JP3577802B2 - Manufacturing method of interior materials - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing an interior material in which a skin material is adhered to a surface of a wooden base material formed into a predetermined shape.
[0002]
[Prior art]
A general method of manufacturing this type of interior material includes two steps of a base material forming step and a sticking step of sticking a skin material to the surface of the formed base material. When a synthetic resin material is used, a heat treatment step of heating the skin material to a predetermined temperature is added between these steps. FIG. 5 shows an example of a conventional manufacturing method. The manufacturing method includes a base material forming step 1, a skin material heat treatment step 2, and a heat-treated skin material placed on the surface of the base material. It consists of a sticking step 3 for sticking.
[0003]
In the manufacturing method, a predetermined amount of a fibrous or powdery wood-based material 1b is laminated on the mold surface of the lower mold 1a in a base material forming step, and the laminated material 1b is combined with the lower mold 1a. The base material 11 is formed by compression molding with the upper mold 1c under heating at 150 ° C. to 250 ° C. Then, in the heat treatment step 2, the skin material 12 is set between the heaters 2a and 2b to 100 ° C. to 150 ° C. After heating, the heated skin material 12 is quickly placed on the base material 11 placed on the mold surface of the vacuum forming die 3a in the attaching step 3, and is evacuated. It is to be adhered by pressing on the surface of the material 11.
[0004]
In the manufacturing method, a material made of a synthetic resin such as polyvinyl chloride or polypropylene is employed as the skin material 12, and the skin material is fused to the base material 11 on the back surface of the skin material 12, or the skin material is previously formed. The hot-melt type adhesive applied to the back surface of No. 12 is melted and bonded.
[0005]
[Problems to be solved by the invention]
By the way, in the manufacturing method, at least two steps of a forming step 1 of the base material 11 and a sticking step 3 of the skin material 12 to the base material 11 are required, and a considerable time is required for manufacturing, and a great deal of time is required. Capital investment is required, which results in an increase in the production cost of interior materials. Accordingly, an object of the present invention is to provide a manufacturing method capable of performing the same process of molding the base material 11 and attaching the skin material 12 to the base material 11, thereby reducing the manufacturing cost of this type of interior material. It is in.
[0006]
[Hand stage solve the problems]
The present invention, in order to achieve the above object, while placing a skin material made of urethane foam on the mold surface of the lower mold , a predetermined amount of fibrous or powdery mixed resin on the upper surface of the skin material woody material product layer, made of the wood-based material by compression molding the laminated the same wood based materials wherein the skin material while heating the upper mold by the lower die having a die surface of a predetermined shape group An object of the present invention is to provide a method for manufacturing an interior material in which a skin material made of the urethane foam is integrally fixed to an upper surface of the material .
[0007]
In the manufacturing method of the present invention described above, a plurality of skin materials are adopted as the skin material,
Placed next to the state of the end portion was polymerized together merging the Hare skin material to the lower mold of the mold surface, compression molding in a heated state, placing the skin material on the mold surface of the lower die Prior to this, the sheet-shaped decorative material is placed on a predetermined portion of the lower mold surface, and the mounting portion of the decorative material and the vicinity of the mounting portion in the lower die are kept at a lower temperature than other portions. In this state, various means such as compression molding under heating can be employed.
[0008]
[Action and Effect of the Invention]
According to the production method of the present invention, since the same step can be performed for molding the base material and attaching the skin material to the base material, at least two steps of the molding step of the base material and the attaching step of the skin material to the base material are performed. Compared with the conventional manufacturing method requiring a process, the manufacturing time of the interior material can be shortened, the capital investment for the manufacturing apparatus can be reduced, and the interior material can be manufactured at low cost.
[0009]
In the manufacturing method of the present invention, by employing a skin material having elasticity composed of each Ki synthetic resin of the urethane foam as the skin material can be formed into the shape of deep drawing using the characteristics of the skin material, the adopted plurality of these skin materials, placed on the lower die of the mold surface state obtained by polymerizing with each other the ends of the case cormorants skin material adjacent, taking the means for compression molding in a heated state, both The superposed portion of the skin material can be formed into a portion which is thicker, softer and more resilient than other portions.
[0010]
Further, in the manufacturing method of the present invention, prior to placing the skin material on the lower mold surface, placing a sheet-shaped decorative material on a predetermined portion of the lower mold surface, In the state where the mounting portion of the decorative material and the vicinity of the mounting portion are kept at a lower temperature than other portions, if means for compression molding under heating is employed, molding of the base material, sticking of the skin material to the base material, In addition, the decorative material can be stuck to a predetermined portion of the skin material at the same time, and this kind of interior material can be manufactured at a lower cost.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
The present invention will be described below with reference to the drawings. FIG. 1 shows a first manufacturing method according to the present invention. In the manufacturing method, as a raw material of the base material 11, a material obtained by mixing a wood fiber, a hemp, a synthetic fiber, or the like formed by cutting a piece of wood with a thermoplastic resin is used. A sheet-shaped urethane foam 12a is employed as a material. As shown in FIG. 1 (a), the skin material 12 is placed on the mold surface 21a of the lower mold 21 and the skin is first formed. The raw material is laminated on the material 12 to a predetermined thickness, and the lower die 21 and the upper die 22 are heated to 220 ° C., and as shown in FIG. Compression molding is performed between the molds 21 and 22.
[0012]
As a result, the laminate 11a is formed into the base material 11 having a predetermined shape, and the surface of the urethane foam 12a that is in contact with the mold surface 21a of the lower mold 21 is once melted or softened and solidified to form a skin material. 12, and the skin material 12 is adhered to the surface of the base material 11 by the adhesive action of the thermoplastic synthetic resin in the laminate 11a, and the door trim of the vehicle door as the interior material shown in FIG. 10a is manufactured.
[0013]
For this reason, the skin material 12 retains flexibility and elasticity, and at the time of molding, the surface layer thereof can be easily subjected to coloring, patterning, embossing, and the like. it can.
[0014]
FIG. 2 shows a second manufacturing method according to the present invention. In this manufacturing method, the same raw materials and materials as those used in the first manufacturing method are used as the raw material of the base material 11 and the material of the skin material 12, but two urethanes are used as the material of the skin material 12. The two urethane foams 12a and 12b are mounted on the mold surface 21a of the lower mold 21 by adopting the foams 12a and 12b such that the ends thereof are overlapped by a predetermined amount as shown in FIG. . Thereafter, the raw material of the base material 11 is laminated on the two urethane foams 12a and 12b to a predetermined thickness, and the lower mold 21 and the upper mold 22 are heated to 220 ° C., as shown in FIG. Then, the urethane foams 12a and 12b and the laminate 11a of the raw material are compression-molded between the two dies 21 and 22. As a result, the door trim 10b shown in FIG.
[0015]
In FIG. 2, reference numeral 13 denotes a metal retainer bracket, and the retainer bracket 13 functions as a mounting member when the door trim 10b is mounted on the inner panel of the door.
[0016]
In this manufacturing method, the overlapped portions of the urethane foams 12a and 12b are also adhered at the time of molding, but heat transfer to a portion inside the overlapped portions of the urethane foams 12a and 12b is small, and the mold of the lower die 21 The degree of heat melting or heat softening is smaller than that of the part in contact with the surface 21a. For this reason, the overlapping portion 12c of the urethane foams 12a and 12b in the door trim 10b can maintain more flexibility and elasticity as compared with other portions, and can improve the quality of the door trim 10b.
[0017]
FIG. 3 shows a third manufacturing method according to the present invention. In this manufacturing method, the same raw materials and materials as those used in the first manufacturing method are used as the raw material of the base material 11 and the material of the skin material 12, but the woven or knitted material that is the sheet-shaped decorative material is further used. Prior to placing the urethane foam 12a on the mold surface 21a of the lower mold 21, the ornament 14 is placed on a predetermined portion of the mold surface 21a as shown in FIG. Then, the urethane foam 12a and the raw material are laminated to a predetermined thickness to form a laminate 11a, and the lower mold 21 and the upper mold 22 are heated to 220 ° C., as shown in FIG. The ornament 14, the urethane foam 12a, and the laminate 11a are compression molded between the two dies 21 and 22. As a result, the door trim 10c shown in FIG.
[0018]
In the manufacturing method, as the lower mold 21, a lower mold in which a heat insulating portion 21c is interposed at a predetermined portion of the mold main body 21b, and a cooling water pipe 21d is disposed at a portion surrounded by the heat insulating portion 21c, is adopted. At the time of molding, cooling water is supplied to the cold water pipe 21d to keep the part where the ornament 14 is placed and a part in the vicinity thereof at a lower temperature than other parts. Thus, the ornament 14 is prevented from being damaged by being heated to a high temperature, and the original appearance, texture, feel, and the like of the ornament 14 are maintained. In this case, an adhesive is applied to the back surface of the ornament 14 in advance, and the ornament 14 is attached to a predetermined surface of the skin material 12 with the adhesive.
[0019]
In this manufacturing method, the molding of the base material 11, the attachment of the skin material 12 to the base material 11, and the attachment of the ornament 14 to a predetermined portion of the skin material 12 can be performed at the same time. There is an advantage that 10c can be manufactured more inexpensively.
[0020]
In each of the above-described manufacturing methods, as shown in FIG. 4A, the lower die 21 and the upper die 22 have portions on both die surfaces 21a and 22a corresponding to the ends of the base material 11 having a shear blade structure. If it is formed and a structure in which the interval between the portions corresponding to the ears of the base material 11 is large is adopted, the adhesion between the surplus portion 11b of the laminate 11a and the urethane foam 12a is prevented, The molded body is released from the mold as shown in FIG. That is, in the door trim, the end face of the terminal portion of the base material 11 is covered with the skin material 12, and the surplus portion 12 d of the skin material 12 can be easily wound around the back side of the terminal portion of the base material 11. .
[Brief description of the drawings]
FIG. 1 is a schematic explanatory view showing a first manufacturing method according to the present invention.
FIG. 2 is a schematic explanatory view showing the second manufacturing method.
FIG. 3 is a schematic explanatory view showing a third manufacturing method.
FIG. 4 is a schematic explanatory view showing a modified example of each manufacturing method.
FIG. 5 is a schematic explanatory view showing a conventional manufacturing method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 ... Base material, 11a ... Laminated body, 11b ... Excess part, 12 ... Skin material, 12a, 12b ... Urethane foam, 12c ... Overlapping part, 12d ... Excess part, 13 ... Retainer bracket, 14 ... Ornament, 21 ... Lower mold , 21a: mold surface, 21b: heat insulating portion, 21c: cooling water pipe, 22: upper mold, 22a: mold surface.

Claims (4)

A skin material made of urethane foam is placed on the lower mold surface, and a predetermined amount of fibrous or powdery wood-based material mixed with resin is laminated on the upper surface of the skin material, and the same wood-based material is laminated. The material and the skin material are compression-molded while being heated in an upper mold and a lower mold having a mold surface of a predetermined shape, so that the skin material made of the urethane foam is integrated with the upper surface of the base material made of the wood-based material. Manufacturing method of interior material adhered to 2. The method for producing an interior material according to claim 1, wherein a thermoplastic resin is mixed with the wood-based material. Adopting a plurality of urethane foams as the skin material, placing the end portions of the adjacent urethane foams on the mold surface of the lower mold in a state where they are superimposed on each other, and compression-molding in a heated state. The method for producing an interior material according to claim 1 or 2, wherein Prior to placing the skin material consisting of the urethane foam on the mold surface of the lower mold, placing a sheet-like decorative material in a predetermined portion of the mold surface of the lower mold, the lower mold of the same decorative material 4. The method for manufacturing an interior material according to claim 1 , wherein the mounting portion and the vicinity thereof are compression-molded under heating while keeping the mounting portion and its vicinity at a lower temperature than other portions.

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