JP2008000999A - Molding method for skin material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding method for a skin material which can further suppress the occurrence of wrinkles on the skin material. <P>SOLUTION: This molding method for the skin material 1 molds the skin material 1 into a solid shape by vacuum-sucking the skin material 1 onto a molding die 6 equipped with a recess section 5. A first pressing utensil 11 which presses a sacrifice section 10 going along a bent section 9 on the inner peripheral surface 13 of the recess section 5 of a sacrifice section 8 of the skin material 1 which is vacuum-sucked onto the bottom surface peripheral edge section of the recess section 5 is prepared. At the same time, the side edge 12E of the pressing surface 12 of the first pressing utensil 11 is formed into a bent shape going along the bent section 9 on the inner peripheral surface 13 of the recess section 5 in advance. When the skin material 1 is vacuum-sucked, the sacrifice section 10 is pressed by the pressing surface 12 under a state in which the side edge 12E of the pressing surface 12 is made to go along the bent section 9 on the inner peripheral surface 13 of the recess section 5. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention
The present invention relates to a method for molding a skin material in which a skin material is vacuum-adsorbed to a molding die having a recess to form a three-dimensional shape.

  The skin material is used as a skin material for an instrument panel of an automobile in which various meters are incorporated. An instrument panel of an automobile consists of a skin material, a base material that is a core material, and a foam interposed between the two, and after forming the skin material into a three-dimensional shape by the above-described vacuum adsorption, The foamed resin stock solution is supplied between the set base material and the skin material and foamed to integrate the skin material and the base material (there is another manufacturing method that integrates by adhesion or the like). The part of the skin material adsorbed on the bottom surface of the concave portion of the mold becomes a parting part, and after the skin material and the base material are integrated, the parting part is cut and removed to form openings in the skin material. Meters are incorporated.

  Since the skin material of the instrument panel is visible to the passenger, it is necessary to prevent wrinkles and the like from being formed on the skin material. However, in the means for vacuum-sucking the skin material with the molding die and molding it into a three-dimensional shape, the part of the skin material vacuum-sucked to the peripheral edge of the bottom surface of the concave portion of the molding die is positioned at or near the bent portion of the recess An excessive force is applied to a part of the parting part, and wrinkles are generated, and the part of the wrinkle is easily formed also in the skin material part that is a product connected to the parting part. Therefore, the parting part is pressed by the pressing surface of the pressing tool during vacuum suction of the skin material.

  Conventionally, the pressing portion of the pressing tool is formed in a simple block shape having a circular cross section, and the pressing surface is formed in a circular shape.

  According to the above-mentioned conventional means, since the parting part is pressed by the pressing tool having a circular pressing surface, the corner (ridge part) of the bent part of the concave part of the mold and the parting part located on both sides thereof are It was impossible to press all at once, and an insufficiently pressed portion was formed around the corner and the surrounding area, which sometimes caused wrinkles.

  An object of the present invention is to provide a method for forming a skin material capable of suppressing the occurrence of wrinkles in the skin material.

The feature of the first invention is
A skin material molding method for forming a three-dimensional shape by vacuum-adsorbing a skin material on a mold having a recess,
A first pressing tool that presses a parting part along the bent part of the inner peripheral surface of the concave part among the parting parts of the skin material vacuum-adsorbed to the bottom peripheral edge of the concave part, and the first pressing tool The side edge of the pressing surface is formed in a bent shape along the bent portion of the inner peripheral surface of the concave portion, and the side edge of the pressing surface is changed to the inner peripheral surface of the concave portion during vacuum suction of the skin material. It is in the point which presses the said parting part with the said press surface in the state along the bending part.

  According to this configuration, since the side edge of the pressing surface of the first pressing tool is along the bent portion of the inner peripheral surface of the concave portion of the molding die, the parting portion is pressed by the pressing surface. It is possible to press the corners (ridges) of the bent portion of the inner peripheral surface and the parting parts located on both sides thereof (the part of the inner peripheral surface of the concave part along the bent part) at once. It can be avoided that an insufficiently pressed portion occurs in the portion.

The feature of the second invention is:
A skin material molding method for forming a three-dimensional shape by vacuum-adsorbing a skin material on a mold having a recess,
Among the parting parts of the skin material vacuum-adsorbed to the bottom peripheral part of the concave part, a second pressing tool that presses the parting part along the bent part of the bottom surface of the concave part is prepared, and the pressing of the second pressing tool The surface is formed in a bent shape along the bent portion of the bottom surface of the concave portion, and the part to be cut off is pressed by the pressing surface during vacuum suction of the skin material.

  According to this configuration, the pressing surface of the second pressing tool is formed in a bent shape along the bent portion of the bottom surface of the concave portion, and the part of the parting off is performed on the pressing surface during vacuum suction of the skin material. Since it presses, the corners (ridges) of the bent portion of the bottom surface of the recess and the parting parts located on both sides thereof (parting portion along the bent part of the bottom surface of the recess) can be pressed at once, It is possible to avoid occurrence of an insufficiently pressed portion.

The feature of the third invention is
A skin material molding method for forming a three-dimensional shape by vacuum-adsorbing a skin material on a mold having a recess,
Of the parting parts of the skin material that are vacuum-adsorbed to the peripheral part of the bottom surface of the concave part, a third part that presses the parting part along the bent part of the inner peripheral surface of the concave part and along the bent part of the bottom surface of the concave part. A pressing tool is prepared, and the side edge of the pressing surface of the third pressing tool is formed in a bent shape along the bent portion of the inner peripheral surface of the recess, and the pressing surface of the third pressing tool is Formed in a bent shape along the bent portion of the bottom surface of the recess, and in the state of the side edge of the pressing surface along the bent portion of the inner peripheral surface of the recess in the vacuum suction of the skin material, The point is that the parting part is pressed by the pressing surface.

  According to this configuration, the side edge of the pressing surface of the third pressing tool is formed in a bent shape along the bending portion of the inner peripheral surface of the concave portion, and the pressing surface of the third pressing tool is formed on the concave portion. In the state where the side edge of the pressing surface is aligned with the bent portion of the inner peripheral surface of the concave portion during vacuum suction of the skin material, Since the parting part is pressed by the surface, the corner (ridge part) of the bent part on the inner peripheral surface of the concave part and the parting part located on the sides on both sides thereof, that is, the corner (ridge part) of the bent part on the bottom surface of the concave part And the parting part (the parting part along the bent part of the inner peripheral surface of the concave part and the part of the bent part of the bottom surface of the concave part) located on both sides thereof can be pressed at once. It is possible to suppress the occurrence of insufficient portions.

  In the first or third aspect of the invention, if the bent portion of the inner peripheral surface of the concave portion is a convex bent portion, the corner (ridge portion) of the convex bent portion and the parting part located on the sides of both sides thereof Can be pressed at a time, and it can be avoided that an insufficiently pressed portion is formed in the parting portion.

According to the first aspect of the present invention, it is possible to avoid the occurrence of an insufficiently pressed portion by the pressing tool at the parting portion along the bent portion of the inner peripheral surface of the concave portion of the mold, so that the occurrence of wrinkles in the skin material can be suppressed. Can provide a method of forming the skin material,
According to the second aspect of the invention, since it is possible to avoid occurrence of an insufficiently pressed portion by the pressing tool at a parting portion along the bent portion of the bottom surface of the concave portion of the molding die, the skin material capable of suppressing the occurrence of wrinkles in the skin material. Can provide a molding method of
According to the third aspect of the present invention, it is avoided that an insufficiently pressed portion by the pressing tool is generated along the bent portion of the inner peripheral surface of the concave portion of the mold and along the bent portion of the bottom surface of the concave portion. Therefore, it was possible to provide a method for forming a skin material capable of suppressing the generation of wrinkles in the skin material.

  Hereinafter, the best mode for carrying out the present invention will be described with reference to the drawings. 1 and 2 show an instrument panel 100 of an automobile. The instrument panel 100 includes a skin material 1, a base material 2, and a polyurethane 3 as a foam interposed between the two, and includes a plurality of openings 4 into which various meters are incorporated. Reference numeral 45 is an upper surface portion, 46 is a front surface portion, and 47 is a bulging portion slightly swollen upward. The skin material 1 is made of thermoplastic olefin (TPO) or polyvinyl chloride having a thickness of 0.3 mm to 1.5 mm, and has a texture pattern on the surface (not limited to the above numerical values and materials).

  When manufacturing the instrument panel 100, after forming the skin material 1 into a three-dimensional shape by a vacuum suction molding method, supply a foamed resin stock solution (urethane stock solution) between the base material 2 and the skin material 1 set in a mold. -The skin material 1 and the base material 2 are integrated by foaming.

Next, three molding methods (skin material molding method (1), skin material molding method (2), skin material molding method (3)) of the skin material 1 of the present invention will be described. For simplification of description, only a part of the lower mold 6 is shown and described, but the other part of the skin material 1 is molded by the same molding method. In any of the three molding methods ((1) to (3)),
[1] Heat the square sheet-shaped skin material 1 from the outside of the upper and lower surfaces (from both the upper and lower sides) in an oven until the softening temperature is reached,
[2] The heated skin material 1 is placed between an upper mold (not shown) and a lower mold 6 (corresponding to a mold) provided with a recess 5 to lower the upper mold and lower mold 6 Raise
[3] The skin material 1 is vacuum-adsorbed to the lower die 6 in a state where the skin material 1 is superposed on the lower die 6.

[Molding method (1) of skin material 1]
FIG. 3 shows a part of the lower mold 6. In FIG. 3, reference numeral 7 denotes a peripheral edge of the bottom surface of the recess 5 of the lower mold 6, and 13 denotes an inner peripheral surface of the recess 5 (also referred to as an inner wall surface, hereinafter the same in the molding methods (1) to (3)), 9 Is a bent portion of the inner peripheral surface 13 of the recess 5, and 14 is a bottom surface of the recess. FIG. 4 shows the skin material 1 after molding. Reference numeral 8 denotes a parting part of the skin material 1 that is vacuum-sucked to the bottom peripheral edge part 7 of the concave part 5 of the lower mold 6, and reference numeral 48 denotes another parting part. The parting parts 8 and 48 are cut and removed from the skin material 1 after the skin material 1, the base material 2, and the polyurethane 3 are integrated. Reference numeral 18 denotes a projecting portion of the skin material 1 projecting in the lateral direction.

The above-described forming method will be described in detail. As shown in FIGS. 5A and 5B, among the parting portions 8 of the skin material 1 vacuum-adsorbed to the bottom peripheral edge portion 7 of the recess 5, the recess 5 While preparing the 1st press tool 11 which presses the parting part 10 along the convex-shaped bending part 9 of the inner peripheral surface 13 of this, the side edge 12E of the press surface 12 of the 1st press tool 11 is made into the inner periphery of the recessed part 5. It is formed in a bent shape along the bent portion 9 of the surface 13. The convex bent portion 9 is a bent portion formed on the overhang portion 18 (see FIGS. 1 and 4) of the skin material 1. The first pressing tool 11 includes a rod-shaped main body portion 16 and a U-shaped pressing portion 17 provided on the distal end side of the main body portion 16 (this pressing portion 17 is a pair of pressing portions having an L-shaped cross section). It may consist of). The front end surface of the pressing portion 17 is the pressing surface 12. Then, when the skin material 1 is vacuum-sucked, the side edge 12E of the pressing surface 12 is closed along the bending portion 9 of the inner peripheral surface 13 of the recess 5 (see FIG. 5 (a)). Press the portion 10. That is, the skin material 1 is vacuum-adsorbed to the lower mold 6 while pressing the parting portion 10 with the pressing surface 12 while the side edge 12E of the pressing surface 12 is along the bent portion 9 of the inner peripheral surface 13 of the recess 5. To do. When pressing the parting portion 10 with the pressing surface 12 of the first pressing tool 11 as described above, the side edge 12E of the pressing surface 12 and the bent portion 9 of the inner peripheral surface 13 are separated by 5 to 10 mm, The parting part 10 is pressed by the pressing surface 12. Reference numeral 19 denotes an air flow path for vacuum suction. The first pressing tool 11 is provided on the upper mold side and operates so as to press the first parting part 10.
As shown by the two-dot chain line in FIG. 5 (b), the bar-shaped main body 16 of the first pressing tool 11 is provided obliquely with respect to the pressing part 17, and the two-dot chain arrow in FIG. 5 (b). The position of the first pressing tool 11 may be changed in this direction to press the pressing surface 12. According to this configuration, it is possible to make it difficult for the pressing portion 17 to interfere with a portion that is a product of the skin material 1 (a portion that overlaps the bent portion 9 of the inner peripheral surface 13). Therefore, the parting part 10 can be pressed by the pressing surface 12 with the side edge 12E of the pressing surface 12 being brought closer to the bent portion 9 of the inner peripheral surface 13.

  When the bent portion 9 of the inner peripheral surface 13 of the concave portion 5 is L-shaped, the pressing portion 17 is formed in an L-shaped cross section. When the bent portion 9 is concave, the first pressing tool 11 that presses the parting portion 10 along the concave bent portion 9 is prepared and the pressing surface 12 of the first pressing tool 11 is not shown. The side edge 12E is formed in a bent shape along the concave bent portion 9, and is molded by the same method as described above. Each concave portion 5 of the lower mold 6 includes the bottom peripheral edge portion 7, the inner peripheral surface 13, and the bent portion 9 of the inner peripheral surface 13, and therefore follows the bent portion 9 of the inner peripheral surface 13 of each concave portion 5. The parting part 10 is pressed by the first pressing tool 11 and vacuum suction is performed.

[Molding method (2) of skin material 1]
FIG. 6 shows a part of the lower mold 6. In FIG. 6, reference numeral 7 indicates a peripheral edge of the bottom surface of the recess 5 of the lower mold 6, 13 indicates an inner peripheral surface of the recess 5, and 24 indicates a bent portion of the bottom surface 14 of the recess 5.

  The above-described forming method will be described in detail. As shown in FIGS. 7A and 7B, among the parting portions 8 of the skin material 1 that is vacuum-sucked to the bottom peripheral edge portion 7 of the recess 5, the recess 5 The second pressing tool 22 that presses the parting portion 10 along the convex bent portion 24 of the bottom surface 14 of the bottom surface 14 is prepared, and the pressing surface 23 of the second pressing tool 22 extends along the bent portion 24 of the bottom surface 14 of the concave portion 5. It is formed in a bent shape. The second pressing tool 22 includes a rod-shaped main body portion 26 and a pressing portion 27 having an L-shaped longitudinal section provided on the distal end side of the main body portion 26. When the skin material 1 is vacuum-adsorbed, the parting part 10 is pressed by the pressing surface 23. That is, the skin material 1 is vacuum-sucked to the lower mold 6 while pressing the parting portion 10 with the pressing surface 23. The second pressing tool 22 is provided on the upper mold side and operates to press the parting part 10.

  When the bent portion 24 of the bottom surface 14 is concave, the second pressing tool 22 that presses the parting part 10 along the concave bent portion 24 is prepared, and the pressing surface 23 of the second pressing tool 22 is not shown. Is formed in a bent shape along the concave bent portion 24 and molded by the same method as described above. For example, when the bent portion 24 is W-shaped, the pressing surface 23 is formed in a W-shaped longitudinal section. When each recessed part 5 of the lower mold 6 includes a plurality of bent portions 24 of the bottom surface 14, the second pressing tool 22 performs pressing and vacuum suction on the parting portion 10 along each bent portion 24. Do.

[Forming method of skin material (3)]
With respect to this molding method, the skin material 1 having a different shape (the shape of the right end toward the skin material 1) from the skin material 1 shown in [Method of molding skin material 1 (1)] is molded. An example of the case will be described. FIG. 8 shows a part of the lower mold 6. In FIG. 8, reference numeral 7 is a peripheral edge of the bottom surface of the recess 5 of the lower mold 6, 13 is an inner peripheral surface of the recess 5, 9 is a bent portion of the inner peripheral surface 13 of the recess 5, and 24 is a bent portion of the bottom surface 14 of the recess 5. It is.

  The above forming method will be described in detail. As shown in FIGS. 9A and 9B, among the parting portions 8 of the skin material 1 that are vacuum-adsorbed to the bottom peripheral edge portion 7 of the recess 5, the recess 5 A third pressing tool 33 that presses the parting portion 10 along the bent portion 9 of the inner peripheral surface 13 and along the bent portion 24 of the bottom surface 14 of the recess 5 is prepared, and the pressing surface 34 of the third pressing tool 33 is prepared. The side edge 34E is formed in a bent shape along the bent portion 9 of the inner peripheral surface 13 of the concave portion 5, and the pressing surface 34 of the third pressing tool 33 is bent along the bent portion 24 of the bottom surface 14 of the concave portion 5. Form in shape. The third pressing tool 33 includes a rod-shaped main body portion 36 and a pressing portion 37 having an L-shaped longitudinal section provided on the distal end side of the main body portion 36. When the skin material 1 is vacuum-adsorbed, the pressing surface 34 is in a state where the side edge 34E of the pressing surface 34 is along the bent portion 9 of the inner peripheral surface 13 of the recess 5 (see FIG. 9A). Then, the parting part 10 is pressed. That is, the skin material 1 is vacuum-adsorbed to the lower mold 6 while pressing the parting portion 10 with the pressing surface 34 in a state where the side edge 34E of the pressing surface 34 is along the bent portion 9 of the inner peripheral surface 13 of the recess 5. To do. The third pressing tool 33 is provided on the upper mold side and operates to press the parting part 10.

[Another embodiment]
(1) The above three molding methods ((1) to (3)) may be performed all at once when one skin material 1 is molded.
(2) As described above, various shapes corresponding to the shapes of the bent portions 9 and 24 can be employed for the shape of the pressing surface and the shape of the side edge of the pressing surface.

Instrument panel perspective view AA sectional view of FIG. Perspective view of part of lower mold Perspective view of molded skin material (A) is a figure which shows the shaping | molding method (1) of a skin material, (b) is AA sectional drawing of Fig.5 (a). Perspective view of part of lower mold (A) is a figure which shows the shaping | molding method (2) of a skin material, (b) is BB sectional drawing of Fig.7 (a). Perspective view of part of lower mold (A) is a figure which shows the shaping | molding method (3) of a skin material, (b) is CC sectional drawing of Fig.9 (a).

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Skin material 2 Base material 3 Polyurethane 4 Opening 5 Recessed part (recessed part of mold)
6 Lower mold (molding mold)
Reference numeral 7: bottom peripheral edge portion of the recess 8, 48 parting part 9 bending part 10 on the inner peripheral surface of the recess parting part 11 first pressing tool 12 pressing surface 12E of the first pressing tool peripheral edge 13 of pressing surface inner peripheral surface 14 of the concave part Bottom 16 Main body portion 17 of first pressing tool First pressing tool pressing portion 18 Overhang portion 22 Second pressing tool 23 Pressing surface 24 of second pressing tool Bending portion 26 of bottom surface of concave portion 27 Main body portion 27 of second pressing tool 2 pressing part 33 pressing part 34 third pressing tool pressing surface 34E pressing surface side edge 36 third pressing tool main body 37 third pressing tool pressing surface 45 instrument panel upper surface 46 instrument Instrument panel front 47 Instrument panel bulge 100 Instrument panel

Claims (4)

A skin material molding method for forming a three-dimensional shape by vacuum-adsorbing a skin material on a mold having a recess,
A first pressing tool is provided that presses a parting part along the bent part of the inner peripheral surface of the concave part among the parting parts of the skin material vacuum-adsorbed on the peripheral edge of the bottom surface of the concave part, and the first pressing tool. The side edge of the pressing surface is formed in a bent shape along the bent portion of the inner peripheral surface of the concave portion, and the side edge of the pressing surface is changed to the inner peripheral surface of the concave portion during vacuum suction of the skin material. A method for forming a skin material in which the parting part is pressed by the pressing surface in a state along the bent part. A skin material molding method for forming a three-dimensional shape by vacuum-adsorbing a skin material on a mold having a recess,
Among the parting parts of the skin material vacuum-adsorbed to the bottom peripheral part of the concave part, a second pressing tool that presses the parting part along the bent part of the bottom surface of the concave part is prepared, and the pressing of the second pressing tool A method for forming a skin material, wherein a surface is formed in a bent shape along a bent portion of a bottom surface of the concave portion, and the cut-off portion is pressed by the pressing surface during vacuum suction of the skin material. A skin material molding method for forming a three-dimensional shape by vacuum-adsorbing a skin material on a mold having a recess,
Of the parting parts of the skin material that are vacuum-adsorbed to the peripheral part of the bottom surface of the concave part, a third part that presses the parting part along the bent part of the inner peripheral surface of the concave part and along the bent part of the bottom surface of the concave part. A pressing tool is prepared, and the side edge of the pressing surface of the third pressing tool is formed in a bent shape along the bent portion of the inner peripheral surface of the recess, and the pressing surface of the third pressing tool is Formed in a bent shape along the bent portion of the bottom surface of the recess, and in the state of the side edge of the pressing surface along the bent portion of the inner peripheral surface of the recess in the vacuum suction of the skin material, A method for forming a skin material in which the parting part is pressed by a pressing surface.   The method for molding a skin material according to claim 1 or 3, wherein the bent portion of the inner peripheral surface of the concave portion is a convex bent portion.

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