JP2001071377A - Vacuum forming method for decorative sheet material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a vacuum forming method capable of beautifully shaping a decorative sheet material of every kind such as a resin film, a fabric or a nonwoven fabric without loosening the corner part thereof. SOLUTION: At the time of vacuum forming of a decorative sheet material S by a vacuum mold 1 having a flange part which has one or more corner part provided to the peripheral edge thereof, the peripheral enfolding part S6 of at least a part of the decorative sheet material S is grasped by a clamp to soften the decorative sheet material S under heating, and the thermally softened decorative sheet material S is arranged to molding surface to be enfolded toward the rear surface of the flange part under vacuum suction and, in such a state that the peripheral enfolding part S6 is enfolded, the corner parts S1-S4 of the decorative sheet material S are pressed to the insides of the corner parts of the vacuum mold 1 by corner part pressing means 3 to be enfolded to the corner parts of the vacuum mold.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for vacuum forming a decorative sheet material, and more particularly, to loosening a corner of a decorative sheet material in a vacuum forming die having a forming surface corresponding to a synthetic resin molded product. The present invention relates to a method for vacuum forming a decorative sheet material that can be rolled up without any problem.

[0002]

2. Description of the Related Art Conventionally, for example, in the production of automobile interior parts, a decorative sheet material is added to a molded article formed of a synthetic resin material for the purpose of decoration. Normally, the resin material is provided with a wood-grain or leather-like resin sheet, a resin sheet in which a foamed resin material is integrated, a cloth, a nonwoven fabric, and the like. This decorative sheet material is joined to a molded product obtained by molding a synthetic resin material, so that good appearance and design as a final product can be obtained.

[0003] A method of forming a decorative sheet material of such a resin material is disclosed in, for example, JP-A-6-198728. According to the molding method disclosed in the publication, a curved-shaped vacuum molding die having a relatively high center and a relatively high elevation is softened by heat using a decorative sheet material in which a foamed resin material is integrated with a resin sheet. The decorative sheet material is approached, and the decorative sheet material is stretched by a clamp, and is stretched from a high ridge near the center to a relatively low ridge around the vacuum contact to form a vacuum. It is carried out.

At the time of this vacuum forming, the decorative sheet material is brought into contact with the center forming surface of the vacuum forming die, and the clamp is gradually approached to the side of the vacuum forming die.
By moving the vacuum forming die toward the decorative sheet material in accordance with the approach of the clamp, a state in which the tensile force is reduced from the molding surface near the center to the molding surface near the side of the decorative sheet material. In this case, the decorative sheet material is substantially along the mold surface of the vacuum forming die, and at this time, the decorative sheet material is formed along the mold surface shape of the vacuum forming die by vacuum suction. Therefore, it is possible to prevent a change in swelling of the decorative sheet material due to a change in the thickness of the foam layer, and it is possible to reliably form a decorative sheet material that can be deep drawn and has a uniform thickness throughout. is there.

For example, Japanese Patent Application Laid-Open No. 9-48067 discloses that an intermediate layer made of a foamed resin material has a surface layer made of a resin material having a predetermined elongation on the front side and a resin layer having a lower elongation than the skin layer on the back side. A decorative sheet material that is a three-layer resin sheet having a barrier layer made of a material, and a vacuum forming method of the decorative sheet material are disclosed. The decorative sheet material disclosed in the publication has a length of the cut position planned for the barrier layer and the intermediate layer at a position outside the planned cut position of the peripheral winding portion of the decorative sheet material. 4 slits extending substantially parallel to the vertical direction and having a substantially triangular cross section are formed.

When vacuum-forming using the decorative sheet material, the decorative sheet material is first preliminarily heated to be softened into a plastically deformable state, and then the decorative sheet material is vacuum-molded. Over the vacuum forming die with a plug for sandwiching the decorative sheet material, and hermetically sealed.
Next, the decorative sheet material is vacuum-sucked to the vacuum forming die through a number of suction holes communicating with the surface of the vacuum forming die, so that the corner portions at the upper and lower ends of the vacuum forming die and the same are formed. A decorative sheet material having a predetermined shape conforming to a mold shape having first to third bent portions corresponding to concave portions which are depressed inward from the lower corner portions is formed. Then, after cooling the decorative sheet material, the excess peripheral winding portion of the decorative sheet material is cut and trimmed.

According to this conventional vacuum forming method, the decorative sheet material has a slit formed at a predetermined position on the decorative sheet material sandwiching plug side with respect to the third bent portion.
At the time of vacuum suction, even if stress concentrates on the third bent portion of the decorative sheet material, the third bent portion is torn in the tensile direction and moves in the extending direction of the decorative sheet material. Therefore, in the second bent portion rather than the third bent portion of the decorative sheet material, the intermediate layer is excessively elongated and becomes thin, so that the soft feeling is not lost, and the breakage of the barrier layer is caused by the breakage of the decorative sheet. There is no danger of reaching the central molded portion of the material and impairing the appearance of the decorative sheet material.

Further, since the surface layer of the third bent portion of the decorative sheet material is made of a resin material having a high elongation, the surface layer is not broken by the tensile force and does not affect the central molded portion. Then, in the decorative sheet material, the position of the inner portion of the slit is shifted inward by the extension of the intermediate layer.
Therefore, it is possible to prevent problems such as a decrease in the thickness of the decorative sheet material in the vicinity of the second bent portion and a break in the surface layer.

[0009]

By the way, in the vacuum forming method of the decorative sheet material disclosed in the above-mentioned Japanese Patent Application Laid-Open No. Hei 6-198728, in order to obtain the above-described effects, the decorative sheet material is formed at the time of vacuum forming. The clamp for clamping the peripheral winding portion of the sheet material is gradually approached to the side of the vacuum forming die, and the vacuum forming die is moved toward the decorative sheet material with the approach of the clamp, JP-A-9-480
In the vacuum forming method for a decorative sheet material disclosed in Japanese Patent Publication No. 67, a slit is formed at a predetermined position of a peripheral winding portion of the decorative sheet material. Even when stress concentrates on the wrapped portion, the peripheral wrapped portion of the decorative sheet material is torn in the tensile direction and moved in the extending direction of the decorative sheet material.

However, in each of the above-mentioned publications, it is not possible to prevent local thinning, breakage, and the like from occurring in the central molded portion of the decorative sheet material or the gently peripherally wound portion that is substantially linear. Although it is possible, the peripherally wound portions of the decorative sheet material wound on the back side of the vacuum forming die during vacuum suction largely extend and expand toward a plurality of corners on the back side of the vacuum forming die. As a result, there is a problem that the corners of the decorative sheet material corresponding to the plurality of corners of the vacuum forming die swell to the outside and rise, thereby impairing the appearance. However, the vacuum forming method of the decorative sheet material disclosed in these publications does not pay any attention or mention the technical problem of removing the slack generated at the corner of the decorative sheet material.

The present invention has been made to solve such a conventional problem, and a specific object of the present invention is to provide beautiful decorative sheet materials such as resin films, cloths and nonwoven fabrics without slackening. It is an object of the present invention to provide a method for vacuum forming a decorative sheet material that can be shaped into a sheet.

[0012]

The above object is effectively achieved by the inventions described in claims 1 to 3 of the present invention. The invention according to claim 1 is a method for vacuum forming a decorative sheet material in a vacuum forming die provided with a flange having one or more corners on a peripheral edge, wherein at least one of the decorative sheet materials is clamped. The decorative sheet material is heated and softened, and the heat-softened decorative sheet material is arranged in the molding die to vacuum-adsorb the central molded portion of the decorative sheet material. At the same time, the peripheral winding portion excluding the corner portion of the decorative sheet material is wrapped by vacuum suction on the back side of the flange portion, and the corner portion of the decorative sheet material is wound in a state where the peripheral winding portion is wrapped. A step of pressing the portion toward the inside of the corner by means of a corner pressing means, and winding the corner into the corner.

According to the above method, when the central forming portion of the decorative sheet material is vacuum-sucked into a vacuum forming die provided with a flange portion having one or more corner portions on the periphery, the corner portion of the decorative sheet material is used. The peripheral winding portion except for the above is sucked and wound on the back surface side of the flange portion. Simultaneously or in a state in which the peripheral winding portion is wound, by pressing the corner of the decorative sheet material by the corner pressing means, it is pressed toward the inside of the corner of the vacuum forming die. Since the corner portion of the decorative sheet material is wrapped around the same corner portion, the local slack that occurs at the corner portion of the decorative sheet material is uniform based on the softening and shrinkage of the decorative sheet material. The vacuum molding die is deformed into a flat shape and is sucked along the back surface of the corner of the vacuum forming die.

[0014] This makes it possible to reliably remove slack generated during the shaping of the decorative sheet material and to obtain a beautiful decorative sheet material having a substantially uniform thickness. Also,
The obtained decorative sheet material is joined to a molded product formed of a synthetic resin material without being locally loosened, and has an excellent appearance design as a final product. The decorative sheet material may be attached to a molded product made of a synthetic resin material in advance, or may be integrated with the molded product by insert molding by injection.

According to a second aspect of the present invention, in addition to the configuration of the first aspect, at least a part of the peripheral winding portion is formed with a slit-shaped notch parallel to the peripheral winding portion, and the slit is formed by the clamp. It is defined that the peripheral winding portion having the cutout portion of the decorative sheet material is sandwiched, and the inner peripheral winding portion of the cutout portion is wound around the back surface of the flange portion by vacuum suction.

It is preferable that the corners of the decorative sheet material are pulled in a tensioned state, and it is preferable that the peripheral winding portions other than the corners of the decorative sheet material are easily wound.

In this vacuum forming method for a decorative sheet material, a slit-shaped notch is formed in at least a part of the peripheral winding portion and is substantially parallel to the peripheral winding portion. Around the outside of the notch. For this reason, the decorative sheet material can be firmly fixed in a tensioned state before the forming is started, and when the forming is started, in addition to the operation and effect of the above-described claim 1, the peripheral winding portion inside the cutout portion is provided. Since there is a degree of freedom, it is possible to freely wind the peripheral winding portion inside the notch portion except for the corner portion of the decorative sheet material by vacuum suction on the back side of the flange portion of the vacuum forming die, It is possible to locally reduce the thickness of the peripherally wound portion of the sheet material and prevent the central molded portion of the decorative sheet material from being torn. Therefore, the decorative sheet material can be more easily and reliably and beautifully shaped.

According to a third aspect of the present invention, in addition to the configuration of the second aspect, the inner and outer peripheral winding portions sandwiching the notch portion are connected to the intermediate portion of the notch portion with a breakable connecting portion. It is specified that the connecting portion is automatically broken at the time of vacuum forming in which the inner peripheral winding portion of the notch portion is wound on the back surface side of the flange portion.

When arranging a decorative sheet material in a vacuum forming mold,
It is preferable that the decorative sheet material is hermetically bonded to the outer peripheral edge of the vacuum forming die between the peripherally wound portion and the clamp, and the cutout portion of the decorative sheet material is set accurately without floating. Is preferred.

In this vacuum forming method, a breakable connecting portion for connecting the inner and outer peripheral winding portions is formed at an intermediate portion of the notch portion,
The outer peripheral winding portion of the decorative sheet material is gripped by the clamp, so that in addition to the operation and effect of the above-described claim 2, the connecting portion is broken particularly at the initial stage of vacuum suction from the time of setting the vacuum forming die. Until this, the connection between the connection portion and the peripheral winding portion ensures good shape retention in the peripheral winding portion of the decorative sheet material, and is formed between the vacuum forming die and the decorative sheet material. The airtightness of the suction space is maintained, and when the decorating sheet material is broken by the tension when vacuum suction is applied, the degree of freedom is given to the inner peripheral winding portion of the cutout portion. , Smooth deformation can be brought about.

[0021]

Preferred embodiments of the present invention will be described below in detail with reference to the accompanying drawings. In addition,
In this embodiment, the decorative sheet material will be described as an example of a glove box lid of an automobile as a final product joined to a molded product obtained by molding a synthetic resin material, but the present invention is not limited to this. Car console lid,
It is also applied to pillar garnishes, rear luggage trims, door trims and ceiling members, or seat backs in general living spaces.

FIG. 1 is a schematic view of a manufacturing apparatus for manufacturing a decorative sheet material by vacuum forming, which is a typical embodiment of the present invention, and FIG. FIG. 2A is a sectional view taken along line AA of FIG. 1, FIG. 2B is a sectional view taken along line BB of FIG. 1, and FIG.
FIG. 3A is a cross-sectional view taken along the line AA of FIG. 1, FIG. 3B is a cross-sectional view taken along the line BB of FIG. 1, and FIG. It is a perspective view which shows the state of the decorative sheet material in the process of vacuum forming a sheet material.

In these figures, reference numeral 1 denotes a vacuum forming die, and this vacuum forming die 1 adopts a male type.
The vacuum forming die 1 has a flat plate portion 1a and a flange portion 1b protruding upward from the flat plate portion 1a, and an annular concave portion 1c depressed inward between the flange portion 1b and the flat plate portion 1a.
Is formed. The flange portion 1b has four corner portions 1d.
A molding surface 1e corresponding to the glove box lid 11 of the present embodiment is formed on the flange portion 1b. The molding surface 1e has a plurality of vacuum suction holes 1f,.
f is drilled at a predetermined site.

According to the illustrated example, a support 2 supported by a movable die that can move up and down is provided above the vacuum forming die 1, and the support 2 is a corner pressing means. A pressing plug 3 for shaping the sheet material is provided. The pressing plug 3 is supported at four corners of the support 2. As shown in FIG. 2 and FIG.
Is disposed via a connecting member 6 installed at the tip of a rod 5a that is driven to expand and contract in the horizontal direction by a cylinder 5 fixedly mounted on a support frame 2a, and inserted into the annular concave portion 1c of the vacuum forming die 1. Get out. Since the pressing plug 3 configured as described above is driven independently of the support 2, it may be simply driven in the horizontal direction by the cylinder 5, and the driving mechanism is simplified.

In this embodiment, the support 2 moves up and down with respect to the vacuum forming die 1 to open and close.
4 for holding a sheet material driven by driving means (not shown)
A plurality of clamps 4 are arranged side by side in the opening and closing direction of the vacuum forming die 1 and the support 2, and a sheet heater for heating a sheet material (not shown) and a sheet material supply unit (not shown) It has. The clamp 4 is moved between the vacuum forming die 1 and the support body 2 while sandwiching the four corners S1 to S4 of the peripheral winding part S6 of the decorative sheet material S.

The molding apparatus 1 constructed as described above
0 is not limited to this, and it is also possible to manually supply the decorative sheet material S without providing the sheet material supply unit, for example, and retreat the clamp 4 to the vacuum forming mold 1. The peripheral winding portion S6 of the decorative sheet material S can be sandwiched by being fixed freely. Further, the decorative sheet material S can be vacuum-formed by matching the movable mold and the fixed mold.

Hereinafter, a method of vacuum-forming the decorative sheet material S for decorating the glove box lid 11 shown in FIG. 9 using the molding apparatus 10 will be described with reference to FIGS. . As shown in FIG. 9, the glove box lid 11 is made of, for example, a synthetic resin material such as polypropylene, and has a decorative sheet material S on the surface thereof, such as foamed polypropylene or foamed polyethylene laminated on the back surface of a thermoplastic resin material such as polyolefin. Are integrally attached. As the decorative sheet material S, a material that can be stretched upon heating is suitable. For example, a woven or knitted fabric, a nonwoven fabric, or a PVC sheet, such as polypropylene, polyethylene, TPO, AB
S, PC, TPE, plain woven fabric, knitted fabrics and the like with a backing material, etc. are applied.

In order to vacuum form the decorative sheet material S, first, the vacuum forming die 1 and the support 2 are opened, the decorative sheet material S is supplied from a sheet material supply section (not shown), and four The four corners S1 to S of the decorative sheet material S are denoted by 4,.
4 is pinched. In this state, the decorative sheet material S is heated and softened by a surface heater (not shown), and the heated softened decorative sheet material S is moved between the vacuum forming die 1 and the support 2 by the clamp 4. Let it. Then, the sheet material supply unit and the surface heater (not shown) are retracted. Here, after the decorative sheet material S sandwiched between the clamps 4 is arranged between the vacuum forming die 1 and the support 2, the decorative sheet material S is heated and softened by a surface heater (not shown). Can also.

Subsequently, as shown in FIG. 2, after the clamp 4 is moved with respect to the vacuum forming die 1, a central forming portion S5 and a peripheral winding portion S of the decorative sheet material S that has been softened by heating are formed.
6 is hermetically bonded from above the molding surface 1e of the vacuum molding die 1. At the same time, the support 2 is
To lower. At this time, the peripheral wrapped portion S6 excluding the corner portions S1 to S4 of the decorative sheet material S is
Since it is not pinched, the tension interval does not change and the thickness interval hardly changes.

On the other hand, the corner portions S1 to S4 of the decorative sheet material S
The thickness interval of the peripheral winding portion S6 is slightly reduced because the clamp 4 is in a tension state. In this state, an annular closed space 7 is formed between the peripheral winding portion S6 of the decorative sheet material S and the annular concave portion 1c of the vacuum forming die 1. Note that the vacuum forming die 1 can be moved with respect to the clamp 4.

Next, as shown in FIG. 3, a vacuum is drawn from a vacuum suction hole 1f of the vacuum forming die 1 via a suction pump (not shown) to form a central forming portion S of the decorative sheet material S.
5 and the peripheral winding portion S6 excluding the corner portions S1 to S4 of the decorative sheet material S sandwiched by the clamp 4 is vacuum-sucked to the back side of the flange portion 1b of the vacuum forming die 1. Get involved.

At this time, as shown in FIG. 4, the thickness of the peripheral winding portion S6 other than the corner portions S1 to S4 of the decorative sheet material S does not change, and the flange portion 1b of the vacuum forming die 1
It is easily wrapped around and adheres to the back side of the base, so that the under-shaped part can be formed neatly and reliably. On the other hand, the peripheral wrapped portion S6 of the excess decorative sheet material S greatly expands and expands toward the four corners 1d of the vacuum forming die 1 so that the peripheral wrapped portion S6 extends to the corners 1d of the vacuum forming die 1. The corresponding corners S1 to S4 of the decorative sheet material S bulge to the outside and float up to a loose shape S9.

When the peripheral winding portion S6 is rolled in at the same time as or when it is rolled up, the cylinder 5
Is contracted and the rod 5a is driven in the horizontal direction, the pressing plug 3 moves toward the annular closed space 7 via the connecting member 6. At this time, the decorative sheet material S
The corners S1 to S4 having the slack-like shape S9 are pressed by the pressing plug 3 toward the inside of the corner 1d of the vacuum forming die 1 so as to resist the tension of the decorative sheet material S. Then, the corners S1 to S4 of the decorative sheet material S are wound around the back surface of the corner 1d of the vacuum forming die 1.

At this time, the thicknesses of the corners S1 to S4 have been restored to the substantially original state. Thereby, as shown in FIG. 8, the decorative sheet material S is formed on the molding surface 1 of the vacuum forming die 1.
It is shaped into a shape along e. According to the present embodiment, the corners S1 to S4 of the decorative sheet material S are pressed in the horizontal direction by the pressing plug 3, but the present invention is not limited to this. The corners S1 to S4 can be pressed by the pressing plug 3 from above to below.

Then, the suction pump (not shown) is stopped, the pressing plug 3 is retracted, the mold is opened, and the clamped state of the clamp 4 is released to form the shaped decorative sheet material S by vacuum forming. Remove from mold 1. Thereafter, the extra peripheral winding portion S6 of the decorative sheet material S is cut and trimmed.

As described above, the corner S1 of the decorative sheet material S
The raised local slack S9 generated in steps S4 to S4 uniformly expands based on the softening and shrinkage of the decorative sheet material S, is deformed flat, and is sucked along the back side of the corner 1d of the vacuum forming die 1. Is done. For this reason, slack S9 generated at the time of shaping the decorative sheet material S can be reliably removed, and a beautiful decorative sheet material S having a substantially uniform thickness can be effectively obtained.

Further, as shown in FIG. 9, the obtained decorative sheet material S is stuck to the glove box lid 11 without being locally loosened, and is excellent in appearance design as a final product. It will be. In this embodiment, the decorative sheet material S is adhered to a molded product formed in advance with a synthetic resin material, but the present invention is not limited to this, and the decorative sheet material S is integrated with the molded product by insert molding by injection. It is also possible to convert.

Next, referring to FIG. 5, there is shown another modified example of the decorative sheet material S and the clamp 4 in the first embodiment. In the first embodiment, the decorative sheet S 4
The four corners S1 to S4 are sandwiched by the four clamps 4,..., But in the second embodiment, at least a part of the peripheral winding part S6 is substantially the same as the peripheral winding part S6. A parallel slit-shaped notch S7 is formed, and the peripheral winding portion S6 having the notch S7 of the decorative sheet material S is clamped by the clamp 4. In FIG. 5, substantially the same members as those in the first embodiment are denoted by the same member names and reference numerals. Therefore, a detailed description of these members will be omitted.

In FIG. 5, slit-shaped notches S7 substantially parallel to the peripheral winding portion S6 are formed on two opposite sides of the peripheral winding portion S6. If the heating time of the decorative sheet material S is long, a curling phenomenon toward the inside is likely to occur due to the shrinkage of the foam layer of the decorative sheet material S. Therefore, the peripheral winding portion of the shaped decorative sheet material S The appearance quality of S6 may be degraded.

Therefore, in the second embodiment, the inner and outer peripheral winding portions S6 sandwiching the notch S7 are further connected to the intermediate portion of the notch S7 with a breakable connecting portion S8. . At the time of vacuum forming, the outer peripheral edge of the peripheral winding portion S6 of the cutout portion S7 is sandwiched by the elongated clamp 4 and the inner peripheral winding portion S6 is wound on the back side of the flange portion 1b of the vacuum forming die 1. The connecting portion S8 is automatically broken. Note that a plurality of connecting portions S8 can be formed in one notch S7.

The vacuum forming method of the decorative sheet material S in the second embodiment is the same as that from the time of setting the vacuum forming die 1 to the initial stage of vacuum suction until the connecting portion S8 is automatically broken. The connection between the connecting portion S8 and the peripheral winding portion S6 ensures good shape retention of the peripheral winding portion S6 of the decorative sheet material S, and is formed between the vacuum forming die 1 and the decorative sheet material S. The airtightness of the closed space 7 is sufficiently maintained. When the connecting portion S8 is automatically broken by the tension when the decorative sheet material S is suctioned under vacuum, the degree of freedom is given to the inner peripheral winding portion S6 of the cutout portion S7, and the decorative sheet material is provided. S
Is deformed smoothly. Thereafter, similarly to the first embodiment, the decorative sheet material S is effectively shaped.

According to this configuration, the inner peripheral winding portion S6 except for the corner portions S1 to S4 of the decorative sheet material S is not restrained by the vacuum suction on the back surface side of the flange portion 1b of the vacuum forming die 1. It becomes possible to freely wrap by vacuum suction, and furthermore, the thickness of the peripheral wrapping portion S6 of the decorative sheet material S is locally reduced, and the center forming portion S5 of the decorative sheet material is broken. Can be prevented beforehand. Therefore, as shown in FIG. 10, the central forming portion S5 and the peripheral wrapping portion S6 of the decorative sheet material S can be more easily, reliably and beautifully shaped.

Further, according to the second embodiment, it is sufficient that the two sides of the peripheral winding portion S6 of the decorative sheet material S are sandwiched by the two long clamps 4, respectively. It is possible to reduce the number of clamps for holding the material S. Even when shaping various types of decorative sheet materials S, only the clamps 4 need to be changed, and it is possible to cope with low cost.

In the second embodiment, two independent cutouts S are provided on one side of the peripheral winding portion S6 of the decorative sheet material S.
7, the present invention is not limited to this, and a single cutout S7 may be formed over a predetermined side of the peripheral winding portion S6 of the decorative sheet material S.

The notch S7 can be formed over the entire periphery of the decorative sheet material S. In this case, as shown in FIG.
A slit-shaped notch S7 substantially parallel to the peripheral winding portion S6 is formed on each of four sides excluding S4.

In the method for vacuum forming the decorative sheet material S in the third embodiment, the four clamps 4,... 4 forming an elongated body as shown in FIG. Similarly, the outer peripheral winding portion S6 outside the notch portion S7 is sandwiched,
At the time of vacuum suction, the inner peripheral winding portion S6 of the notch S7 is sucked and wound on the back surface side of the vacuum forming die 1. Thereby, a degree of freedom is given to the inner peripheral wrapped portion S6 of the cutout portion S7 on four sides, and a smooth deformation is brought about, so that the first and second cut portions S7 are provided.
Similarly to the embodiment, the central forming portion S5 and the peripheral winding portion S6 of the decorative sheet material S are effectively shaped.

In this embodiment, it is possible to effectively employ a device in which the pressing plug 3 is integrally attached to the four long clamps 4 shown in FIG. . In this way, by integrating the clamp 4 and the pressing plug 3, the movable support 2 is formed.
Since it is not necessary to use the device, the device itself can be made compact.

As is clear from the above description, according to the method for vacuum-molding a decorative sheet material according to the present invention, when the central forming portion of the decorative sheet material is vacuum-sucked into a vacuum forming die, the decorative sheet material is not subjected to the decorative process. The peripheral wrapped portion excluding the corners of the sheet material is sucked into the back side of the flange portion of the vacuum forming die and wrapped, and at the same time as wrapping the peripheral wrapped portion, or in a rolled state,
By pressing the corners of the decorative sheet material by the corner pressing means, the corners of the vacuum forming die are pressed inward, and the corners of the decorative sheet material are wound around the corners. Therefore, the raised local slack generated at the same corner portion is uniformly stretched based on the softening and shrinkage of the decorative sheet material, is deformed into a flat shape, and is sucked along the corner back surface side of the vacuum forming die. You.

[0049] This makes it possible to reliably remove slack generated when the decorative sheet material is shaped, and to effectively obtain a beautiful decorative sheet material having a substantially uniform thickness. In addition, the obtained decorative sheet material is joined to a molded product formed of a synthetic resin material without being locally loosened, and has an excellent appearance design as a final product. The present invention is not limited to the above embodiments,
Naturally, the technical scope that can be easily changed by those skilled in the art from those embodiments is also included.

[Brief description of the drawings]

FIG. 1 is a schematic view of a manufacturing apparatus for manufacturing a decorative sheet material by vacuum forming, which is a typical embodiment of the present invention.

FIG. 2 is a cross-sectional view taken along line AA and line BB of FIG. 1 showing a step of vacuum forming a decorative sheet material using the same device.

1. FIG. 3 is a line AA and FIG.
FIG. 4 is a cross-sectional view taken along line B.

FIG. 4 is a perspective view showing a state of the decorative sheet material in a step of vacuum forming the decorative sheet material.

FIG. 5 is a schematic perspective view showing another modified example of a decorative sheet material and a clamp to which the present invention is applied.

FIG. 6 is a schematic perspective view showing still another modified example of the decorative sheet material and the clamp.

FIG. 7 is a schematic view of a manufacturing apparatus according to a modification of the manufacturing apparatus of the present invention.

FIG. 8 is a perspective view showing a shaped decorative sheet material.

FIG. 9 is a partial sectional view of a molded article to which the present invention is applied.

FIG. 10 is a perspective view showing another shaped decorative sheet material.

[Explanation of symbols]

 Reference Signs List 1 vacuum forming die 1a flat plate portion 1b flange portion 1c annular concave portion 1d corner portion 1e forming surface 1f vacuum suction hole 2 support 2a support frame 3 press plug 4 clamp 5 cylinder 5a rod 6 connecting member 7 closed space 10 forming device 11 glove box Lid S Decorative sheet material S1 to S4 Corner S5 Central forming part S6 Peripheral wrapping part S7 Notch S8 Connecting part S9 Loose

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29C 51/42 B29C 51/42 F term (Reference) 4F202 AC03 AG03 AG20 AH26 CA17 CB01 CB26 CK12 CK32 CK52 CL02 CN01 4F208 AC03 AG03 AG20 AH26 MA01 MB01 MB22 MC02 MG04 MH06 MJ22 MW01 MW23

Claims (3)

[Claims] 1. A method of vacuum forming a decorative sheet material on a vacuum forming die having a flange portion having one or more corners on a peripheral edge, wherein at least a part of the decorative sheet material is wound around by a clamp. The decorative sheet material is heated and softened, and the heated and softened decorative sheet material is disposed in the molding die, and the central molded portion of the decorative sheet material is vacuum-adsorbed, and The peripheral wrapped portion excluding the corner portion of the decorative sheet material is wrapped around the back surface of the flange portion by vacuum suction. With the peripheral wrapped portion wrapped, the corner portion of the decorative sheet material is cornered. And pressing the corner portion around the corner portion by pressing the corner portion inside the corner portion by means of a portion pressing means. 2. A slit-shaped notch parallel to the peripheral winding part is formed in at least a part of the peripheral winding part, and the peripheral winding part having the notch of the decorative sheet material is formed by the clamp. 2. The method of vacuum forming a decorative sheet material according to claim 1, further comprising clamping the inner peripheral winding portion of the notch portion on the back surface side of the flange portion by clamping and vacuum suction. 3. An inner and outer peripheral winding portion sandwiching the notch portion at an intermediate portion of the notch portion is connected by a breakable connecting portion,
3. The vacuum forming method for a decorative sheet material according to claim 2, further comprising automatically breaking the connecting portion during vacuum forming in which the inner peripheral winding portion of the cutout portion is wound on the back surface side of the flange portion.