JPH0623883A - Method for molding interior material made of corrugated cardboard - Google Patents

Abstract

PURPOSE:To prevent the deformation due to spring back after molding and to enhance quality or productivity by molding a corrugated cardboard base material by a hot press device and subsequently bonding a decorative skin material to the cardboard base material by a cold press device utilizing the remaining heat of the corrugated cardboard base material. CONSTITUTION:In the molding of an interior material made of corrugated cardboard, at first, a plate-shape corrugated cardboard base material A is molded under pressure at predetermined high temp. by a hot press device B. At this time, the corrugated cardboard base material A is produced by bonding liners 4,5 to both surfaces of a corrugated core 1 through thermoplastic resin films 2, 3. Next, the molded corrugated cardboard base material A' is demolded to be transferred to the molds C1, C2 of a cold press device C and a decorative skin material 7 is superposed on the surface of the molded base material A' through a hot-melt adhesive 6. Continuously, the corrugated cardboard base material A' due to cold press and a decorative skin material 7 are closely bonded under pressure by utilizing the remaining heat of the corrugated cardboard base material A'.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a corrugated board interior material comprising a corrugated board base material formed in a predetermined shape and a decorative skin material laminated on one surface of the corrugated board base material.

[0002]

2. Description of the Related Art This type of corrugated board interior material is used, for example, as an interior material for an automobile ceiling. Conventionally, liners are attached to both sides of a corrugated core via thermoplastic resin films. The flat plate-shaped corrugated board base material is heated and pressure-molded by a predetermined heat press device, and then the same corrugated board base material is molded with the same mold and a decorative skin material, which is usually a resin sheet, is heated with a hot melt sheet or the like. They are stacked with a soluble adhesive interposed therebetween, and then heated and pressed again to melt the adhesive, so that the skin material and the corrugated board base material are bonded together.

[0003]

As described above, according to the conventional method, the molding material for the hot press formed by heating and pressurizing the corrugated board base material is used as it is, and the skin material for the corrugated board base material after molding is used. Since the corrugated board is bonded, the corrugated board is held in a heated state until the bonding between the skin material and the corrugated board is completed, and the resin film for adhering the liner and the core is also in a molten state. Spring back occurs because it does not solidify immediately after the mold is removed and the mold is removed.
Often causes deformation of molded parts. In addition, productivity cannot be improved because the next molding cycle cannot be started until the skin material is completely bonded and the molding die becomes empty. The present invention has been made in view of the above problems of the prior art, and an object thereof is to prevent deformation due to springback after molding to improve quality, and to improve productivity and manufacture. It is also to realize cost reduction.

[0004]

In order to achieve the above object, in the method for molding a corrugated cardboard interior material of the present invention, a flat corrugated cardboard substrate having liners bonded to both sides of a corrugated core via a thermoplastic resin film is provided. The material is first hot-pressed at a high temperature such that residual heat sufficient to melt the heat-soluble adhesive remains on the surface of the corrugated board substrate after molding is completed and demolding, and the corrugated board substrate is formed during molding. The paper is heated and pressure-molded at a temperature at which it does not burn, the molded corrugated board substrate is demolded and transferred to the mold of the cold press machine, and the surface of the decorative skin material is bonded via a heat-soluble adhesive. By stacking and cold pressing, the residual heat of the corrugated board base material is used to melt the adhesive agent to bond the corrugated board base material and the skin material.

[0005]

In the molding method of the corrugated board interior material configured as described above, after the corrugated board base material is hot-pressed, the decorative skin material is bonded to the molded corrugated board base material by the residual heat of the corrugated board base material. Since it is carried out by cold pressing using a resin, the thermoplastic resin that is interposed between the core of the corrugated board base material and the liner and melted in the molding process of the corrugated board base material is cooled and solidified in the process of adhering the skin material, and is removed. When molded, the molded shape is securely retained. In addition, the hot press device used in the corrugated board base material forming process is in a state in which it can be used for the next molding when the skin material adhering process is performed, and the cold press device for performing the skin material adhering process is When the molding process is performed, it is ready for the next use.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. A is a corrugated board base material that constitutes an interior material made of corrugated board. The corrugated board base material A has a corrugated core 1 and thermoplastic resin films 2 and 3 such as polyethylene films on both sides of the corrugated core. And one of the liners 4 is completely adhered to the core 1, while the other liner 5 is formed of the liner 5 and the core 1 during press molding. In order to allow relative sliding of the above, only the both sides thereof are temporarily fixed.

In the method of the present invention, first, the corrugated board base material A is heated and pressed by the hot press machine B to be molded into a predetermined shape. The hot press device B has a conventionally known structure and form consisting of a fixed lower mold B1 and a movable upper mold B2, and although not shown, the molding surface portions of both molds B1 and B2 are formed by a suitable heating means. It is heated to the molding temperature.

The corrugated board base material A is placed on the fixed lower mold B1 of the hot press device B with the liner 5 temporarily fixed to the core 1 as the upper surface, and the movable upper mold B2 is lowered to move both molds B.
Molded by pressurizing and heating between 1 and B2.

[0009] In this hot pressing step, after the molding is completed and the mold is removed, the molding is performed at a high temperature to the extent that residual heat sufficient to melt the heat-soluble adhesive 6 to be described later remains on the surface of the molded corrugated board substrate A '. Sometimes the paper of the corrugated board base material A is heated at a temperature at which it does not burn. For example, heat-soluble adhesive
For hot melt films that melt at 130 ° C, the heating temperature should be 220 ° C.

Generally, in the molding of corrugated board, hot press molding is used to melt the thermoplastic resin films 2 and 3 such as polyethylene film interposed between the core 1 and the liners 4 and 5. The temperature is 130 ° C, which is sufficient to melt the thermoplastic resin films 2 and 3, but by molding at a heating temperature that is much higher than that as described above, the melting of the films 2 and 3 is accelerated, and the pressing time is increased. It can be shortened.

After the molding is completed, the movable upper mold B2 is raised to remove the molded corrugated board base material A'from the fixed lower mold B1. In this state, the resin films 2 and 3 interposed between the core 1 and the liners 4 and 5 are in a molten state and not yet solidified, so that the molded corrugated board base material A ′ undergoes springback. Is in a state of gaining. The corrugated board base material A ′ that has been demolded after the above molding is immediately transferred to the cold press device C, and the heat-soluble adhesive 6 is applied to the surface thereof.
The decorative skin material 7 is overlaid via the and pressed. During this period, more specifically, the corrugated board base material A'with the cold press device C.
While hot pressing the decorative skin material 7, the hot press device B after demolding the molded corrugated board substrate A ′,
Corrugated board substrate A for the next molding cycle is loaded.

The decorative skin material 7 is usually made of a resin sheet, and the heat-soluble adhesive 6 is made of, for example, a polyolefin-based or polyamide-based hot melt film. This hot melt film is as shown in the illustrated example. 7 may be preliminarily laminated on the back side of the sheet 7, or a sheet formed into a film sheet may be used in the cold press device C.
You may make it mount on the molded corrugated-cardboard base material A'which was moved to.

On the other hand, the cold press device C is composed of a fixed lower mold C1 and a movable upper mold C2 like the hot press device B, but is different from the hot press device in that it is not equipped with a heating device, and is necessary. In some cases, a cooling device for cooling the molding surface may be provided. The forming parts of the upper and lower molds C1 and C2 of the cold press device C are hot press devices except that the clearance is formed larger than that of the upper and lower molds B1 and B2 of the hot press device B by an amount corresponding to the thickness of the decorative skin material 7. The upper and lower molds B1 and B2 are formed in exactly the same shape.

In this cold press step, there is still sufficient residual heat of about 130 ° C. to melt the hot melt film 6 in the corrugated cardboard base material A'which has been demolded from the hot press machine B and put therein. The melt film 6 is melted by the residual heat of the molded corrugated board base material A ′, and the corrugated board base material A ′ and the decorative skin material 7 are adhered by pressing.

Then, after the adhesion of the decorative skin material 7, the molds C1 and C2 are opened and demolded to obtain a corrugated board interior material D, which is a product. In the process of this step, the corrugated board base material A is used. The temperature of the thermoplastic resins 2 and 3 between the center core 1 and the liners 4 and 5 is lowered. Therefore, at the time of demolding, the solidification of the thermoplastic resins 2 and 3 proceeds, and the shape of the product D is reliably retained.

Incidentally, the molded corrugated board base material A'and the skin material 7 for the demolding and the next molding cycle of the cold press machine C.
Can be added during the heating and pressurizing time in the hot pressing step.

[Effect] Since the present invention is configured as described above, the following effects can be obtained. (1). After hot-pressing the corrugated board base material, the decorative skin material is bonded to the molded corrugated board base material by cold pressing using the residual heat of the corrugated board base material. The thermoplastic resin, which is interposed and melted in the step of molding the corrugated board substrate, cools in the process of adhering the skin material and solidifies at the time of demolding so that there is no fear of springback. Therefore, the product can surely retain the molded shape and the quality is improved, so that the commercial value can be increased. (2). The hot press machine used in the corrugated board molding process is in a state where it can be used for the next molding when the skin material adhering process is performed, while the cold press machine that performs the skin material adhering process is used for corrugated cardboard substrate molding. When the process is performed, it is ready for the next use, so by operating it alternately, the equipment can be used efficiently, and moreover, the hot press equipment is removed from the die and the corrugated board for the next molding cycle is used. The base material is charged during the pressurizing time of the cold press process, and the mold release of the cold press device and the injection of molded corrugated board equipment and skin material for the next molding cycle are performed during the heating and pressurizing time in the hot press process, respectively. Therefore, it is possible to improve the work efficiency by eliminating the waiting time of the worker. Therefore, productivity is improved,
Production cost is reduced.

[Brief description of drawings]

FIG. 1 is a sectional view of a corrugated board substrate.

FIG. 2 is an explanatory view showing a hot press molding process of a corrugated board base material.

FIG. 3 is an explanatory view showing a step of transferring the molded corrugated board base material to a cold press device.

FIG. 4 is an explanatory diagram showing a step of bonding a molded corrugated board base material and a decorative skin material by cold pressing.

FIG. 5 is an explanatory diagram showing a product demolding process.

FIG. 6 is a cross-sectional view of a product corrugated cardboard interior material.

[Explanation of symbols]

A Corrugated board base material A'Molded corrugated board base material B Hot press machine C Cold press machine D Product Corrugated board interior material 1 Core 2, 3 Thermoplastic resin film 4, 5 Liner 6 Heat soluble adhesive 7 Decorative skin material ( Hot melt film)

Claims (1)

[Claims] 1. A flat corrugated cardboard base material having liners bonded to both sides of a corrugated core with a thermoplastic resin film interposed therebetween is hot-melted by a hot press machine and then heat-soluble on the surface of the corrugated board base material after demolding. The process of heating and press-molding at a temperature high enough to leave residual heat sufficient to melt the adhesive, and at a temperature at which the paper constituting the cardboard base material does not burn during molding. Molding and transferring to a molding die of a cold press device, a process of superimposing a decorative skin material on the surface via a heat-soluble adhesive, the above-mentioned molded corrugated board base material and the skin material are brought into pressure contact with each other by cold pressing, and a corrugated board base material A method of molding a corrugated cardboard interior material, which comprises a step of adhering the two using the residual heat of.