JP2018039245A - Method for producing skin-fitted product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To roll a terminal part of a skin in a base material without reloading an intermediate product passed through a trimming step.SOLUTION: In a size enlargement step, a pre-molded base material 12 is mounted on a vacuum molding die 31 in a rear face 18 of the base material 12, further, a skin material 20 is arranged on the side of a surface 17 of the base material 12, thereafter, the skin material 20 is sucked through the vacuum molding die 31 and the base material 12, thus a main part 22 of the skin material 20 is deformed so as to be adhered to the surface 17 of the base material 12. In a trimming step following the size enlargement step, while retaining the base material 12 to a state of being mounted on the vacuum molding die 31, a residual part 24 not adhered to the surface 17 in the skin material 20 is cut with a trim blade 46 in such a manner that a terminal part 23 is left around the main part 22, thus a skin 21 having the terminal part 23 is formed. In a rolling-in step following the trimming step, while retaining the base material 12 to a state of being mounted on the vacuum molding die 31, the terminal part 23 of the skin 21 is rolled in the side of the rear face 18 of the base material 12 by a rolling-in mechanism 35.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a method for manufacturing a product with an outer skin in which a main part of an epidermis is covered on the surface of a base material and a terminal part around the main part of the epidermis is wound on the back side of the base material.

As a method for manufacturing this type of skin-attached product, a method in which a shaping process, a trimming process, and a winding process are sequentially performed is known (for example, see Patent Document 1).
In the shaping step, a preformed base material is mounted on a vacuum forming die on the back surface of the base material, and a skin material, which is a skin material, is disposed on the surface side of the base material. The skin material is sucked through the vacuum forming die and the base material, so that the main part of the skin material is deformed so as to be in close contact with the surface of the base material.

  In the trimming process, the base material is maintained in a state where it is mounted on the vacuum mold, and trimming is performed so that the surplus portion of the skin material that is not in close contact with the surface of the base material remains at the periphery of the main part. Cut with a blade. By this cutting, a skin having a terminal portion is formed.

  In the winding process, the intermediate product that has undergone the trimming process is transferred from the vacuum forming die to a dedicated jig, and the terminal portion of the skin is bent by the jig and wound on the back side of the substrate.

JP 2007-160595 A

  However, in the manufacturing method described in Patent Document 1, it is expensive to introduce a dedicated jig for winding the terminal portion of the skin. In addition, when winding the terminal portion of the skin, a step of replacing the intermediate product that has undergone the trimming step from the vacuum forming die to the jig is necessary, and there is a problem that the number of manufacturing steps increases accordingly.

  The present invention has been made in view of such circumstances, and the object thereof is a product with a skin capable of winding a terminal portion of the skin around a base material without replacing an intermediate product that has undergone a trimming process. It is in providing the manufacturing method of.

  The manufacturing method of the product with a skin which solves the above-mentioned problem is formed by covering the main part of the skin on the surface of the base material and winding the terminal part around the main part of the skin on the back side of the base material. A method for producing a product with a skin, wherein a base material that has been molded in advance is mounted on a vacuum forming mold on the back surface of the base material, and a skin material that is a material of the skin is provided on the surface side of the base material. After the placement, the shaping step of drawing the skin material through the vacuum mold and the base material to deform the main part of the skin material so as to be in close contact with the surface of the base material, and the shaping After passing through the process, while maintaining the base material in a state where it is mounted on the vacuum forming die, an excess portion of the skin material that is not in close contact with the surface of the base material is disposed around the main part. By cutting with a trim blade so that the part remains. A trimming step for forming the skin having the terminal portion, and a mechanism for entraining the terminal portion of the skin while maintaining the base material mounted on the vacuum forming die after the trimming step. And a winding step of winding on the back side of the substrate.

  According to the above manufacturing method, after the shaping step and the trimming step are sequentially performed using the vacuum forming die, the winding step is performed using the vacuum forming die, so that the main part of the skin is based. A product with a skin is produced, which is placed on the surface of the material and the end portion of the skin is wound on the back side of the base material. In this way, the shaping process, the trimming process, and the winding process are performed using a common vacuum forming mold when the expression is changed in a state where the base material is mounted on the vacuum forming mold. Therefore, unlike the case where the winding process is performed using a dedicated jig provided separately from the vacuum forming die, a dedicated jig is not required. In addition, the intermediate product that has undergone the trimming process does not have to be transferred from the vacuum forming die to a dedicated jig for winding the terminal portion.

  In the method for manufacturing a product with a skin, the base material has a flat boundary surface at the boundary with the front surface, and the trim blade can reciprocate in the direction along the boundary surface. In the trimming step, it is preferable to perform cutting by moving the trim blade along the boundary surface toward the surplus portion and pressing the trim blade against the surplus portion.

  Here, in the trimming process, if the trim blade is moved in a direction perpendicular to the boundary surface of the base material, the excess portion is cut so that the terminal portion remains around the main portion, the terminal portion is , A portion that is adjacent to the main portion and orthogonal to the boundary surface, and a portion that is adjacent to the portion opposite to the main portion and parallel to the boundary surface. The terminal portion becomes longer by the amount of this parallel portion, and as a result, the terminal portion may become longer in a transient manner.

  In this regard, according to the above manufacturing method, a trim blade that can reciprocate in the direction along the boundary surface of the base material is used. In the trimming step, the trim blade is moved along the boundary surface toward the surplus portion and is pressed against the surplus portion. The surplus portion is cut, and the terminal portion remains around the main portion. This terminal portion is constituted only by a portion adjacent to the main portion and orthogonal to the boundary surface. Therefore, the terminal portion does not have a portion parallel to the boundary surface, and the terminal portion is shortened accordingly. As a result, it is possible to suppress the terminal portion from becoming transiently long.

  In the manufacturing method of a product with a skin, the peripheral portion of the base material connects a plurality of straight portions and the adjacent straight portions, and has a plurality of curved corners having a circumferential length shorter than the length of the straight portions. A first trim blade that cuts a portion corresponding to the linear portion of the base material of the surplus portion of the skin material as the trim blade, and a corner portion of the base material. A second trim blade that cuts a corresponding portion, and in the trimming step, the first trim is cut after the surplus portion is cut by the second trim blade while suctioning the skin material by vacuuming. It is preferable to cut the surplus portion with a blade.

  Here, if the cutting of the surplus portion by the first trim blade and the cutting of the surplus portion by the second trim blade adjacent to the first trim blade are performed simultaneously, the first trim blade and the second trim blade approach each other. May interfere with each other.

  In this regard, according to the manufacturing method described above, the cutting with the first trim blade and the cutting with the second trim blade are performed at different timings. For this reason, interference between the first trim blade and the second trim blade hardly occurs.

Moreover, said cutting | disconnection is performed in the state by which the skin material was attracted | sucked by vacuum drawing and the surplus part was pulled by the back surface side of the base material.
However, when the surplus portion is cut while being evacuated, a considerable amount of air is sucked from the cut portion. The force that pulls the surplus portion toward the back side of the substrate is lower than that before cutting, and the surplus portion tends to return to the shape before being pulled by vacuuming.

  As the length of the cut portion increases, the amount of air that is sucked increases, and the degree of reduction in the force that pulls the surplus portion toward the back side of the substrate increases. The length of the part to be cut is shorter than the part corresponding to the straight line part in the part corresponding to the corner part of the base material in the surplus part. The former part is cut first by the second trim blade, and the latter part is cut later by the first trim blade. Therefore, the force for pulling the surplus portion to the back side of the base material before the cutting of the surplus portion is completed compared to the case where the cutting with the first trim blade is performed first and the cutting with the second trim blade is performed later. It becomes difficult to decrease. The surplus portion is unlikely to return to the shape before being pulled by evacuation. In connection with this, the terminal part formed by cut | disconnecting an excessive part also approaches the back surface of a base material.

Therefore, in the winding process performed subsequent to the trimming process, the terminal portion of the skin is suitably wound on the back surface side of the base material by the winding mechanism.
In the manufacturing method of the product with skin, in the winding step, the terminal portion is pushed in a direction orthogonal to the boundary surface by the winding mechanism, and the terminal portion is placed on the back surface including the boundary surface of the base material. It is preferable that the terminal portion is wound by being deformed so as to be in close contact.

  According to the above manufacturing method, in the winding process, the terminal portion of the skin is pushed by the winding mechanism in a direction perpendicular to the boundary surface of the base material while the base material is mounted on the vacuum forming die. The pushed terminal portion is deformed so as to be in close contact with the back surface including the boundary surface of the base material. In this way, the end portion of the skin is wound around the back surface side of the base material without the intermediate product having undergone the trimming process being replaced.

  In the method for manufacturing a product with a skin, the entrainment step is performed in a state where an adhesive is applied to at least a portion of the back surface of the base material where the end portion is to be entrained, and in the entrainment step, It is preferable that the operation of pushing the terminal portion by the winding mechanism to wind is performed in a state in which the base material is restricted from moving in the pushing direction.

Here, in order to firmly adhere the terminal portion pressed by the winding mechanism to the back surface of the base material to which the adhesive is applied, it is important that the terminal portion is strongly pressed against the base material.
In this regard, according to the above manufacturing method, the base material is restricted from moving in the direction of pushing the terminal portion by the winding mechanism. Since the terminal portion is pressed by the winding mechanism in this state, it is strongly pressed against the base material. As a result, the terminal portion is firmly bonded (crimped) to the back surface of the base material.

  In the manufacturing method of a product with a skin, in the winding step, the vacuum forming die is used as the base material in which a rib is formed at a location different from a location where the terminal portion is in close contact with the back surface. By gripping the rib by the chuck mechanism provided in the base, the base member is prevented from moving in the direction in which the terminal portion is pushed by the winding mechanism, and in this state, the terminal portion can be pushed and wound. preferable.

  According to the manufacturing method described above, in the winding process, the rib formed at a location different from the location where the terminal portion is in close contact with the back surface of the substrate is gripped by the chuck mechanism provided in the vacuum forming die. The base material is restricted from moving in the direction in which the terminal portion is pushed by the winding mechanism.

  In the manufacturing method of a product with a skin, the shaping step is performed using a part that is part of the vacuum forming die and provided with a plug that can reciprocate in a direction orthogonal to the boundary surface. Then, the plug is moved to a place where the base material is supported from the back side, and in the trimming step, the plug is retracted to a place off the movement path of the trim blade, and in the winding step, the plug is moved. It is preferable to move the base material from the back side to the place where it is supported.

According to said manufacturing method, the part (remaining part) different from a plug among vacuum forming dies supports a base material from the back surface side also in any of a shaping process, a trimming process, and a winding process.
Moreover, the plug which makes each part of a vacuum forming die and a winding mechanism operate | moves as follows.

In the shaping process, the plug is moved from the back side to the place where the base is supported. Therefore, the base material can be attached to the vacuum forming plug and the remaining portion.
In the trimming step, the plug is retracted to a position off the movement path of the trim blade while the base material is mounted on the remaining portion of the vacuum forming die. For this reason, the plug is unlikely to obstruct cutting of the excess portion by the trim blade.

  In the winding process, the plug is moved from the back surface side to the place where the base material mounted on the remaining portion of the vacuum forming die is supported. During this movement, the end portion of the skin is pushed into the back side of the base material by the plug, whereby the winding is performed.

  In the method for manufacturing a product with a skin, the trim blade has a plurality of teeth arranged in a row, the tip of each tooth is pointed, and the valley between adjacent teeth is a blade. In the trimming step, it is preferable to perform cutting by pressing each tooth of the trim blade against the surplus portion.

  Here, it is assumed that the trim blade is formed in a state where a plurality of teeth having a triangular plate shape with a sharp tip are arranged in a row, and the angle of the blade at the valley of each tooth is the tooth angle. There are the following concerns when the one that grows closer to the root is used. That is, when each tooth is pressed against the surplus part of the skin material, each tooth enters while cutting the epidermis, and in the trough, the surplus part becomes difficult to cut as it approaches the root part of the tooth, and it is torn off. There is a possibility of generating waste.

  In this regard, according to the above manufacturing method, in the trimming step, the trim blade having the above-described configuration is used and each tooth is pressed against the surplus portion. Then, since the blade angle is uniform in the trough, the surplus portion is cut uniformly regardless of the tooth portion. The surplus portion is cut cleanly with the terminal portion remaining around the main portion without the surplus portion being torn off. It is difficult for waste to be generated due to the excess part being torn off.

  According to the method for manufacturing a product with a skin, the terminal portion of the skin can be wound around the base material without replacing the intermediate product that has undergone the trimming process.

It is a figure which shows 1st Embodiment of the manufacturing method of a product with a skin, (a) a partial sectional view which abbreviate | omits and shows a part of product with a skin, (b) expanded a part of FIG. 1 (a). (C) is a top view of a product with a skin. The fragmentary sectional view explaining the shaping process in a 1st embodiment. Similarly, the fragmentary sectional view explaining the shaping process in a 1st embodiment. (A) is a fragmentary perspective view of the trim blade in 1st Embodiment, (b) is a fragmentary sectional view of the tooth | gear in the trim blade of Fig.4 (a), (c) is a fragmentary perspective view of the trim blade of a comparative example. The fragmentary sectional view explaining the trimming process in a 1st embodiment. Similarly, the fragmentary sectional view explaining the trimming process in a 1st embodiment. The fragmentary sectional view explaining the winding process in 1st Embodiment. In 1st Embodiment, the fragmentary sectional view explaining the state which takes out the product with a skin from a vacuum forming die. It is a figure explaining a mode that a surplus part of skin material is cut with a trim blade, and (a) is a fragmentary sectional view showing a case where a trim blade is moved in the direction which meets a boundary surface of a substrate in a 1st embodiment. (B) is a fragmentary sectional view which shows the case where a trim blade is moved in the direction orthogonal to a boundary surface in a comparative example. The schematic plan view explaining the trimming process in 2nd Embodiment of the manufacturing method of a product with a skin. Similarly, the schematic plan view explaining the trimming process in 2nd Embodiment. The fragmentary sectional view explaining the winding-in process in 3rd Embodiment of the manufacturing method of a product with skin.

(First embodiment)
Hereinafter, 1st Embodiment of the manufacturing method of a product with an outer skin is described with reference to FIGS.

<About products with skin>
First, a product with a skin manufactured by the manufacturing method of the first embodiment will be described. As shown in FIGS. 1 (a) to 1 (c), a product 11 with an epidermis is obtained by integrating a base material 12 forming a skeleton part with an epidermis 21 having good decorativeness and touch feeling.

  The main body 13 occupying most of the base material 12 is gently curved so that the central portion bulges more to the front side (upper side in FIG. 1A) than the peripheral portion. The substrate 12 has a peripheral edge 14 around the main body 13. The peripheral edge portion 14 is curved toward the back side of the substrate 12 (the lower side in FIG. 1A). The peripheral edge portion 14 includes a plurality of linear portions 15 and a plurality of corner portions 16 that are located between the adjacent linear portions 15 and connect the two linear portions 15.

  The substrate 12 has a front surface 17 and a back surface 18. The back surface 18 has a flat boundary surface 18 a at the boundary portion with the front surface 17. The boundary surface 18 a is located at a position farthest from the main body portion 13 in the peripheral edge portion 14 of the base material 12.

As the base material 12, a non-breathable material having a vacuum hole or a material made of a breathable material such as a wood-based material is used.
The epidermis 21 includes a main part 22 occupying most of the skin 21 and a terminal part 23 around the main part 22. The main part 22 is put on the front surface 17 of the base material 12, and the terminal part 23 is wound on the back surface 18 side of the base material 12.

  As the skin 21, a non-breathable synthetic resin sheet or a material with a cushion layer lined on the back surface of the non-breathable synthetic resin sheet is used. For example, a polyethylene sheet is lined on the back surface of a TPO (thermoplastic olefin) sheet, and a laminated sheet material excellent in soft feeling can be mentioned.

Examples of the product with skin 11 having such a configuration include interior parts for automobiles such as door trims.
<About the manufacturing apparatus 30>
Next, the manufacturing apparatus 30 used for manufacturing the product with skin 11 will be described.

As shown in FIG. 2, the manufacturing apparatus 30 includes a vacuum forming die 31 having a vacuum suction mechanism (not shown), and an upper die 41 disposed so as to be movable up and down above the vacuum forming die 31.
Projections 32 a and 32 b having a shape corresponding to the back surface 18 of the substrate 12 are formed on the upper part of the vacuum mold 31. These protrusions 32a and 32b are places where the base material 12 is mounted in the shaping process. The vacuum forming die 31 is provided with a winding mechanism 35 for winding the terminal portion 23 of the skin 21 onto the back surface 18 side of the substrate 12. The winding mechanism 35 includes a plug 36 that forms a part of the vacuum forming die 31 and can reciprocate in the vertical direction, which is a direction orthogonal to the boundary surface 18 a of the base material 12. The plug 36 has the protrusion 32b at the upper end. If a portion different from the plug 36 in the vacuum forming die 31 is referred to as a remaining portion 37, a part of the remaining portion 37 has the protrusion 32 a at its upper end. In the remaining portion 37, a cutting groove 38 is formed below the protrusion 32a and on a movement path of the trim blade 46 described later.

  As shown in FIGS. 2 and 5, a recess 42 having a shape corresponding to the surface 17 of the substrate 12 is formed in the lower portion of the upper mold 41. In the upper mold 41, the surplus portion 24 that is not in close contact with the surface 17 of the base material 12 among the skin material 20 that is the material of the skin 21 is left, and the terminal portion 23 remains around the main portion 22 of the skin material 20. A cutting mechanism 45 for cutting is provided. The cutting mechanism 45 is arranged along the peripheral edge portion 14 (see FIG. 1C) of the base material 12 and in directions along the boundary surface 18a of the base material 12 (each left and right direction in FIGS. 2 and 5). A plurality of trim blades 46 that can reciprocate are provided. Each trim blade 46 is reciprocated by an actuator such as an air cylinder.

  As shown in FIGS. 4A and 4B, each trim blade 46 has a plurality of teeth 47 arranged in a row. The tip 48 of each tooth 47 is pointed. The valley portion 49 between the adjacent teeth 47 is formed in a curved state so that the blade angle θ2 is substantially the same as the blade angle θ1 at the tip portion 48 and is uniform regardless of the portion of the valley portion 49. Has been.

Furthermore, as shown in FIG. 3, the manufacturing apparatus 30 includes a clamp frame 51 that moves up and down while gripping the skin material 20.
Next, as an operation of the first embodiment, a method for manufacturing the skinned product 11 using the manufacturing apparatus 30 will be described together with effects.

In carrying out this method, a shaping step, a trimming step, and a winding step are sequentially performed. Next, each step will be described.
<Shaping process>
As shown in FIG. 2, prior to the shaping step, a base material 12 that has been previously molded into a predetermined shape is prepared. In the base material 12, an adhesive is applied to a place where the skin 21 is to be covered. Moreover, the skin material 20 softened by heating is prepared.

  The upper die 41 is raised and separated from the vacuum forming die 31 upward. The plug 36 is moved to the place where the base material 12 is supported from the back surface 18 side, and the height of the protrusion 32 b in the plug 36 is aligned with the height of the protrusion 32 a in the remaining portion 37 of the vacuum forming die 31. This height is a height at which the upper end surface of the protrusion 32b continues to the upper end surface of the protrusion 32a.

  The base material 12 is mounted on the protrusions 32a and 32b having the same height as described above on the back surface 18 thereof. The base material 12 is supported from the back surface 18 side by the plug 36 and the remaining portion 37 in the vacuum forming die 31.

  The skin material 20 is disposed on the surface 17 side of the substrate 12. As shown in FIG. 3, when the clamp frame 51 in a state of gripping the skin material 20 is lowered, the skin material 20 is around the protrusions 32 a and 32 b in the remaining portion 37 of the vacuum forming die 31. It is pressed to a place lower than them. Further, the upper mold 41 is moved (lowered) in the direction indicated by the two-dot chain line arrow in FIG.

  Then, as shown in FIG. 3, the skin material 20 is sucked through the vacuum forming die 31 and the base material 12 by operating the vacuum suction mechanism, that is, between the base material 12 and the skin material 20. The main part 22 of the skin material 20 is deformed so as to be in close contact with the surface 17 of the base material 12 by the air in the air being discharged. The deformed skin material 20 is bonded to the surface 17 of the substrate 12 by an adhesive.

<Trimming process>
In the trimming step performed after the shaping step, the plug 36 is moved in the direction indicated by the two-dot chain line arrow in FIG. 3 with the base material 12 mounted on the remaining portion 37 of the vacuum forming die 31. As a result, the trim blade 46 is retracted to a position off the moving path. Therefore, the plug 36 is unlikely to obstruct the cutting of the skin material 20 by the trim blade 46.

  The cutting mechanism 45 is activated, and the trim blade 46 is moved along the boundary surface 18a of the base member 12 toward the surplus portion 24 of the skin material 20 as shown by the two-dot chain line arrow in FIG. This movement is performed until the tip of the trim blade 46 enters the cutting groove 38 in the remaining portion 37 of the vacuum forming die 31, as shown in FIG. In the course of this movement, each tooth 47 (see FIG. 4A) of the trim blade 46 is pressed against the surplus portion 24. By this pressing, the surplus portion 24 is cut so that the terminal portion 23 remains around the main portion 22 of the skin material 20. Thereafter, the trim blade 46 is moved (retracted) to the side away from the cutting groove 38 along the boundary surface 18 a of the base material 12.

  Here, as the trim blade 55 of the comparative example, as shown in FIG. 4C, a plurality of teeth 56 having a pointed triangular plate shape of the tip portion 57 are arranged in a row, When the blade angle at the valley portion 58 of each tooth 56 becomes larger as it approaches the root portion of the tooth 56, there is the following concern. That is, when each tooth 56 is pressed against the surplus portion 24 of the skin material 20 from the front end portion 57 to the trough portion 58, each tooth 56 enters while cutting the surplus portion 24. As the base portion is approached, the surplus portion 24 becomes difficult to be cut and is torn off, and there is a possibility of generating waste.

  In this regard, in the first embodiment, the trim blade 46 shown in FIG. 4A is used and each tooth 47 is pressed against the surplus portion 24 of the skin material 20. Then, in the trough part 49, since the blade angle θ2 is uniform, the surplus portion 24 is cut uniformly regardless of the tooth 47 part. In the valley portion 49, as in the tip portion 48, the surplus portion 24 is cut cleanly with the terminal portion 23 remaining around the main portion 22 without being cut off. It is difficult for waste to occur due to the excess portion 24 being torn off.

  By the above cutting, the skin material 20 has a main portion 22 bonded to the surface 17 of the base material 12 and a skin 21 composed of a terminal portion 23 around the main portion 22 and a remaining portion pressed by the clamp frame 51. 25 (see FIG. 7). In this way, an intermediate product is obtained in which the skin 21 is bonded to the surface 17 of the substrate 12 at the main portion 22 and is not bonded to the substrate 12 at the terminal portion 23.

<Entrainment process>
In the winding process performed after the trimming process, the base material 12 in the intermediate product is maintained in a state of being attached to the remaining portion 37 of the vacuum forming die 31. The base material 12 continues to be supported from the back surface 18 side by the remaining portion 37.

  As shown in FIG. 7, the terminal portion 23 of the skin 21 is pushed upward by the winding mechanism 35, which is a direction orthogonal to the boundary surface 18 a of the base material 12. Specifically, the plug 36 is moved in the direction indicated by the two-dot chain line arrow in FIG. 6 to the place where the substrate 12 is supported from the back surface 18 side. During this movement, a part of the terminal portion 23 of the skin 21 is pushed into the back surface 18 side of the base material 12 by the plug 36. The terminal portion 23 is deformed so as to be in close contact with the back surface 18 including the boundary surface 18 a of the base material 12. Thus, if the terminal part 23 is wound in the back surface 18 side of the base material 12, and is adhere | attached on the back surface 18 of the base material 12 with an adhesive agent, the product 11 with a skin shown to FIG. Is obtained.

  As described above, the shaping step, the trimming step, and the winding step are performed using the common vacuum forming die 31 when the expression is changed in a state where the base material 12 is mounted on the vacuum forming die 31. Therefore, unlike Patent Document 1 in which the winding process is performed using a dedicated jig provided separately from the vacuum forming die, such a dedicated jig is not required. The cost for introducing the jig becomes unnecessary.

  Moreover, in order to wind up the terminal part 23, it is not necessary to transfer the intermediate product which passed through the trimming process from the vacuum forming die 31 to a dedicated jig. The process of replacing is unnecessary, and the number of manufacturing steps can be reduced accordingly.

  After the winding process, as shown in FIG. 8, the upper die 41 is raised with a cutting mechanism (not shown). Then, the skin-attached product 11 is taken out from the protrusions 32 a and 32 b of the vacuum forming die 31.

According to the first embodiment, the following operations and effects can be obtained in addition to the above.
As a comparative example, as shown in FIG. 9B, even if the trim blade 46 is moved in the vertical direction, which is a direction orthogonal to the boundary surface 18a of the base material 12, the surplus portion 24 of the skin material 20 is It can cut | disconnect so that the terminal part 23 may remain around the main part 22. FIG. However, in this case, the terminal portion 23 is adjacent to the main portion 22 and is perpendicular to the boundary surface 18a. The terminal portion 23 is adjacent to the opposite side of the main portion 22 with respect to the portion 61 and the boundary. It is comprised by the part 62 parallel to the surface 18a. The terminal portion 23 becomes longer by the amount of the parallel portion 62, and as a result, the terminal portion 23 may become transiently longer.

  In this regard, in the first embodiment, as shown in FIG. 9A, a trim blade 46 that can reciprocate in the direction along the boundary surface 18 a of the substrate 12 is used. In the trimming step, the trim blade 46 is moved along the boundary surface 18 a toward the surplus portion 24 of the skin material 20 and is pressed against the surplus portion 24. The surplus portion 24 is cut and the terminal portion 23 remains around the main portion 22. The terminal portion 23 is constituted only by a portion 61 adjacent to the main portion 22 and orthogonal to the boundary surface 18a. Accordingly, there is no portion 62 (see FIG. 9B) parallel to the boundary surface 18a, and accordingly the terminal portion 23 is shortened, and the terminal portion 23 can be prevented from being lengthened transiently.

  Furthermore, if the surplus portion 24 of the skin material 20 is cut at a location where the terminal portion 23 becomes transiently short, it becomes difficult to cause the terminal portion 23 to follow the shape of the back surface 18 including the boundary surface 18a of the base material 12. It becomes difficult to appropriately wind the terminal portion 23 around the back surface 18 side of the base material 12.

  In this regard, in the first embodiment in which the trim blade 46 is moved in the direction along the boundary surface 18a of the base member 12, there is no particular restriction on the height of the path for moving the trim blade 46. Therefore, it is easy to cut the surplus portion 24 of the skin material 20 at a location where the terminal portion 23 has an appropriate length. Thus, in the first embodiment, the length of the terminal unit 23 can be easily controlled.

  -By passing through the trimming process, a cut mark having a shape corresponding to the tooth of the trim blade remains on the terminal portion 23. In 1st Embodiment, as shown to Fig.4 (a), the trim blade 46 with which the trough part 49 curved is used. Therefore, the width of the cut trace (interval between the crest and trough) is narrower than that of the comparative example in which the trim blade 55 shown in FIG. This is because, in the comparative example, the valley portion of the cutting trace has a sharp shape, whereas in the first embodiment, the valley portion has a curved shape, that is, the tip of the sharp portion is removed. It is because it becomes a shape. As a result, the target portion of the surplus portion 24 can be cut more easily than the comparative example, and the position accuracy of the end face of the terminal portion 23 can be increased.

(Second Embodiment)
Next, 2nd Embodiment of the manufacturing method of a product with a skin is described with reference to FIG.10 and FIG.11 in addition to the said FIG.5 and FIG.6.

<About the base material 12>
The peripheral edge 14 around the main body 13 in the substrate 12 is constituted by a plurality of straight portions 15 and a plurality of corner portions 16 that connect the adjacent straight portions 15. In this regard, the second embodiment is common to the first embodiment. Further, each corner portion 16 is curved in an arc shape so as to swell toward the side away from the main body portion 13. Each corner portion 16 has a circumferential length shorter than the length of any straight portion 15.

<About trim blade>
As the plurality of trim blades in the cutting mechanism 45, a plurality of first trim blades 71 and a plurality of second trim blades 72 are used. Each first trim blade 71 is for cutting a portion corresponding to the straight portion 15 of the base material 12 in the surplus portion 24 of the skin material 20 so that the terminal portion 23 remains around the main portion 22. is there. Among the first trim blades 71, the one that cuts the portion corresponding to the relatively long straight portion 15 in the surplus portion 24 is divided into a plurality of portions. Each of the second trim blades 72 cuts a portion corresponding to the corner portion 16 of the base material 12 in the surplus portion 24 of the skin material 20 so that the terminal portion 23 remains around the main portion 22. (See FIG. 5).

<About trimming process>
In the second embodiment, the surplus portion 24 is cut by the second trim blade 72 while the skin material 20 is sucked by vacuuming, and then the surplus portion 24 is cut by the first trim blade 71.

Matters other than the above are the same as in the first embodiment. For this reason, the same elements as those described in the first embodiment are denoted by the same reference numerals, and redundant description is omitted.
Next, a method for manufacturing the skinned product 11 will be described. In carrying out this method, as in the first embodiment, the shaping step, the trimming step, and the entrainment step are sequentially performed. Among these processes, the trimming process is characterized by the second embodiment.

  In the trimming step, as shown in FIG. 5, a place where the plug 36 is removed from the movement path of the first trim blade 71 and the second trim blade 72 in a state where the base material 12 is mounted on the remaining portion 37 of the vacuum forming die 31. Backed up.

  By operating the vacuum suction mechanism, the main portion 22 of the skin material 20 is sucked through the vacuum forming die 31 and the substrate 12, and the surplus portion 24 of the skin material 20 is sucked through the vacuum forming die 31.

  In this state, as shown in FIGS. 5, 6, and 10, the second trim blade 72 corresponds to the corner portion 16 in the surplus portion 24 of the skin material 20 along the boundary surface 18 a of the base material 12. It moves to the side which approaches the place to do (refer the dashed-two dotted line of FIG. 10). In the course of this movement, the second trim blade 72 is pressed against the surplus portion 24. By this pressing, a part of the surplus portion 24 is cut so that the terminal portion 23 remains around the main portion 22 of the skin material 20. At this stage, the portion corresponding to the straight portion 15 in the surplus portion 24 is not cut. Thereafter, the second trim blade 72 is retracted along the boundary surface 18a of the substrate 12 (see the solid line in FIG. 10).

  After the cutting by the second trim blade 72, as shown in FIGS. 5, 6, and 11, the first trim blade 71 extends along the boundary surface 18a of the base member 12 and the surplus portion 24 of the skin material 20 is formed. Among them, it is moved to the side closer to the location corresponding to the straight line portion 15 (see the two-dot chain line in FIG. 11). In the course of this movement, the first trim blade 71 is pressed against the surplus portion 24. By this pressing, the uncut portion of the surplus portion 24 is cut so that the terminal portion 23 remains around the main portion 22 of the skin material 20. Thereafter, the first trim blade 71 is retracted along the boundary surface 18a of the substrate 12 (see the solid line in FIG. 11).

  Here, if the cutting of the surplus portion 24 by the first trim blade 71 and the cutting of the surplus portion 24 by the second trim blade 72 adjacent to the first trim blade 71 are performed simultaneously, the surplus portion is removed from the skin material 20. 24 can be cut in a short time so that the terminal part 23 remains. On the other hand, when cutting, the first trim blade 71 and the second trim blade 72 may approach each other and interfere with each other.

  In this regard, in the second embodiment, as described above, the cutting by the first trim blade 71 and the cutting by the second trim blade 72 are performed at different timings. Therefore, it is possible to suppress the first trim blade 71 and the second trim blade 72 from interfering with each other.

Further, the cutting is performed in a state where the skin material 20 is sucked by evacuation and the surplus portion 24 is pulled toward the back surface 18 side of the substrate 12.
However, when the surplus portion 24 is cut while being evacuated, air is sucked not a little from the cut portion, and the force for pulling the surplus portion 24 toward the back surface 18 side of the base material 12 is lower than before cutting. Therefore, the surplus portion 24 tries to return to the shape before being pulled by vacuuming.

  As the length of the cut portion increases, the amount of air that is sucked increases, and the degree of reduction in the force that pulls the surplus portion 24 toward the back surface 18 side of the substrate 12 increases. The length of the portion to be cut is shorter in the portion corresponding to the corner portion 16 of the substrate 12 in the surplus portion 24 than in the portion corresponding to the straight portion 15. This is because the peripheral length of each corner portion 16 is shorter than the length of any straight portion 15.

  In this regard, in the second embodiment, as shown by a broken line in FIG. 11, the portion 73 corresponding to the corner portion 16 is first cut by the second trim blade 72. Thereafter, the first trim blade 71 cuts a portion corresponding to the straight portion 15. Therefore, the force that pulls the surplus portion 24 toward the back surface 18 side of the base material 12 before the entire cutting of the surplus portion 24 is completed is performed by the first trim blade 71 first, and by the second trim blade 72. Compared with the case where the cutting is performed later, it is less likely to decrease. The surplus portion 24 is less likely to return to the shape before being pulled by evacuation. Accordingly, the terminal portion 23 formed by cutting the surplus portion 24 also approaches the back surface 18 of the substrate 12.

  Therefore, in the winding process performed subsequent to the trimming process, the terminal portion 23 of the skin 21 can be suitably wound on the back surface 18 side of the substrate 12 by the plug 36 of the winding mechanism 35.

(Third embodiment)
Next, 3rd Embodiment of the manufacturing method of a product with an outer skin is described with reference to FIG.
<About the base material 12>
Plate-like ribs 75 for increasing the rigidity of the base material 12 are integrally formed at a plurality of locations on the back surface 18 of the base material 12 different from the locations where the terminal portions 23 are in close contact. Moreover, it is used in order to grasp the base material 12 by a winding process in the several places different from the location where the terminal part 23 closely_contact | adheres in the back surface 18 of the base material 12, and the location where the said rib 75 was formed. A plate-like rib 76 is integrally formed. Both ribs 75 and 76 protrude to the side (back side) away from the surface 17 of the base material 12.

<About upper mold 41>
In the third embodiment, a manufacturing apparatus 30 that does not include the upper mold 41 is used.
<About chuck mechanism 77>
In the vacuum forming die 31, a chuck mechanism 77 is provided at a location close to the rib 76 of the substrate 12. The chuck mechanism 77 includes a pair of arms 78 arranged to face the rib 76 in the thickness direction (the left-right direction in FIG. 12). Each arm 78 is rotatably supported by a shaft 79 at one end (lower side in FIG. 12), and has a claw 81 at the other end (upper side in FIG. 12). In the chuck mechanism 77, as indicated by the solid line in FIG. 12, the ribs 76 are gripped by the claws 81 from both sides in the thickness direction by rotating the arms 78 in a direction in which the distance between the claws 81 is narrowed. On the contrary, as shown by a two-dot chain line in FIG. 12, each arm 78 is rotated in the direction in which the distance between the claws 81 is widened, so that the force to grip the rib 76 is weakened. Further, the chuck mechanism 77 includes a mechanism (not shown) that moves both arms 78 in a state where the ribs 76 are gripped by both claws 81 to the side (downward) away from the ribs 76.

<About the shaping process>
In the base material 12, the adhesive is applied to the portion where the skin 21 is to be covered, as described above. The adhesive is not shown in the first embodiment and the second embodiment, but is indicated by reference numeral 82 in the third embodiment (see FIG. 12). The adhesive 82 is applied to the surface 17 of the base material 12 and is also applied to a portion of the back surface 18 of the base material 12 where the terminal portion 23 is to be wound.

<About the entrainment process>
In the winding process, the operation of pushing the terminal portion 23 by the winding mechanism 35 is performed in a state where the movement of the base material 12 in the pushing direction is restricted by the chuck mechanism 77.

Matters other than the above are the same as in the first embodiment. For this reason, the same elements as those described in the first embodiment are denoted by the same reference numerals, and redundant description is omitted.
Next, a method for manufacturing the skinned product 11 will be described. In carrying out this method, as in the first embodiment, the shaping step, the trimming step, and the entrainment step are sequentially performed. Among these steps, the winding step is characterized by the third embodiment.

  Here, in order to firmly bond the terminal portion 23 pressed by the plug 36 of the winding mechanism 35 to the back surface 18 of the base material 12 to which the adhesive 82 is applied, the terminal portion 23 is attached to the base material 12. It is important that it be pressed firmly.

  In this regard, in the winding process of the third embodiment, as shown by a solid line in FIG. 12, each arm 78 is rotated in the chuck mechanism 77 in a direction in which the distance between the claws 81 is narrowed. Ribs 76 respectively protruding from a plurality of locations on the back surface 18 of the substrate 12 are gripped by both claws 81 of each arm 78 from both sides in the thickness direction. In this state, the plug 36 of the winding mechanism 35 indicated by a two-dot chain line in FIG. 12 is moved to a place where the base material 12 is supported from the back surface 18 side as indicated by a solid line. At this time, the base material 12 is restricted from moving in the direction (upward) in which the terminal portion 23 is pushed by the plug 36. Since a part of the terminal portion 23 is pushed into the back surface 18 side of the base material 12 by the plug 36 in this state, after being deformed along the back surface 18 including the boundary surface 18a of the base material 12, the base material 12 Strongly pressed. As a result, the terminal portion 23 can be firmly bonded (crimped) to the back surface 18 of the substrate 12.

  Further, in the third embodiment, both arms 78 in a state where the ribs 76 are gripped by the pair of claws 81 are moved to the side (downward) away from the ribs 76 as indicated by arrows in FIG. Therefore, a part of the terminal portion 23 can be more firmly bonded (crimped) to the back surface 18 of the base member 12 than that in which such movement is not performed.

In addition, said each embodiment can also be implemented as a modification which changed this as follows.
-As the plug 36, what is comprised by a single component may be used, and what was divided | segmented into plurality along the peripheral part 14 (refer FIG.1 (c)) of the base material 12 is used. May be. In the latter case, there is an advantage that the plug 36 can be moved at an optimal timing for each plug 36.

  The timing for operating the vacuum suction mechanism (suction start timing for the skin material 20) and the timing for stopping the operation of the vacuum suction mechanism (suction stop timing for the skin material 20) may be appropriately changed. For example, when the plug 36 is lowered, the operation of the vacuum suction mechanism may be stopped to release to the atmosphere.

-As shown in FIG. 12, the application | coating location of the adhesive agent 82 in the surface 17 of the base material 12 may be set to the several location spaced apart from each other.
-Also in 1st and 2nd embodiment, the product 11 with an outer skin may be manufactured by the manufacturing apparatus 30 which is not provided with the upper mold | type 41 similarly to 3rd Embodiment.

  A type different from the third embodiment may be used as the chuck mechanism 77 on the condition that the base member 12 can be restricted from moving in the direction in which the terminal portion 23 is pushed by the winding mechanism 35. .

The both arms 78 may be held at a position where the ribs 76 are gripped without being moved to the side (lower side) away from the ribs 76.
-The manufacturing method of the said product with a skin is applicable also when manufacturing the interior part for motor vehicles different from a door trim as a product with a skin.

  -The manufacturing method of the said product with a skin is applicable also when manufacturing the product with a skin different from the interior component for motor vehicles.

  DESCRIPTION OF SYMBOLS 11 ... Product with skin, 12 ... Base material, 14 ... Peripheral part, 15 ... Linear part, 16 ... Corner part, 17 ... Front surface, 18 ... Back surface, 18a ... Interface, 20 ... Skin material, 21 ... Skin, 22 ... Main part, 23 ... terminal part, 24 ... surplus part, 31 ... vacuum forming die, 35 ... winding mechanism, 36 ... plug, 37 ... remaining part, 46 ... trim blade, 47 ... tooth, 48 ... tip part, 49 ... valley 71, first trim blade, 72 ... second trim blade, 75, 76 ... rib, 77 ... chuck mechanism, 82 ... adhesive, [theta] 1, [theta] 2 ... blade angle.

Claims (8)

A method for producing a product with a skin in which the main part of the skin is covered on the surface of the base material, and the terminal part around the main part of the skin is wound on the back side of the base material,
A pre-formed base material is mounted on a vacuum forming die on the back surface of the base material, and a skin material that is the material of the skin is disposed on the surface side of the base material, and then the vacuum forming die and the base A shaping step of deforming the main part of the skin material so as to adhere to the surface of the base material by sucking the skin material through the material;
After passing through the shaping step, while maintaining the base material mounted on the vacuum forming die, the surplus portion of the skin material that is not in close contact with the surface of the base material is around the main part. A trimming step of forming the skin having the terminal part by cutting with a trim blade so that the terminal part remains in
After the trimming step, a winding step of winding the terminal portion of the skin onto the back side of the base material by a winding mechanism while maintaining the base material mounted on the vacuum mold. A method for manufacturing a product with an outer skin. As the base material, the back surface has a flat boundary surface at the boundary portion with the front surface,
As the trim blade, one that can reciprocate in the direction along the boundary surface,
The manufacturing method of the product with a skin according to claim 1, wherein in the trimming step, the trim blade is cut by moving the trim blade to the side approaching the surplus portion along the boundary surface and pressing the trim blade against the surplus portion. The peripheral portion of the base material is composed of a plurality of linear portions and a plurality of curved corner portions connecting the adjacent linear portions and having a peripheral length shorter than the length of the linear portions,
As the trim blade, a first trim blade that cuts a portion corresponding to the linear portion of the base material, and a second portion that cuts a portion corresponding to the corner portion of the base material, of the surplus portion of the skin material. Use the trim blade and
3. The trimming step, wherein the surplus portion is cut by the first trim blade after the surplus portion is cut by the second trim blade while suctioning the skin material by vacuuming. Of manufacturing products with skin.   In the winding step, the terminal portion is pushed in a direction orthogonal to the boundary surface by the winding mechanism, and the terminal portion is deformed so as to be in close contact with the back surface including the boundary surface of the base material. The manufacturing method of the product with a skin of Claim 2 or 3 which winds up the said terminal part. The wrapping step is performed in a state where an adhesive is applied to at least a portion of the back surface of the base material where the terminal portion is to be wound,
The manufacturing method of the product with a skin according to claim 4, wherein, in the winding step, the operation of pushing the terminal portion by the winding mechanism and winding is performed in a state where movement of the base material in the pushing direction is restricted. As the base material, a rib is formed at a location different from the location where the terminal portion is in close contact with the back surface.
In the winding step, the rib is gripped by a chuck mechanism provided in the vacuum forming die, thereby restricting movement of the base material in a direction in which the terminal portion is pushed by the winding mechanism. The method for manufacturing a product with an outer skin according to claim 5, wherein the terminal portion is pushed and wound. As the entrainment mechanism, using a part that forms part of the vacuum forming die and includes a plug that can reciprocate in a direction perpendicular to the boundary surface,
In the shaping step, the plug is moved to a place where the base material is supported from the back side,
In the trimming step, the plug is retracted to a place off the movement path of the trim blade,
The manufacturing method of the product with a skin according to any one of claims 4 to 6, wherein, in the winding step, the plug is moved to a place where the base material is supported from the back surface side. The trim blade has a plurality of teeth arranged in a row, the tip of each tooth is sharp, and the valley between adjacent teeth is uniform in blade angle Use one formed in a curved state,
The manufacturing method of the product with a skin according to any one of claims 1 to 7, wherein in the trimming step, cutting is performed by pressing each tooth of the trim blade against the surplus portion.

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