JP2002331539A - Skin material molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for molding a skin material uniform in thickness as a whole and also having the uniform touch. SOLUTION: Since a molding surface 2 is wider than a coating pattern P, a nozzle 6 is reciprocated several times to coat the molding surface 2 with a urethane resin raw material in both of forward and rearward movements, a spray direction is made obliquely rearward on the basis of the moving direction of a nozzle 6. Concretely, the center spray angle (θ) of the nozzle 6 is inclined at an angle of 30 deg. or less with respect to the line vertical to the molding surface. Therefore, the staining of the nozzle can be effectively prevented.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a covering material for covering the surface of an interior material of an automobile, for example, an instrument panel.

[0002]

2. Description of the Related Art As a method of molding a skin material covering the surface of an instrument panel or the like, a method of applying a resin material to a molding surface of a molding die and curing the resin material is described in WO93 / 232.
No. 37 and Japanese Patent No. 2610308.

[0003]

In the case where the resin material is applied to an area larger than the application pattern, including the above-mentioned prior art, the nozzle is reciprocated several times along the molding surface in consideration of efficiency. Become. In the conventional coating method, there is an example in which the spray angle from the nozzle is inclined with respect to the molding surface to prevent the resin material from being rebounded and scattered in the form of a mist on the molding surface. The return trip is fixed.

[0004] If the spray angle from the nozzle is fixed in both the forward and return paths, for example, in the case of the forward path, the resin material is discharged obliquely rearward with reference to the traveling direction of the nozzle, so that there is no particular problem. However, when moving to the return path in this state, the resin material is discharged obliquely forward with respect to the traveling direction of the nozzle. When the resin material is discharged diagonally forward, the resin material is applied so as to bite into the previously applied portion, and a large amount of mist is generated. And the skin material itself is difficult to become uniform.

[0005]

According to the present invention, there is provided a method for forming a skin material, which comprises reciprocating a nozzle with respect to a molding surface of a molding die so as to cover a wider area than an application pattern. In applying the resin material and curing the resin to form a skin material, the spraying direction of the liquid resin material from the nozzle was set to be obliquely rearward with respect to the moving direction of the nozzle in both the forward and backward passes. In order to change the direction in which the liquid resin material is sprayed from the nozzle, for example, the nozzle may be configured to be rotatable.

[0006] With the above configuration, when the resin material is applied to the molding surface, it is difficult to scatter in a mist form, the dirt of the nozzle is suppressed, and the thickness of the formed skin material becomes uniform.

[0007] If the inclination angle of the nozzle is too large, the coating efficiency deteriorates. In consideration of this, the central spray angle of the nozzle is 30 ° with respect to a vertical line to the molding surface.
It is preferable to set the following angle.

[0008]

Embodiments of the present invention will be described below with reference to the accompanying drawings. 1 (a) to 1 (e) are diagrams illustrating the entire method of molding a skin material according to the present invention, FIG. 2 is a perspective view illustrating the relationship between an application pattern on a molding surface and movement of a nozzle, and FIG. FIG. 4 is a diagram illustrating a relationship between a traveling direction of a nozzle and a spray angle.

In the present invention, first, as shown in FIG. 1 (a), a release agent is applied to a molding surface 2 of a molding die 1. The release agent may be any of a wax type and a soap type, and it is preferable to perform hand wiping with a rag after application in order to eliminate gloss unevenness.

The molding die 1 uses a nickel electroforming mold, and a support 4 is erected on a base 3. The support 4 is swingably supported on the support 4 via a shaft 5.

After the release agent is applied, as shown in FIG. 1B, an in-mold paint (IMP), which is the outermost surface of the skin material, is applied. IMP aims at light resistance in addition to coloring, and is formed with a thickness of 20 to 60 μm. The main component is an acrylic-modified urethane resin, and the dispersion medium may be water, an organic solvent, or a mixture thereof.

After the IMP has been applied, air drying is performed as shown in FIG. 1C, and then a urethane resin material is applied to the molding surface 2 as shown in FIG. 1D. The urethane resin raw material is a two-liquid mixture type of a polyol and MDI, is mixed in a nozzle immediately before discharge, starts a chemical reaction immediately after application, and cures. The thickness of this urethane layer is about 0.9 mm.

Thereafter, as shown in FIG. 1 (e), after the curing is promoted by heating (curing), the mold is removed to obtain a skin material. In order to form the foam inside the skin material, a method is used in which the skin material is set in another mold, and a foamed resin material is placed inside the skin material and heated.

By the way, as shown in FIG. 2, the molding surface 2 is wider than the application pattern P. Therefore, when applying the urethane resin material, the nozzle 6 is reciprocated several times. In the present invention, as shown in FIG. 3, the spraying direction is set obliquely rearward with respect to the moving direction of the nozzle 6 as shown in FIG. Specifically, the center spray angle (θ) of the nozzle 6 is inclined at an angle of 30 ° or less with respect to a vertical line to the molding surface.

In the embodiment, only when urethane resin, which is a raw material of the skin material, is applied, the spraying direction is set obliquely rearward with respect to the moving direction of the nozzle.
Spraying diagonally rearward also when applying MP can effectively prevent the nozzle from being stained.

[0016]

According to the present invention as described above,
The resin material is spray-applied by reciprocating the nozzle on a molding surface with a larger area than the application pattern, and when the resin material is cured to form the skin material, the spraying direction of the nozzle is oblique with respect to the moving direction of the nozzle. Because I was behind,
When the resin material is sprayed on the molding surface, the resin material is not easily scattered, and since the nozzle is located in the front in the traveling direction, the resin material is hardly stained. Furthermore, the thickness of the molded skin material itself becomes uniform.

[Brief description of the drawings]

FIG. 1 is a view for explaining an entire method of forming a skin material according to the present invention.

FIG. 2 is a perspective view illustrating a relationship between an application pattern on a molding surface and movement of a nozzle.

FIG. 3 is a diagram showing a relationship between a nozzle advancing method and a spray angle.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Mold, 2 ... Molding surface, 3 ... Base, 4 ... Prop, 5 ...
Shaft, 6 ... holder, 7 ... shaft.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Toshifumi Matsuda 1-10-1 Shinsayama, Sayama-shi, Saitama Honda Engineering Co., Ltd. (72) Inventor Yuichi Uchiyama 1-10-1 Shin-Sayama, Sayama-shi, Saitama F-term (reference) in Da Engineering Co., Ltd. 4F205 AA42 GA05 GB01 GC04 GF01 GF25 GN07

Claims (2)

[Claims] 1. A method of forming a skin material by applying a liquid resin material to an area wider than an application pattern by reciprocating a nozzle with respect to a molding surface of a molding die, and curing the resin to form a skin material. , Wherein the direction of spraying the liquid resin material from the nozzle is obliquely rearward with respect to the direction of movement of the nozzle in both forward and backward passes. 2. The method for forming a skin material according to claim 1, wherein a central spray angle of the nozzle is inclined at an angle of 30 ° or less with respect to a vertical line to a molding surface. Material molding method.