JP2003300246A - Skin material-covered molded product and manufacturing method for sun visor for vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a skin material-covered molded product capable of easily treating the terminal of a skin material. <P>SOLUTION: In the manufacturing method for a skin material-covered molded product wherein a skin material 2 is bonded to the surface of a core material molded into a product shape, a bendable piece 30 is provided to the peripheral edge part of the core material 3 and the terminal part 2a of the skin material 2 is bonded to the surface of the bendable part 30. Then, the terminal part 2a is bent toward the back surface 3b of the core material 3 along with the bendable part 30 and ultrasonic vibration is applied to the bent end part 30a of the bendable part 30 to plastically deform the bent end part. By this method, the bendable piece 30 and the terminal part 2a are held to the back surface 3b of the core material 3. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a skin material-coated molded product in which a skin material is joined to the surface of a core material molded into a product shape, and a skin material-coated molded product produced by the manufacturing method. The present invention relates to a method for manufacturing a vehicle sun visor manufactured from.

[0002]

2. Description of the Related Art A skin material-covered molded article comprising a core material formed into a product shape and a skin material covering the surface of the core material has been used in various fields in the past, for example, in vehicles. It is used for interior parts and room partitions. The skin material-covered molded article was formed by folding the end portion of the skin material into the back surface of the core material in a state where the skin material was joined to the surface of the core material, and thereby subjecting the skin material to the end treatment. The end treatment of the skin material has heretofore been known by a method of applying an adhesive to the back surface of the core material and attaching the bent end portion of the skin material to the back surface of the core material. Also, a method of attaching the end portion of the skin material to the back surface of the core material by a primer treatment instead of the adhesive has been conventionally known. Further, a protrusion such as a pin is provided on the back surface of the core material, and the skin material folded to the back surface is brought into contact with the protrusion. Also, a method of pressing a hot plate or the like against these to bond the skin material and the protrusions has been conventionally known.

[0003]

However, in the conventional end treatment of the skin material, it is necessary to pull the bent end portion evenly in each direction and to attach it to the back surface of the core material in that state. Alternatively, it was necessary to press a hot plate or the like against the skin material for adhesion. Therefore, the work was difficult. Therefore, the present invention provides a method of manufacturing a skin material-coated molded product capable of easily performing a terminal treatment of a skin material, or a method of manufacturing a vehicle sun visor manufactured from the skin material-coated molded product manufactured by the manufacturing method. The challenge is to provide.

[0004]

SUMMARY OF THE INVENTION The present invention is a method for manufacturing a skin-covered molded article or a vehicle sun visor, which is provided with the structure as described in each of the claims in order to solve the above problems. . According to the invention described in claim 1, the end treatment of the skin material can be facilitated. That is, a bendable piece is provided on the peripheral portion of the core material, and the end portion of the skin material is joined to the surface of the bendable piece. Then, the end portion is bent together with the bent piece toward the back surface side of the core material, and ultrasonic vibration is applied to plastically deform the bent end portion of the bent piece. Therefore, the skin material is bent by bending the bending piece so that its end portion is bent to the back surface of the core material. And the bending piece is subjected to ultrasonic vibration,
The bent end is softened and then hardened to be plastically deformed. Therefore, the bent piece and the terminal portion are held on the back surface side of the core material. Thus, the end treatment of the skin material can be easily performed. The ultrasonic vibration may be applied before bending the bent piece, may be applied during bending, or may be applied after bending.

According to the second aspect of the present invention, the bent piece can be easily provided, and the end portion of the skin material can be easily joined to the bent piece. That is, the skin material is set in the cavity of the mold and the core material is filled in the cavity. As a result, the core material having the bent pieces can be integrally formed, and the skin material can be bonded to the surface of the core material that extends over the bent pieces.

According to the third aspect of the present invention, a part of the back surface of the core member that is brought into proximity by bending the bending piece,
A welding portion is provided between the bent piece and the bent piece. Then, the welded portion is melted by ultrasonic vibration applied when the bent piece is plastically deformed, whereby the bent piece and the back surface are welded via the welded portion. Therefore, the bent piece is welded to the back surface of the core material, and the bent state on the back surface side is stably maintained. Further, the end portion of the skin material is also bent to the back surface side together with the bending piece, and is stably held on the back surface side of the core material. Further, melting of the welded portion utilizes ultrasonic vibration used when the bent piece is plastically deformed. Therefore, the welded portion can be melted without increasing new work.

According to the invention of claim 4, claim 1
A hollow shell-shaped visor body is molded using the skin material-covered molded product manufactured by the manufacturing method according to any one of 1 to 3 above. Therefore, the vehicle sun visor can be easily molded because the skin material-covered molded product is easily manufactured as described above.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION (Embodiment 1) Embodiment 1 of the present invention will be described below with reference to FIGS. In this embodiment, as shown in FIG. 1, a core material 3 formed into a product shape and a skin material 2 bonded to a surface 3a of the core material 3 are used.
And a molded article (skin-covered molded article) having and. For example, the present invention relates to a vehicle interior product (vehicle sun visor, vehicle ceiling panel, glow box, center console, door trim, etc.) and a partition for partitioning a room, and a molded product in which the skin material 2 is joined to the surface side. . The manufacturing method of this molded article will be described below.

First, the core material 3 is molded into a product shape, and the core material 3 is formed.
The skin material 2 is joined to (step S1 shown in FIG. 2). The joining method may be a method in which the core material 3 is formed into a product shape and then the skin material 2 is attached using an adhesive or the like (not shown in the drawing), or the core material 3 A method of joining the skin material 2 to the core material 3 simultaneously with molding, that is, a skin material simultaneous molding method may be used. The skin material 2 may be bonded to the core material 3 by a method in which the skin material 2 is bonded to the entire one side surface of the core material 3 as shown in FIG. This is performed by joining one side surface of the (folded piece 30) and the end portion 2a of the skin material 2.

As shown in FIG. 3, the skin material simultaneous molding method uses one of the molds 1, for example, the lower mold cavity 11a of the lower mold 11.
Set the skin material 2 on. Then, the upper mold 10 is lowered to the lower mold 11. As a result, a cavity 1a is formed between the upper die 10 and the lower die 11 as shown in FIG. Then, the skin material 2 is set in the cavity 1a. Then, the cavity 1a is filled with the core material. Thereby, the core material 3 is injection-molded, and at the same time, the skin material 2 is joined to the surface 3a of the core material 3. The core material used as the core material 3 is a thermoplastic resin such as PP (polypropylene) or ABS resin. The skin material 2 is, for example, a sheet material formed of a thermoplastic resin as a material, or a sheet material formed of a woven or non-woven fabric as a material.

As shown in FIG. 1, the core material 3 has a bulging shape on the surface 3a side, for example, a shell shape or a bowl shape. In addition, a bendable piece 30 is provided on the peripheral edge of the core material 3. That is, the bent piece 30 of the core material 3 is formed integrally with the core material 3. Simultaneously with this molding, the skin material 2 is joined to the surface 3a of the core material 3 extending over the bent piece 30. The bent piece 30 is formed to extend in the height direction of the core 3 as shown in FIG. The bent piece 30 is formed to be thinner (for example, about 0.5 mm) than the other core material 3.

Then, the core material 3 and the skin material 2 are taken out from the molding die 1. After that, the excess skin material 2 is cut or punched with Thomson or the like. Then, the core material 3 and the skin material 2 are set on the receiving jig 12 as shown in FIG. Next, the bending piece 30 is bent to the back surface 3b by the holding jig 13 as shown in FIG. The holding jig 13 has a bending piece 30 as shown in FIG.
Has a guide surface 13a for folding the back surface 3b. The guide surface 13a is formed in a shape that is inclined upward from the end surface side of the core material 3 toward the center side of the core material 3. Therefore, by moving the holding jig 13 downward with respect to the receiving jig 12, the bending piece 30 is moved to the guide surface 13.
The back surface 3b can be bent by a.

The end portion 2a of the skin material 2 has a bent piece 30.
Is joined to the surface 3a side. Therefore, the bent piece 30
By bending, the terminal portion 2a can be bent to the back surface 3b as shown in FIG. Thus, the end portion 2a of the skin material 2 is bent to the back surface 3b of the core material 3, whereby the end treatment of the skin material 2 can be performed (FIG. 2).
Step S2).

The holding jig 13 is provided with an oscillating device for generating ultrasonic vibration. That is, the holding jig 13
Is an ultrasonic oscillating horn. Therefore, the holding jig 13
The ultrasonic vibration can be applied to the core material 3 with respect to the core material 3 when the bending piece 30 is bent, after the bending, or before the bending.

Therefore, the core material 3 is vibrated under pressure by the pressing jig 13, and heat is generated due to the vibration friction caused by this vibration. Particularly, the bent end portion 30 that is a portion where the wall thickness changes greatly
Stress concentration occurs in a, heat is generated, and after being softened, it solidifies and plastically deforms. Therefore, even when the pressing jig 13 is returned upward, the bent piece 30 is maintained in the bent state. In addition, the end portion 2a of the skin material 2 also includes the bent piece 3
0, the state of being bent to the back surface 3b of the core material 3 as shown in FIG. 1 is maintained.

When ultrasonic vibration is applied to the core material 3 when the bending piece 30 is bent, the bending piece 30 is in a state of being softened by heat and further bent with a small pressure by the hammer effect. be able to.

Further, the core material 3 has a corner portion as shown in FIG. 5, and an escape portion 30b having no bent piece 30 is formed at the corner portion. Therefore, even when the bent pieces 30 are bent, the bent pieces 30 can be prevented from overlapping with each other, and the bent pieces 30 can be easily bent, and the end treatment of the skin material 2 can be easily performed. The corner portion here is not limited to the four corners of the core material 3, but may be, for example, a corner portion of R20 mm or less.

The skin material 2 corresponding to the relief portion 30b is
It is pulled by the bending pieces 30 on both sides (see FIG. 5) and bent to the back surface of the core material 3. A molded product (skin material-covered molded product) can be manufactured as described above.

A method (step S3 in FIG. 2) of manufacturing the visor body of the vehicle sun visor from the molded product will be described below. First, the core material 3 molded into the shape of the visor body
Prepare two molded products that are equipped with. And the core material 3 of the molded product
The back surfaces 3b are overlapped with each other so that they face each other, and are bonded. The moldings are joined together by, for example, joining the joining portions formed in a convex shape from the back surface of the core material 3 (for example, claw fitting,
Press-fitting etc.). Thus, the hollow shell-shaped visor body is molded.

The visor body may be molded as follows instead of the above molding method. That is, this is a method in which the molded product has a configuration in which it can be folded in two from left to right or up and down, and the back surfaces of the core materials 3 are folded so that the folded core materials 3 are superposed and joined together.

(Second Embodiment) Next, a second embodiment of the present invention will be described with reference to FIG. This form is different from the above-mentioned embodiment only in the core material and the holding jig. Therefore, the description of the same parts will be omitted here, and the same parts will be described with the same numbers. As shown in FIG. 6, when the bending piece 30 is bent, the core material 3 is provided with the welded portion 31 on a part of the back surface 3b to which the bending piece 30 approaches. The welded portion 31 is formed of the core material 3
The inner edge of the bent piece 30 or the back surface 3 at the peripheral edge of the
It is provided on the b side. The welded portion 31 is formed in a protruding shape toward the bent piece 30 that is bent as shown in FIG. 6, and is formed in a tapered shape. The welded portion 31 is provided between the bent piece 30 and the back surface 3b, as shown in FIG. 6, and on an extension of the back surface 3b. The welded portion 31 is formed by being integrally molded with the core material 3, and is made of a thermoplastic resin as a raw material.

As shown in FIG. 6, the holding jig 13 has a guide surface 13b for guiding the bending piece 30 to be bent on the back surface 3b of the core material 3, and a tip surface of the bending piece 30 to the back surface 3b side. It has a pushing surface 13c to be pushed in at its tip. As shown in FIG. 6, the guide surface 13b is formed by gently inclining upward from the end surface side of the core material 3 toward the center side of the core material 3. The pushing surface 13c is formed to extend downward from the guide surface 13b. Therefore, by moving the holding jig 13 downward with respect to the receiving jig 12, the bending piece 30 can be bent to the back surface 3b by the guide surface 13b. Then, the bending piece 30 can be further bent toward the back surface 3b by the pushing surface 30c, and thus the bending piece 30 can be pressed against the welding portion 31.

Further, the holding jig 13 is provided with an oscillating device for generating ultrasonic vibration. Therefore, the holding jig 13
Can emit ultrasonic vibration while or after bending the bending piece 30. And bent piece 3
The welded portion 31 can be melted by ultrasonic vibration applied when 0 is plastically deformed. That is, the bending piece 30 and the welded portion 31 are vibrated by ultrasonic vibration, and frictional heat is generated in the welded portion 31. Thus, the welded portion 31 is melted by the heat. Then, the welded portion 31 welds the bent piece 30 and the back surface 3b of the core material 3 as shown in FIG. 6 (b).

Therefore, the bent piece 30 has a bent end portion 30a.
The bent state is maintained by the plastic deformation and the welding action of the welding portion 31. Thus skin material 2
The terminal portion 2a is bent along with the bending piece 30 toward the back surface 3b, and the state is maintained. Therefore, the skin material-covered molded product can be easily manufactured. The welded part 3
1 was provided at the position shown in FIG.
It may be provided on the side. Also, the welded part 3
1 may be provided over substantially the entire circumference of the peripheral portion of the core material 3, or may be provided in a scattered manner.

(Embodiments 3 and 4) Next, Embodiments 3 and 4 of the present invention will be described with reference to FIGS. In the third and fourth embodiments, instead of the welded portion 31 in the second embodiment,
Welding portion 32 (see FIG. 7) to welding portion 33 (see FIG. 8)
It is a form having. The welded portions 32 are provided on the back surface 3b of the core material 3 at predetermined intervals as shown in FIG.
Standing portion 32a standing on the back surface 3b and the standing portion 32a
And a protrusion 32b provided at the tip of the. Therefore, the protruding portion 32b comes into contact with the bent piece 30 when the bent piece 30 is bent toward the back surface 3b, and is welded to the bent piece 30 by ultrasonic vibration. The welded portions 33 are also provided on the back surface 3b of the core material 3 at predetermined intervals, and are provided in a protruding shape, for example, a substantially conical shape from the back surface 3b (see FIG. 8). Therefore, the tip of the welded portion 33 comes into contact with the bent piece 30 when the bent piece 30 is bent toward the back surface 3b,
It is welded to the bent piece 30 by ultrasonic vibration. Therefore, also in the third and fourth embodiments, the bent piece 30 is attached to the welded portion 32
It can be welded to the back surface 3b via 33.

[0026]

As described above, according to the present invention, the end treatment of the skin material can be easily performed.

[Brief description of drawings]

FIG. 1 is a side cross-sectional view of a skin material-covered molded product, a receiving jig, and a holding jig, and a diagram showing a method of terminally treating the skin material.

FIG. 2 is a view showing an assembly flow chart of a skin material-covered molded product and a visor body of a vehicle sun visor.

FIG. 3 is a schematic perspective view of a molding die and a skin material.

FIG. 4 is a side sectional view showing a state in which a skin material is set in a molding die.

FIG. 5 is a partially enlarged perspective view showing a corner portion of a skin material-coated molded product.

FIG. 6 is a lateral cross-sectional view of a second embodiment of a skin material-covered molded product, a receiving jig, and a holding jig, and a diagram showing a method of terminal treatment of the skin material.

FIG. 7 is a partial cross-sectional perspective view of a skin material-coated molded product according to the third embodiment.

FIG. 8 is a side cross-sectional view of a skin material-covered molded product according to the fourth embodiment, and is a diagram showing a method of terminal treatment of the skin material.

[Explanation of symbols]

2 ... Skin material 2a ... Terminal 3 ... Core material 3a ... surface 3b ... back side 12 ... Receiving jig 30 ... bent pieces 30a ... bent end 31, 32, 33 ... Welded portion

Claims (4)

[Claims] 1. A method of manufacturing a skin material-covered molded product in which a skin material is joined to the surface of a core material formed into a product shape, wherein a bendable bending piece is provided on a peripheral portion of the core material. At the same time, the end portion of the skin material is joined to the surface of the bent piece, the end portion is bent together with the bent piece to the back side of the core material, and ultrasonic waves are applied to the bent end portion of the bent piece. A method for producing a skin-covered molded article, which is a method of plastically deforming by applying vibration, thereby holding the bent piece and the terminal portion on the back surface side of the core material. 2. The method for manufacturing a skin material-coated molded article according to claim 1, wherein the skin material is set in a cavity of a molding die, and the core material is filled in the cavity, thereby folding the material. A method for producing a skin material-covered molded article, comprising integrally molding a core material having a bent piece, and bonding the skin material to the surface of the core material that extends over the bent piece. 3. The method for manufacturing a skin material-covered molded article according to claim 1, wherein a part of the back surface of the core material is brought into proximity by bending the bent piece, and the bent piece. A welding part is provided between the two, and the welding part is melted by ultrasonic vibration applied when the bending piece is plastically deformed, whereby the bending piece and the back surface are welded via the welding part. A method for producing a skin-covered molded article, comprising: 4. A method for manufacturing a vehicle sun visor, in which a hollow shell-shaped visor body is molded using the skin material-covered molded product manufactured by the manufacturing method according to any one of claims 1 to 3.