JP2020037227A - Manufacturing method of molded body - Google Patents

Abstract

To suppress a situation in which a laminate formed by laminating a base material and a sheet material warps during heating.SOLUTION: Manufacturing method for manufacturing an ornament 20 including a plate-shaped base material 21 containing a thermoplastic resin and a nonwoven fabric 22 attached to one surface of the base material 21 includes: a slit forming step of forming slits 41 and 42 in at least the nonwoven fabric 22 of a preboard 30 in which the base material 21 and the nonwoven fabric 22 are laminated; a heating step that is performed after the slit forming step and heats the preboard 30; and a molding step that is performed after the heating step and press-molds the preboard 30 with a molding die 63.SELECTED DRAWING: Figure 5

Description

  The technology disclosed in the present specification relates to a method for manufacturing a molded article.

  2. Description of the Related Art Conventionally, a molded body including a base material, a sheet material, and a skin material has been known. Patent Document 1 listed below discloses a resin sheet as a base material and a nonwoven fabric as a sheet material. By appropriately selecting the material of the sheet material serving as the intermediate layer, the adhesive force of the skin material can be increased as compared with a configuration in which the skin material is directly bonded to the base material.

Japanese Patent No. 3364737

  By the way, as a method of manufacturing the above-mentioned molded body, a laminate formed by laminating a base material and a sheet material is heated by a heating device, and then the laminate is pressed into a product shape by a molding die. Can be considered. Here, when the material of the base material and the material of the sheet material are different, there is a concern that the laminate may warp during heating due to the difference in the thermal shrinkage of the two members. When transporting the laminate from the heating device to the mold, it is common to transport the laminate through a predetermined transport route. Such a transport route is designed on the premise that the laminate has a flat shape. For this reason, when the laminate is warped, there is a concern that the laminate may be caught on each member (for example, a column or a wall) disposed in the manufacturing facility when the laminate is transported.

  The technology disclosed in the present specification has been completed based on the above circumstances, and aims to suppress a situation in which a laminate formed by laminating a base material and a sheet material warps during heating. And

  As a means for solving the above-mentioned problem, a technique disclosed in the present specification is a molding method comprising: a plate-like base material containing a thermoplastic resin; and a sheet material attached to one surface of the base material. A method for manufacturing a molded body for manufacturing a body, wherein a slit forming step of forming a slit in at least the sheet material of a laminate formed by laminating the base material and the sheet material, and after the slit forming step It is characterized in that it comprises a heating step which is executed and heats the laminate, and a molding step which is executed after the heating step and press-molds the laminate with a molding die. When the sheet material shrinks due to heating in the heating step performed after the slit forming step, the sheet material shrinks for each region partitioned by the slit. As a result, it is possible to suppress a situation in which the laminate warps due to shrinkage of the sheet material.

  The sheet material may include fibers, and in the slit forming step, the slit may be formed to extend along a direction inclined with respect to a direction of the fibers included in the sheet material. it can. When a sheet material made of fibers is heated, it contracts mainly in the direction of the fibers. If the direction in which the slit extends is parallel to the direction of the fiber, the slit hardly affects the shrinkage in the direction of the fiber, and the effect of suppressing the warping of the laminate is reduced. If the direction in which the slits extend is perpendicular to the direction of the fibers, stress concentrates on the slits when the sheet material shrinks, and the laminate is likely to break from the slits. From the above, by setting the extending direction of the slit to the direction inclining with respect to the direction of the fiber constituting the sheet material, the situation in which the laminate warps and the situation in which the laminate breaks from the slit as a starting point is more reliably achieved. Can be suppressed.

  Further, in the slit forming step, the plurality of slits may be formed in the sheet material such that a portion of the sheet material surrounded by the plurality of slits has a diamond shape. The diamond-shaped portion of the sheet material is surrounded by a plurality of slits, and is a portion that is not connected to other portions of the sheet material on the entire circumference. For this reason, it is possible to more reliably suppress the situation where the diamond-shaped portion shrinks in the heating step, which occurs in the surrounding portion.

  Further, in the heating step, the laminate is heated while holding the peripheral end of the laminate by a pair of holding units arranged along the peripheral end of the laminate, and the slit formation is performed. In the step, in the sheet material, the slit may be formed at a position arranged outside the pair of holding portions in the direction in which the pair of holding portions are arranged. When the stacked body is heated while holding the peripheral end of the stacked body by the pair of holding sections, the portion corresponding to the inside of the pair of holding sections is restrained by the pair of holding sections, and thus the warpage of the stacked body is caused. Is difficult to occur, and the portion corresponding to the outside of the pair of holding portions is easily restrained by the pair of holding portions, so that the laminate is likely to warp. For this reason, by forming a slit at a position outside the pair of holding portions in the sheet material, the warpage of the laminate can be effectively suppressed.

  Further, in the slit forming step, the slit may be formed so as to reach the base material from the sheet material. By forming the slit so as to reach the base material, the sheet material can be more reliably divided.

  Further, in the forming step, a part of the laminated body is cut off by the forming die, and in the slit forming step, the slit is formed at a position constituting the part in the sheet material. It can be. The portion where the slit is formed in the sheet material is cut off in the forming step. For this reason, no slit remains in the molded article as a product.

  ADVANTAGE OF THE INVENTION According to this invention, the situation where the laminated body which laminated | stacked a base material and a sheet material at the time of heating can be suppressed.

Front view showing a door trim in one embodiment of the present invention. Sectional view showing the ornament (corresponding to the view cut along the line II-II in FIG. 1) Diagram showing the process of manufacturing a nonwoven fabric Diagram showing the preboard molding process Diagram showing the slit forming process Perspective view showing a molding device Diagram showing pre-board hung on hanger Diagram showing the press molding process (with the mold open) Diagram showing press molding process (mold closed) Diagram showing the skin material attaching process Sectional view showing preboard Sectional view showing warped preboard View of the pre-board during transfer viewed from above View of the pre-board in a transported and warped state viewed from above Sectional view showing the slit formation location of the preboard Sectional view showing the slit formation location of the preboard after heating The figure which shows the preboard in which the slit extended along the direction of a fiber was formed. The figure which shows the pre-board in which the slit extended in the direction orthogonal to the direction of the fiber was formed.

  One embodiment of the present invention will be described with reference to FIGS. In the present embodiment, an ornament 20 included in a vehicle door trim 10 is illustrated as a molded body. As shown in FIG. 1, the door trim 10 mainly includes a trim board 12. The ornament 20 is a decorative member attached to the trim board 12, and is arranged, for example, above an armrest 13 provided on the trim board 12.

  As shown in FIG. 2, the ornament 20 includes a plate-shaped base material 21 and a sheet-like nonwoven fabric 22 (a surface on the vehicle interior side, one surface of the base material) attached to a surface 21 </ b> A of the base material 21. And a skin material 24 attached to the surface of the nonwoven fabric 22 with an adhesive layer 23 interposed therebetween. That is, in the ornament 20, the base material 21, the nonwoven fabric 22, the adhesive layer 23, and the skin material 24 are stacked in this order from the outside of the vehicle compartment (the lower side in FIG. 2) to the vehicle interior side (the upper side in FIG. 2). I have.

  The base material 21 includes a vegetable fiber, a thermoplastic resin, and a thermally expandable capsule. Examples of the plant fibers contained in the base material 21 include bast plant fibers such as kenaf, and wood fibers obtained by unraveling fiber wood and the like. The base material 21 is obtained by press-molding a fiber mat 28 described later, and the thermoplastic resin functions as a binder for binding the vegetable fibers. Examples of the thermoplastic resin contained in the base material 21 include a polyolefin resin (eg, polypropylene, polyethylene), a polyester resin (eg, an aliphatic polyester resin such as polylactic acid and polycaprolactone, and an aromatic polyester resin such as polyethylene terephthalate). can do.

  In the present embodiment, as the substrate 21, an example including a vegetable fiber obtained from kenaf and polypropylene is exemplified, but the material of the substrate 21 is not limited thereto, and can be appropriately changed. The thermally expandable capsule included in the base material 21 has a shell wall (capsule) made of a thermoplastic resin and a foaming agent contained in the shell wall. When such a heat-expandable capsule is heated in the process of molding the base material 21, the internal foaming agent foams (expands), and the softened shell wall is expanded by the foaming to expand the volume. It has a configuration. By including such a heat-expandable capsule, the base material 21 having low basis weight and high rigidity can be molded. In addition, the base material 21 does not need to include a thermally expandable capsule.

  The nonwoven fabric 22 is configured to include at least one type of thermoplastic resin fiber selected from a polyester-based resin and a polyamide-based resin. In the nonwoven fabric 22, the fibers constituting the nonwoven fabric 22 are oriented in one direction. The nonwoven fabric 22 has a configuration in which the adhesive force to the adhesive layer 23 is higher than that of the base material 21. Specifically, the nonwoven fabric 22 is made of a thermoplastic resin having higher wettability than the thermoplastic resin contained in the base material 21. That is, the nonwoven fabric 22 is made of a different material from the base material 21 and has a different heat shrinkage.

  In the present embodiment, as the nonwoven fabric 22, a nonwoven fabric made of polyethylene terephthalate fiber is exemplified, but the present invention is not limited to this. The nonwoven fabric 22 is preferably made of a thermoplastic resin fiber whose melting temperature is higher than that of the thermoplastic resin contained in the base material 21 from the viewpoint that the nonwoven fabric 22 is not easily melted in a press molding step described later. The adhesive layer 23 is formed by solidifying an adhesive mainly containing a thermoplastic resin called a hot melt. As such an adhesive, a reactive hot melt adhesive containing a urethane resin as a main component is used, but is not limited thereto.

  The skin material 24 is in the form of a sheet and is made of fabric, synthetic leather or genuine leather, a flexible resin sheet, or the like. In the present embodiment, as the skin material 24, a material made of a fabric made of a thermoplastic resin such as polyethylene terephthalate is exemplified. As shown in FIG. 2, the skin material 24 has a main body 26 attached to the surface of the base member 21 and a pleated folded portion 27 connected to the main body 26. The plurality of folded portions 27 are provided in a line in one direction. By providing the folded portion 27, the skin material 24 can have a three-dimensional appearance, and the design can be enhanced. When such a folded portion 27 is provided, it is assumed that the occupant grips the folded portion 27 and pulls the skin material 24. For this reason, in the present embodiment, the nonwoven fabric 22 is interposed between the base material 21 and the skin material 24 so that the adhesiveness of the skin material 24 is further improved.

  Next, a method for manufacturing the ornament 20 will be described. The method for manufacturing the ornament 20 includes a preboard forming step of integrating the base material 21 and the nonwoven fabric 22 to form a preboard 30 (laminate), a slit forming step of forming a slit (described in detail later) in the preboard 30, A heating step of heating the preboard 30 with a molding die to form a product shape of the ornament 20 (a molding step); and a skin material for attaching the skin material 24 to the nonwoven fabric 22. Attaching step.

  The nonwoven fabric 22 is manufactured using, for example, a nonwoven fabric manufacturing apparatus 31 as shown in FIG. The nonwoven fabric manufacturing apparatus 31 includes a fiber supply unit 32, a card machine 33, an entanglement unit 34 (for example, a needle punch device), and a cutter 35. When manufacturing the nonwoven fabric 22, first, fibers constituting the nonwoven fabric 22 are charged into the fiber supply unit 32. Then, the fibers fed into the fiber supply unit 32 are continuously supplied to the card machine 33 to form the fiber web 36. Next, the fiber web 36 is entangled by the entanglement means 34 to form the nonwoven fabric 22. The nonwoven fabric 22 is cut into a predetermined size by, for example, a cutter 35. The fibers in the nonwoven fabric 22 are aligned in a predetermined direction in the card machine 33. In addition, the direction of the fibers in the nonwoven fabric 22 is, for example, along the transport direction (the left-right direction in FIG. 3) in the nonwoven fabric manufacturing apparatus 31.

  In the preboard forming step, as shown in FIG. 4, the fiber mat 28 on which the nonwoven fabric 22 is placed is heated and pressed between a pair of belt conveyors 38 using a double belt press 37. As a result, the fiber mat 28 becomes the plate-shaped base material 21 and forms the preboard 30 in which the base material 21 and the nonwoven fabric 22 are integrated. The fiber mat 28 is impregnated with a thermally expandable capsule in a previous step. In the process of heating and pressing the fiber mat 28 on which the nonwoven fabric 22 is placed, the thermoplastic resin contained in the fiber mat 28 melts and a part of the thermoplastic resin permeates the nonwoven fabric 22. Then, the fiber mat 28 on which the nonwoven fabric 22 is placed passes between the pair of belt conveyors 38, 38 and is cooled, so that the thermoplastic resin contained in the fiber mat 28 is solidified. Thereby, the nonwoven fabric 22 is stuck to the base material 21.

  In the slit forming step performed after the preboard forming step, as shown in FIG. 5, a plurality of slits 41 and 42 are formed on the preboard 30 from the nonwoven fabric 22 side using the slit forming blade 39 (slit). See FIG. 7 for 42). In the slit forming step, the slit 41 (and the slit 42) is formed such that the slit 41 (and the slit 42) reaches the base material 21 from the nonwoven fabric 22. That is, the depth of the slit 41 and the depth of the slit 42 are larger than the thickness of the nonwoven fabric 22, and the slits 41 and 42 divide the nonwoven fabric 22. Note that the slits 41 and 42 need only be formed at least in the nonwoven fabric 22, and need not reach the base material 21.

  As shown in FIG. 7, each of the slits 41 and 42 extends along a direction inclined with respect to the direction of the fibers constituting the nonwoven fabric 22 (the left-right direction in FIG. 7). A plurality of slits 41 and slits 42 are respectively formed. The plurality of slits 41 are arranged at predetermined intervals. The plurality of slits 42 are arranged at predetermined intervals. The slit 41 extends so as to intersect the slit 42. In the nonwoven fabric 22, a portion 22A surrounded by two adjacent slits 41 and two adjacent slits 42 has a diamond shape. That is, in the slit forming step, the plurality of slits 41 and 42 are formed in the nonwoven fabric 22 so that the portion 22A surrounded by the plurality of slits 41 and 42 in the nonwoven fabric 22 has a diamond shape.

  In a heating step and a press forming step described later, as shown in FIG. 7, an operation is performed on the pre-board 30 (plate-like body) suspended from the hanger 43. The hanger 43 includes a shaft 44 arranged above the pre-board 30 and three holding portions 45, 45, 46 attached to the shaft 44. The three holding parts 45, 45, 46 are arranged along the upper end (peripheral end) of the preboard 30. The holding units 45 and 46 are configured by, for example, clamps, and are capable of holding (clamping) the upper end of the preboard 30 by the clamps. The holding portion 46 arranged on the center side holds a portion corresponding to the center portion of the pre-board 30 in the left-right direction. A pair of holding parts 45 arranged on both left and right sides respectively hold both ends in the left-right direction at the upper end (peripheral end) of the pre-board 30.

  In the slit forming step, in the nonwoven fabric 22, at least slits are provided at locations A1, A1 arranged outside the pair of holding portions 45, 45 in the direction in which the pair of holding portions 45, 45 are arranged (the horizontal direction in FIG. 7). 41 and 42 are formed. In FIG. 7, a portion A <b> 2 of the preboard 30 that becomes the ornament 20 by being formed by the press forming process is illustrated by a two-dot chain line. In the press forming step, a portion A3 (part of the laminate) other than the portion A2 serving as the ornament 20 is cut off by shearing of the forming die 63 (see FIG. 6). In other words, in the slit forming step, the slits 41 and 42 are formed in the nonwoven fabric 22 at the positions constituting the portion A3.

  The heating step and the press forming step are performed using, for example, a forming apparatus 60 shown in FIG. The forming device 60 includes a heating furnace 61, the above-mentioned hanger 43, a transfer device 62 for transferring the hanger 43 and the pre-board 30 in the heating furnace 61, a forming die 63, a hanger 43 and a pre-board 30 coming out of the heating furnace 61. And a transfer device 64 for transferring the sheet to the molding die 63. The heating furnace 61 is a heating furnace of a hot air circulation type, and is capable of heating the preboard 30 by blowing hot air on the internal preboard 30. In the heating furnace 61, a plurality of preboards 30 are heated.

  The transport device 62 is constituted by a pair of left and right chain conveyors 62A, 62A. Each of both ends of the shaft 44 of the hanger 43 is placed on each of the chain conveyors 62A, 62A. The transfer device 64 includes a slide rail 65 and a cylinder 66 that can push out the hanger 43 placed on the slide rail 65 in a horizontal direction. The hanger 43 transported by the transport device 62 slides down a slope 67 provided on the downstream side of the transport device 62 and is then placed on the slide rail 65. The hanger 43 placed on the slide rail 65 is configured to be extruded in the horizontal direction by the cylinder 66 and head toward the forming die 63. The molding die 63 includes a core die 68 and a mold die 69 that can be closed and opened. Each of the core mold 68 and the mold 69 has a molding surface that follows the surface shape of the ornament 20.

  In the heating step performed after the slit forming step, the pre-board 30 suspended from the hanger 43 is heated in the heating furnace 61 as shown in FIG. That is, in the heating step, the preboard 30 is heated while the upper end of the preboard 30 is held by the three holding portions 45, 46, 46. When the preboard 30 is heated, the preboard 30 is softened, and at the same time, the thermally expandable capsule included in the base member 21 expands, and the thickness of the preboard 30 increases.

  In the press forming step performed after the heating step, as shown in FIG. 8, the softened preboard 30 is transferred from the heating furnace 61 to the forming die 63 (press die), and then, as shown in FIG. The mold 68 and the mold mold 69 are closed. By closing the core mold 68 and the mold mold 69, the preboard 30 is formed into a shape that follows the shape of each molding surface of the core mold 68 and the mold mold 69. The part A3 other than the part A2 that becomes the ornament 20 is cut by the shear blade 68A of the core mold 68. Thereby, the pre-board 30 is formed in the shape of the ornament 20. In the following description, the preboard 30 press-formed by the forming die 63 is referred to as an ornament main body 20A. As shown in FIG. 7, in the present embodiment, the case where the ornament main bodies 20A, 20A corresponding to the pair of right and left ornaments 20, 20 of the vehicle are formed from one preboard 30 is illustrated. It is not limited to.

  In the skin material sticking process performed after the press molding process, the skin material 24 is crimped to the ornament body 20A using the crimping device 70 shown in FIG. In the skin material attaching step, as shown in FIG. 10, the ornament main body 20A in a state where the adhesive 23A is applied to the surface of the nonwoven fabric 22 is set on the upper mold 71 of the crimping device 70, and the adhesive 23A is applied to the back surface. The finished skin material 24 is set on the lower mold 72 of the crimping device 70 with the back surface facing upward. At this time, the skin material 24 may be held by a pin 72A provided on the lower die 72 or a clamp (not shown).

  Then, the upper mold 71 and the lower mold 72 are closed with the adhesive 23A heated and melted. After a predetermined time has elapsed, as shown in FIG. 2, the adhesives 23A and 23A are solidified to form the adhesive layer 23, and the skin material 24 is attached to the nonwoven fabric 22 via the adhesive layer 23. Attached. As a result, the base material 21, the nonwoven fabric 22, the adhesive layer 23, and the skin material 24 are laminated, and the ornament 20 is completed.

  Next, effects of the present embodiment will be described. In the heating step, when the flat pre-board 30 (see FIG. 11) is heated, there is a concern that the non-woven fabric 22 shrinks and the pre-board 30 warps as shown in FIG. When transferring the preboard 30 from the heating furnace 61 to the forming die 63, if the preboard 30 has a flat plate shape, as shown in FIG. 13, the members 73 (for example, columns and walls) of the forming apparatus 60 are formed. Can be passed without getting caught in the car. On the other hand, in a state where the pre-board 30 is warped, there is a concern that the pre-board 30 may be caught by the member 73 constituting the molding device 60 and a conveyance failure may occur, as shown in FIG.

  Therefore, in the present embodiment, a plurality of slits 41 and 42 are formed in the pre-board 30 in the slit forming step. Accordingly, as shown in FIGS. 15 and 16, when the nonwoven fabric 22 contracts by being heated in the heating step performed after the slit forming step, the plurality of slits 41 and 42 are formed in the nonwoven fabric 22. Each region (part 22A in FIG. 16) is contracted. As a result, it is possible to suppress the situation where the preboard 30 warps due to the shrinkage of the nonwoven fabric 22. FIG. 15 is a sectional view showing the preboard 30 before heating, and FIG. 16 is a sectional view showing the preboard 30 after heating.

  In order to suppress the situation where the preboard 30 is warped in the heating step, it is conceivable to heat only the nonwoven fabric 22 before attaching the nonwoven fabric 22 to the substrate 21. However, in such a method, if the heating of the nonwoven fabric 22 is insufficient, there is a concern that the preboard 30 may warp in the heating step. By forming the slits 41 and 42 as in the present embodiment, the situation where the preboard 30 warps can be suppressed more reliably.

  The nonwoven fabric 22 contains fibers, and in the slit forming step, slits 41 and 42 extending along a direction inclined with respect to the direction of the fibers contained in the nonwoven fabric 22 are formed. When the nonwoven fabric 22 composed of fibers is heated, it contracts mainly in the direction of the fibers. As shown in FIG. 17, if a slit 141 extending in parallel with the fiber direction (left-right direction in FIG. 17) is formed in the preboard 30, the slit 141 hardly affects shrinkage in the fiber direction. The effect of suppressing the situation where the 30 is warped is reduced.

  Further, as shown in FIG. 18, if a slit 241 extending in a direction perpendicular to the direction of the fiber is formed in the preboard 30, stress is concentrated on the location where the slit 241 is formed when the nonwoven fabric 22 contracts, The preboard 30 is easily broken starting from 241. From the above, by setting the extending direction of the slits 41 and 42 to be the direction inclined with respect to the direction of the fiber constituting the nonwoven fabric 22, the preboard 30 warps and the preboard 30 starts from the slits 41 and 42. Breaking can be more reliably suppressed.

  Further, in the slit forming step, the plurality of slits 41 and 42 are formed in the nonwoven fabric 22 so that a portion 22A surrounded by the plurality of slits 41 and 42 in the nonwoven fabric 22 has a diamond shape. The diamond-shaped portion 22A of the nonwoven fabric 22 is surrounded by the plurality of slits 41 and 42, and is a portion that is not connected to other portions of the nonwoven fabric 22 on the entire circumference. Therefore, it is possible to more reliably suppress a situation in which the diamond-shaped portion 22 </ b> A contracts in the heating process, which occurs in the surrounding portion.

  Further, in the heating step, the preboard 30 is heated while at least the upper end of the preboard 30 is held by the pair of holding portions 45, 45 arranged along the upper end of the preboard 30, and in the slit forming step, In the nonwoven fabric 22, slits 41, 42 are formed at locations A1, A1 arranged outside the pair of holding portions 45, 45 in the direction in which the pair of holding portions 45, 45 are arranged. When the preboard 30 is heated while holding the upper end of the pre-board 30 by the pair of holding parts 45, 45, portions corresponding to the inside of the pair of holding parts 45, 45 are restrained by the pair of holding parts 45, 45. Therefore, the preboard 30 is unlikely to be warped, and the portion corresponding to the outside of the pair of holding portions 45, 45 is easily restrained by the pair of holding portions 45, 45, so that the preboard 30 is likely to be warped ( See FIG. 14). For this reason, by forming the slits 41 and 42 at locations A1 and A1 outside the pair of holding portions 45 and 45 in the nonwoven fabric 22, warpage of the preboard 30 can be effectively suppressed.

  In the slit forming step, the slits 41 and 42 are formed so as to reach the substrate 21 from the nonwoven fabric 22. By forming the slits 41 and 42 so as to reach the base material 21, the nonwoven fabric 22 can be more reliably divided.

  In the press forming step, a part of the preboard 30 (the part A3 other than the part that becomes the ornament 20) is cut off by the forming die 63. In the slit forming step, the part A3 is formed in the nonwoven fabric 22. Slits 41 and 42 are formed at the locations. The places where the slits 41 and 42 are formed in the nonwoven fabric 22 are cut off in the molding step. Therefore, the slits 41 and 42 do not remain in the ornament 20, which is a product.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.
(1) In the above embodiment, the heating method of the pre-board 30 in the heating step is not limited to the hot air circulation type. For example, the preboard 30 may be heated using a heater or the like.
(2) In the above embodiment, the nonwoven fabric is exemplified as the sheet material, but the present invention is not limited to this, and the sheet material may be a film or the like. However, since the nonwoven fabric has high elasticity, it is easy to follow the product shape of the ornament 20 and is suitable.
(3) In the above embodiment, the ornament 20 is illustrated as a molded body, but the invention is not limited to this. The molded body may be a component of a door trim other than the ornament, or may be a vehicle interior material (instrument panel, luggage trim, package tray, etc.) other than the door trim. Further, the molded body may be an interior material (vehicle interior material) mounted on a vehicle other than the vehicle, or may be a member other than the interior material.
(4) The skin material 24 may not have the pleated folded portion 27.

Reference numeral 20: ornament (formed body), 21: base material, 21A: surface of the base material (one surface of the base material), 22: nonwoven fabric (sheet material), 22A: place surrounded by a plurality of slits in the sheet material, Reference numeral 30 denotes a preboard (laminated body), 41 and 42 ... slits, 45 ... holding parts, 63 ... molding dies, A1 ... a portion arranged in the sheet material outside the pair of holding parts in the arrangement direction of the pair of holding parts, A3. … Parts other than ornaments (part of laminate)

Claims (6)

A plate-shaped base material containing a thermoplastic resin, and a sheet material attached to one surface of the base material, and a method for manufacturing a formed body including a formed body including:
A slit forming step of forming a slit in at least the sheet material out of a laminate formed by laminating the base material and the sheet material,
A heating step that is performed after the slit forming step and heats the laminate,
A molding step performed after the heating step and press-forming the laminate with a molding die. The sheet material includes fibers,
2. The method according to claim 1, wherein, in the slit forming step, the slit extending along a direction inclined with respect to a direction of the fibers included in the sheet material is formed. 3.   The molded article according to claim 1, wherein in the slit forming step, the plurality of slits are formed in the sheet material such that a portion of the sheet material surrounded by the plurality of slits has a diamond shape. Manufacturing method. In the heating step, the laminate is heated while holding the peripheral end of the laminate by a pair of holding units arranged along a peripheral end of the laminate,
The slit according to any one of claims 1 to 3, wherein, in the slit forming step, the slit is formed at a position of the sheet material, which is arranged outside the pair of holding portions in a direction in which the pair of holding portions are arranged. 13. A method for producing a molded article according to the above item.   5. The method according to claim 1, wherein, in the slit forming step, the slit is formed so as to reach the base material from the sheet material. 6. In the molding step, a part of the laminate is cut off by the molding die,
The method for manufacturing a molded article according to any one of claims 1 to 5, wherein, in the slit forming step, the slit is formed at a position constituting the part in the sheet material.

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