JP3553131B2 - Manufacturing method of products with skin - Google Patents

Manufacturing method of products with skin Download PDF

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Publication number
JP3553131B2
JP3553131B2 JP11599994A JP11599994A JP3553131B2 JP 3553131 B2 JP3553131 B2 JP 3553131B2 JP 11599994 A JP11599994 A JP 11599994A JP 11599994 A JP11599994 A JP 11599994A JP 3553131 B2 JP3553131 B2 JP 3553131B2
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base material
skin
skin material
outer peripheral
peripheral edge
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JPH07299868A (en
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日吉 石川
裕造 伊藤
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Inoac Corp
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Inoac Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/36—Bending and joining, e.g. for making hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B29C63/04—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/567—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using a tamping or a swaging operation, i.e. at least partially deforming the edge or the rim of a first part to be joined to clamp a second part to be joined
    • B29C65/568—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using a tamping or a swaging operation, i.e. at least partially deforming the edge or the rim of a first part to be joined to clamp a second part to be joined using a swaging operation, i.e. totally deforming the edge or the rim of a first part to be joined to clamp a second part to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61—Joining from or joining on the inside
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

【０００１】
【産業上の利用分野】
本発明は、車両のピラーガーニッシュ等の表皮付き製品を製造する方法に関する。
【０００２】
【従来の技術】
ピラーガーニッシュ等の車両内装部品には、射出成形されたポリプロピレン樹脂やＡＢＳ樹脂等の基材表面を、意匠性に優れたファブリックや塩化ビニル樹脂等の表皮材で覆ったものが多用されている。
斯る表皮付き製品は、基材表面を覆う表皮材の外周縁を基材裏面に巻き込んで接合するため、従来の手作業では、表皮材と基材の位置合わせに手間取り、生産効率が悪った。こうしたことから、この製造を機械化する試みの下、圧着成形，真空成形，スタンピング等の各種製造法が提案されてきた。
ところが、真空成形では表皮材の無駄が多く、また、通気性のあるファブリック等を使用することができなかった。同様に、スタンピング方式においても、表皮材の仕様に制約を受けるものがあった。
そこで、制約の少ない圧着成形が専ら用いられてきた。その圧着成形の製造工程について以下に説明する（図９〜図１８）。
【０００３】
まず、図９に示すごとく、下型３１の凹所３ａ内にやや浮いた状態で表皮材２を配設し、表皮材２の外周縁２１に設けた係止孔（図略）を、下型３１の上面から突出するセットピン３３に装着して位置決めする。一方、上型３４については、上記凹所３ａに嵌合する突出部３５の頂面に沿って基材１を装着する。突出部３５内に設けた公知の保持具３６で保持されたクリップ１３が、この基材１を位置決め固定する。尚、上記基材１には、予め接着剤を塗布しておく。
【０００４】
次に、上型３４を下降させ、その突出部３５を下型３１の凹所３ａ内に嵌入させる（図１０）。そして、基材１が表皮材２の一般部に密接するようにして、基材１を凹所３ａ底面へ圧接させる。その後、保持具３６によるクリップ１３の支持を解消し（図１１）、セットピン３３を下方へ引き込む（図１２）。これにより、表皮材２の外周縁２１がフリーとなり、自身の弾性力で斜めに浮き上がる。
【０００５】
しかる後、左右の表皮材外周縁２１の外側から内側（表皮材の巻き込み側）へスライド入れ子３７を進出させる（図１３）。表皮材外周縁２１は、上型突出部３５の側面に沿った位置に立ち上がる。その後、上型３４を上昇させ、突出部３５を下型凹所３ａ内から退出させる（図１４）。そうして、背後をスライド入れ子３７により押された表皮材外周縁２１を下型凹所３ａの開口内へ折り曲げていく（図１５）。そして、再び上型３４が下降し、その突出部３５を下型凹所３ａ内へ進入させ、表皮材外周縁２１を基材１の外周縁裏面へ折り込んでいく（図１６）。
かくして、基材１を表皮材２で覆った表皮付き製品が製造される。製品は、上型３４を再び上昇させて（図１７、図１８）、下型３１から取り出されることになる。
【０００６】
【発明が解決しようとする課題】
しかるに、上記圧着成形法によれば、表皮材の基材への装着作業が機械化できても、スライド入れ子等を設けた型構造が複雑且つ高価なものとなった。
更に、基材を表皮材の一般部へ圧着する操作と、表皮材外周縁を基材裏面へ折り込む操作とについて、上型をその都度上下動させなければならない二往復を必要とし、その結果、成形サイクルが長くなり、生産性が低かった。
【０００７】
本発明は上記問題点を解決するもので、型構造の複雑化とコストアップを招くことがなく、広い範囲の表皮材に適用でき、更には、サイクルタイムの短縮化をも実現できる表皮付き製品の製造方法を提供することを目的とする。
【０００８】
【課題を解決するための手段】
本第一発明の表皮付き製品の製造方法は、基材の表面を表皮材で覆ってなる表皮付き製品の製造方法であって、上記基材には裏面の外周縁に複数の係止突起を設け、該係止突起は、その基端部へ近づくに従い、基材の端縁からの距離を長くするよう配設され、また、該係止突起に対応させて上記表皮材には外周縁に複数の係止孔を設けて、上記基材裏面の少なくとも外周縁に接着剤を塗布する一方、該基材の表面を上記表皮材で覆い且つ該基材の外周縁に沿って裏面側へ折り曲げ、次いで、上記係止孔を上記係止突起に装着して表皮材を基材に位置決めした後、該表皮材の表面を下側にして下型上に載置し、その後、該基材を介して上方から該表皮材の一般部を押し型に係る主型の下降により押圧し、続いて、該基材の裏面に折り曲げられた表皮材の外周縁を上方から基材裏面に押し型に係る補助型の下降により押圧し、しかる後、更に、上記係止突起を表皮材の外周縁上に押し型に係る熱型の下降によりかしめ変形させることを特徴とする。
【０００９】
ここで、「上記基材裏面の少なくとも外周縁に接着剤を塗布する一方、斯る基材の表面を上記表皮材で覆い且つこの基材の外周縁に沿って裏面側へ折り曲げ、次いで、上記係止孔を上記係止突起に装着して表皮材を基材に位置決めした後、表皮材の表面を下側にして下型上に載置し、」では、基材裏面の外周縁に接着剤を塗布する動作は、その他の動作の前後、又は同時進行であってよい。例えば、表皮材を基材に位置決めした後に接着剤を塗布する場合を含む。
「表皮材の一般部」とは、表皮材の外周縁を除いた製品面を形成する中央部分をいう。
【００１０】
【作用】
本第一発明の表皮付き製品の製造方法によれば、基材表面を覆って設けた表皮材は、基材の裏面側へ折り曲げた外周縁の係止孔が基材裏面の係止突起に装着されると、確実に位置決めされる。この状態で、表皮材の表面を下側にして基材を上方から上記表皮材の一般部へ向かって押圧すると、表皮材一般部が外周縁方向へしごかれて皺等があっても消失する。
更に、基材の裏面に折り曲げられた上記表皮材の外周縁を上方より基材裏面に押圧すると、基材裏面の外周縁には接着剤が塗布されているので、表皮材の外周縁が接着材を塗布した基材裏面に接合されることになる。
斯る製法によれば、係止孔と係止突起によって、表皮材は基材裏面に折り曲げた状態で基材に保持されているので、従来の如き、スライド入れ子等を成形型に設ける必要はなく型構造が簡易化される。
そして、基材の表皮材一般部への圧接と、表皮材外周縁の基材裏面への圧接を同方向の上方より連続して行うことができるので、製造サイクルタイムが短縮化される。
【００１１】
加えて、係止突起を、その基端部へ近づくに従い、基材の端縁から遠のくよう配すると、表皮材の外周縁が基材裏面へ押し型に係る補助型の下降により押圧される過程で、基材の表側にある表皮材を引き寄せながら表皮材全体がピンと張った状態になり、表皮材の弛みが消失する。
また、係止突起が表皮材の外周縁上に押し型に係る熱型の下降によりかしめ変形させられるので、表皮材の基材への固定化をより確実なものとする。
【００１２】
【実施例】
以下、本発明を実施例に基づいて詳述する。
図１〜図８は、本発明に係る表皮付き製品の製造方法の一実施例を示す。ピラーに適用したものである。図１は基材を裏面側より見た全体斜視図、図２は表皮材外周縁を巻き込んだ状態の全体斜視図、図３は図２のIII −III 線に沿う断面図、図４は表皮材を装着した基材を挿置した金型の断面図、図５は図４のＡ部拡大断面図、図６〜図８は係止突起の他の例を示す斜視図である。
【００１３】
符号１は長板状の基材を示す。基材１の裏面側には、外周縁１１に沿って、円柱状の係止突起１２が適宜間隔をおいて形成されている。基材１は、ポリプロピレン樹脂（ＰＰ）製の射出成形品で、係止突起１２も一体成形したものである。基材１の材質としては、ＰＰの他、ＰＰＦ，ＡＢＳ，ＡＳＧ等が使用される。
基材１は、その端縁近くで湾曲する形状で、上記係止突起１２を図５のように基材１の外周縁で垂直に立設させる構成にしている。従って、係止突起１２は、その基端部に近づくにつれ端縁１３からの距離が長くなるように配設されている。尚、係止突起１２は、基材１に必ずしも垂直に立設されるものでなく、基材１の端縁付近の湾曲状態によって変わる。係止突起１２は、その基端部へ近づくに従い端縁１３から遠ざかる構成であればよい。
符号２は、基材１と相似形で、これよりもやや大きく成形された表皮材を示す。ここでは、パウダースラッシュ成形で造った塩化ビニル樹脂製表皮材２を用いている。表皮材２としては、他に発泡塩化ビニル樹脂等をラミネートしたもの、更には、ファブリック，本革等であってもよい。表皮材２の外周縁には、係止孔２２が各係止突起１２に対応する位置に設けられている。
【００１４】
表皮付き製品の製造方法は、まず、基材１の裏面外周縁１１に接着剤を塗布する。そして、図２に示すごとく、基材１の表面を表皮材２上に置いて、表皮材２の外周縁２１を基材１の外周縁１１に沿ってその裏面に折り曲げる。続いて、表皮材２の係止孔２２を、これに対応する基材１の係止突起１２に装着させることで、表皮材２を基材１へ位置決めする（図３）。尚、係止孔２２を係止突起１２に係合させる段階で接着剤を塗布しても構わない。
【００１５】
次に、表皮材２を装着した基材１を下型３１の凹所３ａ内に挿置する（図４）。凹所３ａは、表皮付き製品の外形に相当する凹みになっている。
【００１６】
その後、上方から押し型３２を下降させる。押し型３２は、主型３２Ａと補助型３２Ｂと熱型３２Ｃとで構成される。
主型３２Ａは、基材１の一般部にほぼ匹敵する大きさである。ここで、「基材の一般部」とは、基材１の外周縁を除いた略中央部分をいい、表皮材２の一般部が当接する部分である。補助型３２Ｂは、主型３２Ａの外周に位置し、基材１の各係止突起１２に対応する部分を除いてほぼ基材外周縁１１に沿う形状である。熱型３２Ｃは、補助型３２Ｂに付設されて基材１の各係止突起１２に対応する位置に設けられている。これら各型３２Ａ〜３２Ｃは、それぞれ異なるエアシリンダ４Ａ〜４Ｃの作動によって下降する。
【００１７】
最初に、主型３２Ａが下降し、基材１の一般部を押圧する。この押圧によって、表皮材２の一般部が型面に圧接する。この動作過程で、表皮材２の一般部は、外周縁２１方向へしごかれることになり、皺等があっても伸ばされ消失する。
従来のごとく表皮材２の一般面にも接着剤を塗布することができるが、そうすると、接着剤によって表皮材２の動きが拘束され、皺が残る傾向にある。しかるに、本実施例のごとく、一般面に接着剤を塗布しなければ、主型３２Ａが表皮材２の一般部をアイロンごてで押し当てたような状態とし、且つその弛みを外周縁２１の方へ押しやることができるので好都合となる。
【００１８】
続いて、補助型３２Ｂを下降させる。補助型３２Ｂが、係止突起１２に係止された表皮材外周縁２１を基材１の裏面外周縁１１に向けて押圧していく（図５）。この過程で、係止突起１２に装着された係止孔２２が係止突起１２の基端部に向かうに従って、上記主型３２Ａの動作により発生した弛みを吸収し、更に、基材１の表側に配した表皮材２を基材裏面側へ引き寄せていく。そして、外周縁１１に塗布した接着剤によって、基材１と表皮材２とが圧接固定される。
外周縁２１に寄せられた表皮材２の弛みは、補助型３２Ｂが基材１の裏面外周縁１１へ押圧していく過程で消え去る。そして、外周縁１１で、基材１の裏面へ表皮材２が弛みのない状態で綺麗に固着されていく。基材１の裏面外周縁１１寄りの形状が円弧を描いており、係止突起１２から外周縁１１までの距離が基材１に近づくにつれ長くなっているためである（図３〜図５）。尚、裏面外周縁１１では、表皮材２の皺等が寄っても不都合はない。製品の裏側に相当する部分だからである。
【００１９】
その後、熱型３２Ｃを下降させ、係止突起１２を押し潰して表皮材外周縁２１上に熱変形させ、かしめ状態とする。
熱かしめでは、加熱された熱型３２Ｃを係止突起１２に当てがい、この係止突起１２の先端を押し潰して表皮材２と基材１とを一体化させる。リベット状のかしめ部が形成されるよう、係止突起１２を押し潰す熱型３２Ｃ側に窪みを設けると、より好適となる。かくして、表皮材外周縁２１は確実に基材外周縁１１に固定されることになる。
上記係止突起１２としては、前述の円柱形以外に、図６に示す円筒形、図７に示すきのこ形、図８の二股形等種々の形状が使用できる。ここで、係止突起１２の長さは熱かしめで変形させることから短かめの方が良い。但し、短かすぎると、位置決めされた表皮材２が基材１から外れ易くなるため、図７，図８の形状とするのが好ましい。特に、図８ごとくの二股形の係止突起１２は、二股形によって表皮材２を装着し易く、更に一旦装着されると頭部がストッパとして働き、他のもの以上に好ましい形状になっている。尚、頭部のストッパは、内側だけに形成するものであってもよい。
【００２０】
その後、押し型３２（主型３２Ａ，補助型３２Ｂ，熱型３２Ｃ）を上昇させることで、所望の表皮付き成形品が取出せるようになる。
尚、製品の組み付けに支障がなく、表皮材２の装着強度も充分であれば、係止突起１２を熱変形させることは特に必要ない。斯る場合、係止突起１２が製品の組み付けに障害となるなら切削除去する。
【００２１】
このように構成した表皮付き成形品は、係止突起１２に係止孔２２を係合させることで表皮材２の基材１へのセットが容易になり、これに伴って、従来の圧着成形で要したスライド入れ子や基材の保持具等がいらなくなる。従って、下型は簡易治具でも足り、イニシャルコストが下がる。
また、表皮材２の巻き込み困難な箇所には、予め係止突起１２を設けることによって、接着剤の塗布作業が簡単となる。
更に、表皮材２を基材１へ固着する工程は、主型３２Ａ，補助型３２Ｂ，熱型３２Ｃへと順に皺を伸ばす方向で操作され、製品面とならない基材の裏面側へ皺や捩れが追いやられるので、品質欠陥を解消することになる。加えて、補助型３２Ｂの下降によって、係止孔２２が係止突起１２の基端部へと降りていくが、端縁１３と係止突起１２との距離が徐々に長くなっていくので、表皮材２を基材１の裏面側へ引き寄せる力が働き、表皮材全体の皺，弛み等を伸ばし、高品質製品を造りあげる。
そして、これら主型３２Ａ，補助型３２Ｂ，熱型３２Ｃの動作は、従来の圧着成形のように二往復する動作と異なり、上方から順次降下していく一方向動作であるので、成形サイクルが短くなり生産性が向上する。
もちろん、真空引き等をする製法でないため、表皮材の材質に制約はなく、広い範囲の表皮材を使用することが可能となる。
【００２２】
尚、本発明においては、前記実施例に示すものに限られず、目的，用途に応じて本発明の範囲で種々変更できる。基材１，表皮２の形状，材質等は実施例に限定するものでない。接着剤の基材への塗布は、その外周縁以外に行なうこともできる。更に、必要に応じて表皮材２側に塗布しても構わない。押し型３２を使用せず、手作業で基材１と表皮材２を押圧接合するようにしてもよい。
【００２３】
【発明の効果】
以上のごとく本発明の表皮付き製品の製造方法は、型構造を簡易にして種々の表皮材の適用が可能であるにとどまらず、生産性を向上させ、更には高品質製品を造りあげるなど優れた効果を発揮する。
【図面の簡単な説明】
【図１】本発明方法を説明する、基材を裏面側より見た全体斜視図である。
【図２】表皮材外周縁を巻き込んだ状態の基材裏面の全体斜視図である。
【図３】図２のIII −III 線に沿う断面図である。
【図４】表皮材を装着した基材を挿置した金型の断面図である。
【図５】図４のＡ部拡大断面図である。
【図６】係止突起の他の例を示す斜視図である。
【図７】係止突起の他の例を示す斜視図である。
【図８】係止突起の他の例を示す側面図である。
【図９】従来の製造方法を説明する金型の断面図である。
【図１０】従来の製造方法を説明する金型の断面図である。
【図１１】従来の製造方法を説明する金型の断面図である。
【図１２】従来の製造方法を説明する金型の断面図である。
【図１３】従来の製造方法を説明する金型の断面図である。
【図１４】従来の製造方法を説明する金型の断面図である。
【図１５】従来の製造方法を説明する金型の断面図である。
【図１６】従来の製造方法を説明する金型の断面図である。
【図１７】従来の製造方法を説明する金型の断面図である。
【図１８】従来の製造方法を説明する金型の断面図である。
【符号の説明】
１ 基材
１１ 外周縁
１２ 係止突起
１３ 端縁
２ 表皮材
２１ 外周縁
３１ 下型
３２ 押し型
３２Ａ 主型
３２Ｂ 補助型
３２Ｃ 熱型[0001]
[Industrial applications]
The present invention relates to a method for producing a product with a skin, such as a pillar garnish of a vehicle.
[0002]
[Prior art]
As vehicle interior parts such as pillar garnishes, those in which a base material surface such as injection-molded polypropylene resin or ABS resin is covered with a fabric having excellent design properties or a skin material such as vinyl chloride resin are often used.
In such a product with a skin, the outer peripheral edge of the skin material covering the base material surface is wound around and joined to the back surface of the base material, so that in the conventional manual work, it takes time to position the skin material and the base material, resulting in poor production efficiency. Was. For this reason, in an attempt to mechanize this production, various production methods such as compression molding, vacuum molding, and stamping have been proposed.
However, in vacuum forming, a large amount of skin material is wasted, and a breathable fabric or the like cannot be used. Similarly, in the case of the stamping method, there is a case in which the specifications of the skin material are restricted.
Therefore, compression molding with less restrictions has been exclusively used. The manufacturing process of the compression molding will be described below (FIGS. 9 to 18).
[0003]
First, as shown in FIG. 9, the skin material 2 is arranged in a slightly floating state in the recess 3 a of the lower mold 31, and a locking hole (not shown) provided in the outer peripheral edge 21 of the skin material 2 is moved downward. It is mounted on a set pin 33 protruding from the upper surface of the mold 31 and positioned. On the other hand, as for the upper mold 34, the base material 1 is mounted along the top surface of the protruding portion 35 fitted into the recess 3a. The clip 13 held by a known holder 36 provided in the protrusion 35 positions and fixes the substrate 1. Note that an adhesive is applied to the base material 1 in advance.
[0004]
Next, the upper mold 34 is lowered, and the protrusion 35 is fitted into the recess 3a of the lower mold 31 (FIG. 10). Then, the base material 1 is pressed against the bottom surface of the recess 3a so that the base material 1 comes into close contact with the general portion of the skin material 2. Thereafter, the support of the clip 13 by the holder 36 is released (FIG. 11), and the set pin 33 is pulled downward (FIG. 12). As a result, the outer peripheral edge 21 of the skin material 2 becomes free and floats obliquely by its own elastic force.
[0005]
Thereafter, the slide insert 37 is advanced from the outside of the left and right skin material outer peripheral edges 21 to the inside (the side where the skin material is wound) (FIG. 13). The outer peripheral edge 21 of the skin material stands up at a position along the side surface of the upper mold projection 35. Thereafter, the upper mold 34 is raised, and the protruding portion 35 is retracted from the lower mold recess 3a (FIG. 14). Then, the outer peripheral edge 21 of the skin material pressed behind by the slide insert 37 is bent into the opening of the lower mold recess 3a (FIG. 15). Then, the upper mold 34 descends again, and the projecting portion 35 enters the lower mold recess 3a, and the outer peripheral edge 21 of the skin material is folded into the outer peripheral back surface of the base material 1 (FIG. 16).
Thus, a product with a skin in which the base material 1 is covered with the skin material 2 is manufactured. The product is removed from the lower mold 31 by raising the upper mold 34 again (FIGS. 17 and 18).
[0006]
[Problems to be solved by the invention]
However, according to the above-mentioned press-molding method, even if the work of attaching the skin material to the base material can be mechanized, the mold structure provided with the slide inserts and the like becomes complicated and expensive.
Furthermore, for the operation of pressing the base material to the general portion of the skin material and the operation of folding the outer peripheral edge of the skin material to the back surface of the base material, the upper die needs to be moved up and down each time, which requires two reciprocations. The molding cycle was longer and the productivity was lower.
[0007]
The present invention solves the above-mentioned problems, and can be applied to a wide range of skin materials without incurring a complicated mold structure and an increase in cost, and further, a product with a skin that can also achieve a reduction in cycle time. It is an object of the present invention to provide a method for producing the same.
[0008]
[Means for Solving the Problems]
The method of manufacturing a product with a skin of the first invention is a method of manufacturing a product with a skin in which the surface of a base material is covered with a skin material, wherein the base material has a plurality of locking projections on an outer peripheral edge of a back surface. The locking projections are disposed so as to increase the distance from the edge of the base material as approaching the base end, and the outer peripheral edge is provided on the skin material corresponding to the locking projections. A plurality of locking holes are provided, and an adhesive is applied to at least the outer peripheral edge of the back surface of the base material, while the front surface of the base material is covered with the skin material and bent toward the back surface along the outer peripheral edge of the base material. Then, after positioning the skin material on the base material by attaching the locking hole to the locking projection, the skin material is placed on a lower mold with the surface of the skin material facing down, and then the base material is removed. From above, the general part of the skin material was pressed by the lowering of the main die relating to the pressing die, and then bent to the back surface of the base material The outer peripheral edge of the skin material is pressed against the back surface of the base material from above by the lowering of the auxiliary die according to the pressing die. It is characterized by swaging.
[0009]
Here, "while applying an adhesive to at least the outer peripheral edge of the back surface of the base material, the surface of the base material is covered with the skin material and bent along the outer peripheral edge of the base material to the back surface side, After attaching the locking holes to the locking projections and positioning the skin material on the base material, place the skin material on the lower mold with the surface of the skin material facing down. The operation of applying the agent may be before, after, or simultaneously with other operations. For example, the case where the adhesive is applied after positioning the skin material on the base material is included.
The “general portion of the skin material” refers to a central portion that forms a product surface excluding an outer peripheral edge of the skin material.
[0010]
[Action]
According to the method for manufacturing a product with a skin of the first invention, the skin material provided so as to cover the surface of the base material has locking holes at the outer peripheral edge bent toward the back surface side of the base material to the locking projections on the back surface of the base material. Once mounted, it is reliably positioned. In this state, when the base material is pressed from above toward the general portion of the skin material with the surface of the skin material facing downward, the general skin portion is squeezed in the outer peripheral direction and disappears even if there are wrinkles or the like. I do.
Further, when the outer peripheral edge of the skin material bent on the back surface of the base material is pressed against the rear surface of the base material from above, an adhesive is applied to the outer peripheral edge of the back surface of the base material. It will be joined to the back surface of the substrate to which the material has been applied.
According to such a manufacturing method, the skin material is held by the base material in a state of being bent to the back surface of the base material by the locking holes and the locking projections. And the type structure is simplified.
Then, the pressing of the base material to the general part of the skin material and the pressing of the outer peripheral edge of the skin material to the back surface of the base material can be continuously performed from above in the same direction, so that the manufacturing cycle time is shortened.
[0011]
In addition, when the locking projections are arranged farther away from the edge of the base material as they approach the base end, the outer peripheral edge of the skin material is pressed toward the back surface of the base material by the lowering of the auxiliary die relating to the die. As a result, the whole skin material becomes taut while pulling the skin material on the front side of the base material, and the slack of the skin material disappears.
In addition, since the locking projections are caulked and deformed on the outer peripheral edge of the skin material by the downward movement of the pressing die, the fixing of the skin material to the base material is further ensured.
[0012]
【Example】
Hereinafter, the present invention will be described in detail based on examples.
1 to 8 show one embodiment of a method for producing a product with a skin according to the present invention. Applied to pillars. 1 is an overall perspective view of the base material viewed from the back side, FIG. 2 is an overall perspective view of a state in which the outer peripheral edge of the skin material is wrapped around, FIG. 3 is a cross-sectional view taken along line III-III of FIG. 2, and FIG. FIG. 5 is a cross-sectional view of a mold in which a base material on which a material is mounted is inserted, FIG. 5 is an enlarged cross-sectional view of a portion A in FIG. 4, and FIGS. 6 to 8 are perspective views showing other examples of locking projections.
[0013]
Reference numeral 1 denotes a long plate-shaped substrate. On the back side of the base material 1, cylindrical locking projections 12 are formed along the outer peripheral edge 11 at appropriate intervals. The base material 1 is an injection molded product made of polypropylene resin (PP), and the locking projection 12 is also integrally formed. As a material of the base material 1, PPF, ABS, ASG, or the like is used in addition to PP.
The base material 1 has a shape that curves near the edge thereof, and has a configuration in which the locking projections 12 are vertically erected on the outer peripheral edge of the base material 1 as shown in FIG. Therefore, the locking projection 12 is arranged so that the distance from the edge 13 becomes longer as approaching the base end. Note that the locking projections 12 are not necessarily provided upright on the substrate 1, but change depending on the curved state near the edge of the substrate 1. The locking projection 12 may be configured to be away from the edge 13 as it approaches the base end.
Reference numeral 2 denotes a skin material having a shape similar to the base material 1 and slightly larger than this. Here, a vinyl chloride resin skin material 2 made by powder slush molding is used. The skin material 2 may be a material obtained by laminating a foamed vinyl chloride resin or the like, or may be a fabric, genuine leather, or the like. On the outer peripheral edge of the skin material 2, a locking hole 22 is provided at a position corresponding to each locking projection 12.
[0014]
In the method for producing a product with a skin, first, an adhesive is applied to the outer peripheral edge 11 of the back surface of the base material 1. Then, as shown in FIG. 2, the surface of the base material 1 is placed on the skin material 2, and the outer peripheral edge 21 of the skin material 2 is bent to the back surface along the outer peripheral edge 11 of the base material 1. Subsequently, the skin material 2 is positioned on the base material 1 by attaching the locking holes 22 of the skin material 2 to the corresponding locking projections 12 of the base material 1 (FIG. 3). Note that an adhesive may be applied at a stage where the locking holes 22 are engaged with the locking projections 12.
[0015]
Next, the substrate 1 on which the skin material 2 is mounted is inserted into the recess 3a of the lower mold 31 (FIG. 4). The recess 3a is a recess corresponding to the outer shape of the product with the skin.
[0016]
Thereafter, the pressing die 32 is lowered from above. The pressing die 32 includes a main die 32A, an auxiliary die 32B, and a thermal die 32C.
The main mold 32 </ b> A has a size almost comparable to the general portion of the base material 1. Here, the “general portion of the base material” refers to a substantially central portion of the base material 1 excluding the outer peripheral edge, and is a portion where the general portion of the skin material 2 abuts. The auxiliary mold 32B is located on the outer periphery of the main mold 32A, and has a shape substantially along the outer peripheral edge 11 of the substrate 1 except for a portion corresponding to each locking projection 12 of the substrate 1. The thermal mold 32C is attached to the auxiliary mold 32B and is provided at a position corresponding to each locking projection 12 of the base material 1. These dies 32A to 32C are lowered by the operation of the different air cylinders 4A to 4C, respectively.
[0017]
First, the main mold 32A descends and presses the general portion of the substrate 1. By this pressing, the general portion of the skin material 2 is pressed against the mold surface. In the course of this operation, the general portion of the skin material 2 is squeezed in the direction of the outer peripheral edge 21 and is stretched and disappears even if there are wrinkles or the like.
The adhesive can also be applied to the general surface of the skin material 2 as in the related art, but in this case, the movement of the skin material 2 is restricted by the adhesive, and wrinkles tend to remain. However, as in the present embodiment, if the adhesive is not applied to the general surface, the main mold 32A is pressed against the general portion of the skin material 2 with an ironing iron. It is convenient because it can be pushed to the side.
[0018]
Subsequently, the auxiliary mold 32B is lowered. The auxiliary mold 32B presses the outer peripheral edge 21 of the skin material locked by the locking projection 12 toward the outer peripheral edge 11 of the back surface of the base material 1 (FIG. 5). In this process, as the locking hole 22 attached to the locking projection 12 moves toward the base end of the locking projection 12, the slack generated by the operation of the main mold 32A is absorbed, and The skin material 2 disposed on the base material is drawn toward the back surface of the base material. Then, the base material 1 and the skin material 2 are pressed and fixed by the adhesive applied to the outer peripheral edge 11.
The slack of the skin material 2 brought to the outer peripheral edge 21 disappears in the process of the auxiliary mold 32B pressing the outer peripheral edge 11 of the back surface of the substrate 1. Then, at the outer peripheral edge 11, the skin material 2 is firmly fixed to the back surface of the base material 1 without slack. This is because the shape close to the outer peripheral edge 11 of the back surface of the substrate 1 draws an arc, and the distance from the locking projection 12 to the outer peripheral edge 11 becomes longer as approaching the substrate 1 (FIGS. 3 to 5). . In addition, there is no inconvenience even if wrinkles or the like of the skin material 2 approach on the back outer peripheral edge 11. This is because it corresponds to the back side of the product.
[0019]
Thereafter, the heat mold 32C is lowered, and the locking projections 12 are crushed to be thermally deformed on the outer peripheral edge 21 of the skin material to be in a caulked state.
In the heat staking, the heated thermal mold 32C is applied to the locking projection 12, and the tip of the locking projection 12 is crushed to integrate the skin material 2 and the base material 1. It is more preferable to provide a depression on the side of the thermal mold 32C that crushes the locking projection 12 so that a rivet-shaped caulked portion is formed. Thus, the outer peripheral edge 21 of the skin material is securely fixed to the outer peripheral edge 11 of the base material.
In addition to the above-mentioned columnar shape, various shapes such as a cylindrical shape shown in FIG. 6, a mushroom shape shown in FIG. 7, and a forked shape shown in FIG. Here, since the length of the locking projection 12 is deformed by heat staking, a shorter length is better. However, if the length is too short, the positioned skin material 2 tends to come off from the base material 1, and therefore it is preferable to adopt the shapes shown in FIGS. 7 and 8. In particular, the bifurcated locking projection 12 as shown in FIG. 8 has a bifurcated shape so that the skin material 2 can be easily mounted, and once mounted, the head functions as a stopper, and has a more preferable shape than others. . The stopper on the head may be formed only on the inside.
[0020]
Thereafter, by raising the pressing die 32 (the main die 32A, the auxiliary die 32B, and the heat die 32C), a desired molded product with a skin can be taken out.
In addition, as long as the assembly of the product is not hindered and the mounting strength of the skin material 2 is sufficient, it is not particularly necessary to thermally deform the locking projections 12. In such a case, if the locking projection 12 hinders the assembly of the product, it is cut off.
[0021]
In the molded product with the skin configured as described above, the engagement of the engagement holes 22 with the engagement protrusions 12 facilitates the setting of the skin material 2 on the base material 1, and accordingly, the conventional press-molding. This eliminates the need for the slide nest and the holder for the substrate, which are required in the above. Therefore, a simple jig is sufficient for the lower mold, and the initial cost is reduced.
Further, by providing the locking projections 12 in advance at places where the skin material 2 is difficult to be wound, the application of the adhesive is simplified.
Further, the step of fixing the skin material 2 to the base material 1 is performed in the direction of extending wrinkles in order to the main mold 32A, the auxiliary mold 32B, and the heat mold 32C, and wrinkles and twists are formed on the back side of the base material which does not become a product surface. Will be rejected, eliminating quality defects. In addition, the lowering of the auxiliary mold 32B causes the locking hole 22 to descend to the base end of the locking projection 12, but since the distance between the edge 13 and the locking projection 12 gradually increases, The force of pulling the skin material 2 toward the back side of the base material 1 acts to extend wrinkles, looseness, and the like of the whole skin material, thereby producing a high quality product.
The operation of the main mold 32A, the auxiliary mold 32B, and the heat mold 32C is a one-way operation that descends sequentially from above unlike a conventional two-way reciprocating operation such as pressure bonding, so that the molding cycle is short. Productivity is improved.
Of course, since the manufacturing method is not a method of vacuuming or the like, there is no restriction on the material of the skin material, and a wide range of skin materials can be used.
[0022]
It should be noted that the present invention is not limited to those shown in the above embodiments, but can be variously changed within the scope of the present invention depending on the purpose and application. The shape, material, and the like of the base material 1 and the skin 2 are not limited to the examples. The application of the adhesive to the base material can be performed at an area other than the outer peripheral edge. Furthermore, you may apply | coat to the skin material 2 side as needed. The base material 1 and the skin material 2 may be pressed and joined manually without using the pressing mold 32.
[0023]
【The invention's effect】
As described above, the method for manufacturing a product with a skin according to the present invention is not only capable of applying a variety of skin materials by simplifying the mold structure, but also improving the productivity and further producing a high quality product. It exerts its effect.
[Brief description of the drawings]
FIG. 1 is an overall perspective view of a substrate, viewed from the back side, for explaining the method of the present invention.
FIG. 2 is an overall perspective view of the back surface of the base material in a state where the outer peripheral edge of the skin material is rolled up.
FIG. 3 is a sectional view taken along the line III-III in FIG. 2;
FIG. 4 is a sectional view of a mold in which a base material on which a skin material is mounted is inserted.
FIG. 5 is an enlarged sectional view of a portion A in FIG. 4;
FIG. 6 is a perspective view showing another example of the locking projection.
FIG. 7 is a perspective view showing another example of the locking projection.
FIG. 8 is a side view showing another example of the locking projection.
FIG. 9 is a sectional view of a mold for explaining a conventional manufacturing method.
FIG. 10 is a sectional view of a mold for explaining a conventional manufacturing method.
FIG. 11 is a sectional view of a mold for explaining a conventional manufacturing method.
FIG. 12 is a sectional view of a mold for explaining a conventional manufacturing method.
FIG. 13 is a sectional view of a mold for explaining a conventional manufacturing method.
FIG. 14 is a sectional view of a mold for explaining a conventional manufacturing method.
FIG. 15 is a sectional view of a mold for explaining a conventional manufacturing method.
FIG. 16 is a cross-sectional view of a mold for explaining a conventional manufacturing method.
FIG. 17 is a sectional view of a mold for explaining a conventional manufacturing method.
FIG. 18 is a cross-sectional view of a mold for explaining a conventional manufacturing method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Base material 11 Outer edge 12 Locking projection 13 Edge 2 Skin material 21 Outer edge 31 Lower mold 32 Push mold 32A Main mold 32B Auxiliary mold 32C Thermal mold

Claims (1)

基材の表面を表皮材で覆ってなる表皮付き製品の製造方法であって、上記基材には裏面の外周縁に複数の係止突起を設け、該係止突起は、その基端部へ近づくに従い、基材の端縁からの距離を長くするよう配設され、また、該係止突起に対応させて上記表皮材には外周縁に複数の係止孔を設けて、上記基材裏面の少なくとも外周縁に接着剤を塗布する一方、該基材の表面を上記表皮材で覆い且つ該基材の外周縁に沿って裏面側へ折り曲げ、次いで、上記係止孔を上記係止突起に装着して表皮材を基材に位置決めした後、該表皮材の表面を下側にして下型上に載置し、その後、該基材を介して上方から該表皮材の一般部を押し型に係る主型の下降により押圧し、続いて、該基材の裏面に折り曲げられた表皮材の外周縁を上方から基材裏面に押し型に係る補助型の下降により押圧し、しかる後、更に、上記係止突起を表皮材の外周縁上に押し型に係る熱型の下降によりかしめ変形させることを特徴とする表皮付き製品の製造方法。What is claimed is: 1. A method for manufacturing a product with a skin, comprising covering a surface of a base material with a skin material, wherein the base material has a plurality of locking projections on an outer peripheral edge of a back surface, and the locking projections are connected to a base end thereof. It is arranged so that the distance from the edge of the base material increases as it approaches, and a plurality of locking holes are provided in the outer peripheral edge of the skin material corresponding to the locking projections, and the back surface of the base material is provided. While applying an adhesive to at least the outer peripheral edge of the base material, the front surface of the base material is covered with the skin material and bent along the outer peripheral edge of the base material toward the rear surface side. After mounting and positioning the skin material on the base material, the skin material is placed on a lower mold with the surface of the skin material facing down, and then the general part of the skin material is pressed from above through the base material. Then, the outer peripheral edge of the skin material bent on the back surface of the base material is pressed from above onto the back surface of the base material. The auxiliary projection is lowered by the lowering of the auxiliary die, and thereafter, the locking projection is further caulked and deformed on the outer peripheral edge of the skin material by the lowering of the hot die relating to the pressing die. .
JP11599994A 1994-05-03 1994-05-03 Manufacturing method of products with skin Expired - Fee Related JP3553131B2 (en)

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JP11599994A JP3553131B2 (en) 1994-05-03 1994-05-03 Manufacturing method of products with skin

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Application Number Priority Date Filing Date Title
JP11599994A JP3553131B2 (en) 1994-05-03 1994-05-03 Manufacturing method of products with skin

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JP3553131B2 true JP3553131B2 (en) 2004-08-11

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Publication number Priority date Publication date Assignee Title
AT413677B (en) * 2004-05-27 2006-04-15 Pro Te X Engineering Gmbh METHOD AND DEVICE FOR BENDING THE OUTSTANDING EDGE OF A CEILING OR DECORATIVE LAYER
JP4716418B2 (en) * 2005-11-24 2011-07-06 株式会社豊和化成 Interior material with skin
FR2903630B1 (en) * 2006-07-13 2008-10-10 Piero Paita METHOD FOR MANUFACTURING LEFT SHAPE PIECES AND COMPRISING A DECOR
DE102011015818A1 (en) * 2011-04-01 2012-10-04 Faurecia Innenraum Systeme Gmbh Umbugverfahren, Umbugvorrichtung and component with Umbug
JP2014213672A (en) * 2013-04-24 2014-11-17 株式会社豊和化成 Interior material with skin
HUE042247T2 (en) 2014-12-22 2019-06-28 Dr Stoffel Kai Konstantin Method and device for edgefolding
SE541042C2 (en) 2016-11-16 2019-03-19 Scania Cv Ab A welding arrangement and a vehicle comprising such a welding arrangement
JP6922004B2 (en) * 2020-01-07 2021-08-18 豊田鉄工株式会社 Manufacturing equipment for parts with surface layer and manufacturing method for parts with surface layer
CN112519253A (en) * 2020-10-23 2021-03-19 深圳市维克胜精密电子有限公司 Cloth covering device and cloth covering method thereof
CN114643670B (en) * 2022-03-16 2023-06-30 中山拓飞电器科技有限公司 Anti-edging hot-press forming die and thin film anti-edging forming process

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