JPH06190928A - Manufacture of laminate - Google Patents

Abstract

PURPOSE:To improve a production efficiency by a method wherein a process of forming a heat softening sheet and a process of bonding it to a low-density molded body are performed in one process. CONSTITUTION:A heat softening sheet 11 is supplied below a vacuum forming tool 6, air in the vacuum forming fool 6 is sucked by operating an air sucking device, and the heat softening sheet 11 is sucked through suction holes 7 and vacuum-formed in the same shape as a retainer 8. On the occasion, the sheet 11 is heated beforehand or the retainer 8 of the tool 6 is heated by an appropriate means. Thereby the sheet 11 being in contact with this retainer 8 is heated and it is formed in a prescribed shape and retained. A heat softening sheet formed body 11' vacuum-formed in the same shape as the retainer 8 of the vacuum forming tool 6 is made to engage with the upper side of a low-density molded body 5 and pressed thereon, while it is kept sucked.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a laminated body in which a thermosoftening sheet molded body is laminated on a low density molded body,
More specifically, the present invention relates to a method for producing a laminate that is preferably used for automobile interior materials such as dash insulators and floor insulators, various sound insulating materials, sound absorbing materials, cushioning materials and the like.

[0002]

2. Description of the Related Art In the case of producing a laminated body in which a heat-softenable sheet molded body is laminated on a low-density molded body such as a fiber assembly, conventionally, the heat-softenable sheet is vacuumed in advance. Molded into a desired shape by a molding method, a compressed air pressing method or a press molding method, and bonding the thermosoftening sheet molded body and the low density molded body in a mold different from the mold in which the thermosoftening sheet is molded. Method (JP-A-2-95838)
Have been adopted.

However, the manufacturing method of the above-mentioned laminate is
Two steps, a step of molding the heat-softenable sheet and a step of adhering the heat-softenable sheet to the low-density molded body are required, and therefore the production efficiency is low. Further, the adhesion between the heat-softening sheet molded body and the low-density molded body is performed by externally applying pressure to these in the mold, but the low-density molded body such as a fiber assembly is Since it is easily deformed by pressure, the low-density molded body may be locally over-pressurized during the bonding using the mold. Therefore, the locally over-pressurized portion of the low-density molded article has a higher density than other portions, resulting in inferior soundproofing performance, and there is a problem in that the mold is deformed.

The present invention has been made in view of the above circumstances.
It is an object of the present invention to provide a method for producing a laminated body, which is capable of industrially advantageously adhering a thermosoftening sheet and adhering a thermosoftening sheet molding to a low-density molding.

[0005]

In order to achieve the above object, the present inventor has, as a first aspect of the present invention, a method for producing a laminate comprising a heat-softening sheet molded body adhered and laminated on a low density molded body. At the same time, the low-density molded body is placed in the cavity of the lower mold, and an adhesive or pressure-sensitive adhesive is applied to the upper surface of the low-density molded body, while the lower-density molded body is engaged with the upper surface and communicates with the inside. A thermo-softening sheet is supplied to the lower surface of a vacuum forming die having a lower surface with holes formed therein, and the sheet is heated, and at the same time, the inside of the vacuum forming die is vacuum-sucked so that the heat-softening property is obtained through the suction holes. The sheet is sucked to form the sheet into a shape corresponding to the lower surface of the vacuum forming die, and then the thermosoftening sheet molded body is pressed against the upper surface of the low density molded body,
Provided is a method for producing a laminated body, which comprises adhering.

As a second aspect of the present invention, in producing a laminated body in which a heat-softening sheet molded body is adhered and laminated on a low-density molded body, the low-density molded body is resistant to a pressing force from above. Then, it is placed in a cavity of a lower mold having an elastically deformable cushion body, an adhesive or a pressure-sensitive adhesive is applied to the upper surface of the low density molded body, and the upper surface of the low density molded body is engaged with the upper surface. Press the heat-softening sheet molded body molded into
Provided is a method for producing a laminated body, which comprises adhering.

Further, as a third invention, on a low density molded body
Manufacture a laminated body by adhering and laminating thermosoftening sheet moldings
When building, apply the above-mentioned low-density molded body to the pressing force from above.
Of a lower mold equipped with a cushion body that is elastically deformable against
It is placed in the cavity and an adhesive or
Applies the adhesive while engaging the upper surface of the low-density molded product
And has a bottom surface with a suction hole communicating with the inside.
A heat-softening sheet is supplied to the lower surface of the blank mold and this is applied.
In addition to heating, vacuum suction inside the vacuum mold
From the heat-softening sheet through the suction holes
The sheet into a shape corresponding to the bottom surface of the vacuum forming mold.
The heat-softening sheet is then formed on the upper surface of the low-density molded body.
Of a laminated body characterized by pressing and adhering a molded sheet
A manufacturing method is provided.

[0008]

According to the first aspect of the present invention, since the step of forming the heat-softenable sheet and the step of adhering it to the low-density formed body can be performed in one step, the production efficiency is increased. According to the second aspect of the invention, since the pressing of the heat-softening sheet molded body to the low-density molded body is uniformly performed by the elastic action of the cushion body, the upper and lower shapes of the low-density molded body are different. In this case, even if pressure is applied uniformly without damaging each shape, partial overpressurization of the low-density molded product is eliminated as much as possible, and one part of the low-density molded product is replaced by another part. It will not be denser than
Since the low density state can be maintained uniformly and the mold is not deformed, a laminate having a desired shape can be easily and surely manufactured. Therefore, the laminate according to the present invention is preferably used as a sound insulation material.

In particular, according to the third aspect of the present invention, such a laminate can be manufactured more industrially advantageously.

[0010]

EXAMPLES The method for producing a laminated body of the present invention is one in which a low-density molded body and a heat-softening sheet molded body are laminated using an adhesive or a pressure-sensitive adhesive while pressing the low-density molded body. The low-density molded product used in the present invention preferably has a soft average apparent density of 0.04 to 0.15 g / cm ³ , and if the average apparent density is in this range, the material is not particularly limited. Although not a thing, the fiber distribution is 3
A short fiber having a cut length of 0 to 100 denier and a cut length of 10 to 100 mm and a binder mixed therein is preferably used.

The fibers may be inorganic fibers, organic fibers, natural fibers or synthetic fibers, but practically they are polystyrene, polypropylene, polyester, polyamide, rayon, vinylon, acrylic, polyurethane, acetate. , Cupra, cellulose, cotton, wool, hemp, etc. are used. You may use these individually by 1 type or in mixture of 2 or more types.

As the binder, powder or fiber having a melting point lower than that of the fiber material is preferably used. Generally, thermoplastic polyethylene, polypropylene,
Polyester, polyamide, polyvinyl chloride, EVA
(Ethylene vinyl acetic acid copolymer), resins such as polyurethane, and bituminous powders and fibers are used. Further, a thermosetting resin such as phenol resin is also used. Furthermore, as the binder, a composite type fiber called a sheath core type or a side-by-side type is also used. 1 binder
The seeds may be used alone or in combination of two or more. The blending ratio of these binders is usually 5 to 40% by weight, preferably 5 to 20% by weight of the fiber material.

Incidentally, such a low-density molded product can be manufactured by, for example, the method described in JP-A-2-95838.

On the other hand, the heat-softening sheet is not particularly limited as long as it has heat-softening property.
A thermoplastic resin sheet having a sound insulating property is preferably used from the viewpoints of performance, cost, ease of molding, etc. Further, a thermoplastic resin sheet having an increased density by blending an inorganic filler such as calcium carbonate was used. In this case, the sound insulation performance is further improved. As the thermoplastic sheet, specifically, sheets of polyvinyl chloride, polyethylene, polypropylene and the like can be used, but polyvinyl chloride is preferably used from the viewpoint of performance and productivity. From the viewpoint of performance, the density of these heat-softenable sheets is 1.2 g / cm ³ or more, particularly 1.5-2.
It is preferably 5 g / cm ³ . When a polyvinyl chloride sheet is used as the heat-softening sheet, it is preferably heated to 100 to 150 ° C. and used from the viewpoint of ease of molding.

The adhesive and pressure-sensitive adhesive for adhering the above-mentioned low-density molded product and the heat-softening sheet are not particularly limited, and the method of adhering may be point adhesion, line adhesion or surface adhesion. Although a method may be used, an acrylic emulsion type is preferably used when the heat-softening sheet and the low-density molded body are adhered over the entire surface. Also, when adhering, dozens to hundreds of grams / 60 to 80 ° C. for 5 to 20 seconds.
It is preferable to apply a pressure of cm ² .

Next, an example of manufacturing a laminated body according to the present invention will be described with reference to FIG. 1. In FIG. 1, reference numeral 1 denotes a lower mold integrated with a pedestal, and the upper surface of the cavity 2 of the lower mold 1. A cushion body 4 composed of an airbag 3 having the same shape as the upper surface of the cavity 2 (the lower surface of a low-density molded body 5 described later) is disposed in the. The airbag 3 is connected to an air introducing / exhausting device (not shown) such as a compressor through an air inlet (not shown) for introducing air into the inside and discharging the inside air, Of the cavity can be expanded into the same shape as the upper surface of the cavity (lower surface of the low-density molded body 5), and the low-density molded body 5 is placed on this.

Reference numeral 6 denotes a hollow body 9 having a shape capable of engaging with the upper surface of the low-density molded body 5 and having a lower plate 8 having a large number of suction holes 7 formed therein. This is a vacuum forming die for forming the same shape as the lower plate 7, and an air suction device (not shown) such as a vacuum pump is connected to the hollow body 9 through its suction port 10, and this air suction is performed. The air in the hollow body 9 is sucked by the operation of the device.

When a laminated body is manufactured using this apparatus, as shown in FIG. 1 (B), the thermosoftening sheet 11 is supplied to the lower side of the vacuum forming mold 6 and the air suction device is operated. The air in the vacuum forming die 6 is sucked, and the thermosoftening sheet 11 is sucked through the suction holes 7, whereby the sheet 11 is sucked.
Is vacuum-formed into the same shape as the lower plate 8. In this case, the sheet 11 is preheated, or the lower plate 8 of the mold 6 is heated by an appropriate means, so that the sheet 1 coming into contact with the lower plate 8 is heated.
1 is heated to form and maintain the sheet 11 in a predetermined shape.

On the other hand, the low-density molded body 5 is placed on the cushion body 4 (airbag 3) arranged on the cavity 2 of the lower mold 1, and the adhesive or pressure-sensitive adhesive 12 is placed on the upper surface thereof.
Apply.

Then, as shown in FIG.
Same shape as the lower plate 8 of the empty molding die 6 (upper surface of the low-density molding 5)
The heat-softening sheet molded body 11 'vacuum-formed into
Engage and press on the upper surface of the low-density molded body 5 while maintaining suction.
It At the same time as or before this, the air introduction / exhaust device
The air bag 3 is activated by introducing the air into the airbag 3,
Inflate the bag 3 (at this time, the air pressure of the airbag 3
Is 0.1 to 1 kgf / cm² Is preferable).

As a result, the cushioning action of the airbag 3 causes the low-density molded body 5 to be formed by the heat-softening sheet molded body 11 '.
Since the pressing force to be equalized and local overpressurization is eliminated, the low-density molded body 5 maintains the shape of the surface (upper surface) without densification due to local overpressurization. The heat-softening sheet molded body 11 ′ is bonded to the low density molded body 5.

FIG. 2 illustrates another method of the present invention. In this example, the lower mold 1 is formed in a plate shape having the same shape as the lower surface of the low density molded body 1, and This lower mold 1
The pedestal 1'is arranged at a predetermined interval on the lower side of the lower die 1, and the upper ends of a large number of support legs 13 are fixed to the lower surface of the lower mold 1, and these support legs 13 are attached to the upper wall of the pedestal 1 '. The lower die 1 and the pedestal 1'on the support legs 13 respectively.
The coil spring 14 is wound around the upper wall,
The cushion body 4 is formed by the coil spring 14 in this way, and this device is provided with a thermosoftening sheet molding 11 '.
The coil spring 1 is pressed by the pressing force applied to the low-density molded body 5 by
4 is reduced, the pressing action equalizes the pressing force, and the local overpressurization is eliminated. in this case,
The reaction force of the coil spring is preferably several hundred grams.
Since the other configurations and effects are the same as those in the case of FIG. 1, the same reference numerals are given to the same components, and the description thereof will be omitted.

In the present invention, as the cushion body, the air bag and the coil spring are used in the above-mentioned embodiment, but other air cushion mechanism or mechanical cushion mechanism may be used, and the density of the low density molded body can be increased by local pressure. It is not particularly limited as long as it does not cause and can maintain the shape of the surface.

Further, in the above embodiment, the heat-softening sheet is vacuum-formed and is pressed and adhered to the low-density molded article as it is while utilizing the cushioning effect of the cushion body. A heat-softening sheet molded body molded by another mold may be used, and this may be pressed against the low-density molded body by utilizing the cushioning action of the cushion body. If necessary, the cushion body may be omitted, and the vacuum-molded thermosoftening sheet may be directly adhered to the low-density molded article to form the thermosoftening sheet and bond the low-density molded article to the molded article. By carrying out the process, the processing can be performed in a short time, and thus the product cost can be significantly reduced.

Next, the present invention will be described more specifically with reference to experimental examples.

[Experimental Example 1] 6-8 denier and an average length of 4
0 mm polyester fiber with 4 denier and an average length of 5
A low-melting point polyester fiber having a diameter of 0 mm was mixed in an amount of 20% by weight of the above polyester fiber and molded to give an apparent density of 0.
A porous molded body (low density molded body) of 08 g / cm3 was obtained.

On the other hand, a polyvinyl chloride sheet having a thickness of 3 mm and a density of 1.7 g / cm ³ is used as the heat-softening sheet,
This was heated to 145 ° C., an acrylic emulsion type adhesive was applied to the surface of the porous molded body, and a laminate was obtained according to the steps shown in FIG. That is, the polyvinyl chloride sheet is formed by lowering the vacuum forming die by the elevating device and performing vacuum suction, and then the porous formed body and the sheet formed body are engaged with each other at 80 ° C. for 20 seconds and at the same time, air is formed. Air was injected into the bag, and the sheet molded body was adhered thereto while pressing the porous molded body.

[Experimental Example 2] Using the same porous molded body, acrylic emulsion adhesive and polyvinyl chloride sheet as in Experimental Example 1, a porous molded body and a heat softening sheet were prepared according to the steps shown in FIG. A laminated body of was obtained.

[0029]

According to the present invention, a laminated body of a low-density molded product useful as a sound insulating material, a sound absorbing material, a cushioning material, etc. and a heat softening sheet has uniform physical properties as a whole, and, for example, is superior in sound insulation. It can be produced industrially advantageously in the absence of

[Brief description of drawings]

FIG. 1 is a schematic sectional view illustrating an embodiment of the present invention,
(A) shows a state in which a vacuum forming die is arranged above the lower die,
(B) is a state in which a low-density molded body is placed on the lower mold and a heat-softening sheet is arranged below the vacuum molding mold, (C)
FIG. 3 is a cross-sectional view showing a state in which a low-density molded body and a heat-softening sheet molded body are bonded together.

FIG. 2 is a schematic sectional view illustrating another embodiment of the present invention,
(A), (B), and (C) are shown in FIG.
It is sectional drawing of the same shape as (B) and (C).

[Explanation of Codes] 1 Lower mold 3 Air bag 4 Cushion body 5 Low-density molded body 6 Vacuum molding mold 11 Thermosoftening sheet 12 Adhesive agent 14 Coil spring

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Internal reference number FI technical display location B29L 31:58 4F

Claims (3)

[Claims] 1. A low-density molded body is adhered and laminated on a low-density molded body to produce a laminate, wherein the low-density molded body is placed in a cavity of a lower mold, While applying an adhesive or a pressure-sensitive adhesive to the upper surface of the molded body, the lower surface of the vacuum molding die having a lower surface that engages with the upper surface of the low density molded body and has a suction hole communicating with the internal hollow portion is heat-softened While supplying the sheet and heating it, the inner hollow part of the vacuum forming die is vacuum-sucked to suck the thermosoftening sheet through the suction hole, and the sheet is placed on the lower surface of the vacuum forming die. A method for producing a laminate, which comprises molding into a corresponding shape, and then pressing and adhering the heat-softening sheet molded body onto the upper surface of the low-density molded body. 2. A low-density molded article can be elastically deformed against a pressing force from above when producing a laminated body by bonding and laminating a heat-softening sheet molded article on the low-density molded article. Placed in the cavity of the lower mold equipped with a simple cushion,
An adhesive or a pressure-sensitive adhesive is applied to the upper surface of the low-density molded body, and a thermosoftening sheet molded body molded into a shape that engages with the upper surface is pressed and adhered to the upper surface of the low-density molded body. Method for manufacturing laminated body. 3. A low-density molded article can be elastically deformed against a pressing force from above when producing a laminate by bonding and laminating a heat-softening sheet molded article on the low-density molded article. Placed in the cavity of the lower mold equipped with a simple cushion,
While applying an adhesive or a pressure-sensitive adhesive to the upper surface of the low-density molded body, the lower surface of the vacuum molding die having a lower surface formed with a suction hole that engages with the upper surface of the low-density molded body and communicates with the internal hollow portion Supply a heat softening sheet and heat it,
The thermosoftening sheet is sucked through the suction holes by vacuum suction of the inner hollow portion of the vacuum forming die to form the sheet into a shape corresponding to the lower surface of the vacuum forming die, and then the low density. A method for producing a laminate, comprising pressing and adhering the thermosoftening sheet molded body onto the upper surface of the molded body.