CN1073013C - 制造叠层体的方法 - Google Patents
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Abstract
本发明的目的是提供一种车门内装饰板等的叠层体的制造方法,该叠层体不必用板状的表面层而且不用粘接剂,就能使基板和表面层一体化,长期使用能够保持粘接效果。在一对成形模具31、32之间挤压制成规定形状的多孔性基板11和供给该多孔性基板11的外表面的并成为表面层的熔融树脂材料12melt,使得上述熔融树脂材料12melt浸渍上述多孔性基板11内部的至少外表面的同时,使熔融树脂材料12melt硬化。这样得到的车门内装饰板因构成表面层12的树脂和多孔性基板11以锚住方式接合而保持可靠的接合强度。
Description
所属领域
本发明涉及车辆的车门内装饰、车辆用内装饰和室内装饰等使用的叠层体及其制造方法。
背景技术
已经公知了一种上述用途的叠层体,这种叠层体是在由加工成规定形状的木质材料或树脂材料构成的基板上覆盖树脂层而成的。特开平2-286315号公报揭示了这样的一种叠层体例子,这种叠层体是由基板和表面层构成,并用作为车门装饰板,其中的基板由制成车门内装饰板形状的木质硬板纸构成,而表面层通过与该基板粘合完全覆盖住该基板。
在制造这样构成的车门内装饰板的过程中,首先,如图12(a),将制成规定形状的基板203和其表面增添适当设计图案的表面层204分别吸引保持在真空成型模具的上模具201和下模具202的模具加工面上,然后,通过两模具201、202压两部件203和204,使得基板203和表面层204在粘接剂作用下连成一体。于是在两部件203和204一体化后,如图12(b)所示那样,切断表面层204,但要使其端部露出基板203少许。然后,如图12(c)所示那样,对该表面层204的露出部分204a进行卷包基板203的接合处理,从而表面层204不会露出,因此不破坏其美观。
但是,在上述现有车门内装饰板中,因为基板203和表面层204的接合需用粘接剂,所以接合部分处涉及到基板203、表面层204和粘接剂三种材料。因此,如果长期使用该车门内装饰板时,由于这三种材料的热膨胀系数等的物理化学性质不同,接合部分存在因粘接剂与两部件203和204出现分离而使基板203和表面层204相互剥离的可能性。在利用上述现有的制造方法制造车门内装饰板过程中,在制造时有可能形成因粘接剂涂覆不均引起的粘接效果不好的部分。另外,在这种制造方法中,由于需要涂覆粘接剂,因此必然需要向基板203或表面层204供给粘接剂的装置和步骤,同时,与基板203粘接的表面层204必须预先制成板,而且还需要用于制成表面层204的单独的装置和步骤,从而增加了一系列的装置及制造步骤,以致于制造更为复杂。
发明的公开
本发明是为解决上述问题而提出的,其目的是提供一种车门内装饰板等的叠层体和降低使用材料且简化叠层体的制造工艺。本发明不必将表面层制成板状,且不必使用粘接剂,只要将基板和表面层连成一体,就能够长期维持接合效果。
为完成上述目的,本发明的叠层体是由制成规定形状的多孔性基板和覆盖该多孔性基板的外侧表面的树脂材料表面层构成,构成上述表面层的树脂在浸渍上述多孔性基板内部的至少外侧面的状态下硬化。
制造上述叠层体的方法是挤压位于一对成型模具之间的制成规定形状的多孔性基板和供给多孔性基板表面上的成为表面层的熔融树脂材料,使上述熔融树脂材料浸渍上述多孔性基板内部的至少外侧面内并使这些树脂材料硬化。
制造相同叠层体的方法是把制成规定形状的多孔性基板放置在成型的两模具之间,然后,在两模具间的多孔性基板的外表面上浇注形成表面层的熔融树脂材料,使上述熔融树脂材料浸渍上述多孔性基板内部的至少外表面并使这些树脂材料硬化。
在这种制造方法中,为了提高相对于形成表面层的熔融树脂材料的多孔性基板的浸湿性,在浸渍熔融树脂材料之前,可以预先对多孔性基板内部的至少外表面上用表面改性剂进行处理。
本发明所用的多孔性基板也可以用树脂成形板或木质成形板构成。
本发明的叠层体最好用作为车辆的车门内装饰板或车辆用内装饰板。
对于这样构成的本发明的叠层体,由于构成表面层的树脂材料在直接浸渍在多孔性基板的至少外表面上的状态下硬化,因此接合部仅涉及到表面层和多孔性基板二种材料并因为这两种材料以直接锚住效果接合在一起,所以不会如现有的用粘接剂接合的那样,发生粘接剂层剥落的现象。而且,即使长期使用该叠层体,表面层和多孔性基板也不会剥离。因为不使用粘接剂,所以不可能形成因粘接剂涂覆不均引起的完全不粘接的地方。
可以利用挤压一对成型模具间的多孔性基板和成为表面层的熔融树脂材料,使上述熔融树脂材料浸渍上述多孔性基板内部的至少外表面并使这些树脂材料硬化的简单方法就能够制造这种叠层体(即相对于权利要求4记载的制造方法)。同样的叠层体也可以用权利要求5记载的制造方法很简单地制成,即通过在放置于一对成型模具间的多孔性基板的外表面上浇注熔融树脂材料,使熔融树脂材料浸渍在多孔性基板内部的至少外表面并使其硬化的方法制成。而且,根据本发明的叠层体的制造方法,不需要现有制造方法中所必须的粘接剂的涂覆过程和表面层的成形过程,因此能够简化制造过程。而且因不使用粘接剂,能够减少所用材料。
在这种制造方法中,特别是熔融树脂材料和多孔性基板的浸湿性很差的情况下,在浸渍熔融树脂材料之前,预先用表面改性剂对多孔性基板内部的至少外表面进行处理,就能够提高成为表面层的熔融树脂材料相对于多孔性基板的浸湿性。
附图的简要说明
图1是本发明所述的叠层体的一个实施例(车门内装饰)的透视图。
图2是沿图1中的线2-2剖开的纵截面图。
图3是说明本发明所述的叠层体的制造方法的第一实施例的车门内装饰板的制造方法的附图。
图4是说明本发明所述的叠层体的制造方法的第二实施例的车门内装饰板的制造方法的附图。
图5是说明本发明所述的叠层体的制造方法的第三实施例的车门内装饰板的制造方法的附图。
图6是说明本发明所述的叠层体的制造方法的第四实施例的车门内装饰板的制造方法的附图。
图7是说明本发明所述的叠层体的制造方法的第五实施例的车门内装饰板的制造方法的附图。
图8是说明本发明所述的叠层体的制造方法的第六实施例的车门内装饰板的制造方法的附图。
图9是说明本发明所述的叠层体的制造方法的第七实施例的车门内装饰板的制造方法的附图。
图10是说明本发明所述的叠层体的制造方法的第八实施例的车门内装饰板的制造方法的附图。
图11是借助于应用本发明的叠层体的制造方法的制造方法A和制造方法B制造的车门内装饰板的纵截面图(对应于图2)。
图12(a)、(b)及(c)是说明现有制造车门内装饰板的制造方法的工艺图。
本发明的最佳实施方式
作为本发明的实施例,采用车辆用的车门内装饰板,下面说明其结构的同时,参照附图说明该车门制造方法。
本实施例的车门内装饰板是如图1及图2所示的汽车用车门内装饰板10,并由制成车门形状的基板11和覆盖该基板11的外表面的表面层12构成,根据需要,表面层12的一部分用饰物13装饰。该基板11是木质成形件,该木质成形板是这样形成的:将木质纤维和作为粘接剂的酚醛树脂以93∶7的比例混合,形成混合物,然后将混合物加工成形并确保其多孔性。表面层12由为热塑性树脂的聚丙烯树脂形成。多孔性基板11和表面层12的接合部成为表面层12的热塑性树脂浸渍并充填在多孔性基板11的内部的孔内并硬化的状态。
在这样构成的车门内装饰板10中,该接合部仅由表面层12和多孔性基板11构成,即仅涉及二种材料。因为这二种材料以直接锚固方式接合,所以不象现有的使用粘接剂接合的技术那样,使粘接剂层承受一定的应力,即使长期使用本发明的叠层体,表面层12和多孔性基板11也不会剥离。另外,因为不使用粘接剂,在制造时不可能形成因粘接剂涂覆不均引起的粘接不可靠的地方。
下面,根据附图说明本发明的制造方法的实施例,即上述结构的车门内装饰板的制造方法。
图3是示出了用于说明本发明制造方法的第一实施例的车门内装饰板制造方法,即图1及图2所示的车门内装饰板10的制造方法。在该制造方法中,使用了一对上下成形模具31、32和熔融树脂的排出装置33,其中,下模具31形成车门内装饰板的内侧成形面31a,上模具32是刻有制作表面层表面的设计图案的花纹的,用于形成外侧成形面32a。
在制造过程中,把成形模具31、32中的下模具31的成形面31a预热到20℃-30℃温度,首先把由车门内装饰板之形状的木质成形板构成的多孔性基板11(20℃-60℃)设置在下模具31的成形面31a上,然后,用排出装置33以约1500g/分的速度向该多孔性基板11的上表面提供约12秒的形成表面层的熔融状态的聚丙烯树脂12melt(180℃-200℃)。此时,熔融树脂12melt以厚度为制品厚度+0.1mm而供给幅度为制品幅度x0.95的程度供给配合车门内装饰板的形状。接着,在上模具32和下模具31之间施加30kgf/cm2以上的压力,在2-3秒的挤压时间内把熔融树脂12melt(树脂温度降至140℃-160℃)压扁。压扁后的树脂12浸渍并充填在多孔性基板11内部的至少外表面侧的孔内。如果保持30kgf/cm2以上压力挤压同时冷却30秒,使树脂12硬化,则多孔性基板11的整个外侧表面被树脂12所覆盖,从而形成车门内装饰板10。
图4是用于说明本发明的制造方法的第二实施例,即制造图1及图2所示的车门内装饰板10的方法的示意图。在本实施例中,使用形成外侧成形面42a的上模具42和形成内侧成形面41a的下模具41。该下模具41与实施例1的下模具的不同点仅在于:该下模具41是内设其出口分散在内侧成形面41a的整个面上的不同位置上的树脂供给通路44(在该树脂供给通路44的供给途中设置有防止熔融树脂12melt的温度下降的加热器45)的模具和从注入装置43注入熔融树脂12melt经树脂供给通路44供给多孔性基板11的外则表面。
图5是用于说明本发明的制造方法的第三实施例,即制造图1及图2所示的车门内装饰板10的方法的示意图。在本实施例中,使用形成外侧成形面52a的上模具52和形成内侧成形面51a的下模具51。该上模具52与实施例1的上模具的不同点仅在于:该上模具52是内设其出口分散在外侧成形面52a的整个面上的不同位置上的树脂供给通路54(在该树脂供给通路54的供给途中设置有防止熔融树脂12melt的温度下降的加热器55)的模具和从注入装置53注入熔融树脂12melt经树脂供给通路54供给多孔性基板11的外侧表面。
图6是示出了用于说明本发明制造方法的第四实施例的车门内装饰板制造方法,即图1及图2所示的车门内装饰10的制造方法。在该制造方法中使用的一对上下成形模具31、32中,用下模具61形成车门内装饰板的内侧成形面61a,上模具62用于形成外侧成形面62a。在下模具61的成形面61a上也刻有制作表面层表面的设计图案的花纹。
在使用这些成形模具61、62制造车门内装饰板的过程中,把成形模具61、62中的下模具61的成形面61a预热到20℃-30℃温度,然后,用排出装置63以约1500g/分的速度、供给时间12秒/块向下模具61的成形面61a上提供形成表面层的熔融状态的聚丙烯树脂12melt(180℃-200℃)。另一方面,把由车门内装饰板之形状的木质成形板构成的多孔性基板11(20℃-60℃)设置在上模具62的成形面62a上。接着,通过在上模具32和下模具31之间施加30kgf/cm2以上的压力并持续2-3秒,把多孔性基板和熔融树脂12melt压紧,使得熔融树脂12melt浸渍并充填在多孔性基板11内部的至少外表面侧的孔内。通过保持压紧状态并同时冷却30秒使树脂12硬化,则多孔性基板11的整个外侧表面被树脂12所覆盖,从而形成车门内装饰板10。
图7是用于说明本发明的制造方法的第五实施例的示意图。在本实施例中,使用形成外侧成形面71a的下模具71和形成内侧成形面72a的上模具72。该下模具71与实施例4的下模具的不同点仅在于:该下模具71是内设其出口分散在外侧成形面71a的整个面上的不同位置上的树脂供给通路74(在该树脂供给通路74的供给途中设置有防止熔融树脂12melt的温度下降的加热器75)的模具和从注入装置73注入熔融树脂经树脂供给通路74供给多孔性基板11的外侧表面。
图8是用于说明本发明的制造方法的第六实施例的示意图。在本实施例中,使用形成外侧成形面81a的下模具81和形成内侧成形面82a的上模具82。该上模具82与实施例1的下模具的不同点仅在于:该上模具82是内设其出口分散在内侧成形面82a的整个面上的不同位置上的树脂供给通路84(在该树脂供给通路84的供给途中设置有防止熔融树脂12melt的温度下降的加热器85)的模具和从注入装置43注入熔融树脂12melt经树脂供给通路84供给多孔性基板11的外侧表面。
图9是示出了用于说明本发明制造方法的第四实施例的车门内装饰板制造方法,即图1及图2所示的车门内装饰10的制造方法。在该实施例的制造方法中,把多孔性基板11设置在一对上下成形模具91、92的各成形面91a、92a之间。然后,利用注入装置93通过树脂供给通路94向多孔性基板11的外侧表面和下模具91的成形面91a之间高压(100-300kg/cm2)注入形成表面层的熔融树脂12melt(180℃-200℃),熔融树脂12melt浸渍并充填在多孔性基板11内部的至少外表面侧的孔内,并使熔融树脂12melt直接硬化,多孔性基板11的整个外侧表面被树脂12所覆盖,从而形成图1及图2所示的车门内装饰板10。这里,在内设于图9所示的下模具91内的树脂供给通路94上,为防止熔融树脂12melt在供给途中温度下降,而设置了加热器95。如果树脂供给通路94的通向成形面的开口位置不是设在图9所示的位置上,而是在车门内装饰板端部或安装饰物13的位置,则在表面层表面的与树脂供给通路开口的位置对应的部位上即使出现毛口,因为从外面看不见,所以不破坏把该车门内装饰板安装到汽车门上的设计性。
图10是用于说明本发明的制造方法的第八实施例的示意图。在本实施例中,使用形成外侧成形面101a的下模具101和形成内侧成形面102a的上模具102。该上模具102与实施例七的下模具的不同点仅在于:该上模具102是内设其出口分散在内侧成形面102a的整个面上的不同位置上的树脂供给通路104(在该树脂供给通路104的供给途中设置有防止熔融树脂12melt的温度下降的加热器105)的模具和从注入装置103注入熔融树脂12melt经树脂供给通路104供给多孔性基板11的外侧表面。
根据上述的第一至第八的各实施例的制造方法,不必要现有制造方法中所必须的粘接剂涂覆工艺、表面层成形工艺,能够简化制造过程。由于不使用粘接剂,因此还能减少材料的使用量。
如各图所示,因为在表面层上设置制作设计图案的花纹,可以用在上述各实施例的制造方法中使用的外侧成形面32a、42、52a、61a、71a、81a、91a、101a设置了在表面层上制作出设计图案的花纹,所以能够在将表面层12覆盖在多孔性基板11上的同时在表面层12的外表面上形成设计图案。另外,这些实施例的两模具31、32、41、42、51、52、61、62、71、72、81、82、91、92、101、102的成形面31a、32a、41a、42a、51a、52a、61a、62a、71a、72a、81a、82a、91a、92a、101a、102a形成一定间隔,以便于通过该间隔向多孔性基板11和成形面31a、32a、41a、42a、51a、52a、61a、62a、71a、72a、81a、82a、91a、92a、101a、之间供给熔融树脂12melt,而且因为构成表面层12的树脂能够完全覆盖多孔性基板的端面,所以不必要以下二个步骤,即使上述现有的表面层与多孔性基板接合成一体的制造方法中必须的使表面层的端部伸出基板少许并切断步骤(参照图12(b))和使该表面层的伸出部分卷包基板端部的包覆步骤(参照图12(c)),而且可能在形成表面层12的同时不破坏车门内装饰板10端部的美观性。
在上述实施例中,多孔性基板使用木质纤维和酚醛树脂以93∶7的比例混合物作原料而制成的木质成形板,但也可以使用80%木质纤维,10%酚醛树脂,和10%烯烃类纤维混合而成的多孔性木质成形板。作为其它的多孔性基板,也可使用由硬质发泡尿烷构成的多孔性树脂类成形板。另外还可以使用以酚醛树脂或环氧、聚乙烯树脂等的热硬性树脂或聚丙烯树脂、ABS树脂等的热塑性树脂为主,适当添加增强剂或防静电的导电剂的多孔性树脂成形板或加压金属纤维成形的多孔性成形板、由碳素材料形成的成形板、由金属网或无纺布等构成的支承件上覆盖或叠层多孔性树脂而成的成形板等。例如,也可以把在聚丙烯树脂或聚乙烯树脂中混合了10-30%硅化镁填料的混合物作为多孔性成形板的原料。在由这些材料构成的基板和构成表面层的树脂的湿润性较差时,通过在基板表面上涂抹或浸渍变性烯烃等表面改性剂,提高熔融树脂渗透到多孔性基板的孔内的渗透性,就能够提高两者的接合强度。例如基板是聚丙烯树脂,表面层是氯乙烯时,可以使用以聚氯乙烯为表面改性剂。
在上述实施例中,虽然使用聚丙烯树脂作为表面层材料,但也可以使用在聚丙烯树脂中添加了10-50%的乙烯丙烯树脂,添加量的不同可得到不同的成形性和硬化性。最好添加50%的乙烯丙烯树脂。下表中,示出了聚丙烯树脂和乙烯丙烯树脂的配比不同时的成形性(流动性)及硬化性的评价。MFR(熔化比):由JISK6760确定的流动
单位g/min
肖氏硬度A:由肖氏硬度计测得的硬度
单位 Hs
No.1:聚丙烯树脂∶聚烯丙烯树脂=90∶10
No.2:聚丙烯树脂∶聚烯丙烯树脂=80∶20
No.3:聚丙烯树脂∶聚烯丙烯树脂=50∶50
No.4:聚丙烯树脂∶聚烯丙烯树脂=60∶40
作为表面层材料,可以单独或两者配合地使用其它的烯烃树脂,例如氯乙烯或聚乙烯,乙烯-丙烯共聚物,乙烯-醋酸乙烯酯共聚物,乙烯-丙烯酸聚合物,丙烯腈-丁二烯-苯乙烯共聚物(ABS树脂)等,或聚酰胺树脂,ABS树脂等热塑性树脂。考虑到其它一些性能,可以适当地在表面层材料中添加增加光泽的增亮剂或阻燃剂。
上述成形模具31、32、41、42、51、52、61、62、71、72、81、82、91、92、101、102虽然是用A1制成的模具,但可用铁或ZAS(三井金属矿业(株)的亚铅合金的商品名)、树脂等形成的模具。
在上述各实施例中,用一对成形模具把构成表面层材料的熔融树脂压扁在多孔性基板上并使树脂硬化,来制作图1及图2所示的车门内装饰板,但为了使表面层具有柔软感,可以使表面层局部发泡来制作如图11所示的车门内装饰板110。该车门内装饰板110由多孔性基板111和覆盖该多孔性基板111的外侧表面的表面层112构成,其中多孔性基板111由木质材料或树脂材料构成,与图2所示的装饰板一样,根据需要,可以在表面层112的局部上装饰饰物13。表面层112由使热塑性树脂的聚丙烯树脂发泡且硬化后的发泡层112a和不使相同树脂发泡但硬化的表皮112b构成。多孔性基板111和表面层112的接合部是表面层112的热塑性树脂浸渍且填充多孔性基板内部孔内且硬化而成,即两部件11和12以锚住方式接合。
在制造这样的车门内装饰板时,与上述实施例1至8相比,不同点仅在于采用发泡性熔融树脂材料作为构成表面层112的材料以及在一对成形模具之间将该发泡性熔融树脂材料压扁在基板11的整个外表面上,然后,使该对模具相互离开一定距离,来形成发泡层112a和表皮112b。因此,作为制造图11所示的车门内装饰板方法的具体实例,说明对应上述第一实施例(参照图3)的制造方法(以下称为制造方法A)和对应第七实施例(参照图9)的制造方法(以下称为制造方法B)。
首先,说明制造方法A,因为使用与图3所示的成形模具相同的成形模具31、32及排出装置33,所以使用与图3所示的相同符号来说明这些成形模具及供给装置。在制造车门内装饰板110时,首先,将成形模具31、32预热到50℃至80℃温度,然后,把木质材料制成车门内装饰板形状的多孔性基板111设置在下模具31的成形面31a上,接着,用排出装置33向该多孔性基板111的表面上供给混入惰性气体(如氮气)并搅拌的熔融的聚丙烯树脂112melt(180℃-220℃)(在下面说明该制造方法A时,图3中的12melt对应于112melt。)。然后,在上模具32和下模具31之间进行挤压,将熔融树脂112melt压扁。此时,为了使多孔性基板111和上模具32之间的距离约为1mm,约1秒地瞬时挤压熔融树脂112melt。在此状态下,保持1秒之后,当两模具31、31的间隔为1mm时,因为与上模具32的成形面32a接触的表面附近的熔融树脂的冷却速度快,所以在其外表面上由花纹刻出了设计图案,并保持原状地硬化,另一方面,因为多孔性基板111附近的熔融树脂112melt的冷却速度慢,所以一边发泡一边硬化,这样分别形成表皮112b和发泡层112a(参照图11)。浸渍在多孔性基板的孔内的熔融树脂112melt硬化,形成由表面层112覆盖多孔性基板111的整个外表面的车门内装饰板110。
下面说明制造方法B,因为使用与第七实施例的图9所示的成形模具相同的成形模具91、92及注入装置93,所以使用与图9所示的相同符号来说明这些成形模具及供给装置。在制造车门内装饰板110时,首先,把木质材料制成车门内装饰板形状的多孔性基板111设置在一对成形模具91、92的各成形面91a、92a之间。将多孔性基板111和下模具91之间的间隔保持为约1mm。接着,用注入装置93通过树脂供给通路94向该多孔性基板111的外表面和下模具91的成形面91a之间高压(100-300kg/cm2注入混合了氮气并搅拌均匀的熔融聚丙烯树脂112melt(180℃-220℃)(在下面说明该制造方法B时,图7中的12melt对应于112melt。),再将熔融树脂112melt压扁在基板111的整个表面上。如果从该状态下使两模具91、92保持约1mm的间距,则因为与下模具91的成形面91a接触的表面附近的熔融树脂的冷却速度快,所以在其外表面上由花纹刻出了设计图案,并保持原状地硬化,另一方面,因为多孔性基板111附近的熔融树脂112melt的冷却速度慢,所以一边发泡一边硬化,这样分别形成表皮112b和发泡层112a(参照图11)。浸渍在多孔性基板的孔内的熔融树脂112melt硬化,形成由表面层112覆盖多孔性基板111的整个外表面的车门内装饰板110。
而且,根据由上述制造方法A和制造方法B制造车门内装饰板,因为不必进行现有的制造方法中必不可少的表层板和发泡板板的制造过程,所以能够简化制造过程。另外,因为不需要用单独的部件将这样构成表面层112的两层112a和112b粘接起来,所以两层112a和112b不会出现剥离现象。另外因能使表面层112的发泡层的厚度和多孔度均匀的同时,表皮112b的表面与模具面完全吻合,所以能够提供具有均匀弹性和触感的外形美观的叠层体。
Claims (14)
1、一种制造叠层体的方法,包括如下步骤:
将制成规定形状的多孔性基板设置在一对预热的成形模具之间;
向该预热的成形模具之间的上述多孔性基板的外表面注入一定量的熔融热塑性树脂;
将成形模具压合在一起,使得注入的熔融热塑性树脂在压力下在该多孔性基板的外表面上铺开,引起该熔融的热塑性树脂在该多孔性基板外表面处浸渍该多孔性基板内部;并且
冷却浸渍到多孔性基板的热塑性树脂熔体,以在该多孔性基板上整体形成表皮层。
2、如权利要求1所述的制造叠层体的方法,其特征在于,在所述的注入步骤之前,用表面改性剂对该多孔性基板的外表面进行处理,以增强熔融热塑性树脂对多孔性基板的孔的浸渍性。
3、如权利要求1所述的制造叠层体的方法,其特征在于,所述的多孔性基板是由木质纤维和酚醛树脂的混合物制造的。
4、如权利要求1所述的制造叠层体的方法,其特征在于,所述的叠层体的形式是车辆的车门内装饰板或内部材料。
5、如权利要求2所述的制造叠层体的方法,其特征在于,所述的表面改性剂是烯烃。
6、如权利要求1所述的制造叠层体的方法,其特征在于,所述的热塑性树脂熔体是聚丙烯树脂。
7、如权利要求1所述的制造叠层体的方法,其特征在于,所述的热塑性树脂熔体是聚丙烯树脂和乙烯丙烯弹性体的混合物。
8、一种制造叠层体的方法,包括如下步骤:
将制成规定形状的多孔性基板保持在下模具的成形面上;
将一定量的热塑性熔融树脂熔体注入到该多孔性基板的外表面上,其条件是该下模具已被预热;
将被预热的上模具降至下模具,以压合在下模具上的该注入的热塑性树脂熔体和该多孔性基板,使得该热塑性树脂熔体在该多孔性基板上铺开,并浸渍到该多孔性基板外表面处的多孔性基板内部;并且
冷却浸渍到多孔性基板外表面内部的热塑性树脂熔体,以在该多孔性基板上整体形成表皮层。
9、一种制造叠层体的方法,包括如下步骤:
将制成规定形状的多孔性基板以这样的方式设置在一对模具之间,使得在该多孔性基板的外表面和两个模具中的任一个的成形面之间形成膜腔;
预热该模具至预定的升高的温度;
向该膜腔中注入一定量的熔融热塑性树脂熔体,使得该热塑性树脂熔体在该任一个模具的成形面铺开,并在该多孔性基板的外表面处浸渍到该多孔性基板的内部;
冷却该模具,以硬化浸渍到该多孔性基板内部的热塑性树脂,并由此在该多孔性基板的外表面上整体形成表皮层。
10、一种制造叠层成形结构的方法,包括如下步骤:
a)将预成形的多孔性基板的背侧表面置于由一对模具部件所限定的膜腔内,使得该预成形的多孔性基板的背侧表面与由第一模具部件限定的一个形状一致的成形面相对,并且,该预成形的多孔性基板的外表面与第二模具部件的另一个形状一致的成形面相对;
b)将热塑性树脂的熔体注入到该预成形多孔性基板的外表面和所述的第二模具部件的所述的另一个形状一致的成形面之间的膜腔中;
c)闭合该对模具部件,向该热塑性树脂的熔体施加压力,由此引起该熔体在该预成形的多孔性基板的外表面上铺开,并浸渍入其中;以及
d)在按照步骤c)施加的压力下冷却该热塑性树脂的熔体,以形成成形的叠层结构,该叠层结构具有所述的热塑性树脂的固化层,该固化层整体地锚住所述的预成形基板,并且与所述的预成形基板形状一致。
11、如权利要求10所述的方法,其特征在于,该注入步骤b)包括将热塑性树脂的熔体直接注入该预成形多孔性基板的外表面上。
12、如权利要求10所述的方法,其特征在于,该注入步骤b)包括将热塑性树脂的熔体经过该预成形的多孔性基板注入,使该热塑性树脂的熔体沉积在该基板的外表面上。
13、如权利要求10所述的方法,其特征在于,该注入步骤b)包括将热塑性树脂的熔体注入到所述第二模具部件的所述的另一个形状一致的成形面上。
14、如权利要求10所述的方法,其特征在于,该方法包括在注入步骤b)之前,预热该对模具部件的步骤。
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JP (1) | JP3820268B2 (zh) |
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CN1129920A (zh) | 1996-08-28 |
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