压坯料放置在承载台上的状态的剖视图，图8是表示使贴合了无纺布的层压坯料脱模的状态的剖视图，图9是层压板的剖视图。
本实施方式的底板(层压板)19具备：热塑性树脂制的主体部20；以及用无纺布(包覆材料)5包覆了主体部20的表面(外面)20a侧的包覆部24。
主体部20做成3层构造，具备多个纵壁部21和通过该纵壁部21层压的作为一对板部的背面侧板部22及表面侧板部23。而且，上述无纺布5贴合在表面侧板部23的表面23b上。
再有，作为一方的板部的表面侧板部23的端部23a向作为另一方的板部的背面侧板部22的端部22a弯曲地形成并熔敷在背面侧板部22上。
该底板19通过对层压坯料1进行末端处理而形成。
如图2所示，层压坯料1具备：形成多个圆柱状的压花部2a并具有纵壁部2b的断面凹凸状的芯板2；熔敷在该芯板2上，形成层压坯料1的背面1c的板状的盖板(板状部件)3；以及，熔敷在该芯板2上，形成层压坯料1的表面1b的板状的盖板(板状部件)4。即，层压坯料1做成通过具有纵壁部2b的芯板2层压一对盖板3、4的构造。而且，在本实施方式中，芯板2及盖板3、4分别由非透气性的聚丙稀树脂(热塑性树脂)形成。
在本实施方式中，通过在盖板4的表面4a，即层压坯料1的表面1b上接合无纺布(包覆材料)5而形成带包覆材料的层压坯料1d。
带包覆材料的层压坯料1d做成剪断成比敷设的行李箱的底面的轮廓形状，即底板19的轮廓形状还稍大(在本实施方式中大5～6mm)的形状，如图1所示，该带包覆材料的层压坯料1d的周边部(层压坯料的周边部)1a成为被加热的区域(图1的斜线部分)。
接着，说明用于层压板的末端处理的装置。
加热装置6做成大致箱形，其具备：容纳向上方吹出热风的吹出装置(未图示)，并在上方开口的吹出装置容纳室6a；以及，载置在吹出装置容纳室6a的上部，用于夹入住带包覆材料的层压坯料1d进行包覆的层压坯料包覆单元7。
在该层压坯料包覆单元7上形成有用于向外部吹出热风的热风吹出槽7a。在本实施方式中，该热风吹出槽7a由后述的铁板8的槽部、钢板12及钢板13形成。而且，以如下方式形成该热风吹出槽7a，即当将带包覆材料的层压坯料1d载置在加热装置6上时，使该带包覆材料的层压坯料1d的周边部1a向热风吹出槽7a一侧突出。
在本实施方式中，层压坯料包覆单元7具备：具有槽部的大致矩形板状的铁板8；以及从其表面和背面夹住带包覆材料的层压坯料1d并支撑它的作为支撑部件的绝热件9。
具体地说，如图5所示，铁板8具备：轮廓形状比带包覆材料的层压坯料1d的轮廓形状稍小的的内侧铁板8a；挖通有轮廓形状比带包覆材料的层压坯料1d的轮廓形状稍大的孔的大致矩形板状的外侧铁板8b；以及，架设在这些内侧铁板8a及外侧铁板8b上的桥接用铁板8c。而且，通过将内侧铁板8a配置在外侧铁板8b的内侧，使得在内侧铁板8a的外侧面和外侧铁板的内侧面之间形成槽部，并且如图5所示，以将桥接用铁板8c架设在内侧铁板8a及外侧铁板8b上的状态进行焊接，从而形成了形成有槽部的铁板8。
再有，在外侧铁板8b的上面设有沿外侧铁板8b的内周立起的钢板12，如图5所示，该钢板12利用螺栓15安装在外侧铁板8b的内侧周边部上。
绝热件9具备：从背面侧支撑带包覆材料的层压坯料1d的固定绝热件11；以及，从表面侧支撑的可动绝热件10。
固定绝热件11通过用上侧固定绝热件11a和下侧固定绝热件11b夹住内侧铁板8a而固定在铁板8上。
上侧固定绝热件11a做成沿外周切去上侧角部的形状，如图5所示，在上侧固定绝热件11a的侧面及斜面的外周上设有钢板13。
另一方面，下侧固定绝热件11b做成与内侧铁板8a的轮廓形状对应的轮廓形状，在其上部设有当安装在内侧铁板8a上时用于嵌合桥接用铁板8c的嵌合槽(未图示)。再有，在下侧固定绝热件11b的下面设有不锈钢板16。
而且，在本实施方式中，如图5所示，在层压这些上侧固定绝热件11a、内侧铁板8a、下侧固定绝热件11b以及不锈钢板16的状态下，通过从下方穿过螺栓14而固定在铁板8上。
还有，在上侧固定绝热件11a的上方配置有用于与固定绝热件11的上侧固定绝热件11a一起夹持带包覆材料的层压坯料1d的可动绝热件10。
另外，在上述加热装置6中，可拆卸地安装有上述层压坯料包覆单元7。因此，若形成多个热风吹出槽的轮廓形状不同的层压坯料包覆单元，则可以适当更换它们，可以对各种轮廓形状的层压板进行末端处理。
冲模17及承载台18是用于同时进行带包覆材料的层压坯料1d的末端处理及脱模的装置，在冲模17上设有使轮廓形状与底板19的轮廓形状对应的切断刀17a。
接着，说明底板19的制造方法。
首先，说明第一工序。
首先，如图3及图4所示，将在盖板4的表面4a上贴合了无纺布5的带包覆材料的层压坯料1d载置在加热装置6上。具体地说，在将带包覆材料的层压坯料1d载置在固定绝热件11上，使得其周边部1a突出于在层压坯料包覆单元7上所形成的热风吹出槽7a侧的状态下，使可动绝热件10下降，用固定绝热件11和可动绝热件10夹持该带包覆材料的层压坯料1d。
然后，在夹持带包覆材料的层压坯料1d的状态下从图外的热风吹出装置向上方吹出热风。另外，图5中的箭头表示热风的流动。这时，通过热风吹出槽7a向外部吹出的热风吹到向热风吹出槽7a侧突出的带包覆材料的层压坯料1d的周边部1a上，周边部1a被加热软化。在本实施方式中，以大约5m/s的风速向上方吹出大约300℃的热风。而且，通过将该热风吹到带包覆材料的层压坯料1d的周边部1a上大约10～15秒钟，则使周边部1a加热软化。
其次，说明第二工序。
接着，使加热软化了周边部1a的带包覆材料的层压坯料1d移动而载置在承载台18上。在本实施方式中，带包覆材料的层压坯料1d以使无纺布5朝上的状态载置在承载台18上。再有，带包覆材料的层压坯料1d以如下定位的状态载置在承载台上，即可以用冲模17的切断刀17a切断其周边部1a。另外，该带包覆材料的层压坯料1d的定位可以用各种方法进行，例如将吸附在存储动作的自动机臂的吸盘上的带包覆材料的层压坯料1d载置在承载台18的规定位置上的方法等。
然后，使冲模17的切断刀17a与载置于承载台18上的带包覆材料的层压坯料1d的周边部1a接触的同时，向承载台18推压该冲模17。
于是，在表面4a上贴合了无纺布5的盖板4被冲模17的切断刀17a推压而弯曲地形成的同时，与盖板3接触并熔合在一起。若进一步推压冲模17，则带包覆材料的层压坯料1d被冲模17的切断刀17a切断，作为层压板的底板19从该带包覆材料的层压坯料1d予以脱模。
这样便形成了如下的底板19，即该底板19具备具有多个纵壁部21和通过该纵壁部21层压的背面侧板部22及表面侧板部23的主体部20，表面侧板部23的端部23a向背面侧板部22的端部22a弯曲地形成并熔敷在背面侧板部22上。
根据以上本实施方式，首先，加热软化在层压坯料1的表面1b上接合了无纺布5的带包覆材料的层压坯料1d的周边部(层压坯料的周边部)1a，上述层压坯料1通过具有纵壁部2b的芯板2层压一对盖板3、4而成，然后，只是通过使冲模17的切断刀17a与该加热软化了的周边部1a接触，使一方的盖板4与另一方的盖板3接触而熔合在一起，就可以使底板19从带包覆材料层压材料1d脱模。因此，可以将进行了末端处理的状态的底板19的轮廓形状做成复杂的形状，能够提高底板19的形状自由度。
另外，通过使用带包覆材料的层压坯料1d，由于可以在层压坯料1的表面1b上贴合了无纺布5的状态下进行脱模，因而能够容易得到提高了外观设计性的底板19。
另外，根据本实施方式，当加热软化带包覆材料的层压坯料1d的周边部1a时，通过用绝热件9夹持该带包覆材料的层压坯料1d的加热软化了的周边部1a以外的区域(包覆区域)，从而能够抑制该包覆区域被加热。其结果，能够抑制由热引起的包覆区域的线膨胀，当形成底板19时，能够抑制在该底板19上产生变形。
另外，根据本实施方式，由于底板19做成如下构造，即将作为一方的板部的表面侧板部23的端部23a向作为另一方的板部的背面侧板部22的端部22a弯曲地形成的同时，熔敷在背面侧板部22上，因此可以将层压板19的末端精加工得很美观。
另外，根据本实施方式，由于底板19做成在主体部20的表面20a上贴合包覆材料而形成了包覆部24的构造，因此能够提高层压板19的外观设计性。
以上，虽然对本发明的层压板的适当的实施方式进行了说明，但本发明并不局限于上述实施方式，在不脱离本发明的宗旨的范围内可以采用各种实施方式。
例如，在上述实施方式中，虽使用了聚丙烯树脂制的层压坯料，但只要是热塑性树脂制的层压坯料即可，例如也可以是用聚乳酸树脂等植物性树脂形成的层压坯料。
另外，在本实施方式中，作为包覆材料虽使用了无纺布，但也可以使用其它纤维或皮革表皮等。
另外，在本实施方式中，虽然使用了在层压坯料的表面上贴合了无纺布的带包覆材料的层压坯料，但既可以使用在层压坯料的表面和背面两面上贴合了无纺布的材料，也可以使用未贴合无纺布的层压坯料。
另外，在本实施方式中，虽使用了形成有圆柱状的压花部的芯板，但不局限于此，也可以使用具有纵壁部的各种板。
另外，在上述实施方式中，作为层压板虽举例说明了底板，但使用其它车辆用或建筑用的内装材料或外装材料也能实施本发明。

Claims (5)

1.一种层压板的末端处理方法，其特征在于，具有以下工序：
用支撑部件支撑通过纵壁部层压一对板状部件的热塑性树脂制的层压坯料，以使该层压坯料的周边部露出，将热风吹到上述周边部上使该周边部加热软化的第一工序；以及，
使冲模的切断刀与上述加热软化了的周边部接触并将上述一对板状部件的一方的板状部件向另一方的板状部件推压，使上述一对板状部件彼此接触并熔合在一起，并且使层压板从上述层压坯料脱模的第二工序。
2.根据权利要求1所述的层压板的末端处理方法，其特征在于，
上述支撑部件是绝热件。
3.根据权利要求1或2所述的层压板的末端处理方法，其特征在于，
在上述层压坯料的外面贴合有包覆材料。
4.一种层压板，具备具有纵壁部和通过该纵壁部层压的一对板部的热塑性树脂制的主体部，其特征在于，
上述一对板部中一方的板部的端部向另一方的板部的端部弯曲的形成并熔敷在该另一方的板部上。
5.根据权利要求4所述的层压板，其特征在于，
形成有包覆上述主体部的外面的包覆部。
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