JP2554791B2 - Method for manufacturing epidermal adhesive member and epidermal adhesive sheet - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a base material such as a door trim, a ceiling, a backboard, an armrest and an instrument panel, and a brushed skin material adhered to the surface of a pad material, which is not used for automobile interior materials. The present invention relates to a skin adhesive member and a method for manufacturing a skin adhesive sheet, which enables efficient mass production of a skin adhesive member and a skin adhesive sheet.

[0002]

2. Description of the Related Art As interior materials and sheet materials for automobiles,
After setting the base material or pad material and brushed skin material on the lower mold, pressurizing with the upper mold to bond the brushed skin material to the base material or pad material Although it has become the mainstream, there is a problem that when such a napped skin material is used, the nap is pressed by the mold in the pressure-bonding step and the hair collapses and the quality is remarkably deteriorated.

Therefore, as disclosed in Japanese Patent Laid-Open Nos. 61-162317 and 61-172712, the needle-like protrusions formed on the surface of the mold prevent hair from collapsing while the raised skin material is used as a base. Although a method of bonding and integrating is considered, such a method requires a mold having needle-shaped protrusions, so that the manufacturing cost of the mold becomes very high and the needle-shaped protrusions are broken or deformed. If you do, it is difficult to repair or replace the mold.Especially for door trims and bucket-shaped seats with uneven surfaces, the entire surface of the base material and pad material Since the mold surfaces are not orthogonal to each other, it is unavoidable to partially collapse the hair even if the above-mentioned forming mold having needle-like projections is used.

[0004]

SUMMARY OF THE INVENTION The present invention solves the conventional problems as described above, and the surface is formed even for a base material of a door trim or a pad material such as a bucket-like sheet whose surface is formed in an uneven shape. A skin-adhesive member with a low manufacturing cost of a molding die, which can bond a napped skin material having a nap to the hair without fluffing and can be easily replaced even if the needle-like protrusion is damaged. And it was completed for the purpose of manufacturing the epidermis adhesive sheet.

[0005]

DISCLOSURE OF THE INVENTION The present invention, which has been made to solve the above-mentioned problems, is to set a base material and a raised skin material between a lower mold and an upper mold and pressurize the upper mold to raise the raised skin. In a method for manufacturing a skin adhesive member in which a material is bonded and integrated with the surface of a base material whose surface is formed into an uneven shape, a shape corresponding to the uneven shape of the base material is formed between the upper mold and a raised skin material. The method for producing a skin-adhesive member is characterized in that pressurization is performed by interposing a needle cloth having an innumerable number of needle-shaped projections protruding toward the nap of the napped skin material as the first invention, and the method is provided on the lower mold. In the method for producing a skin adhesive member and a skin adhesive sheet, wherein a pad material and a brushed skin material are set, pressure is applied by an upper mold, and the brushed skin material is bonded and integrated to the surface of the pad material whose surface is formed into an uneven shape, Between the upper mold and the raised skin material, the raised skin material The upper mold is a split mold that interposes a clothing cloth with innumerable needle-like protrusions protruding toward the bristles, and each split mold descends in a direction substantially orthogonal to the entire surface of the pad material. The second aspect of the present invention is a method for manufacturing a skin adhesive sheet, which is characterized in that the pad material and the brushed skin material are set on the lower mold, and then the upper mold is pressed to form an uneven surface on the brushed skin material. In a method for manufacturing a skin adhesive member and a skin adhesive sheet that are integrally bonded to the surface of a pad material formed in, a shape corresponding to the uneven shape of the pad material is formed between the upper mold and the raised skin material. A third aspect of the present invention is a method for producing an epidermal adhesive sheet, characterized in that pressurization is performed by interposing a formed garment having innumerable needle-shaped protrusions protruding toward the nap of the napped skin material.

[0005]

The present invention will now be described in detail with reference to the illustrated embodiments. FIG. 1 shows a molding process of a door trim having irregularities used as an automobile interior material according to the first aspect of the present invention, in which a base material 3 made of wood board and a raised fabric are provided between a lower mold 1 and an upper mold 2. The skin material 4 is set, and the raised skin material 4 is formed by laminating a cushion layer 7 on the back surface of a ground cloth 4b having a raised hair 4a on the surface, and a hot melt adhesive or the like on the back surface of the cushion layer 7. Adhesive 5
Has been applied. Then, the raised skin material 4 and the lower mold 1
The use of the upper mold 2 and the upper mold 2 is the same as that used in the production of the conventional skin adhesive member, but in the present invention, a plurality of needle-shaped protrusions 9 are provided between the raised skin material 4 and the upper mold 2. At the same time, a breathable sheet material 10 formed in a shape corresponding to the irregular shape of the base material 3 is interposed to pressurize between the lower mold 1 and the upper mold 2 to raise the raised skin material 4 and the base material. The feature is that the material 3 and the material 3 are bonded and integrated.

That is, when pressure is applied between the lower mold 1 and the upper mold 2, the tips of the needle-like protrusions 9 of the cloth for cloth 10 enter between the naps 4a and press the ground cloth 4b to press the napped skin material 4. The whole of the nap is pressed to bond the napped skin material 4 to the uneven base material 3 integrally. In this case, the napped 4a
Unlike the conventional case, the hair is not directly pressed by the lower surface of the upper mold 2 and hair fall is reliably prevented.

The clothing 10 is made of, for example, a breathable fiber knitting or metal knitting, or a synthetic resin plate, and is easily and inexpensively molded. Innumerable needle-shaped projections 9 are formed. Further, in order to effectively prevent hair fall, the needle-like protrusions 9 are preferably about 0.5 to 2.5 times as long as the length of the naps 4a, and the needle diameter is about 0.1 to 1.0 mm. The clothing 10 is attached along the uneven shape in the upper mold 2, and both ends thereof are fixed to the upper mold 2 by, for example, a clamper 11 or the like. In addition to the wooden board, the base material 3 may be a hard material such as a synthetic resin plate or an iron plate, or a soft material such as rubber or urethane.

In order to add the raised skin material 4 along the uneven shape in the upper mold 2, for example, the raised skin material 4 vacuum-formed or press-formed into the same shape as the base material 3 in a separate step is used as the upper mold. It may be inserted into the upper mold 2 and vacuumed from the upper mold 2 through the breathable needle cloth 10 to bring the upper mold 2 into close contact. In this case, the napped skin material 4 is surely held by the woven cloth 10 formed in a shape corresponding to the uneven shape of the base material 3 without causing a set deviation, and the napped skin material 4 is pressed at the time of pressurization. Will be integrally bonded to the base material 3 having irregularities while being accurately positioned.

In the embodiment, when the upper mold 2 and the lower mold 1 are pressure-bonded to each other, the raised skin material 4 is heated by supplying a heating fluid such as steam or hot air to the upper surface of the raised skin material 4. The heating fluid is applied uniformly and smoothly without causing unevenness, wrinkles, etc., and the heating fluid has a plurality of discharge holes 2a provided on the lower surface of the upper mold 2 and a plurality of through holes provided on the clothing cloth 10. It is configured so as to be uniformly ejected to the surface of the raised skin material 4 having air permeability through the pores 10a. After the raised skin material 4 and the base material 3 are bonded and integrated as described above, the upper mold 2 and the needle cloth 10 are lifted to take out the skin adhesive member, and thereafter the same process is repeated to raise the raised hair 4a. Thus, the skin adhesive member of excellent quality with no hair fall is continuously produced.

2 to 4 show a molding process of a sheet material for an automobile according to the second invention, in which 4 is set between the lower mold 1 and the upper mold 2 to form the lower mold 1. A raised skin material adhered to a pad material 6 made of polyurethane foam placed on the raised skin material, wherein the raised skin material 4 has raised hairs 4a on the surface as in the first invention. The configurations of the material 4 and the lower mold 1 and the use of the upper mold 2 are the same as those used in the production of the conventional skin adhesive member and skin adhesive sheet. Further, in the present invention, a flexible sheet-shaped cover cloth 10 having a plurality of needle-like projections 9 is interposed between the raised skin material 4 and the upper mold 2 to interpose the lower mold 1 and the upper mold 2. By applying pressure between them, the raised skin material 4 and the pad material 6 are bonded and integrated, and the upper die 2 is composed of split dies 21 and 22 corresponding to the uneven shape of the sheet material. The napped skin material 4 is napped 4a of the napped skin material 4 such that the split molds 21, 22 and the like descend in a direction substantially orthogonal to the surface.
It is characterized in that the pressure is applied through the clothing 10 oriented in the same direction as.

That is, a sheet-shaped needle cloth 10 having a large number of needle-like protrusions 9 facing the raised hairs 4a of the raised hair skin material 4 is provided on the lower surface of the raised hair skin material 4 covering the pad material 6 on the lower mold 1. When the upper die 2 pressurizes the needle-like protrusions 9, the tips of the needle-like protrusions 9 enter between the naps 4a and press the ground cloth 4b to press the whole napped skin material 4 against the pad material 6. The upper surface of the upper mold 2 is composed of divided dies 21, 22 and the like corresponding to the uneven shape of the sheet material. Lower mold 1 so as to descend in a direction substantially orthogonal to the entire surface of
It is assumed that the needle-like projections 9 of the clothing cloth 10 interposed between the upper mold 2 and the upper mold 2 are always pressed in the same direction as the bristle direction.
In this case, the raised hairs 4a are not directly pressed by the lower surface of the upper mold 2 as in the conventional case, and the hair fall is surely prevented.

The clothing 10 is formed easily and inexpensively by using, for example, a synthetic resin plate, and in the embodiment, when the upper mold 2 and the lower mold 1 are pressure-bonded to each other, a raised skin is used. The heating fluid such as steam or hot air is supplied to the upper surface of the material 4 so that it can be uniformly and smoothly attached to the raised skin material 4 without causing irregularities or wrinkles. A plurality of discharge holes 2a provided on the lower surface of the mold 2 and a plurality of vent holes 10a provided on the clothing 10.
It is made to spray uniformly on the surface of the breathable raised skin material 4 through.

It should be noted that each of the divided molds 21 and 22 of the upper mold 2 described above may be independent as shown in FIG.
Of course, as shown in FIG. 4, they may be connected by a hinge 13. And then, brushed skin material 4
After the pad material 6 and the pad material 6 are bonded and integrated, the upper mold 2 and the needle cloth 10 are lifted to take out the skin adhesive sheet, and thereafter, the same steps are repeated to obtain an excellent quality in which the raised hairs 4a do not fall over. Will be continuously produced.

Next, FIG. 5 is for explaining the embodiment of the third invention, and although the explanation of the portions common to the second invention is omitted, the upper mold 2 and the raised skin material 4 are shown. Instead of the needle cloth interposed between the pad material 6 and the pad material 6, a shape-retaining shape having a number of needle-like protrusions 9 preformed in a shape corresponding to the uneven shape of the pad material 6 and directed toward the nap of the napped skin material 4 Formed Cloth 20
If the molding cloth 20 is pressed by the upper mold 2, the upper mold 2 is pressed downward without using the split mold unless the unevenness of the pad material 6 is complicated or is deep. The formed clothing 20 can be pressed by the pressure in a direction substantially orthogonal to the entire surface of the pad material 6, and the same effect as the second invention can be expected.

In addition, the molded clothing 20 is, for example, a spring.
If it is connected to the upper part of the upper mold 2 by 14, the molded clothing 20 can be synchronized with the operation of the upper mold 2 without using any special driving means. Even in the third invention, after the raised skin material 4 and the pad material 6 are bonded and integrated,
Raise the upper die 2 and the forming cloth 20 to take out the skin adhesive sheet, and then repeat the same steps to raise the hair.
4a will be continuously produced with excellent quality epidermal adhesive sheet without hair fall. In any of the above-mentioned first to third inventions, when the needle-like projection 9 is damaged, it can be easily repaired only by replacing the clothing cloth 10 or the formed clothing cloth 20, and the workability and It is also economical.

[0016]

As is apparent from the above description, the present invention provides a skin adhesive member which does not cause hair fall even when a door trim base material having an uneven surface and a pad material such as a bucket-like sheet are used. And the skin adhesive sheet can be produced efficiently, and the manufacturing cost of the mold is extremely low.
When the needle-like protrusion is broken, it can be replaced only by changing the cover cloth, so that it is possible to exert an excellent effect on maintenance workability. Therefore, the present invention is extremely large in that it contributes to the development of industry as a method for producing a skin adhesive member and a skin adhesive sheet that eliminates the conventional problems.

[Brief description of drawings]

FIG. 1 is a partially cutaway front view showing a bonding step of an embodiment of the first invention.

FIG. 2 is a partially cutaway front view showing an adhering step of an embodiment of the second invention.

FIG. 3 is an enlarged cross-sectional view of an essential part showing a state before bonding in the second invention.

FIG. 4 is a partially cutaway front view of an essential part showing a bonding step of another embodiment of the second invention.

FIG. 5 is a partially cutaway front view showing a bonding step of an example of the third invention.

[Explanation of symbols]

 1 Lower mold 2 Upper mold 3 Lower mold 4 Raised skin material 4a Raised 6 Pad material 9 Needle-like protrusions 10 Needle cloth 20 Molded needle cloth 21 Split type 22 Split type

Claims (5)

(57) [Claims] 1. A base material and a raised skin material are set between a lower mold and an upper mold, and pressure is applied by the upper mold to bond and integrate the raised skin material to the surface of a base material having an uneven surface. In the method for manufacturing a skin adhesive member, innumerable needle-shaped projections are formed between the upper mold and the raised skin material in a shape corresponding to the irregular shape of the base material, and are projected toward the raised hair of the raised skin material. A method for manufacturing a skin-adhesive member, which comprises pressurizing by interposing the above-mentioned clothing. 2. The method for producing a skin-adhesive member according to claim 1, wherein the heating fluid is supplied through a breathable cloth to apply pressure. 3. A skin adhesive member in which a pad material and a napped skin material are set on a lower mold, and the napped skin material is adhered and integrated with the surface of a pad material having an uneven surface by pressurizing by the upper mold. In the method for manufacturing an epidermal adhesive sheet, a needle cloth having innumerable needle-shaped projections protruding toward the raised hair of the raised skin material is interposed between the upper die and the raised skin material, and the upper die has an uneven shape. A method for manufacturing a skin adhesive sheet, which is a corresponding split mold, and is lowered and pressed in a direction substantially orthogonal to the entire surface of the pad material. 4. A skin adhesive member in which a pad material and a napped skin material are set on a lower mold, and the napped skin material is adhered and integrated with the surface of a pad material having an uneven surface by pressurizing by the upper mold. In the method for manufacturing the skin adhesive sheet, innumerable needle-shaped projections are formed between the upper mold and the napped skin material to have a shape corresponding to the uneven shape of the pad material, and the innumerable needle-shaped projections for napping of the napped skin material are projected. A method for producing a skin adhesive sheet, which comprises pressurizing by interposing a molded clothing. 5. The method for producing a skin adhesive sheet according to claim 3, wherein the heating fluid is supplied through a breathable cloth to pressurize.