JP3550819B2 - Method and apparatus for manufacturing interior materials - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention provides a method of manufacturing an interior material including a base material formed into a predetermined shape, and a skin material locally adhered to a predetermined portion of a surface of the base material, and a method of manufacturing the interior material. The present invention relates to a manufacturing device such as a molding die and a skin material conveying / sucking device used for the embodiment.
[0002]
[Prior art]
As an example of this type of interior material, a door trim of a vehicle door can be cited as a typical example. As shown in FIGS. 8 and 9, the door trim includes an interior member 10a having a skin material and a skin material. The interior material 10 is formed by overlapping the interior portions of both interior members 10a and 10b with each other, and joining the overlapped portions by screws or the like. I have.
[0003]
In the interior material, each of the base materials 11a and 11b is separately formed, and a skin material 12 is attached to the surface of one of the base materials 11a to form one interior member 10a and the other base material 11b It is formed by joining these two interior members 10a and 10b with itself as the other interior member 10b.
[0004]
[Problems to be solved by the invention]
By the way, as for the interior material 10, as described above from the viewpoint of its structure, a step of separately molding each of the base materials 11 a and 11 b, a step of attaching the skin material 12 to the surface of the base material 11 a, A step of joining the members 10a and 10b to each other is required. For this reason, there are many manufacturing steps of the interior material 10, and the production requires considerable time and labor, and the production cost of the interior material increases.
[0005]
Accordingly, it is an object of the present invention to change the structure of the interior material, reduce the number of manufacturing steps, reduce the time and labor required for the production, and enable automation of the production of the interior material.
[0006]
In order to achieve the above object , the present invention provides a method in which a skin material is detachably adsorbed to a predetermined portion of an upper mold surface by a negative pressure, and is melted on a lower mold surface facing the same mold. An interior material in which a synthetic resin in a state is supplied, the synthetic resin is compressed by the upper mold and the lower mold to form a base material having a predetermined shape, and the skin material is adhered to the surface of the base material. In the manufacturing method, in the step of adsorbing the skin material on the mold surface of the upper mold, an excess portion of the skin material is cut, and the skin material is attached to the surface of the base material. It is a creation method of a characteristic interior material.
[0009]
In carrying out the method for manufacturing an interior material according to the present invention,
It is desirable to adopt a molding die in which an adsorption site where the skin material is adsorbed on the mold surface of the upper die is formed of a breathable material, and the adsorption site is connected to a negative pressure supply source. .
[0010]
In carrying out the method for manufacturing an interior material according to the present invention,
A transport / adsorption device for transporting and adsorbing the skin material to the upper mold, wherein the clamping means is provided on a transport trolley and sets the skin material in a tensioned state, and is set by the clamp means. Positioning means for positioning the skin material with respect to the mold surface of the upper mold, and the skin material set on the clamp means by a lifting operation provided so as to be able to ascend and descend below the clamp means, and employing a lifting means for adsorbing at tough position of the mold surface of the upper die, the transport and adsorption apparatus provided with a cutting means for cutting the excess portion of the skin material is sucked and held on the mold surface of the upper die It is desirable.
[0012]
[Action and Effect of the Invention]
According to the manufacturing method of the interior material according to the present invention, since it is possible to perform the molding of the base material, the sticking of the skin material to the surface of the substrate at the same time, as in the conventional method of manufacturing the interior material, and to adopt a pre-split two forming step of forming separately the two substrates, and affixing step adhering the skin material to the surface of one substrate, and the bonding step of bonding the two interior members together In comparison, the manufacturing process is simple, the time required for manufacturing the interior material can be shortened, and the labor can be reduced, so that the required interior material can be provided at low cost.
[0013]
Further, in implementing the method for manufacturing an interior material according to the present invention, if the above-described molding die and the conveying / sucking device are employed, the loading of the skin material set in the tension state into the molding die, positioning, and the positioning of the skin material are performed. The adsorption of the upper mold surface to a predetermined portion can be performed mechanically, and these operations can be automated.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described with reference to the drawings. FIGS. 1 to 4 show a work sequence for manufacturing an interior material by a manufacturing method according to an example of the present invention. This manufacturing method is a method for manufacturing the door trim 10 of the vehicle door shown in FIG. 7, and the door trim 10 is attached to a base material 11 formed in a predetermined shape and a predetermined portion on the surface of the base material 11. And a covered skin material 12. The base material 11 is integrally formed of a synthetic resin, and the skin material 12 is a woven or knitted fabric, nonwoven fabric, synthetic leather, or the like made of various fibers. The manufacturing method is carried out using a skin material transport / suction device 20 shown in FIGS. 1 to 3 and 5 and a molding die 30 shown in FIG.
[0015]
As shown in FIGS. 1 and 5 in particular, the transport / suction device 20 constitutes a transport trolley 21, a guide mechanism 22 provided along the outer surface of the upright wall 21a on the trolley 21, and a guide mechanism 22. A frame-shaped clamp 23 is provided on the upper bracket 22a so as to protrude outward, and an elevating member 24 is attached to a pair of pillars 22c located between the upper and lower brackets 22a and 22b constituting the guide mechanism 22 so as to be able to ascend and descend. ing. The upper bracket 22a is provided with a pair of positioning holes 22a1.
[0016]
The clamp 23 sets the skin material 12 in a tensioned state with the skin material 12 sandwiched between frames, and the elevating member 24 is located below the clamp 23. The elevating member 24 includes a plate-shaped base portion 24a, a convex portion 24b provided on the base portion 24a, and a blade portion 24c disposed between the base portion 24a and the convex portion 24b. The elevating member 24 is attached to the two column portions 22c so as to be able to move up and down by a base portion 24a, and is moved up and down by a hydraulic cylinder (not shown).
[0017]
The convex part 24b has a surface 24b1 corresponding to a skin material adsorption site on a mold surface of an upper die constituting the molding die 30 described later, and the blade part 24c has a base part 24a as shown in FIG. And a plurality of compression springs 24d are interposed between the base part 24a and the convex part 24b, and the convex part 24b is resilient to the base part 24a. It is supported and assembled.
[0018]
As shown in FIG. 4, the molding die 30 includes a lower die 31 and an upper die 32. The lower die 31 has a die surface 31a of a predetermined shape on the upper side, and a synthetic resin R melted on the die surface 31a. It has a supply path 31b for supplying. The upper mold 32 is composed of a non-breathable first mold part 32a and a gas-permeable second mold part 32b, and has a mold surface 32c of a predetermined shape below and a ventilation path 32d. . The second mold part 32b is made of a porous block made of a casting and is fitted to the first mold part 32a. The lower surface is exposed to form a part of the mold surface 32c of the upper mold 32, and the upper surface is a ventilation passage. It is exposed to 32d.
[0019]
The mold surface formed by the second mold portion 32b forms an adsorption site of the skin material 12. The upper die 32 is provided with a pair of positioning rods 32e at the end of the first die 32a. The positioning rod 32e protrudes downward by a predetermined length, and is formed so as to be inserted into each positioning hole 22a1 provided in the upper bracket 22a of the transport / suction device 20.
[0020]
The manufacturing method according to the present invention is carried out using the above-described conveying / sucking device 20 and the forming die 30. In the manufacturing, first, as shown in FIG. The skin material 12 is set in a tension state on the clamp 23, and the set skin material 12 is transported between the upper and lower heaters H, and heated until the surface temperature of the skin material 12 becomes about 120 ° C. to 150 ° C. The temperature is raised to a temperature at which vacuum forming is possible.
[0021]
Next, the transport / suction device 20 is transported to the molding process, and the clamp 23 is disposed below the upper die 32 of the molding die 30 as shown in FIG. The position is adjusted so that it can be inserted into each positioning hole 22a1 of the guide mechanism 22, and then the upper die 32 is lowered and each positioning rod 32e is inserted into each positioning hole 22a1 to position the clamp 23.
[0022]
Next, the elevating member 24 of the transport / suction device 20 is lifted to lift the set skin material 12 at the surface 24b1 of the convex portion 24b, and as shown in FIG. It is resiliently brought into contact with the suction site on the surface 32c. In the upper mold 32, a negative pressure is supplied to the second mold part 32b through the negative pressure supply path 32d. As a result, the skin material 12 that is in contact with the suction portion of the mold surface 32c of the upper mold 32 is sucked and held by the suction portion.
[0023]
Further, after the convex portion 24b comes into contact with the mold surface 32c of the upper die 32 and stops rising, the base 24a of the elevating member 24 slightly deflects the compression spring 24d to rise integrally with the blade portion 24c. As shown in FIG. 6, the cutting edge of the blade portion 24c abuts on the skin material 12 held by suction, and cuts off an excess part of the skin material 12.
[0024]
Next, after the transport / suction device 20 is retracted from the molding device, the synthetic resin R in a molten state is supplied onto the mold surface 31a of the lower mold 31 of the molding die 30 as shown in FIG. The synthetic resin R is compression-molded between the two dies 31 and 32 to produce the base material 11. At this time, the skin material 12 adsorbed and held on the mold surface 32c of the upper mold 32 is attached to the surface of the base material 11, and when the supply of the negative pressure to the second mold portion 32b of the upper mold 32 is stopped, the skin material is 12 is separated from the mold surface 32c of the upper mold 32. Thereby, the door trim shown in FIG. 7 is manufactured.
[0025]
As described above, according to the manufacturing method of the present invention, the molding of the base material 11 and the attachment of the skin material 12 to the surface of the base material 11 can be performed at the same time. Of conventional interior materials manufactured by adopting two molding steps for separately molding the surface, a sticking step of sticking a skin material to the surface of one base material, and a joining step of joining both interior members to each other The manufacturing process is simpler than the method, the time required for manufacturing the door trim 10 can be shortened, the labor can be reduced, and the door trim 10 can be provided at a low cost.
[0026]
Further, by employing the transfer-suction device 2 0 Contact and mold 30 according to the present invention, tension in the loading to the mold 30 of the set skin material 12, positioning, and the skin material 12 of the upper mold 32 Adsorption to a predetermined portion of the mold surface can be performed mechanically, and these operations can be automated.
[Brief description of the drawings]
FIG. 1 is a side view of a transport / suction apparatus showing a state in which a skin material set by the transport / suction apparatus according to the present invention is subjected to a heat treatment.
FIG. 2 is a partially omitted vertical cross-sectional view of the transport / suction device and the upper mold, showing a state in which a skin material is carried in below the upper die by the transport / suction device.
FIG. 3 is a partially omitted vertical sectional view of the transport / suction device and the upper mold, showing a state in which a skin material is in contact with a mold surface of the upper die by the transport / suction device.
FIG. 4 is a longitudinal sectional view showing a state immediately before molding of a molding die according to the present invention.
FIG. 5 is a perspective view of the transport / suction device.
FIG. 6 is an enlarged view of a portion indicated by an arrow 6 in FIG. 3 showing an operation state of a blade unit in the transport / suction device.
FIG. 7 is a longitudinal sectional view of a door trim manufactured by the manufacturing method of the present invention.
FIG. 8 is a longitudinal sectional view of a conventional door trim.
FIG. 9 is a schematic explanatory view showing an example of manufacturing the door trim.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Door trim, 11 ... Substrate, 12 ... Skin material, 20 ... Transport / suction device, 21 ... Transportation trolley, 24b ... Protrusion, 24c ... Blade part, Conveyance trolley, 22 ... Guide mechanism, 23 ... Clamp, 24 ... Lifting member, 30 molding die, 31 lower die, 31a die surface, 32 upper die, 32a first die portion, 32b second die portion, 32c die surface.

Claims (6)

The skin material is removably adsorbed to a predetermined portion of the upper mold surface by negative pressure, and a synthetic resin in a molten state is supplied to the lower mold surface located opposite to the upper mold, and the synthetic resin is removed. In the method of manufacturing an interior material in which the upper mold and the lower mold are compressed to form a base material having a predetermined shape and the skin material is adhered to the surface of the base material.
An interior material , wherein an excess portion of the skin material is cut in the step of adsorbing the skin material onto the mold surface of the upper mold, and the skin material is attached to the surface of the base material. Manufacturing method. When adsorbing the skin material on a predetermined portion of the upper mold surface, the surface temperature of the skin material is heated to a predetermined temperature. One Manufacturing method of interior material described in. The suction part where the skin material is adsorbed on the upper mold surface is formed of a gas-permeable material, and the suction part is connected to a negative pressure supply source. Mold for interior material used to carry out the method of manufacturing. A transport / suction device for transporting and adsorbing the skin material to the upper mold, wherein the clamping device is provided on a transport carriage and sets the skin material in a tensioned state, and is set by the clamp device. Positioning means for positioning the skin material with respect to the mold surface of the upper mold, and the skin material set on the clamp means by a lifting operation provided so as to be able to ascend and descend below the clamp means, and 2. The apparatus according to claim 1, further comprising: lifting means for adsorbing a predetermined portion of the upper mold surface, and cutting means for cutting an excess portion of the skin material adsorbed and held on the upper mold surface. Or a transport / suction device used to carry out the production method according to 2. The skin material is detachably adsorbed to a predetermined portion of the upper mold surface by negative pressure, and a base material molded in a predetermined shape in advance is placed on the lower mold surface, and the base material together with the base material In a method for manufacturing an interior material in which the skin material is compressed by the upper mold and the lower mold so that the skin material is adhered to the surface of the base material,
  In the step of adsorbing the skin material to a predetermined portion of the mold surface of the upper mold, an excess portion of the skin material is cut and the skin material is locally adhered to the surface of the base material. A method for producing an interior material, comprising: 6. The method for manufacturing an interior material according to claim 5, wherein the surface temperature of the skin material is heated to a predetermined temperature when the skin material is adsorbed to a predetermined portion of the upper mold surface.

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