JP2002172686A - Vacuum molding method for decorative sheet material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a vacuum molding method for a decorative sheet material by which the corner parts of various kinds of decorative sheet materials such as a resin film, a cloth and a non-woven fabric can be neatly shaped without looseness. SOLUTION: When a decorative sheet material S is vacuum-molded using a vacuum molding die 1 with a flange part 1b having angular parts 1d formed on the peripheral edge, the peripheral rolled-in part S2 of the decorative sheet material S is pinched by a clamp 6, then the sheet material S is thermally softened and arranged on a molding face 1e. Further, the corner parts S3-S6 of the decorative sheet material S are rolled in by pressing the parts S3-S6 toward the inside of the angular parts 1d of the vacuum molding die 1 with the help of a pressing plug 3. Next, the central molding part S1 of the decorative sheet material S is vacuum-sucked and at the same time, the peripheral rolled-in part S2 is pressed toward the inside of the angular parts 1d of the flange part 1b with the assistance of a pressing plug 4 in such a state that the central molding part S1 is rolled in on the back of the flange part 1b by vacuum suction. After that, the peripheral rolled-in part S1 is rolled in near the angular parts 1d. Thus the corner parts S3-S6 uniformly extend based on the softening and shrinking properties of the decorative sheet material S and then are deformed flat. Besides, the loosened apart part generated at the corner parts S3-S6 is squashed flat and brought into contact tightly, all along, with the back of the angular parts 1d.

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. By joining this decorative sheet material and a molded product obtained by molding a synthetic resin material, an interior component having a good appearance and design as a final product can be obtained.

An example of a method for forming a decorative sheet material of this kind of resin material is disclosed in, for example, Japanese Patent Application Laid-Open No. 6-198728. According to the molding method disclosed in the publication, a decorative sheet material in which a foamed resin material is integrated with a resin sheet is used to form a curved-shaped vacuum molding die with a relatively high center and an elevated shape. Vacuum forming by approaching the softened decorative sheet material, stretching the decorative sheet material with a clamp, and stretching and contacting the higher ridge near the center to the relatively lower ridge around it 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, in a state where the tensile force from the center forming surface to the side forming surface of the decorative sheet material is relaxed. Generally along the mold surface of the vacuum mold,
At this time, a decorative sheet material is formed by vacuum suction along the surface shape of the vacuum forming die. 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. Four 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, an 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. It is said that there is no risk 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 decorative sheet material is not broken by the tensile force and does not affect the central molded portion. 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 the thickness of the decorative sheet material in the vicinity of the second bent portion from decreasing, and prevent the surface layer from being broken.

[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-mentioned functions and effects,
At the time of vacuum forming, the clamp for clamping the peripherally wound portion of the decorative 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. ing.

On the other hand, in the vacuum forming method of the decorative sheet material disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 9-48067, a slit is formed at a predetermined position of the peripheral winding portion of the decorative sheet material, so that the vacuum suction is performed. In some cases, even when stress concentrates on the peripherally wound portion of the decorative sheet material, the peripherally wound portion of the decorative sheet material is broken in the tensile direction and moves in the extending direction of the decorative sheet material.

However, in each of the above-mentioned publications, local thinning, breakage, and the like are prevented from occurring in the central molded portion of the decorative sheet material and the gently peripherally wound portion that forms a substantially straight line. Although it can be performed, the peripheral winding portions of the decorative sheet material wound on the back surface side of the vacuum forming die at the time of vacuum suction largely extend and expand toward a plurality of corners on the back surface 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.
In the vacuum forming method of the decorative sheet material disclosed in these publications, no attention or reference is made to the technical problem of removing the slack generated at the corner of the decorative sheet material.

The present invention has been made to solve the above-mentioned conventional problems, and a specific object of the present invention is to provide a decorative sheet material such as a resin film, a cloth, a non-woven fabric or the like which has a beautiful corner without slack. It is an object of the present invention to provide a method for vacuum forming a decorative sheet material, which is capable of shaping into a shape.

[0013]

The invention according to claim 1 of the present invention is a method for vacuum forming a decorative sheet material in a vacuum forming die having a flange having one or more corners on a peripheral edge. By clamping at least a part of the peripherally wound portion of the decorative sheet material with a clamp, heating and softening the decorative sheet material, disposing the heat-softened decorative sheet material in the molding die, Pressing the corners of the decorative sheet material except for the central molded portion toward the inside of the corners by first corner pressing means, and winding the corners into the corners; While vacuum-absorbing the central molded part of the material,
The decorative wrapping sheet material is wound around the backside of the flange portion except for the corner portion by vacuum suction, and the corner portion of the decorative sheet material is wrapped around the peripheral wrapping portion. And pressing the slack portion adjacent to the outside of the portion toward the inside near the corner by a second corner pressing means, and winding the slack portion into the vicinity of the corner. It is in a vacuum forming method for decorative sheet materials.

[0014] According to the above method, the corner of the heat-softened decorative sheet material is pressed by the first corner pressing means to form the corner of a vacuum forming die having a flange having one or more corners on the periphery. It is pressed toward the inside of the portion, and the corner portion of the decorative sheet material is wound around the corner portion without wrinkling. In a state where the corners are rolled in, the central forming portion of the decorative sheet material is vacuum-sucked into a vacuum forming die. Then, the decorative sheet material is adsorbed on the back surface side of the flange portion and wound around the peripheral winding portion except for the corner portion of the decorative sheet material, or simultaneously with the decorative sheet material by the second corner portion pressing means in the wound state. The loose portion generated adjacent to the outside of the corner is pressed toward the inside of the vacuum forming die adjacent to the corner and wound.

As described above, since the corners of the decorative sheet material and the adjacent portions are sucked and rolled into the corners of the vacuum forming die and the vicinity thereof in two stages, the corners of the decorative sheet material are ,
The decorating sheet material expands uniformly based on its softness and shrinkage, and is formed into a flat shape without wrinkles. The locally loosened portion can also be squashed into a flat shape and closely adhered to the back surface near the corner of the vacuum mold so as to be molded.

In this way, it is possible to reliably remove the slack generated during the shaping of the decorative sheet material and to 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 slackened, and becomes excellent in appearance and design as a final product. The decorative sheet material may be attached to a molded product formed 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, at least a part of the peripheral winding portion is formed with a slit-shaped notch parallel to the peripheral winding portion, and the notch of the decorative sheet material is formed by the clamp. The peripheral wrap portion is sandwiched, and the inner wrap portion inside the notch portion is wrapped 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 method of vacuum forming a decorative sheet material, a slit-shaped notch is formed in at least a part of the peripheral winding portion so as to be substantially parallel to the peripheral winding portion. The peripheral winding portion outside the notch is sandwiched. For this reason, the decorative sheet material can be firmly fixed in a tensioned state before the start of molding, and when the molding is started, the peripheral winding portion inside the notch has a degree of freedom,
By the vacuum suction, the peripheral winding portion inside the notch except for the corner portion of the decorative sheet material can be freely wound around the back side of the flange portion of the vacuum forming die, and the peripheral winding portion of the decorative sheet material It is possible to prevent the thickness of the decorative sheet material from being locally reduced or to prevent the center 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, at least two cutouts are formed, and a connecting portion between the cutouts is formed by vacuum forming in which an inner peripheral winding portion of the cutout is wound on the back side of the flange portion. It is characterized by breaking automatically.

When placing 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,
Since the outer peripheral winding portion of the decorative sheet material is gripped by the clamp, the connection portion and the peripheral winding portion are particularly preferably set from the time of setting the vacuum forming die to the initial stage of vacuum suction until the connection portion is broken. Good shape retention is secured in the peripheral wrapping part of the decorative sheet material by connecting with the wrapping part, and the airtightness of the suction space formed between the vacuum forming die and the decorative sheet material is maintained. When the connecting portion is broken by the tension when the decorative sheet material is vacuum-suctioned, the degree of freedom is given to the inner peripheral winding portion of the cutout portion, and a smooth deformation can be brought about. .

According to a fourth aspect of the present invention, the first corner portion pressing means has a sheet material pressing surface for pressing the corner portion of the decorative sheet material, and a flange portion of the vacuum forming die. A press plug having a wedge-shaped protrusion for pushing in a corner of the decorative sheet material is provided in an inwardly depressed sheet material pressing recess formed near the corner on the back side, and a corner of the decorative sheet material is used. The slack portion adjacent to the corner portion is pushed into the sheet material pushing concave portion of the vacuum forming die by the wedge-shaped projection of the pressing plug, and the peripheral winding portion of the decorative sheet material is wound around the back surface of the flange portion. At the time of vacuum forming, control is performed such that a part of the slack portion is generated near the sheet material pressing concave portion.

According to this method of vacuum forming the decorative sheet material, the slack portion adjacent to the corner of the decorative sheet material is inserted into the concave portion of the vacuum forming die by the wedge-shaped projection of the pressing plug. During the vacuum forming, in which the peripheral winding portion is wound on the back surface side of the flange portion of the vacuum forming die, a part of the slack portion can be controlled to be generated in the vicinity of the sheet material pressing concave portion. The slack portion of the decorative sheet material, which is greatly extended and expanded at the time of vacuum forming in which the peripheral winding portion is wound on the back surface side of the flange portion of the vacuum forming die, can be gathered toward the sheet material pressing recess.

According to a fifth aspect of the present invention, in the decorative sheet material, a pressing plug having a wedge-shaped projection fitted into the sheet material pressing recess of the vacuum forming die is used as the second corner portion pressing means. The present invention is characterized in that a part of the slack portion exposed is crushed, and all the slack portions of the peripheral winding portion of the decorative sheet material are rolled up along the sheet material pressing recess of the vacuum forming die.

Before the vacuum forming, the above-mentioned corner portion of the decorative sheet material is pressed in advance toward the inside of the corner portion of the flange portion in the vacuum forming die using a pressing plug as the first corner portion pressing means. Does not cause wrinkles in the corners of the molded product, but the entrapment around the decorative sheet material except for the corners is carried out by vacuum suction of the decorative sheet material to be performed subsequently. When wrapping around the back side of
Local slack occurs in the peripheral wrapping portions on both sides pressed by the wedge-shaped projections of the pressing plug.

The locally loosened portion of the decorative sheet material is
The wedge-shaped projection of the pressing plug, which is the second corner portion pressing means, pushes into the sheet material pressing recess of the vacuum forming die to remove a part of the loosened portion of the decorative sheet material exposed to the sheet material pressing recess. By crushing and winding in along the inside, the local slack portion can also be removed from the surface of the decorative sheet material.

[0028]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be specifically described below with reference to the accompanying drawings. In the present embodiment, as a final product in which the decorative sheet material is joined to a molded product obtained by molding a synthetic resin material, a glove box lid of an automobile will be described as an example, but the present invention is not limited to this. Instead, for example, a 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 S by vacuum forming, which is a typical embodiment of the present invention, and FIG. 2 is a schematic view partially showing the manufacturing apparatus. It is.

In these figures, reference numeral 1 denotes a vacuum forming die, and the vacuum forming die 1 adopts a male type. This vacuum forming die 1 has a flat plate portion 1a and a flange portion 1b projecting upward from the flat plate portion 1a, and an annular concave portion recessed inward between the flange portion 1b and the flat plate portion 1a. 1c
Is formed. The flange portion 1b has four corners 1d,..., 1d on the periphery, and a molding surface 1e to be joined to the central molding portion S1 of the decorative sheet material S is formed above the flange portion 1b. Have been. The molding surface 1e and the annular concave portion 1c have a plurality of minute vacuum suction holes 1f,.
1f is drilled at a predetermined site.

As shown in FIG. 2, substantially V-shaped sheet material pushing recesses 1 g, 1 g which are recessed inward are formed at both sides of the corners of the annular recess 1 c of the vacuum forming mold 1. ing. When the decorative sheet material S is vacuum formed, all of the raised slack portions S7 of the decorative sheet material S that are greatly extended and expanded are formed on the back side of the flange portion 1b of the vacuum forming die 1 during the vacuum forming of the decorative sheet material S. It is for escape.

Above the vacuum forming die 1, there is provided a support 2 supported by a movable die which can move up and down. At the four corners of the support 2, a pressing plug 3 for shaping the sheet material, which is a first corner pressing means of the decorative sheet material S, is provided so as to be horizontally movable, and the support 2 is provided. In the four peripheral portions excluding the corners, the sheet material shaping pressing plug 4 which is on the same horizontal plane as the pressing plug 3 and is the second corner portion pressing means of the decorative sheet material S is horizontally movable. It is provided in.

Each of the pressing plugs 3 and 4 has a pressing surface corresponding to the annular concave portion 1c of the vacuum forming die 1, and wedge-shaped projections 3a and 3a projecting forward are provided on both side edges of the pressing surface. 4
a are protrudingly provided. These wedge-shaped projections 3a,
Reference numeral 4a denotes a substantially triangular prism half-split wedge shape that matches the shape of the sheet material pressing recess 1g of the vacuum forming die 1 in a state of being joined to each other, and is fitted to the sheet material pressing recess 1g. Has become.

The wedge-shaped projections 3a of the pressing plug 3 are used to press the corners S3 to S6 of the decorative sheet material S into the sheet material pressing recess 1g before vacuum forming. The slack portion S7 adjacent to S6 is pushed into the sheet material pressing recess 1g by the wedge-shaped protrusion 3a of the pressing plug 3, and a part of the slack portion S7 is exposed near the sheet material pressing recess 1g during vacuum forming. Control. The wedge-shaped projection 4a of the pressing plug 4 crushes the slack portion S7 floating in the sheet material pressing recess 1g and forms all the slack portions S7 of the peripheral winding portion S2 into the sheet during vacuum forming. Material pushing recess 1
It rolls in along g.

As shown in FIG. 7, the pressing plugs 3, 4 are supported via a connecting member at the rod end of a cylinder 5 fixed to the support frame 2a of the support 2, and the vacuum forming die 1
Is horizontally inserted into and removed from the annular concave portion 1c. Since the pressing plugs 3 and 4 configured as described above are driven independently of the support 2, they need only be driven in the horizontal direction by the cylinder 5, and the driving mechanism is simplified.

In this embodiment, the support 2 is
Opening and closing is performed by moving the vacuum forming die 1 in the vertical direction. The four sheet material clamping clamps 6,..., 6 forming a long body driven by driving means (not shown)
It is provided side by side on a horizontal plane between the vacuum forming die 1 and the support 2, and further includes a sheet heater (not shown) for heating the sheet material and a sheet material supply unit (not shown). I have. According to the illustrated example, the clamp 6 moves between the vacuum forming die 1 and the support 2 while sandwiching the peripheral winding part S2 including the four corners S3 to S6 of the decorative sheet material S. It has become.

The manufacturing apparatus 7 configured as described above
However, the present invention is not limited to this. For example, it is also possible to manually supply the decorative sheet material S without providing the sheet material supply unit. It is also possible to fix the sheet so that it can be retracted and sandwich the peripheral winding portion S2 of the decorative sheet material S. Further, the decorative sheet material S can be vacuum-formed by matching the movable mold and the fixed mold.

The vacuum forming method of the decorative sheet material S of the present invention is carried out by using the above-mentioned manufacturing apparatus 7. 3 to 8
Shows a typical method. Hereinafter, the glove box lid 8 shown in FIG.
A method of vacuum forming a decorative sheet material S for decorating a sheet will be described with reference to FIGS.

FIGS. 3 to 5 are partial perspective views showing one example of a step of vacuum forming the decorative sheet material S, and FIGS.
FIGS. 6A to 8C are partial cross-sectional views showing the same step.
(A) shows a vacuum forming step for the vacuum forming die 1 on the cross-sectional side along the line AA in FIG. 3, and FIGS. 6 (b) to 8 (b).
Represents a vacuum forming step for the vacuum forming die 1 on the cross-sectional side along the line BB in FIG.

The glove box lid 8 to which the present invention is applied shown in FIG. 9 is made of a synthetic resin material such as polypropylene, for example, and has a back surface made of a thermoplastic resin material such as polyolefin as the decorative sheet material S. , Foamed polypropylene or foamed polyethylene, etc. are integrally attached. As the decorative sheet material S, a material which can be stretched when heated is suitable, for example, a woven or knitted fabric, a nonwoven fabric,
Polypropylene, polyethylene, TP on PVC sheet
A material provided with a backing material such as O, ABS, PC, and TPE is applied.

In order to vacuum form the decorative sheet material S, first, the vacuum forming die 1 and the support 2 are opened, and the decorative sheet material S is supplied from a sheet material supply section (not shown). The four corners S3 to S4 of the decorative sheet material S according to 6,.
The peripheral winding part S2 including S6 is sandwiched. In that state,
After the decorative sheet material S is heated and softened by a surface heater (not shown), the heated softened decorative sheet material S is horizontally moved between the vacuum forming die 1 and the support 2 by the clamp 6. After that, the sheet material supply unit and the surface heater (not shown) are retracted. Here, after arranging the decorative sheet material S sandwiched between the clamps 6 between the vacuum forming die 1 and the support 2,
The decorative sheet material S can be heated and softened by a surface heater (not shown).

After the decorative sheet material S has been heated and softened, as shown in FIGS. 3 and 6, the decorative softened sheet material S is heated and softened.
Are hermetically joined from above the molding surface 1e of the vacuum molding die 1. At the same time, the support 2 is lowered with respect to the vacuum forming die 1. At this time, the vacuum forming die 1 can be moved with respect to the decorative sheet material S. The thickness of the peripherally wound portion S2 of the decorative sheet material S is slightly reduced because it is in a tensioned state by the clamp 6. In this state, an annular closed space is formed between the decorative sheet material S and the annular concave portion 1c of the vacuum forming die 1.

Next, by extending the cylinder 5 and driving it in the horizontal direction, the pressing plug 3 is horizontally moved toward the inside of the corner 1d of the flange portion 1b of the vacuum forming die 1 through the annular closed space. Move. 4 and 7
As shown in (b), the corners S <b> 3 to S <b> 6 of the decorative sheet material S excluding the central molding part S <b> 1 are formed by the pressing surface of the pressing plug 3.
Is pressed against the tension to be wound inside the corner 1d of the flange 1b, and the corner S of the decorative sheet material S is pressed.
3 to S6 are brought into close contact with the corners of the annular concave portion 1c of the vacuum forming die 1. At the same time, with the wedge-shaped projection 3a of the pressing plug 3,
A part of the peripheral winding portion S2 of the decorative sheet material S is pulled and pushed into the sheet material pressing recess 1g adjacent to the corner of the annular concave portion 1c. Thereby, it can be controlled so that a part of the slack portion S7 adjacent to the corners S3 to S6 of the decorative sheet material S is exposed in the vicinity of the sheet material pressing concave portion 1g.

Subsequently, the central forming portion S1 of the decorative sheet material S is vacuum-sucked by vacuum suction through a vacuum suction hole 1f of the vacuum forming die 1 via a suction pump (not shown), and the decorative sheet material is also sucked. The peripheral winding portion S2 excluding the corner portions S3 to S6 of S is wound by vacuum suction on the back side of the flange portion 1b of the vacuum forming die 1 so as to resist the tension. The peripheral winding portion S2 of the decorative sheet material S greatly extends and expands toward the four corners of the annular concave portion 1c of the vacuum forming die 1. As shown in FIG. 4 and FIG. 7A, the loosened portion S7 of the decorative sheet material S which greatly expands and spreads gathers toward the inside of the sheet material pressing concave portion 1g, and the decorative sheet material S is locally localized outside. And the slack portion S7 of the decorative sheet material S rises.

At this time, when the peripheral winding portion S2 is rolled in at the same time or in the rolled state, the cylinder 5
Is extended and driven in the horizontal direction, and the pressing plug 4 is moved through the annular closed space between the peripheral winding portion S2 of the decorative sheet material S and the annular recessed portion 1c of the vacuum forming die 1 to form the vacuum forming die 1 It is moved toward the back side of the flange portion 1b. As shown in FIGS. 5 and 8A, the wedge-shaped protrusion 4a of the pressing plug 4
Then, the loosened portion S7 of the decorative sheet material S that has risen up is inserted into the sheet material pushing concave portion 1g adjacent to the corner of the annular concave portion 1c.
While being crushed along the inside, it is wound on the back side of the flange portion 1b of the vacuum forming die 1. As a result, the wedge-shaped protrusion 4a of the pressing plug 4 is fitted into the sheet material pressing recess 1g,
The decorative sheet material S is formed into a shape along the forming surface 1e of the vacuum forming die 1. Peripheral winding part S of decorative sheet material S
The thickness of the under-shaped portion 2 is not changed, and is easily wrapped and adhered to the back surface side of the flange portion 1b of the vacuum forming die 1, so that the under-shaped portion can be formed clearly and reliably.

Then, the suction pump (not shown) is stopped, the pressing plugs 3, 4 are withdrawn, the mold is opened, and the clamp 6 is released to release the shaped decorative sheet material S into a vacuum forming mold. Remove from 1. Then, the corner S of the decorative sheet material S
An extra peripheral winding portion S2 including 3 to S6 is cut and trimmed.

As described above, the corner portion S3 of the decorative sheet material S
Local slack portion S raised near S6
7 are uniformly stretched and flattened based on the softening and shrinkage of the decorative sheet material S, and are raised at the corners S3 to S6 of the decorative sheet material S. Is squashed flat and adheres closely along the back side of the corners of the vacuum forming die 1, and is sucked along the forming surface 1 e of the vacuum forming die 1. For this reason, the slack portion S7 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, the obtained decorative sheet material S is stuck to the glove box lid 8 without being locally loosened, and has an excellent appearance design as a final product. In the present embodiment, the decorative sheet material S is attached to a molded product molded in advance with a synthetic resin material, but the present invention is not limited to this, and the decorative sheet material S may be formed by injection molding by injection molding. It is also possible to integrate them.

FIGS. 10 to 12 show modified examples of the decorative sheet material S and the clamp 6 in the above embodiment. In the first embodiment, the peripheral winding portion S2 including the four corner portions S3 to S6 of the decorative sheet material S is sandwiched by the four long clamps 6,. In this modification, at least a part of the peripheral winding portion S2 is clamped by the clamp 6. Further, as another modification, a slit-shaped notch S8 substantially parallel to at least one peripheral edge of the peripheral winding portion S2 is formed, and the decorative sheet material S is formed.
A part of the peripheral winding portion S <b> 2 having the notch S <b> 8 is clamped by the clamp 6. In these drawings, members that are substantially the same as those in the above embodiment are given the same reference numerals and member names. Therefore, a detailed description of these members will be omitted.

In FIG. 10, four corners S3 to S6 of the decorative sheet material S are connected to four short clamps 6,.
It is pinched by. According to the first modification, at the time of vacuum suction of the decorative sheet material S, the corner portions S3 to S3 to
The peripheral winding portion S2 excluding S6 can be freely wound without being restrained on the back side of the flange portion 1b of the vacuum forming die 1, and the central forming portion S1 and the peripheral winding portion S2 of the decorative sheet material S can be freely wound. Can be shaped neatly.

In the second modified example, as shown in FIG. 11, two opposing sides of the peripheral winding portion S2 have slit-shaped notches S8 substantially parallel to the peripheral edge of the peripheral winding portion S2. Are formed respectively. The cutout portion S8 is for freely winding the inner peripheral winding portion S2 of the decorative sheet material S on the back surface side of the flange portion 1b of the vacuum forming die 1.

If the heating time of the decorative sheet material S is long during vacuum forming, a curl phenomenon inward is likely to occur due to shrinkage of the foamed layer of the decorative sheet material S. , The appearance quality of the peripheral winding portion S2 may be degraded. In this second modified example, the inner and outer peripheral winding portions S2 sandwiching the notch S8 are connected to a middle portion of the notch S8 by a breakable connecting portion S9. At the time of vacuum forming, the outer peripheral edge of the peripheral winding portion S2 of the cutout portion S8 is clamped by a long clamp 6, and the inner peripheral winding portion S2 is wound on the back side of the flange portion 1b of the vacuum forming die 1.
The connecting portion S9 is automatically broken. Note that a plurality of connecting portions S9 can be formed in one notch S8.

The method of vacuum forming the decorative sheet material S in the second modified example is performed from the time of setting the vacuum forming die 1 to the initial stage of vacuum suction until the connecting portion S9 is automatically broken. The connection between the connecting portion S9 and the peripheral winding portion S2 ensures good shape retention of the peripheral winding portion S2 of the decorative sheet material S, and the space between the vacuum forming mold 1 and the decorative sheet material S. The airtightness of the formed closed space is sufficiently maintained. When the connecting portion S9 is automatically broken by the tension when the decorative sheet material S is vacuum-sucked, a degree of freedom is given to the inner peripheral winding portion S2 of the cutout portion S8, and the decorative sheet is provided. The material S is deformed smoothly. Thereafter, similarly to the first embodiment, the decorative sheet material S is effectively shaped.

According to the second modification, the inner peripheral wrapped portion S2 except for the corners S3 to S6 of the decorative sheet material S is restrained by the vacuum suction on the back side of the flange portion 1b of the vacuum forming die 1. It is possible to freely take in by vacuum suction without involving, and furthermore, the peripheral winding portion S2 of the decorative sheet material S
It is possible to prevent the thickness of the decorative sheet material S from locally decreasing or the central molded portion S1 of the decorative sheet material S from being torn. Therefore, the center forming portion S1 and the peripheral winding portion S2 of the decorative sheet material S can be more finely shaped.

Further, according to the second modified example, it is sufficient that the two sides of the peripheral winding portion S2 of the decorative sheet material S are sandwiched by the two long clamps 6, respectively. It is possible to reduce the number of clamps for holding S, and even when shaping various types of decorative sheet materials S, only the clamps 6 need to be changed, and it is possible to cope with low cost. In addition, in the said 2nd modification, although two independent notch parts S8 are formed in one side of the peripheral winding part S2 of the decorative sheet material S, this invention is not limited to this. Instead, a single notch S8 may be formed over a predetermined side of the peripheral winding portion S2 of the decorative sheet material S.

Further, it is possible to form the notch S8 over the entire circumference of the decorative sheet material S. In this case, as shown in FIG.
A slit-shaped notch S8 substantially parallel to the peripheral edge of the peripheral winding portion S2 is formed on each of the four sides excluding S6.

In the vacuum forming method of the decorative sheet material S in the third modified example, as shown in FIG. 12, four elongated clamps 6,... Similarly to the above, the outer peripheral winding portion S2 of the notch S8 is sandwiched, and the inner peripheral winding portion S2 of the notch S8 is sucked and wound on the back surface side of the vacuum forming die 1 during vacuum suction. Thereby, the inner peripheral winding portion S2 of the notch S8 on the four sides is formed.
And the central shaping portion S1 and the peripheral winding portion S2 of the decorative sheet material S are effectively shaped.

Further, the pressing plugs 3, 4 are directed to the four corners of the four clamps 6,..., 6 in the third modified example, toward the lower surface of the corner 1 d of the flange 1 b of the vacuum forming die 1. It can also be provided integrally so that it can advance and retreat, in this case,
Since the clamp 6 and the pressing plugs 3 and 4 can be integrated,
There is no need to use the movable support 2, and the apparatus itself can be made compact.

[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 schematic view partially showing the manufacturing apparatus.

FIG. 3 is a partial perspective view showing a step of vacuum forming a decorative sheet material.

FIG. 4 is a partial perspective view showing a step subsequent to FIG.

FIG. 5 is a partial perspective view showing a step subsequent to FIG.

FIG. 6 is a partial cross-sectional view showing a step of vacuum forming a decorative sheet material.

FIG. 7 is a partial cross-sectional view showing a step subsequent to FIG. 6;

FIG. 8 is a partial sectional view showing a step subsequent to FIG. 7;

FIG. 9 is a perspective view of a molded product to which the present invention is applied.

FIG. 10 is a perspective view showing a first modified example of the decorative sheet material and the clamp.

FIG. 11 is a perspective view showing a second modified example of the decorative sheet material and the clamp.

FIG. 12 is a perspective view showing a third modified example of the decorative sheet material and the clamp.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Vacuum forming die 1a Flat plate part 1b Flange part 1c Annular concave part 1d Corner part 1e Molding surface 1f Vacuum suction hole 1g Sheet material pushing concave part 2 Support 2a Support frame 3,4 Press plug 3a, 4a Wedge-shaped protrusion 5 Cylinder 6 Clamp 7 Manufacturing equipment 8 Glove box lid S Decorative sheet material S1 Central forming part S2 Peripheral winding part S3 to S6 Corner part S7 Loose part S8 Notch part S9 Connecting part

 ──────────────────────────────────────────────────の Continued on the front page F term (reference) 4F202 AA03 AC03 AH25 AH26 CA17 CB01 CK32 4F208 AA03 AC03 AH25 AH26 MA01 MB01 MC02 MG01 MH06 MJ22 MK02

Claims (5)

[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. Sandwiching the embedding portion and heating and softening the decorative sheet material, disposing the heat-softened decorative sheet material in the molding die,
Pressing the corners of the decorative sheet material except for the center molded portion toward the inside of the corners by first corner pressing means, and winding the corners into the corners; Along with vacuum-adsorbing the central molded portion of the material, the peripheral winding portion excluding the corner portion of the decorative sheet material is wound around the back surface of the flange portion by vacuum suction, and the peripheral winding portion is wound. In the state, the loosened portion adjacent to the outside of the corner portion of the decorative sheet material is further pressed toward the inside near the corner portion by the second corner portion pressing means, and the loosened portion is pressed near the corner portion. A method for vacuum forming a decorative sheet material, comprising: 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 for 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. The notch portion is formed two or more, and a connection portion between the notch portions is automatically broken at the time of vacuum forming in which an inner peripheral winding portion of the notch portion is wound on the back side of the flange portion. 3. The method of vacuum forming a decorative sheet material according to claim 2, comprising: 4. The first corner portion pressing means has a sheet material pressing surface for pressing the corner portion of the decorative sheet material, and a corner of a back surface side of a flange portion of the vacuum forming die. A press plug having a wedge-shaped protrusion for pressing the corner of the decorative sheet material is used in the inwardly recessed sheet material pressing recess formed in the vicinity, and the slack adjacent to the corner of the decorative sheet material is used. Part is pressed into the sheet pressing recess of the vacuum forming die by the wedge-shaped projection of the pressing plug, and the slack is formed at the time of vacuum forming in which the peripheral winding part of the decorative sheet is wound on the back side of the flange part. The method for vacuum forming a decorative sheet material according to any one of claims 1 to 3, further comprising controlling a part of the portion to be generated near the sheet material pressing recess. 5. A part of the decorative sheet material that is exposed by using a pressing plug having a wedge-shaped protrusion fitted into the sheet material pressing recess of the vacuum forming die as the second corner part pressing means. The method according to claim 1, further comprising: crushing a slack portion, and winding all slack portions of the peripheral winding portion of the decorative sheet material along the sheet material pressing recess of the vacuum forming die. 5. The vacuum forming method of the decorative sheet material according to 4.