CN114174075A

CN114174075A - Method for manufacturing decorative member

Info

Publication number: CN114174075A
Application number: CN202080054125.6A
Authority: CN
Inventors: 高塚招次; 雨森纪平
Original assignee: TS Tech Co Ltd
Current assignee: TS Tech Co Ltd
Priority date: 2019-08-07
Filing date: 2020-07-17
Publication date: 2022-03-11
Also published as: WO2021024763A1; JPWO2021024763A1; JP7393676B2

Abstract

Provided is a method for manufacturing a decorative member, which can make a decorative material follow the shape of a base material and restrain the weight increase of the decorative member when the decorative material is adhered to the base material. A method for manufacturing a decorative panel (P) having a decorative material (2) on a surface of a panel base material (1), comprising the steps of disposing the decorative material (2) at a position facing the surface of the panel base material (1); disposing a flexible molding member (40) at the boundary between a lower frame (21) having one opening and an upper frame (11) having an opening on the lower frame (21), and abutting the lower frame (21) and the upper frame (11) to form a closed lower space (20A) formed by the lower frame (21) and the molding member (40) and a closed upper space (10A) formed by the upper frame (11) and the molding member (40); a step of forming the decorative material (2) into a specific shape by the forming member (40) in a state where the pressure of the lower space (20A) is lower than that of the upper space (10A); and a step of attaching the decorative material to the panel base material (1).

Description

Method for manufacturing decorative member

Technical Field

The present invention relates to a method for manufacturing a decorative member, and particularly to a method for manufacturing a decorative member in which a decorative material is attached to a surface of a base material.

Background

In a vehicle interior such as a door trim or an instrument panel, a decorative material portion including a veneer of natural wood is bonded to a surface of a base material made of a thermoplastic resin or the like in order to highlight a high-grade feeling.

For example, patent document 1 discloses a method for manufacturing a decorative panel, which includes a step of abutting two frames with a decorative material disposed at the boundary therebetween to form a closed lower space formed by the lower frame and the decorative material and a closed upper space formed by the upper frame and the decorative material; a step of forming the decorative material into a specific shape in a state where the pressure of the lower side space is smaller than that of the upper side space; and a step of attaching the decorative material to the surface of the base material.

Patent document 1: international publication No. 2017/217416

Disclosure of Invention

In the method for manufacturing a decorative panel described in patent document 1, in the step of forming the decorative material into a specific shape, a formed member such as a thermoplastic film may be used for the adhesive layer in order to make the decorative material follow the shape of the base material. The prior art uses a formed part in the adhesive layer, which results in an increase in the weight and thickness of the trim part.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for manufacturing a decorative member, which can make a decorative material follow the shape of a base material and suppress an increase in weight of the decorative member when the decorative material is attached to the base material.

The problem is solved by the following means. A method for manufacturing a decorative member having a decorative material on a surface of a base material, comprising the step of disposing the decorative material at a position facing the surface of the base material; disposing a flexible molding member at a boundary between a first housing having one opening and a second housing having the first housing opening, and bringing the first housing and the second housing into abutment with each other to form a sealed first space formed by the first housing and the molding member and a sealed second space formed by the second housing and the molding member; a step of forming the decorating material provided in the first space into a specific shape by the forming member in a state where the pressure of the first space is smaller than that of the second space; and a step of attaching the decorative material to the surface of the base material.

According to the above-described decorative member manufacturing method, when the decorative material is attached to the base material, the decorative material can follow the shape of the base material by the flexible molding member, and the molding member and the decorative member are separate members, so that the weight increase of the decorative member is suppressed.

In the method for manufacturing a decorative member, the decorative member is preferably bonded to the surface of the base material with an adhesive having air permeability.

In the above configuration, air can be prevented from remaining between the finishing material and the base material, and air accumulation can be prevented from occurring.

In the above method for manufacturing a decorative member, the molded member is preferably an elastic body.

In the above configuration, since the molded member is an elastic body and is easily stretched, the trim material can be effectively made to follow the shape of the base material.

In the above decorative member manufacturing method, it is preferable that the molding member is formed of silicone rubber.

In the above configuration, since the molding member is made of silicone rubber, it does not become hard even when heated, and can be used repeatedly.

In the decorative member manufacturing method, it is preferable that the decorative member has a resin-impregnated veneer, a breathable layer, and an adhesive layer bonded to the base material, and the breathable layer is disposed between the resin-impregnated veneer and the base material.

In the above configuration, the air-permeable layer is disposed between the resin-impregnated single sheet and the base material, thereby preventing the occurrence of air pockets.

In the above decorative member manufacturing method, it is preferable that an elastic layer is provided between the decorative member and the base material.

In the above configuration, since the elastic layer is provided between the decorative material and the base material, the decorative material is formed into an appropriate shape after being attached to the base material, thereby improving design properties.

In the above decorative member manufacturing method, it is preferable that the decorative material and the elastic layer have a larger surface area than the base material.

In the above configuration, the decorative material and the elastic layer can be effectively bonded to the base material.

In the above decorative member manufacturing method, it is preferable that the decorative material is formed to be thinner than the elastic layer.

In the above configuration, since the decorative material is formed thinner than the elastic layer, the decorative material can be deformed by reducing the pressure while retaining the elasticity of the elastic layer.

In the above decorative member manufacturing method, it is preferable that the base material and the decorative material are supported by a support jig.

In the above configuration, the base material and the decorative material are appropriately supported, and the decorative material can be effectively bonded to the base material.

In the above method for manufacturing a decorative member, it is preferable that at least a part of the support jig has flexibility.

In the above configuration, the support jig is bent, so that the following property when the molded member is deformed is improved, and therefore the decorative material more favorably follows the surface shape of the base material.

In the above decorative member manufacturing method, it is preferable that a step of coating a surface protective layer on a surface of the decorative member is further provided before the step of disposing the decorative member at a position facing the surface of the base material.

In the above configuration, since the surface protective layer is applied to the surface of the decorative material before the decorative material is formed into the specific shape, the application operation of the surface protective layer becomes easier as compared with the case where the surface protective layer is applied to the surface of the decorative material of the specific shape. As a result, the number of manufacturing steps can be reduced.

In the above decorative member manufacturing method, it is preferable that the decorative member further includes a surface protective layer on a surface of the decorative member, the surface protective layer contains an acrylic resin having a glass transition temperature of 66 ℃ to 135 ℃, as a main component, the surface protective layer has a thickness of 10 μm to 40 μm, and a total thickness of the decorative member and the surface protective layer is 0.3mm to 1.5 mm.

In the above configuration, by optimizing the resin material as the main component of the surface protective layer, the glass transition temperature of the resin material, and the thickness of the surface protective layer, it is possible to improve the molding processability while simultaneously achieving both the followability and weather resistance of the surface protective layer at the time of manufacturing the decorative part.

In the above decorative member manufacturing method, it is preferable that the decorative member has a three-dimensional structure, and a corner R portion which blunts a corner portion of the decorative material bonded to the surface of the base material is formed at the corner portion, and a radius of curvature of the corner R portion is 0.5mm or more.

In the above configuration, since the corner R portion having a curvature radius of 0.5mm or more is formed at the corner portion of the decorative member, the molding workability of the decorative member can be improved (cracking during molding can be suppressed).

In the above method for producing a decorative member, it is preferable that the surface protective layer contains the acrylic resin and a pigment, and the acrylic resin is contained in an amount of 50 to 90% by mass and the pigment is contained in an amount of 1 to 15% by mass, respectively, based on the total mass of the surface protective layer.

In addition, the surface protection layer further contains a weather resistant agent for improving the weather resistance of the decorative member, and the content of the weather resistant agent is 1 to 10% by mass relative to the total mass of the surface protection layer.

In the above configuration, by optimizing the contents of the acrylic resin, the pigment and/or the weather resistant agent, it is possible to manufacture a decorative member having improved weather resistance while further ensuring appearance.

According to the method for manufacturing a decorative member of the present invention, when the decorative material is attached to the base material, the decorative material can follow the shape of the base material by the flexible molding member, and the weight increase of the decorative member is suppressed because the molding member and the decorative member are separate bodies.

In addition, according to the method for manufacturing a decorative member of the present invention, air can be prevented from remaining between the decorative material and the base material, thereby preventing the occurrence of air entrapment.

In addition, according to the method for manufacturing a decorative member of the present invention, since the molded member is an elastic body and is easily stretched, the decorative material can be effectively made to follow the shape of the base material.

In addition, according to the method for manufacturing a decorative member of the present invention, since the molded member is made of silicone rubber, it is not hardened by heating and can be used repeatedly.

In addition, according to the method for manufacturing a decorative member of the present invention, since the air-permeable layer is disposed between the resin-impregnated veneer and the base material, the occurrence of air pockets is prevented.

In addition, according to the method for manufacturing a decorative member of the present invention, since the elastic layer is provided between the decorative material and the base material, the decorative material is formed into an appropriate shape after being attached to the base material, thereby improving design properties.

In addition, according to the method for manufacturing a decorative member of the present invention, the decorative material and the elastic layer can be effectively bonded to the base material.

In addition, according to the method for manufacturing a decorative member of the present invention, since the decorative material is formed thinner than the elastic layer, the decorative material can be deformed by reducing the pressure while retaining the elasticity of the elastic layer.

In addition, according to the method for manufacturing a decorative member of the present invention, the base material and the decorative material are appropriately supported, and the decorative material can be effectively bonded to the base material.

In addition, according to the method for manufacturing a decorative member of the present invention, since the following property when the molded member is deformed is improved by bending the supporting jig, the decorative material can follow the shape of the base material more favorably.

In addition, according to the method for manufacturing a decorative member of the present invention, the coating operation of the surface protective layer becomes easier than the case of coating the surface protective layer on the surface of the decorative material having a specific shape. As a result, the number of manufacturing steps can be reduced.

Further, according to the method for manufacturing a decorative part of the present invention, by optimizing the resin material as the main component of the surface protective layer, the glass transition temperature of the resin material, and the thickness of the surface protective layer, it is possible to improve the molding processability while simultaneously achieving both the followability and weather resistance of the surface protective layer at the time of manufacturing the decorative part.

In addition, according to the method for manufacturing a decorative member of the present invention, since the corner R portion having a curvature radius of 0.5mm or more is formed at the corner portion of the decorative member, the molding workability of the decorative member can be improved (cracking during molding can be suppressed).

In addition, according to the method for manufacturing a decorative member of the present invention, by optimizing the contents of the acrylic resin, the pigment and/or the weather resistant agent, it is possible to manufacture a decorative member having improved weather resistance while further ensuring the appearance.

Drawings

Fig. 1 is a view showing an example of a door trim including a decorative panel manufactured by the decorative member manufacturing method according to the present embodiment.

Fig. 2 is a perspective view showing the structure of the decorative panel.

3 fig. 3 3 3 is 3 a 3 sectional 3 view 3 a 3- 3 a 3 of 3 fig. 32 3. 3

Fig. 4 is a sectional view B-B of fig. 3.

Fig. 5 is a flowchart of a method for manufacturing a decorative panel according to the present embodiment.

Fig. 6 is a view for explaining a method of manufacturing a decorative panel.

Fig. 7 is a view for explaining a method of manufacturing a decorative panel.

Fig. 8 is a view for explaining a method of manufacturing a decorative panel.

Fig. 9 is a view for explaining a method of manufacturing a decorative panel.

Fig. 10 is a view for explaining a method of manufacturing a decorative panel.

Fig. 11 is a view for explaining a method of manufacturing a decorative panel.

Fig. 12 is a view for explaining a method of manufacturing a decorative panel.

Fig. 13 is a view for explaining a method of manufacturing a decorative panel.

Fig. 14 is a diagram illustrating a support jig according to modification 1.

Fig. 15 is a diagram illustrating a support jig according to modification 1.

Fig. 16 is a diagram illustrating a support jig according to modification 2.

Fig. 17 is a diagram illustrating a support jig according to modification 3.

Fig. 18 is a diagram illustrating a support jig according to modification 4.

Fig. 19 is a diagram illustrating a support jig according to modification 5.

Fig. 20 is a schematic sectional view showing a configuration of a decorative panel according to a modification.

Fig. 21 is a schematic sectional view showing the configuration of the decorative panel according to embodiment 2.

Fig. 22 is a cross-sectional view C-C of fig. 21.

Fig. 23 is a flowchart showing a method for manufacturing a decorative panel according to embodiment 2.

Detailed Description

A method for manufacturing a decorative member according to an embodiment of the present invention (hereinafter, this embodiment) will be described below with reference to fig. 1 to 23, taking a decorative panel manufacturing method as an example. In the present embodiment, the decorative panel is a part used for a part of an interior material such as a door trim or an instrument panel.

The embodiment described below is merely an example for facilitating understanding of the present invention, and is not intended to limit the present invention. That is, the shape, size, arrangement, etc. of the components described below are not to be construed as being modified or improved without departing from the gist of the present invention, and it is needless to say that the present invention includes equivalents thereof.

< decorative panel P >

Fig. 1 to 4 show a decorative panel P as an example of a decorative member manufactured by the decorative panel manufacturing method according to the present embodiment. As shown in fig. 1 by a door trim D provided on the side surface on the inside of the door of the passenger vehicle, a decorative panel P is a decorative member provided on the upper part of the door trim D. The door trim D is a member for decorating the vehicle interior side of the door, and is composed of a member group attached to a door inner panel, not shown.

As shown in fig. 2 to 4, the decorative panel P has a curved cross-sectional shape. The decorative panel P is configured by attaching a decorative material 2 to the panel base material 1, and the decorative material 2 includes a resin-impregnated veneer 2A formed by processing a veneer, which is a plate material obtained by thinning wood. According to the method for manufacturing a decorative panel of the present embodiment, the decorative panel P can be manufactured by appropriately attaching the decorative material 2 including a single sheet to the curved three-dimensional panel base 1.

As shown in fig. 3 and 4, the decorative panel P is a decorative member having a decorative material 2 on a surface of a panel base material 1. The panel base 1 is preferably a member composed of a resin manufactured by, for example, injection molding.

The decorative material 2 has a resin-impregnated single sheet 2A, a breathable layer 2B, and an adhesive layer 2C adhered to the panel base material 1. The resin-impregnated single sheet 2A is a member in which a single sheet (e.g., a thin sheet of natural wood) is impregnated with a resin (e.g., a synthetic resin). In this way, by containing resin in the ducts or fibers inside the veneer, stress concentration inside the veneer can be relaxed.

The air-permeable layer 2B is a back material having air permeability, which is composed of a nonwoven fabric, a face portion, or the like, disposed between the resin-impregnated single sheet 2A and the panel base 1. The air-permeable layer 2B prevents air from remaining between the resin-impregnated veneer 2A and the panel base material 1, thereby preventing air from accumulating.

The adhesive layer 2C is a layer to which the panel base 1 is adhered. For example, by using a thermosetting resin hardened by heating or a thermoplastic resin softened by heating as the adhesive layer 2C, the panel base material 1 and the decorative material 2 can be adhered by a heating process. When the adhesive layer 2C is made of an adhesive having air permeability, it is preferable to prevent air from remaining between the finishing material 2 and the panel base material 1 and air from accumulating.

A decorative panel manufacturing method according to the present embodiment is a method of manufacturing a decorative panel in which a decorative material including a veneer is bonded to a surface of a panel base material using a vacuum forming machine capable of reducing a pressure in a closed space formed by butting a first frame having one opening and a second frame having a first frame side opening.

< brief summary of decorative panel production method >

Fig. 5 is a flowchart of a method for manufacturing a decorative panel according to the present embodiment. A decorative panel manufacturing method according to the present embodiment is a manufacturing method of a decorative panel P including a decorative material 2 on a surface of a panel base material 1, and a step of disposing the decorative material 2 at a position facing the surface of the panel base material 1 (step ST 1); a step of disposing a flexible molding member 40 at a boundary between the lower frame 21 having one opening and the upper frame 11 having the lower frame 21 opening, and bringing the lower frame 21 into abutment with the upper frame 11 to form a closed lower space 20A formed by the lower frame 21 and the molding member 40 and a closed upper space 10A formed by the upper frame 11 and the molding member 40 (step ST 2); a step (ST3) of forming the garnish 2 into a specific shape by the forming member 40 in a state where the pressure of the lower space 20A is lower than that of the upper space 10A; and a step of bonding the finishing material 2 to the surface of the panel base material 1 (ST 4).

The outline of the method for manufacturing a decorative panel according to the present embodiment will be described below. The method for manufacturing a decorative panel according to the present embodiment specifically includes the following steps (1) to (11).

(1) A step of placing the panel base 1 on a vertically movable table 22A provided in a lower frame 21 as a first frame, and disposing the finishing material 2 at a position facing the surface of the panel base 1;

(2) a step of disposing a flexible molding member 40 at a boundary between the lower frame 21 and the upper frame 11 as a second frame;

(3) a step of forming a lower space 20A as a first space, which is sealed by the lower frame 21 and the molding member 40, and an upper space 10A as a second space, which is sealed by the upper frame 11 and the molding member 40, by abutting the upper frame 11 and the lower frame 21;

(4) a step of depressurizing the lower space 20A and the upper space 10A, respectively;

(5) a step of heating by a heater 12 provided in the upper frame 11;

(6) a step of heating the garnish material 2 by heating steam S before forming the garnish material 2 into a specific shape;

(7) a step of moving the table 22A upward and bringing the decorative material 2 into contact with the surface of the panel base material 1 by the molding member 40;

(8) a step of releasing the decompression of the upper space 10A and forming the decorative material 2 into a specific shape by the forming member 40;

(9) a step of attaching the decorative material 2 to the surface of the panel base material 1;

(10) a step of taking out the decorative panel P from the vacuum forming machine;

(11) a step of trimming the end of the finishing material 2.

Details of each step are described below with reference to the drawings.

< vacuum forming machine VF >

A general configuration of the vacuum forming machine VF used in the decorative panel manufacturing method according to the present embodiment will be described with reference to fig. 6. Fig. 6 to 12 schematically show cross sections of the vacuum forming machine VF. As shown in fig. 6, the vacuum forming machine VF includes an upper unit 10 and a lower unit 20.

The upper unit 10 includes an upper housing 11 as a second housing and a heater 12 disposed inside the upper housing 11. In the present embodiment, the heater 12 is attached to the upper surface of the inner wall of the upper housing 11, and is composed of, for example, a plurality of heating elements.

The upper frame 11 is a box-shaped cabin member having one opening. Specifically, a part of the lower surface of the upper frame 11 is open. The upper frame 11 is vertically movable, and abuts against a lower frame 21 described later, whereby the internal space of the upper frame 11 can be sealed. As shown in fig. 6, the pipe 14, the pipe 16, and the pipe 19 are connected to the inner wall of the upper housing 11.

The pipe 14 is a pipe for supplying the heating steam from the steam supply device 13 to the inside of the upper housing 11. Further, the pipe 14 is provided with an on-off valve 15 at a portion connecting between the upper housing 11 and the steam supply device 13. Then, only while the on-off valve 15 is open, the heating steam is supplied to the inside of the upper housing 11.

An on-off valve 17 is provided in a part of the pipe 16, and the on-off valve 17 is closed when the internal space of the upper housing 11 is closed and depressurized. Thereafter, the pressure in the internal space of the depressurized upper housing 11 can be returned to the atmospheric pressure by opening the on-off valve 17.

The pipe 19 is connected to a suction pump 24 via an on-off valve 18 and a pipe 25. After the internal space of the upper housing 11 is sealed, air is sucked by the suction pump 24 with the on-off valve 18 opened, whereby the internal space of the upper housing 11 can be brought into a reduced pressure state (vacuum state).

Next, the lower unit 20 will be explained. As shown in fig. 6, the lower unit 20 includes a lower housing 21 as a first housing, a table 22A disposed inside the lower housing 21, and a movable mechanism 22 for vertically moving the table 22A.

The lower frame 21 is a box-shaped cabin member having an opening on the upper frame 11 side. Specifically, a part of the upper surface of the lower frame 21 is opened. The openings of the upper frame 11 and the lower frame 21 are provided at opposite positions. As described above, the lower frame 21 and the upper frame 11 are butted against each other, whereby the internal space of the lower frame 21 can be sealed. That is, the space formed by the upper frame 11 and the lower frame 21 abutting against each other is a sealed space.

As shown in fig. 6, a pipe 25 is connected to the inner wall of the lower housing 21. The pipe 25 is a pipe connecting the lower frame 21 and the suction pump 24, and an on-off valve 26 is provided between the pipe 25 and the suction pump 24. After the internal space of the lower housing 21 is sealed, air is sucked by the suction pump 24 with the open/close valve 26 opened, and the internal space of the lower housing 21 can be brought into a reduced pressure state (vacuum state).

< description of method for producing decorative Panel >

Next, a procedure of attaching the decorative material 2 to the panel base material 1 to manufacture the decorative panel P will be described in detail with reference to fig. 6 to 13, taking an example of an operation using a vacuum forming machine VF. In the initial state, the on-off

valves

15, 17, 18, and 26 are all closed.

[ step (1) ]

First, as shown in fig. 6, the panel base 1 is placed on the stage 22A. Specifically, a support jig 30 having a housing portion 30a along the shape of the lower surface of the panel base material 1 is provided on the table 22A, and the lower surface of the panel base material 1 is disposed in contact with the support jig 30. Accordingly, the position of the panel base 1 with respect to the movable mechanism 22 is fixed. The decorating material 2 is disposed at a position facing the surface of the panel base material 1.

As shown in fig. 6, a flexible molded member 40 is placed so as to cover the opening of the upper frame 11. That is, the molding member 40 is disposed so that the inner space of the upper housing 11 is sealed by the molding member 40. The shaping member 40 is a member for shaping the finishing material 2 into a specific shape along the surface of the panel base material 1.

The forming member 40 is a flexible sheet-like or film-like member (sheet-like or film-like member) which is an elastic body. If the molding member 40 is an elastic body such as an elastic sheet or an elastic film, it is easily stretched when a force is applied, and therefore the decorative material 2 can be made to effectively follow the shape of the panel base material 1. In addition, the molding member 40 may be made of a thermoplastic resin (e.g., olefin or polyurethane) or silicone rubber having heat resistance. If the shaping member 40 is a thermoplastic plate or film made of a thermoplastic resin, it is easily stretched upon heating, and therefore the decorating material 2 can be made to effectively follow the shape of the panel base material 1. Further, if the molding member 40 is a silicone rubber sheet made of silicone rubber, it does not become hard even when heated, and can be repeatedly used in the step of attaching the decorative material 2 to the panel base material 1.

[ step (2) and step (3) ]

Next, as shown in fig. 7, the lower frame 21 is moved upward until the lower frame 21 comes into contact with the molding member 40, and then the molding member 40 is sandwiched between the upper frame 11 and the lower frame 21 (step (2)). In other words, the upper frame 11 and the lower frame 21 are butted against each other, whereby the molding member 40 can be sandwiched between the upper frame 11 and the lower frame 21.

In this step, a closed upper space 10A formed by the upper frame 11 and the molding member 40 and a closed lower space 20A formed by the lower frame 21 and the molding member 40 are formed (step (3)). In this step, heating may be started when the switch of the heater 12 is ON. Thereafter, the heater 12 continues to heat until the end of the step. In the drawing, the heater 12 is black to show the heater is ON.

[ Steps (4) and (5) ]

Next, after the on-off

valves

18 and 26 are opened, the upper space 10A and the lower space 20A start to be depressurized by the suction pump 24 until the respective spaces are in a vacuum state (step (4)). Fig. 8 shows a state of the upper space 10A and the lower space 20A in a vacuum state. In the present embodiment, the inside of the circular hole is filled with a dot to indicate a vacuum state. After the pressure is reduced to the vacuum state, the on-off

valves

18 and 26 may be closed again. Further, even in the state where the upper space 10A and the lower space 20A are depressurized, the heater 12 is heated (step (5)).

[ step (6) ]

Next, the table 22A is raised to the position shown in fig. 9. Then, as shown in fig. 10, before the decorating material 2 is deformed along the panel base material 1, the heating steam S from the steam supply device 13 is injected into the upper side space 10A. Accordingly, the decorative material 2 including the resin-impregnated single sheet 2A can be easily deformed.

[ step (7) ]

Next, as shown in fig. 11, the table 22A is moved upward by the movable mechanism 22, and the panel base 1 and the decorative material 2 are pressed against the molding member 40. In this way, the surface of the panel base material 1 is brought into contact with the adhesive layer 2C of the trim material 2 by the molding member 40.

[ Steps (8) and (9) ]

Next, as shown in fig. 11, by opening the on-off valve 17, the pressure of the upper space 10A is restored from the depressurized state to the atmospheric pressure (that is, the depressurization is released), and at the same time, the heated steam by the steam supply device 13 is switched to the pressurized state.

Further, the movable mechanism 22 further moves the table 22A upward, and the panel base 1 and the trim 2 are strongly pressed against the molding member 40, whereby the trim 2 is molded into a shape along the surface of the panel base 1. In this way, the trim material 2 is shaped into a specific shape along the surface of the panel base material 1 (step (8)). At this time, the decorating material 2 is heated by bringing the decorating material 2 close to the heater 12.

In this step, the upper space 10A is continuously pressurized, and the lower space 20A is maintained in a vacuum state. Due to the pressure difference between the upper space 10A and the lower space 20A thus generated, the trim material 2 is strongly pressed from above against the panel base material 1 by the molding member 40, and the panel base material 1 is also strongly pressed from below against the trim material 2 by the support from the table 22A.

At this time, the resin-impregnated single sheet 2A of the decorative material 2 is easily and flexibly deformed by the heating steam S and the heating by the heater 12. Accordingly, the resin-impregnated single sheet 2A can be prevented from cracking. Further, since the resin-impregnated single sheet 2A is impregnated with resin, stress concentration can be relaxed, and cracking is further reduced. Then, according to this step, the decorative material 2 is bonded to the surface of the panel base material 1 (step (9)).

In this way, the decorative material 2 is molded into a specific shape by the flexible molding member 40, and the decorative material 2 is bonded to the surface of the panel base material 1, whereby the decorative material 2 can follow the shape of the panel base material 1 by the molding member 40. In addition, since the molding member 40 is separate from the decorative panel P, the weight increase of the decorative panel P can be suppressed.

[ Steps (10) and (11) ]

Next, after the decorative panel P is cooled as necessary after the above step (9), the upper frame 11 is moved upward (fig. 12), and the decorative panel P is removed from the support jig 30 and taken out from the vacuum forming machine VF (step (10)). Then, as shown in fig. 13, the end portions of the trim material 2 are trimmed (step (11)), and the decorative panel P is completed (fig. 13). The trimming can be performed by physical cutting or laser.

< modification example >

The present invention is not limited to the above embodiments. In the above embodiment, the first housing (lower housing 21) and the second housing (upper housing 11) are arranged in the vertical direction, and the first housing and the second housing may be arranged in the horizontal direction.

Next, a modified example of the support jig 30 will be described with reference to fig. 14 to 19. As shown in fig. 14 and 15 (modification 1), the support jig 30 may include an upright portion 31 protruding upward around the housing portion 30 a. In this case, it is preferable that the standing portion 31 has a recessed portion 32 for supporting the finishing material 2

According to this configuration, since the panel base material 1 and the decorative material 2 are appropriately disposed and supported by the support jig 30, the decorative material 2 can be effectively bonded to the panel base material 1. Specifically, by deforming the forming member 40 from the state shown in fig. 14 to the state shown in fig. 15, the end of the trim material 2 is separated from the concave portion 32, and is deformed to be gradually followed along the shape of the surface of the panel base material 1 and is pressed, whereby the trim material 2 can be effectively bonded to the panel base material 1.

As shown in fig. 16 (modification 2), the standing portion 31 may not have a recessed portion that is grooved to support the garnish 2. As shown in fig. 17 to 19, the standing part may be formed as a separate body from the main body of the support jig 30.

The height of the standing portion 31X in fig. 17 (modification 3) is configured to be higher than the upper end portion of the panel base material 1 held in the housing portion 30 a. The height of the standing portion 31Y in fig. 18 (modification 4) is configured to substantially match the upper end portion of the panel base material 1 held in the housing portion 30 a. The height of the standing portion 31Z in fig. 19 (modification 5) is lower than the upper end portion of the panel base material 1 held in the housing portion 30 a.

From the viewpoint of stable holding, the housing portion 30a of the support jig 30 is preferably made of a material having high hardness. The standing part in fig. 14 to 19 may be made of the same material as the main body of the support jig 30 or may be made of a flexible material. Since the following property when the molding member 40 is deformed is improved by bending a part of the supporting jig 30, specifically, the standing portion disposed around the housing portion 30a, the following property of the trim material 2 with respect to the surface shape of the panel base material 1 becomes more favorable.

Fig. 20 is a schematic sectional view showing a configuration of a decorative panel PX according to a modification. The decorative panel PX has an elastic layer 2X between the decorative material 2 and the panel base material 1. The elastic layer 2X may be made of a material having elasticity such as polyurethane, and a thin layer of a polyurethane plate may be mentioned, but is not limited thereto. If the elastic layer 2X is disposed, the shape of the finishing material 2 becomes more appropriate after being attached to the panel base material 1, thereby improving design.

In this case, if the surface area of the decorative material 2 and the elastic layer 2X is larger than that of the panel base 1, the decorative material 2 and the elastic layer 2X can be effectively bonded to the panel base 1. In addition, the trim material 2 may be formed thinner than the elastic layer 2X. By forming the trim material 2 to be thinner than the elastic layer 2X, the trim material 2 can be deformed by reducing the pressure while retaining the elasticity of the elastic layer 2X.

Further, by providing a surface protection layer (not shown) made of a colorless paint or a transparent film on the resin-impregnated single sheet 2A, the surface of the decorative material 2 can be protected.

The method for manufacturing a decorative member according to the present embodiment has been described above by taking an example of the method for manufacturing a decorative panel, but the method for manufacturing a decorative member according to the present embodiment is not limited to the method for manufacturing a decorative panel, and can be applied to decorative members other than decorative panels. The decorative member is not limited to a door trim of a vehicle or an interior trim of an instrument panel or the like, and may be a decorative member other than a vehicle.

< decorative panel P of embodiment 2 >

Next, a decorative panel P2 according to embodiment 2 will be described with reference to fig. 21 to 23.

Note that description overlapping with the decorative panel P described above is omitted.

The decorative panel P2 of embodiment 2 is a decorative member having a three-dimensional structure in which the decorative material 102 is provided on the surface of the panel base material 101, and the surface protective layer 103 is provided on the surface of the decorative material 102.

The decorative material 102 includes a resin-impregnated single sheet 102A, a breathable layer 1002B, and an adhesive layer 102C bonded to the surface of the panel base 101.

The surface of the decorative material 102 (resin-impregnated single sheet 102A) is provided with the uneven pattern 104 in advance by a known method. Therefore, for example, by expressing the appearance of the original texture (open porous structure), the design of the decorative panel P2 can be improved.

In addition, a corner R portion 105 for blunting the corner is formed at the corner of the decorative material 102, and the radius of curvature of the corner R portion 105 is 0.5mm or more. Therefore, the molding workability of the decorative panel P2 can be improved. That is, the decorative material 102 can be prevented from being broken at the time of molding.

The surface protection layer 103 is configured as a protection layer containing "acrylic resin", "pigment", "matting agent", and "weather resistant agent" as main components.

The thickness of the surface protection layer 103 is preferably 10 μm or more and 40 μm or less.

The reason is that if the thickness of the surface protective layer 103 is less than 10 μm, it is confirmed that the surface protective layer 103 is cracked or broken when the decorative panel P2 is molded. It has been confirmed that if the thickness of the surface protection layer 103 exceeds 40 μm, the glossiness of the surface protection layer 103 is improved, and the appearance marketability of the decorative panel P2 cannot be ensured.

In this case, if the total thickness of the decorative material 102 and the surface protective layer 103 is 0.3mm to 1.5mm, the moldability and the appearance marketability can be further improved.

In the surface protection layer 103, it is preferable that the mass content of the "acrylic resin" is 50 to 90%, the mass content of the "pigment" is 1 to 15%, the mass content of the "matting agent" is 1 to 5%, and the mass content of the "weather resistant agent" is 1 to 10% with respect to the total mass thereof.

The "acrylic resin" is preferably an acrylic resin having a glass transition temperature of 66 ℃ to 135 ℃, more preferably 82 ℃ to 135 ℃, and still more preferably 100 ℃.

In addition, the "acrylic resin" is preferably an acrylic resin not containing TX. TX-free means that toluene or xylene, which are substances that are the subjects of limitation to induce the indoor air pollution syndrome, are not contained.

The "weather resistant agent" is an additive for improving the weather resistance of the decorative panel P2, and is preferably an ultraviolet absorber or a light stabilizer.

In the above, it has been confirmed that if the mass content of the "acrylic resin" is less than 50%, the physical properties (particularly, weather resistance) of the entire decorative panel P2 are lowered. It has also been confirmed that if the mass content of the "acrylic resin" exceeds 90%, it becomes difficult to adjust the gloss and color tone of the decorative panel P2.

In addition, in the above, it has been confirmed that if the glass transition temperature of the "acrylic resin" is less than 66 ℃, the heat resistance of the decorative panel P2 is poor. It has also been confirmed that if the glass transition temperature of the "acrylic resin" exceeds 135 deg.c, the decorative material 2 is broken during the formation of the decorative panel P2.

In addition, in the above, it has been confirmed that if the mass content of the "pigment" is less than 1%, the appearance marketability of the decorative panel P2 is lowered. It has also been confirmed that if the "pigment" content exceeds 15% by mass, the viscosity of the surface protective layer 103 is reduced and the decorative material 102 is broken during the forming process.

In addition, in the above, it has been confirmed that if the mass content of the "matting agent" is less than 1%, the color (gloss value) of the decorative panel P2 becomes high, and the appearance marketability is lowered. It has been confirmed that if the "matting agent" is contained in an amount exceeding 5% by mass, the surface protection layer 103 is deteriorated in coatability and also in appearance marketability.

In addition, in the above, it has been confirmed that if the mass content of the "weather resistant agent" is less than 1%, the weather resistance of the decorative panel P2 is lowered. It has also been confirmed that if the "weather resistant agent" is contained in an amount exceeding 10% by mass, the cost increases.

In addition, in the above description, if the "weather resistant agent" is an ultraviolet absorber, the weather resistance of the surface protection layer 103 can be effectively improved by absorbing ultraviolet rays of a certain wavelength.

In addition, in the above, if the "weather resistant agent" is a light stabilizer, the progress of deterioration of the surface protective layer 103 when exposed to ultraviolet rays is suppressed, and the weather resistance can be effectively improved.

Next, a method for manufacturing a decorative panel according to embodiment 2 (steps ST1-1 to ST4) will be described with reference to fig. 23.

The method for manufacturing a decorative panel according to embodiment 2 includes the steps of: a step of coating a surface protective layer 103 on the surface of the decorative material 102 (step ST 1-1); a step of disposing the decorative material 102 at a position facing the surface of the panel base material 101 (step ST 1-2); a step of forming a closed lower space 20A formed by the lower frame 21 and the molding member 40 and a closed upper space 10A formed by the upper frame 11 and the molding member 40, as shown in fig. 7 (step ST 2); a step of molding the decorative material 102 provided in the lower space 20A into a specific shape by the molding member 40 in a state where the pressure of the lower space 20A is smaller than that of the upper space 10A (step ST 3); a step of bonding the decorative material 102 to the surface of the panel base material 101 (step ST 4).

In detail, in step ST1-1, the surface protective layer 103 is coated on the surface of the decorative material 102 in a uniform thickness, for example, using a roll coater. After application, the coating is dried thoroughly.

With the above-described step ST1-1, for example, the application operation of the surface protective layer 103 becomes easier than in the case where the surface protective layer 103 is applied to the surface of the decorative material 102 after molding. For example, the thickness of the surface protection layer 103 can be made more uniform than spraying.

Description of the symbols

D door trim

P, PX, P2 decorative panel (decorative component)

1. 101 Panel substrate (substrate)

2. 102 decorative material

2A, 102A resin-impregnated veneer

2B, 102B breathable layer

2C, 102C adhesive layer

2X elastic layer

103 surface protective layer

104 embossing pattern

105 corner R part

VF vacuum plastic suction forming machine

10 upper side unit

10A Upper side space (second space)

11 Upper frame body (second frame body)

12 heating device

13 steam supply device

14 piping

15 switch valve

16 piping

17 switching valve

18 on-off valve

19 piping

20 lower side unit

20A lower side space (first space)

21 lower frame body (first frame body)

22 moving mechanism

22A bench

24 suction pump

25 piping

26 switch valve

30 support clamp

30a accommodating part

31. 31X, 31Y, 31Z standing parts

32 concave part

40 formed part

S heating steam

Claims

1. A method for manufacturing a decorative member having a decorative material on a surface of a base material, the method comprising:

a step of disposing the decorative material at a position opposite to the surface of the base material;

disposing a flexible molding member at a boundary between a first housing having one opening and a second housing having the first housing opening, and bringing the first housing and the second housing into abutment with each other to form a sealed first space formed by the first housing and the molding member and a sealed second space formed by the second housing and the molding member;

a step of forming the decorating material provided in the first space into a specific shape by the forming member in a state where the pressure of the first space is smaller than that of the second space;

and a step of attaching the decorative material to the surface of the base material.

2. The method for manufacturing a decorative member according to claim 1, wherein:

the decorative material is adhered to the surface of the base material through an adhesive with air permeability.

3. The method for manufacturing a decorative member according to claim 1, wherein:

the shaped part is an elastomer.

4. The method for manufacturing a decorative member according to claim 1, wherein:

the forming member is formed of silicone rubber.

5. The method for manufacturing a decorative member according to claim 1, wherein:

the decorative material is provided with a resin impregnated veneer, a breathable layer and an adhesive layer bonded with the base material;

the air-permeable layer is arranged between the resin-impregnated veneer and the base material.

6. The method for manufacturing a decorative member according to claim 1, wherein:

an elastic layer is provided between the decorative material and the base material.

7. The method of manufacturing a decorative member according to claim 6, wherein:

the decorative material and the elastic layer have a larger surface area than the base material.

8. The method of manufacturing a decorative member according to claim 6, wherein:

the finishing material is formed in a thinner manner than the elastic layer.

9. The method for manufacturing a decorative member according to claim 1, wherein:

the base material and the decorative material are held by a holding jig.

10. The method of manufacturing a decorative member according to claim 9, wherein:

at least a portion of the support fixture is flexible.

11. The method for manufacturing a decorative member according to claim 1, wherein:

the method further comprises a step of coating a surface protective layer on the surface of the decorative material before the step of disposing the decorative material at a position opposite to the surface of the base material.

12. The method for manufacturing a decorative member according to claim 1, wherein:

the decorative member further includes a surface protective layer on a surface of the decorative material;

the surface protection layer contains acrylic resin having a glass transition temperature of 66 ℃ to 135 ℃ as a main component; the thickness of the surface protection layer is more than 10 mu m and less than 40 mu m;

the total thickness of the decorative material and the surface protective layer is more than 0.3mm and less than 1.5 mm.

13. The method of manufacturing a decorative member according to claim 12, wherein:

the trim component has a three-dimensional configuration;

a corner R portion for blunting a corner portion of the decorative material attached to the surface of the base material;

the radius of curvature of the corner R portion is 0.5mm or more.

14. The method of manufacturing a decorative member according to claim 12, wherein:

the surface protection layer contains the acrylic resin and a pigment;

the mass content of the acrylic resin is 50-90% and the mass content of the pigment is 1-15% of the total mass of the surface protection layer.

15. The method of manufacturing a decorative member according to claim 14, wherein:

the surface protective layer further contains a weather-resistant agent for improving weather resistance of the decorative member;

the weather-resistant agent is contained in an amount of 1 to 10% by mass relative to the total mass of the surface protective layer.