JP2782613B2 - Manufacturing method of interior materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an interior material of an automobile or the like having a deep drawing portion, an undercut molding portion, a post-processing portion, and the like. , Door trim, rear parcel, dashboard, etc.

[0002]

BACKGROUND OF THE INVENTION For example, an automobile door trim (1) as shown in FIG. 6 is composed of a base material (2) and a skin material (3) attached to the surface of the base material (2). A portion (4) protrudes, and a decorative material (5) of a different color, a different pattern, or a different material from the skin material (3) is applied on the upper side of the pocket portion (4).

[0003]

2. Description of the Related Art Conventionally, as shown in FIG. 7, a base material (2) of a door trim (1) is made of a molding material (6) such as a resin felt, a synthetic resin-impregnated polyurethane foam sheet and a thermoplastic plastic sheet as an upper mold. Mold consisting of (8) and lower mold (9)
(7), and as shown in FIG. 8, the molding material (6) is manufactured by press molding or vacuum molding between the upper mold (8) and the lower mold (9).

At the time of the above molding, a pocket portion (2A), a fitting groove (2B) for fitting the peripheral edge of the decorative material and the like are formed. After molding, the upper edge bent portion (2C) and the pocket portion are formed by post-processing. The door trim (1) shown in FIG. 9 is provided with an opening (2D) of (2A).
Substrate (2).

[0005]

In the above-mentioned conventional manufacturing method, the pressing force at the time of forming the fitting groove (2B), which is a deep drawing forming part, at the time of forming has a large stretching force on the parts shown in FIGS. The structure of this part becomes coarse or thin and the mechanical strength decreases, and the upper edge bent part (2C), which becomes the undercut part in molding, requires post-processing. In addition, when an opening (2D) is further provided in the pocket portion (2A), it is difficult to perform a cutting process such as press cutting in terms of shape.

[0006]

According to the present invention, as a means for solving the above-mentioned conventional problems, a substrate (2) having a predetermined shape is provided.
In an interior material comprising a skin material (3) adhered to the surface of the base material (2), divided portions (2E, 2F, 2G) obtained by dividing the base material (2) at predetermined locations are formed. And the divided part (2E, 2F, 2G)
To provide a method for manufacturing an interior material in which the divided portions (2E, 2F, 2G) are joined by forming a base material (2) and applying a skin material (3).

The base material used in the present invention includes:
Sheets of thermoplastics such as polyethylene, polypropylene, polyvinyl chloride, acrylonitrile-butadiene-styrene copolymer, thermoplastic polyurethane, polyamide, and polyester, resin felt, synthetic resin-impregnated polyurethane foam, etc. In the case of a sheet impregnated with a thermosetting resin such as an impregnated polyurethane foam sheet, hot pressing is mainly applied, and in the case of a thermoplastic sheet, the sheet is mainly cold-pressed and / or heated and softened. Vacuum forming is applied.

The skin material used in the present invention may be a thermoplastic sheet such as a polyvinyl chloride sheet, a thermoplastic elastomer sheet (for example, a polyolefin-based thermoplastic elastomer sheet or a polyester-based thermoplastic elastomer sheet), or the thermoplastic sheet. A laminated sheet of a sheet and a plastic foam such as a polyethylene foam, a polypropylene foam, a polyvinyl chloride foam, and a polyurethane foam, a fiber woven fabric, a nonwoven fabric, natural leather, and synthetic leather are used.

As the material of the decorative material used in the present invention, there is the same material as the skin material, but accents are given as a different color, a different pattern, or a different material from the skin material.

In the present invention, the base material is not integrally formed, but each divided portion is molded at a predetermined position, and then the divided portions are combined to form a base material. In the case of a divided portion that requires post-processing such as a shape that does not exert a large stretching force during molding, a shape in which an undercut portion is not formed in molding each divided portion, and a cutting process of an opening, etc. Care must be taken to provide a shape that facilitates processing.

The above-mentioned divided parts are combined to form a base material, and the divided parts are joined by applying a skin material. A hot-melt sheet, a hot-melt adhesive, or a normal adhesive is used for applying the skin material.

[0012]

In the present invention, the base material (2) is divided into the divided portions (2E, 2E).
(F, 2G) has a shape that does not exert a large stretching force during molding, or a shape that does not form an undercut portion during molding, or a shape that facilitates post-processing when post-processing is required As a result, the structure of each of the divided portions (2E, 2F, 2G) is extremely easy, and since no stretching force is applied, the structure is prevented from becoming coarse or thin. Also, post-processing for the divided portion (2G) requiring post-processing is easy. In addition, if different shapes, sizes, designs, etc. are combined for each divided part, various interior materials can be assembled by arbitrarily selecting, for example, the shape, size, presence / absence of a decorative portion, etc. of the armrest. It also reduces costs. The divided portions (2E, 2F, 2G) thus formed or post-processed are combined and joined by the skin material (3).

[0013]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to one embodiment shown in FIGS. 1 to 5. As shown in FIG. 1, a base material (2) of a door trim is composed of an upper part (2E), a center part (2F), and a lower part. It is divided into parts (2G). An upper edge bent portion (2C) is formed in the upper portion (2E). As shown in FIG. 2, the upper die (11) and the lower die (12) of the molding die (10) are formed.
There is no undercut formed portion when formed between.

In the central portion (2F), the upper side and the left and right side portions of the fitting groove (2B) of the decorative material peripheral portion are formed.
As shown in FIG. 3, the lower edge of the central portion (2F) is a free end, and the pressing force at the time of forming the fitting groove (2B) slides in the direction of the arrow of the portion C shown in FIG. And no stretching force acts on the portion C.

Further, the lower portion (2G) is formed with a lower side portion of a fitting groove (2B) at the periphery of the decorating material, and as shown in FIG. 4, the upper edge portion of the lower portion (2G) is formed. Is the free end and the mating groove
(2B) The pressing force at the time of molding is absorbed by the sliding of the portion of the hook shown in FIG. 4 in the direction of the arrow, the stretching force does not act on the portion of the hook, and the pressing force of the lower portion (2G) is lower. Since the edge is also a free end, the shaping of this part is merely a bending and bending shaping, and naturally no stretching force is exerted. The lower portion (2G) has a substantially flat shape and is easily supported by a jig or the like, and the cutting of the opening (2D) is extremely easy.

The upper part (2E), the center part (2F) and the lower part (2G) provided with the opening (2D) are combined as shown in FIG. 5, and a skin material (3) is attached. It is joined by doing.

[0017]

Therefore, in the present invention, interior materials for automobiles and the like having a deep drawing portion, an undercut forming portion, a post-processed portion and the like can be formed very easily, and there is no reduction in strength due to the stretching force at the time of forming.

[Brief description of the drawings]

 1 to 5 show one embodiment of the present invention.

FIG. 1 is a perspective view of a divided state.

FIG. 2 is an explanatory view of an upper part molding state.

FIG. 3 is an explanatory view of a central part forming state.

FIG. 4 is an explanatory view of a lower part molding state.

FIG. 5 is a side sectional view of a door trim.

FIG. 6 is a perspective view of a door trim. FIGS. 7 to 9 show a conventional example.

FIG. 7 is an explanatory view before molding.

FIG. 8 is an explanatory view of a molding state.

FIG. 9 is a perspective view of a door trim base material.

[Explanation of symbols]

 1 Door trim 2 Base material 2A Pocket 2B Fitting groove 2C Upper edge bend 2E Upper part 2F Central part 2G Lower part

Claims (1)

(57) [Claims] 1. An interior material comprising a base material having a predetermined shape and a skin material adhered to the surface of the base material, each of which is formed by dividing the base material into predetermined portions. A method for producing an interior material, comprising forming a base material by combining parts and joining the divided parts by applying a skin material.