JP2003117939A - Method for producing skin integrated resin molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a skin integrated resin molded article wherein the skin is bonded to the resin molded article and an excellent decorative surface is provided. SOLUTION: The skin integrated resin molded article integrally having a substrate 2 and a bag like skin 3 arranged to an outer surface side 201 of the substrate 2, is manufactured. The skin 3 is formed in a bag shape by providing a seamed part 30 formed by seaming in at least one part of a part in which an external form of the skin integrated resin molded article 1 is curved. The bag like skin 3 is arranged in a cavity 60 formed with an inner mold 62 positioned to a rear surface side 302 of the skin 3 and an outer die 61 positioned to a front side 301 of the skin 3. A synthetic resin material 21 for the substrate is filled between the skin 3 and the inner mold 62, the skin 3 is pushed onto the outer die 61 by a pressure of the filling and the substrate 2 is formed to the rear surface side 302 of the skin 3.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for manufacturing a skin-integrated resin-molded product integrally including a resin-molded product and a bag-shaped skin disposed on the outer surface side of the resin-molded product.

[0002]

2. Description of the Related Art For example, as shown in FIGS. 22 and 23, a box-shaped component such as an upper lid 9 of a console provided beside a driver's seat of an automobile is a box-shaped base material 92 made of synthetic resin. The outer surface side 921 is provided with a bag-shaped outer skin 93 formed of synthetic leather or the like. As shown in FIG. 23, in the upper lid 9 of the console, an intermediate layer 94, which is softer than the base material 92, is arranged between the base material 92 and the skin 93 in order to improve cushioning performance. .

In manufacturing the upper lid 9 of the console, first, a preformed base material 92 is placed in a cavity formed by an outer mold and an inner mold, and the intermediate layer is formed on the outer surface side 921 of the base material 92. In-mold molding is performed to fill the synthetic resin material for use. Then, as shown in FIG.
Intermediate 9 in which the base material 92 and the intermediate layer 94 are integrated
Mold 0.

On the other hand, as shown in FIG. 25, the outer skin 93 is formed into a bag shape by stitching the respective end portions 932 of a plurality of raw materials 931 so as to cover the intermediate body 90. . Then, the bag-shaped skin 93 is covered on the molded intermediate body 90, and the intermediate body 90 is attached using an adhesive or the like.

After that, as shown in FIG. 23, the peripheral end portion 935 located on the open side of the bag-shaped outer skin 93 is attached to the base material 9.
The fastener 98 such as a tucker is folded back to the inner surface side 922 of No. 2
Then, the upper lid 9 of the console is manufactured.

[0006]

However, in the conventional method for manufacturing the upper lid 9 of the console, the suture portion 9 is used.
By forming 30, the end portions 932 of the plurality of materials 931 are arranged on the back surface side 902 of the outer skin 93. Therefore, when the outer skin 93 is attached by covering the intermediate body 90, the end portions 932 of the plurality of raw materials 931 cause the space between the outer surface side 905 of the intermediate body 90 and the rear surface side 932 of the outer skin 93. The gap 991 may be generated. In addition, due to the respective end portions 932 of the plurality of materials 931, unevenness 9 is formed on the design surface 901 of the upper lid 9 of the console.
92 may occur.

The present invention has been made in view of the above conventional problems, and it is an object of the present invention to provide a skin-integrated resin molded product in which the skin and the resin molded product are in close contact with each other and which has an excellent design surface. is there.

[0008]

According to a first aspect of the present invention, there is provided a method for producing a skin-integrated resin-molded article integrally having a base material and a bag-shaped skin provided on the outer surface side of the base material, wherein the skin is , A bag-like shape is formed by providing a stitching portion formed by stitching on at least a part of a portion where the outer shape of the resin-in-skin integrated product bends, and the inner mold located on the back surface side of the skin and the outer skin The bag-shaped skin is placed in a cavity formed by an outer mold located on the front surface side, the synthetic resin material for the base material is filled between the skin and the inner mold, and the filling pressure is set. According to the method for producing a skin-integrated resin molded article, the outer skin is pressed against the outer mold and the base material is molded on the back surface side of the skin (claim 1).

In the present invention, the skin is previously formed in a bag shape by providing a stitching portion formed by stitching on at least a part of a portion where the outer shape of the skin-integrated resin molded article is bent. . Further, in the present invention, the skin is directly placed in a cavity formed by the inner mold and the outer mold, and a synthetic resin material for the base material is filled between the skin and the inner mold in the cavity. To do. At this time, the outer skin is pressed against the outer mold by the pressure of filling the synthetic resin material for the base material, and the surface side of the outer skin is shaped by the outer mold. Therefore, when the base material is formed on the back surface side of the skin, unevenness or the like that deteriorates the design is hardly generated on the front surface side of the skin.

Further, the synthetic resin material for the base material, which has flowed in between the back surface side of the skin and the inner mold, is filled with almost no gap between the back surface side of the skin and the inner mold. It Therefore, it is possible to obtain a state in which the base material is closely adhered to the back surface side of the epidermis having a large unevenness due to the presence of the stitching portion without any gap. Therefore, according to the manufacturing method of the present invention, it is possible to manufacture a skin-integrated resin-molded product that has excellent adhesion between the skin and a base material that is a resin-molded product, and that has an excellent design surface.

A second aspect of the present invention is that a base material, a bag-shaped skin provided on the outer surface side of the base material, and an intermediate layer provided between the base material and the skin are integrated. In the method for manufacturing a skin-integrated resin molded article according to 1., the skin is formed in a bag shape by providing a stitching portion formed by stitching on at least a part of a portion where the outer shape of the skin-integrated resin molded article is bent. , The synthetic resin for the intermediate layer is placed face-to-face with a molding die for adjusting the shape of the surface side of the skin in a state in which the above-mentioned skin is covered on the preformed base material, and between the skin and the base material. Manufacture of a skin-integrated resin molded product characterized by filling a material, pressing the skin against the molding die by the pressure of the filling, and molding the intermediate layer between the skin and the base material. Method (Claim 5).

Also in the present invention, the skin is previously formed in a bag shape by providing a stitching portion formed by stitching on at least a part of a portion where the outer shape of the skin-integrated resin molded article is bent. . Then, in the present invention, the base material is molded in advance, and the skin covered with the base material is placed face-to-face with the molding die. Then, the synthetic resin material for the intermediate layer is filled between the skin and the base material. At this time, the skin is pressed against the mold by the pressure of filling the synthetic resin material for the intermediate layer, and the surface of the skin is shaped by the mold.
Therefore, when the intermediate layer is formed between the skin and the base material, almost no unevenness or the like that deteriorates the design is generated on the surface side of the skin.

The synthetic resin material for the intermediate layer, which has flowed in between the skin and the base material, is filled between the back surface side of the skin and the outer surface side of the base material with almost no gap. It Therefore, the intermediate layer formed of the synthetic resin material for the intermediate layer is in close contact with the front surface side of the base material and the back surface side of the epidermis having large irregularities due to the presence of the stitching portion without any gap. be able to. Therefore, according to the manufacturing method of the present invention, it is possible to manufacture a skin-integrated resin-molded product in which the skin, the base material which is the resin-molded product, and the intermediate layer are in close contact with each other and which has an excellent design surface. it can.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION The preferred embodiments of the present invention described above will be described. The above-mentioned skin-integrated resin molded article can be applied to various parts manufactured by covering the outer surface of a base material having a box shape with a bag-shaped outer skin. In particular, it can be applied to various parts used in an automobile, for example, an upper lid of a console provided beside a driver's seat of an automobile, a headrest of a seat, or an armrest.

In the first and second inventions, various synthetic resin materials such as polypropylene resin material and ABS resin material can be used as the synthetic resin material for the base material. Further, for the above-mentioned outer skin, for example, genuine leather, synthetic leather, TPO leather, vinyl chloride or the like can be used.

In the second aspect of the invention, the material for the intermediate layer is various synthetic resin materials or various synthetic resin foams which become a synthetic resin softer than the base material after the intermediate layer is molded. Materials for the body, various synthetic rubber materials that are synthetic rubbers softer than the above base materials, materials for various synthetic rubber foams, and the like can be used. For example,
A urethane rubber material or the like can be used as the material for the intermediate layer.

In the first aspect of the invention, the skin has a cushion layer that is softer than the base material on at least a part of the back surface side, and the synthetic resin material for the base material is not filled. It is preferable to perform the step between the skin and the inner mold and between the cushion layer and the inner mold to form the base material on the back surface side of the skin and the cushion layer (claim 2).

In this case, by providing the cushion layer on at least a part of the outer skin, cushioning performance such as impact absorption of the outer skin-integrated resin molded article can be improved. Further, a soft foam resin can be used for the cushion layer. Further, for the cushion layer, a slab material formed by cutting a slab formed by freely foaming without limiting the foaming space to a desired size can be used. For example, the cushion layer may be made of urethane foam made of the slab material (slab urethane).

Further, in the first and second inventions, it is preferable that at least a part of an end portion of the cushion layer is arranged along the sewn portion.
8). In this case, when the cushion layer is provided on the back surface side of the epidermis, a step generated on the back surface side of the epidermis can be arranged along the stitched portion. Therefore, it is possible to prevent unevenness or the like from being generated on the design surface of the molded resin product with integral skin after molding due to the step due to the cushion layer.

The cushion layer can be attached to the back surface of the bag-shaped epidermis after the suturing and integrated with the epidermis. Alternatively, the cushion layer may be attached to the back surface side of the material before forming the epidermis, and then the end portion of the material to which the cushion layer is attached may be sewn to be integrated with the epidermis. At this time, the stitched portion is formed including the cushion layer.

In the first invention, the inner mold is provided with an injection port communicating with the cavity,
It is preferable to fill the synthetic resin material for the base material from the injection port (claim 4). In this case, the synthetic resin material for the base material can be easily injected from the back surface side of the skin through the injection port of the inner mold.

In the second aspect of the invention, the skin has a cushion layer softer than the base material on at least a part of its back surface side, and the synthetic resin material for the intermediate layer is not filled. It is preferable that the intermediate layer is formed on the back surface side of the skin and the cushion layer by carrying out between the skin and the base material and between the cushion layer and the base material (claim 6).

In this case, by providing the cushion layer on at least a part of the outer skin, cushioning performance such as impact absorbing power of the outer skin-integrated resin molded article can be improved. Further, a soft foam resin can be used for the cushion layer. Further, for the cushion layer, a slab material formed by cutting a slab formed by freely foaming without limiting the foaming space to a desired size can be used. For example, the cushion layer may be made of urethane foam made of the slab material (slab urethane).

The intermediate layer is preferably made of foamed resin having a hardness higher than that of the cushion layer (claim 7). In this case, the cushion layer can have higher rigidity than the cushion layer. In addition, the cushion layer can be arranged on the back side of the epidermis that is frequently touched by the human body to realize a softer feel than the intermediate layer. Further, the intermediate layer is preferably a foamed resin having a hardness lower than that of the base material. In this case, even on the back surface side of the skin where the cushion layer is not arranged, the intermediate layer can be arranged to realize a softer touch than the base material.

Further, the above-mentioned base material is provided with a through hole,
It is preferable to fill the synthetic resin material for the intermediate layer through the through hole (claim 9). In this case, the through hole communicates between the base material and the outer skin when the outer skin covered with the base material is placed facing the molding die. Then, the injection of the synthetic resin material for the base material can be easily performed from the back surface side of the skin through the through hole of the base material.

Further, in the first and second inventions, the stitched portion is a main stitched portion obtained by stitching the bent portions in a state where a pair of opposite ends of the material forming the epidermis are bent. And a stitch stitching portion sewn in a state where each end portion of the material is folded back so as to overlap the back surface side of the outer skin on both sides of the main stitching portion (claim 10).

In this case, the strength of the sewn portion can be increased, and the stitch-sewn portion can produce a skin-integrated resin molded product having a more excellent design surface. In addition, the pair of end portions of the material are sewn together by the stitch stitching portion so as to overlap with the back surface side of the skin, and thus the synthetic resin material for the base material or the intermediate layer is filled. In doing so, it is possible to prevent the pair of end portions of the material from moving in an unstable state on the back surface side of the skin. Therefore, when the filling is performed, the positions of the pair of end portions of the material can be stabilized on the back surface side of the skin, and the filling can be smoothly performed.

[0028]

Embodiments of the present invention will be described below with reference to the drawings. (Embodiment 1) As shown in FIGS. 3 and 4, in the manufacturing method of this embodiment, the base material 2 and the outer surface side 201 of the base material 2 are used.
A skin-integrated resin-molded product 1 integrally having a bag-shaped skin 3 disposed in the above is manufactured. The outer skin 3 has a pair of opposite end portions of a material forming the outer skin 3, at least a part of a portion where the outer shape of the outer skin integrated resin molded article 1 is bent,
That is, a suture portion 30 formed by suturing a suture end portion 351 of a first material piece 35 and a suture end portion 361 of a second material piece 36, which will be described later, is provided to form a bag shape.

As shown in FIGS. 12 and 13, the skin 3 is
The bag-shaped outer skin 3 is placed in a cavity 60 formed by an inner mold 62 located on the back side 302 of the outer mold 61 and an outer mold 61 located on the front side 301 of the outer skin 3. As shown in FIG. 14, the synthetic resin material 21 for the base material is filled between the outer skin 3 and the inner die 62, and the outer skin 61 is pressed against the outer die 61 by the pressure of the filling. The base material 2 is formed on the back side 302 of the skin 3.

This will be described in detail below. As shown in FIGS. 1 and 2, in this example, the skin-integrated resin molded product 1 is the upper lid 1 of the console provided beside the driver's seat of the automobile. The upper lid 1 of this console is formed in a box shape having a three-dimensional shape with one surface open. The top lid 1 of the console in this example has a front surface 11 located on the front side of the automobile, an upper surface 12 located on the upper side, a rear surface 13 located on the rear side, and a pair of side surfaces 14 located on both side surfaces. At the same time, it is formed in a box shape having an opening 15 on the lower side.

As shown in FIGS. 3 and 4, in this embodiment, the outer skin 3 is formed in a bag shape so as to follow the shape of the upper lid 1 of the console. The sewn portion 30 is formed in a portion where the outer shape of the skin-integrated resin molded product 1 is bent in the direction of the both side surfaces (lateral direction), and the pair of facing materials of the skin 3 are opposed to each other. It is formed by stitching the ends.

Specifically, as shown in FIG. 5, the skin 3
Is formed by stitching the ends of three materials. One of these three materials is the front surface 11,
First material piece 35 forming the surfaces of the upper surface 12 and the rear surface 13
The remaining two are composed of second material pieces 36 which are respectively located on the left and right sides of the first material piece 35 and which form the surface of the side surface 14.

Further, in the first material piece 35 and the second material piece 36, respective sides to be sewn by facing each other are
Suture end portions 351 and 36 for forming the suture portion 30
Have one. Further, the remaining sides of the first material piece 35 and the second material piece 36 have folding margins 352, 362 for folding back to the inner surface side 202 of the base material 2.
In this example, the sutured portion 30 is the first
The sewn end 351 of the material piece 35 and the sewn end 361 of the second material piece 36 are formed by stitching.

The outer skin 3 has a cushion layer 5 softer than the base material 2 on the back side 302 of the first material piece 35 in order to improve cushioning performance such as impact absorption of the upper lid 1 of the console. Have This cushion layer 5
Has a shape conforming to the shape of the first material piece 35, and end portions 51 on both side surfaces thereof are arranged along the suture portion 30. Thereby, when the cushion layer 5 is provided, a step due to the end portion 51 of the cushion layer 5 is arranged along the sewn portion 30, and unevenness or the like occurs on the design surface of the upper lid 1 of the console after molding. Can be prevented.

The cushion layer 5 is attached to the back side 302 of the first material piece 35 so as to cover the stitched end 351 of the first material piece 35. The cushion layer 5 is made of soft foam resin (specifically, slab urethane). As a result, cushioning performance such as impact absorption can be improved on the upper surface 12 of the upper lid 1 of the console that is likely to come into frequent contact with the human body, and a soft tactile sensation can be realized.

Next, a method for forming the skin 3 will be described. As shown in FIG. 6, in the present example, first, the suture end portion 351 of the first material piece 35 and the second material piece 36.
In a state in which the suture end portions 361 are folded, the bent portion 353 of the suture end portion 35 and the bent portion 363 of the suture end portion 36 are sutured to form the main suture portion 37.

Then, as shown in FIG. 7, the suture end portions 351 of the first material piece 35 are provided on both sides of the main suture portion 37.
And the stitching end portion 361 of the second material piece 36 is folded back so as to overlap the back surface side 302 of the first material piece 35 and the back surface side 302 of the second material piece 36, respectively, and the stitch stitching portion 38 is formed. Form.

The front side 301 of the skin 3 has the main stitching portion 37 and the stitch stitching portion 38, and the back side 302 of the skin 3 has the stitching end portion 351 of the first material piece 35 and the second stitching portion. The suture portion 30 having the suture end portion 361 of the material piece 36 is formed. In this way, it is possible to form the bag-shaped skin 3 having the sewn portion 30 having high strength and excellent appearance design.

Although not shown, when the skin 3 is formed, the folding margin 352 of the first material piece 35 is provided at the peripheral end 305 which is the open end of the skin 3. The end portion provided and the end portion provided with the folding margin 362 of the second material piece 36 are located. In addition, the stitch stitched portion 38
Can be also formed at the end portion where the folding back portions 352, 362 are formed, and the folding back portions 352, 362 can be folded back and fixed to the inner surface side 202 of the base material 2 with the stitch stitching portion 38 as a boundary. Be prepared to do so.

Then, as shown in FIG. 8, the cushion layer 5 is attached from the back side 302 of the first material piece 35. This attachment is performed by aligning the end portion 51 of the cushion layer 5 with the main stitching portion 37 of the stitching portion 30. In this way, after the cushion layer 5 is attached, the cushion layer 5 is
On the back side 502 of the first material piece 35
The second material piece 3 of the epidermis 3 has a step 503 formed by 1.
A step 303 is formed on the back side 302 of the sewing machine 6 by the suture end 361.

As described above, in this example, the skin 3 is formed by sewing the above three materials. On the other hand, as shown in FIG. 9, the skin 3 is made of one material 3
9 may be formed by stitching. That is, the material 39 is sewn to the portion where the outer shape of the upper lid 1 of the console is bent so as to form a loop 391 on the back side 302 of the outer skin 3. Then, the stitching portion 30 having the main stitching portion 37 and the stitch stitching portion 38 may be formed.

Next, using the skin 3 formed as described above,
A method of manufacturing the upper lid 1 of the console will be described. As shown in FIG. 10, in this example, the skin 3
Located on the back side 302 of the inner side 2 of the base material 2
An inner mold 62 having an inner molding surface 621 for molding 02,
The skin 3 is located on the front side 301 of the skin 3 and
A molding die 6 including an outer die 61 having an outer molding surface 611 for adjusting the shape of the front surface side 301 is used.

Further, the outer die 61 has a sandwiching portion for sandwiching the peripheral end portion 305 of the outer skin 3 between the outer die 61 and the inner die 62 over the entire circumference of the opposite side end surface 615 facing the inner die 62. 63
have. The sandwiching portion 63 is provided at the peripheral end portion 30 of the skin 3.
It is possible to prevent the synthetic resin material 21 from leaking through the gap when the synthetic resin material 21 for the base material is filled by closing the gap between the inner mold 62 and the inner mold 62. Further, in the inner mold 62, when the inner mold 62 is arranged inside the outer mold 61 and a cavity 60 is formed between them, a synthetic resin material for a base material that communicates with the cavity 60. Twenty-one injection ports 622 are provided.

Although not shown, when the inner mold 62 is arranged inside the outer mold 61 and the cavity 60 is formed between them, the positions of the inner mold 62 and the outer mold 61 are not shown. The relationship is fixed.

As shown in FIG. 11, in manufacturing the upper lid 1 of the console, first, the outer skin 3 previously formed is placed inside the outer mold 61. At this time,
The front surface side 301 of the outer skin 3 and the outer molding surface 611 of the outer mold 61 face each other. Then, as shown in FIG. 12, the outer die 61 and the inner die 62 on which the outer skin 3 is arranged are relatively moved, and the inner molding surface 621 of the inner die 62 faces the back surface side 302 of the outer skin 3. In this way, it is arranged inside the outer mold 61.

Then, as shown in FIG.
The holding part 63 of No. 1 is moved toward the inner mold 62, and the holding part 63 moves the peripheral end portion 305 of the outer skin 3 into the inner mold 6.
Then, the peripheral end portion 305 of the outer skin 3 is sandwiched between the sandwiching portion 63 and the inner mold 62. At this time, the inner mold 62
A cavity 60 is formed between the outer mold 61 and the outer mold 61 and is surrounded by the inner mold 62, the outer mold 61 and the sandwiching portion 63. Further, the skin 3 is arranged in the cavity 60, and in the cavity 60, a space 64 for molding the base material 2 is formed.

Next, as shown in FIG. 14, in the cavity 60, the synthetic resin material 21 for the base material is injected from the injection port 622 of the inner mold 62. Then, the synthetic resin material 21 for the base material is applied to the back surface side 3 of the skin 3.
02 and the back surface side 502 of the cushion layer 5 and the inner mold 6
The space between the two inner molding surfaces 621 is filled.

At this time, the skin 3 is pressed against the outer molding surface 611 of the outer mold 61 by the pressure of filling the synthetic resin material 21 for the base material. The surface side 301 of the skin 3 is shaped by the outer molding surface 611. Therefore, when the base material 2 is molded on the back surface side 302 of the outer skin 3 and the back surface side 502 of the cushion layer 5, unevenness or the like that deteriorates the design may be generated on the front surface side 301 of the outer skin 3. Absent.

At the time of the filling, the synthetic resin material 21 for the base material follows the shape of the step 303 formed on the back surface side 302 of the skin 3 and the back surface side 302 of the skin 3 and the inner mold. It flows in between 62. In addition, the synthetic resin material 21 for the base material forms the cushion layer 5 along the shape of the step 503 formed on the back surface side 502 of the cushion layer 5.
It flows into between the back surface side 502 and the inner mold 62.

Therefore, the synthetic resin material 21 for the above base material
Is filled so as to fill most of the space 64 in the cavity 60, that is, between the back surface side 302 of the skin 3 and the back surface side 502 of the cushion layer 5 and the inner mold 62 with almost no gap. . Therefore, due to the presence of the sutured portion 30, the skin 3 having large unevenness
It is possible to obtain a state in which the base material 2 is closely adhered to the back side 302 of the above without any gap.

The stitch stitching portion 38 is stitched in a state in which the stitching end portion 361 of the second material piece 36 is folded back so as to overlap the back surface side 302. for that reason,
It is possible to stabilize the position of the suture end portion 361 on the back surface side 302 and smoothly perform the filling.

In this way, the base material 2 is in-molded in the space 64, and the upper lid 1 of the console integrally including the base material 2, the skin 3 and the cushion layer 5 is formed. Also, a molded product 22 made of the same material as the base material 2 is molded in the injection port 622 of the inner mold 62.
Is connected to the base material 2.

Then, as shown in FIG.
After the base material 2 is molded on the back surface side 302 and the back surface side 502 of the cushion layer 5, the holding portion 63 is attached to the upper mold 62.
It is moved in a direction away from to release the sandwiching of the epidermis 3. Then, the inner mold 62 and the outer mold 61 are relatively moved, and the upper lid 1 of the console after molding is taken out from the cavity 60.

Thereafter, as shown in FIGS. 3 and 4, the molded product 22 connected to the above-mentioned molded base material 2 is cut off. In addition, the folding-back margin 3 at the peripheral edge portion 305 of the skin 3
52 and 362 are folded back to the inner surface side 202 of the base material 2 and fixed to the base material 2 by a fixture 8 such as a tucker.
Thus, according to the manufacturing method of this example, the skin 3 and the base material 2 are
It is possible to manufacture the upper lid 1 of the console which is in close contact with and has an excellent design surface.

(Embodiment 2) As shown in FIGS. 16 and 17, in this embodiment, the base material 2 and the outer surface side 20 of the base material 2 are used.
1. A skin-integrated resin-molded product 1 integrally having a bag-shaped skin 3 disposed on the base 1 and an intermediate layer 4 disposed between the base material 2 and the skin 3 is manufactured. The outer skin 3 has a pair of opposite end portions of the material forming the outer skin 3, that is, a suture end portion of the first material piece 35, in at least a part of a portion where the outer shape of the outer skin integrated resin molded product 1 is bent. A sewn portion 351 formed by stitching 351 and the sewn end portion 361 of the second material piece 36 is provided to form a bag shape.

Then, as shown in FIG.
Is placed face-to-face with a molding die 7 for adjusting the shape of the front surface side 301 of the skin 3 while covering the preformed base material 2. As shown in FIG. 20, the synthetic resin material 41 for the intermediate layer is filled between the skin 3 and the base material 2, and the skin 3 is pressed against the molding die 7 by the pressure of the filling. The intermediate layer 4 is provided between the skin 3 and the base material 2.
To mold.

This will be described in detail below. Also in this example, the skin-integrated resin molded product 1 is the upper lid 1 of the console provided beside the driver's seat of the automobile. The outer skin 3 is formed in a bag shape by the first material piece 35 and the left and right second material pieces 36. Further, the skin 3 has a cushion layer 5 softer than the base material 2 on the back surface side 302 of the first material piece 35.

A step 503 is formed on the back surface side 502 of the cushion layer 5 by the protrusion of the stitching end 351 of the first material piece 35, and on the back surface side 302 of the second material piece 36 of the skin 3. Step 3 due to the suture end 361
03 is formed. The intermediate layer 4 is made of a foamed resin having a hardness lower than that of the base material 2 and higher than that of the cushion layer 5. Other configurations are the same as those in the first embodiment.

Next, using the above-mentioned skin 3 made in advance,
A method of manufacturing the upper lid 1 of the console will be described. In this example, as shown in FIGS. 19 and 20, a molding die 7 having an outer molding surface 711 located on the front surface side 301 of the outer skin 3 and adjusting the shape of the front surface 301 of the outer skin 3 is used. Further, in the present example, instead of the inner mold 62, a clamp 71 that holds the peripheral end portion 305 of the outer skin 3 between the inner mold 62 and the base material 2 is used. The clamp 71 can also perform positioning between the base material 2 and the molding die 7 when the base material 2 covered with the skin 3 is placed inside the molding die 7. In addition, the base material 2 is provided with a through hole 25 that communicates between the skin 3 and the base material 2 in a state where the base material 2 is covered with the skin 3.

As shown in FIG. 18, in manufacturing the upper lid 1 of the console, first, the preformed skin 3 is placed inside the molding die 7. At this time, the surface side 301 of the skin 3 and the outer molding surface 711 of the molding die 7
And face each other.

Then, as shown in FIG. 19, the base material 2 is
The outer surface side 201 is arranged inside the molding die 7 so as to face the back surface side 302 of the outer skin 3. Then, by the clamp 71, the peripheral end portion 3 of the skin 3 is
05 is folded back to the inner surface side 202 of the base material 2,
The base material 2 and the skin 3 are grasped. At this time, clamp 7
1 and the base material 2 sandwich the peripheral edge portion 305 of the skin 3,
The gap between the inner surface side 202 of the base material 2 and the back surface side 302 of the skin 3 is closed. In this way, the skin 3 is placed face-to-face with the molding die 7 while being covered with the base material 2 that has been molded in advance.

The clamp 71 positions the base material 2 and the molding die 7. When this positioning is performed, a space 65 for molding the intermediate layer 4 is formed between the base material 2 and the molding die 7. Further, an injection portion 72 for injecting the synthetic resin material 41 for the intermediate layer is arranged on the back surface side 302 of the base material 2,
The injection port 721 of the injection part 72 is formed through the through hole 2 of the base material 2.
Connect to 5.

Then, as shown in FIG. 20, the synthetic resin material 41 for the intermediate layer is injected into the injection port 721 of the injection portion 72.
Further, it is injected between the skin 3 and the cushion layer 5 and the base material 2 through the through hole 25 of the base material 2. Then, the synthetic resin material 41 for the intermediate layer is filled between the back surface side 302 of the skin 3 and the back surface side 502 of the cushion layer 5, and the outer surface side 201 of the base material 2.

At this time, the skin 3 is pressed against the outer molding surface 711 of the molding die 7 by the pressure of this filling,
The surface side 301 of the skin 3 is shaped by the outer molding surface 711 of the molding die 7. Therefore, when the intermediate layer 4 is formed between the skin 3 and the cushion layer 5 and the base material 2, almost no unevenness or the like that deteriorates the design is generated on the design surface of the console upper lid 1. There is no.

At the time of the filling, the synthetic resin material 41 for the intermediate layer is formed along the shape of the step 303 formed on the back side 302 of the skin 3 and the back side 302 of the skin 3 and the base material. 2 flows in between the outer surface side 201. Further, the synthetic resin material 41 for the intermediate layer is used for the cushion layer 5
Along the shape of the step 503 formed on the back surface side 502, it flows between the back surface side 502 of the cushion layer 5 and the outer surface side 201 of the base material 2.

Therefore, the synthetic resin material 4 for the intermediate layer
1 fills most of the space 65 between the base material 2 and the molding die 7, that is, the back surface side 302 of the skin 3 and the back surface side 502 of the cushion layer 5 and the base material 2
Is filled with almost no gap between the outer surface 201 and the outer surface side 201. Therefore, the synthetic resin material 41 for the intermediate layer
The intermediate layer 4 formed by the
1, and the presence of the sutured portion 30 makes it possible to obtain a state in which the back surface 302 of the outer skin 3 having large irregularities is closely attached without a gap.

In this way, the intermediate layer 4 is placed in the space 65.
By in-molding the base material 2, the skin 3, the intermediate layer 4
And the upper lid 1 of the console integrally having the cushion layer 5 is formed. Also, a molding 42 made of the same material as that of the intermediate layer 4 is molded at the injection port 721 of the injection part 72,
The molded product 42 is connected to the mid layer 4.

Next, as shown in FIG. 21, the skin 3
After forming the intermediate layer 4 between the cushion layer 5 and the back surface side 302 of the base material 2, the clamp 71 is separated from the base material 2 and the outer skin 3, and the sandwiching of the outer skin 3 is released. Moreover, the injection part 72 is retracted. Then, the upper lid 1 of the molded console is taken out from the inside of the outer mold 61.

After that, as shown in FIGS. 16 and 17, the molded product 42 connected to the intermediate layer 4 after the molding is cut off. Further, the folding back portions 352, 362 in the peripheral end portion 305 of the outer skin 3 are folded back to the inner surface side 202 of the base material 2 and fixed to the base material 2 by a fixture 8 such as a tacker. As described above, according to the manufacturing method of this example, it is possible to manufacture the upper lid 1 of the console in which the layers of the skin 3, the intermediate layer 4, and the base material 2 are in close contact with each other and which has an excellent design surface. In addition, it is possible to obtain the same effect as that of the first embodiment.

[Brief description of drawings]

FIG. 1 is a perspective view showing a design surface side of an upper lid of a console in a first embodiment.

FIG. 2 is a perspective view showing the back surface side of the upper lid of the console in the first embodiment.

FIG. 3 is a lateral cross-sectional view of the upper lid of the console in the first embodiment.

FIG. 4 is a cross-sectional view of the top lid of the console in the front-rear direction according to the first embodiment.

FIG. 5 is an explanatory view showing a first material piece and a second material piece that form the epidermis in the first embodiment.

FIG. 6 is a diagram showing a method of forming an epidermis in Example 1, and an explanatory diagram showing a state in which a main suture portion is formed.

FIG. 7 is a diagram illustrating a method of forming an epidermis in Example 1, and an explanatory diagram illustrating a state in which a stitch stitching portion is formed.

FIG. 8 is a diagram illustrating a method of forming a skin according to the first embodiment and is an explanatory diagram illustrating a state in which a cushion layer is attached.

FIG. 9 is an explanatory view showing a sutured portion formed by another epidermis forming method in the first embodiment.

FIG. 10 is an explanatory cross-sectional view showing a molding die including an outer die and an inner die according to the first embodiment.

FIG. 11 is a diagram illustrating a method of manufacturing the upper lid of the console according to the first embodiment and is a cross-sectional explanatory diagram illustrating a state in which a skin is arranged on an outer mold.

FIG. 12 is a diagram illustrating the method of manufacturing the upper lid of the console according to the first embodiment, and is a cross-sectional explanatory diagram illustrating a state in which the inner mold is arranged in the outer mold with the outer skin.

FIG. 13 is a view showing the method of manufacturing the upper lid of the console in Embodiment 1, and a cross-sectional explanatory view showing a state in which a cavity is formed between the outer die and the inner die.

FIG. 14 is a diagram illustrating the method of manufacturing the upper lid of the console according to the first embodiment and is a cross-sectional explanatory diagram illustrating a state in which the base material is molded on the back surface side of the skin.

FIG. 15 is a view showing the method of manufacturing the upper lid of the console in Embodiment 1, and a cross-sectional explanatory view showing a state where the upper lid of the console is removed from the molding die.

FIG. 16 is a lateral cross-sectional view of the upper lid of the console according to the second embodiment.

FIG. 17 is a cross-sectional view of the top lid of the console in the front-rear direction according to the second embodiment.

FIG. 18 is a diagram illustrating a method of manufacturing the upper lid of the console according to the second embodiment and is a cross-sectional explanatory diagram illustrating a state in which a skin is arranged inside the molding die.

FIG. 19 is a view showing the method of manufacturing the upper lid of the console in Example 2, and a cross-sectional explanatory view showing a state in which the base material is arranged inside the molding die in which the skin is arranged.

FIG. 20 is a view showing the method of manufacturing the upper lid of the console in Embodiment 2, and a cross-sectional explanatory view showing a state in which an intermediate layer is formed between the skin and the base material.

FIG. 21 is a diagram illustrating the method of manufacturing the console upper lid in the second embodiment and is a cross-sectional explanatory diagram illustrating a state in which the console upper lid is removed from the molding die.

FIG. 22 is a perspective view showing a back surface side of an upper lid of a console in a conventional example.

FIG. 23 is a lateral cross-sectional view of the upper lid of the console in the conventional example.

FIG. 24 is a cross-sectional explanatory view showing an intermediate body in which a base material and an intermediate layer are integrated in a conventional example.

FIG. 25 is a cross-sectional explanatory view showing a bag-shaped outer skin in a conventional example.

[Explanation of symbols]

1. ． ． Skin-integrated resin molded product (console top cover), 2. ． ． Base material, 201. ． ． Outer side, 202. ． ． Inner side, 21. ． ． Synthetic resin material for base material, 3. ． ． Epidermis, 301. ． ． Front side, 302. ． ． Back side, 30. ． ． Suture, 4. ． ． Middle class, 41. ． ． Synthetic resin material for the intermediate layer, 5. ． ． Cushion layer, 6. ． ． Mold, 60. ． ． cavity, 61. ． ． External type, 62. ． ． Inner mold, 7. ． ． Mold,

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 4F206 AD08 AD17 AD20 AD27 AG03                       AH26 JA07 JF05

Claims (10)

[Claims] 1. A method for producing a skin-integrated resin molded product integrally having a base material and a bag-shaped skin disposed on the outer surface side of the base material, wherein the skin is the skin-integrated resin molded product. An outer mold located on the back surface side of the epidermis and an outer mold located on the back surface side of the epidermis formed by forming a bag-like shape by providing a sutured portion formed by stitching on at least a part of the outer shape The bag-shaped outer skin is placed in the cavity formed by, and the synthetic resin material for the base material is filled between the outer skin and the inner mold, and the outer skin is formed by the filling pressure. A method for producing a skin-integrated resin-molded product, which comprises pressing the base material on the back surface side of the skin and molding the base material on the back surface side of the skin. 2. The skin according to claim 1, wherein the skin has a cushion layer that is softer than the base material on at least a part of the back surface side, and the filling of the synthetic resin material for the base material is the above-mentioned. A skin-integrated resin molded article characterized by molding between the skin and the inner mold, and between the cushion layer and the inner mold, and molding the base material on the back surface side of the skin and the cushion layer. Production method. 3. The method for manufacturing a skin-integrated resin molded article according to claim 2, wherein at least a part of an end portion of the cushion layer is arranged along the sewn portion. 4. The method according to claim 1, wherein
A method for manufacturing a skin-integrated resin-molded product, wherein the inner mold is provided with an injection port communicating with the cavity, and the synthetic resin material for the base material is filled from the injection port. 5. An integrated skin having a base material, a bag-shaped skin disposed on the outer surface side of the base material, and an intermediate layer disposed between the base material and the skin. In the method for producing a resin molded product, the outer skin is formed in a bag shape by providing a stitching portion formed by stitching on at least a part of a portion where the outer shape of the outer skin integrated resin molded product is bent, and the outer skin is formed. While facing the preformed base material, the base material is placed face-to-face with a molding die for adjusting the shape of the surface side of the skin, and a synthetic resin material for the intermediate layer is filled between the skin and the base material. A method for producing a skin-integrated resin molded article, characterized in that the skin is pressed against the molding die by the pressure of the filling, and the intermediate layer is molded between the skin and the base material. 6. The skin according to claim 5, wherein at least a part of the back surface of the skin has a cushion layer softer than the base material, and the filling of the synthetic resin material for the intermediate layer is performed by the above-mentioned method. A skin-integrated resin molded article, characterized in that the intermediate layer is formed between the skin and the base material and between the cushion layer and the base material, and the intermediate layer is formed on the back surface side of the skin and the cushion layer. Production method. 7. The method for manufacturing a skin-integrated resin molded article according to claim 6, wherein the intermediate layer is made of foamed resin having a hardness higher than that of the cushion layer. 8. The method for manufacturing a skin-integrated resin molded article according to claim 6 or 7, wherein at least a part of an end portion of the cushion layer is arranged along the stitched portion. 9. The method according to claim 5, wherein
A method for manufacturing a skin-integrated resin-molded product, wherein the base material is provided with through holes, and the synthetic resin material for the intermediate layer is filled through the through holes. 10. The main seam according to any one of claims 1 to 9, wherein the stitched portion is a state in which a pair of opposite ends of a material forming the epidermis are bent, and the bent portions are stitched together. A skin-integrated resin molded article, comprising a stitched portion and a stitch stitched portion that is sewn in a state in which both ends of the material are folded back so as to overlap the back surface side of the skin on both sides of the main stitched portion. Production method.