JP4235305B2 - Ornament assembly manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing an ornament assembly used for a part of automobile interior materials such as door trims, quarter trims, and instrument panels.
[0002]
[Prior art]
Ornaments provided on automobile door trims and the like may be gathered to give a luxurious feeling. FIGS. 14-16 shows the fragmentary sectional view of the main member of the ornament assembly 2 which formed such a gather, and the door trim 1 which attached this. As shown in FIG. 14, for example, a pad 4 made of urethane foam or the like having substantially the same contour shape as this on the core plate 3 made of iron plate or the like in which six mounting claws 3a are integrally cut and formed. It is attached by bonding or the like. On the other hand, as shown in FIG. 15, the skin 5 in which the upper and lower edges 5a are shrunk by gather stitching to form a large number of pleats 5b is covered with the core plate 3 and the pad 4 bonded thereon, The portion 5a is wound around and adhered to the back side of the core plate 3 to form the ornament assembly 2. In order to facilitate this bonding, a plurality of V-cut portions 5c are provided at the corners of the outer periphery of the skin 5. As shown in FIG. 16, the ornament assembly 2 is brought into contact with a part of the door trim 1 on the upper side of the armrest 6, passes the mounting claws 3 a through the holes provided in the door trim 1, and bends the tip. It is attached.
[0003]
Alternatively, as shown in FIG. 17, an ornament assembly 7 in which a pad 8 such as a urethane foam is bonded to the back surface of the skin 9 in which upper and lower edges are sewn and formed with pleats 9a in the same manner as described above. It is also conceivable that the edge is sandwiched between the door trim base 11 and the lower edge 12a of the door trim upper 12, and the lower edge is sandwiched between the door trim base 11 and the inner end edge 6a of the armrest 6.
[0004]
[Problems to be solved by the invention]
However, in the prior art ornament assembly 2 shown in FIGS. 14 to 16, the three components of the core plate 3, the pad 4 and the skin 5 have to be assembled by hand, which increases the number of components and the number of processing steps. Manufacturing cost increases. Moreover, since it is necessary to pull the skin 5 with a considerable force when it is wound around and adhered to the back surface of the core plate 3 in order to reduce the shape deviation, the peripheral portion of the pad 4 is compressed to a considerable inner side, A tight feeling cannot be given to the joint portion between the door trim 1 and the armrest 6. Both of these problems occur regardless of whether the outer skin 5 is gathered or not. On the other hand, in gather sewing for forming gathers on the outer skin 5, the quality varies depending on the characteristics of the sewing machine, the material of the leather, the working environment such as temperature and humidity, the skill level of the operator, etc. Have difficulty. In addition, since this gather sewing requires a considerable amount of labor, there is a problem that it causes an increase in cost.
[0005]
On the other hand, the ornament assembly 2 of FIG. 17 has a reduced number of parts, but in order to obtain a non-uniform gathering, careful attention is required when sandwiching the periphery thereof, so considerable effort is required for assembly. The manufacturing cost increases accordingly. Further, since the peripheral portion of the ornament assembly 7 is sandwiched and attached between the door trim base 11, the door trim upper 12 and the armrest 6, the peripheral portion of the pad 8 is compressed to a considerably inner side, and as in the above case, the door trim upper 12 and A tight feeling cannot be given to the joint portion with the armrest 6. Both of these problems are unrelated to whether or not the outer skin 5 is gathered. As in the case described above, it is difficult to stabilize the quality of the gathering of the skin, which causes an increase in cost. The object of the present invention is to solve each of these problems.
[0006]
[Means for Solving the Problems]
The method of manufacturing an ornament assembly according to the present invention includes forming a flat outer peripheral surface at the peripheral portion of one side surface, forming a molding surface dug out from the outer peripheral surface at the central portion, and forming a portion surrounding the molding surface of the outer peripheral surface. A sheet-shaped skin material is placed on one side surface of the skin-side molding die formed with a shallow concave step portion, and its periphery is lightly pressed against the outer peripheral surface, and the molding surface is provided in the skin-side molding die. By sucking the air between the skin material and the molding surface through a suction passage having a large number of air intake holes, the skin material is brought into close contact with the molding surface while drawing the peripheral portion of the skin material into the molding surface. The peripheral portion of the contact surface on one side of the side mold is brought into contact with the outer peripheral surface of the skin-side mold through the skin material, and the outer peripheral portion is not substantially restrained by the outer peripheral surface and the contact surface. Between the abutment surface and a flexible, substantially non-breathable sheet-like barrier material Is characterized in that to form a foam filled between the by foaming the sheet to foam material contact surface and the barrier material and the skin material which the the outer side than the barrier material.
[0007]
The foam material is foamed and filled between the contact surface, the barrier material, and the outer skin material outside the barrier material. When the foam material finishes the reaction and the foam is formed, the ornament assembly Molding ends. When the skin material is sucked into close contact with the molding surface, its peripheral part is drawn into the molding surface, so that the skin material is compressed in the tangential direction at the rising part around the molding surface, resulting in the skin material within the molding surface. The resulting tensile stress is negligible. The part of the skin material corresponding to the peripheral rising part and the recessed step adjacent to the outside is outside the barrier material, and the foamed foam material directly contacts the back surface of these parts of the skin material. Since the impregnation is performed, the skin material and the foam are integrated, but the back surface of the skin material covered with the barrier material on the inner side is not impregnated with the foam material.
[0008]
It is preferable that a plurality of ridges for forming pleats for forming gathers on the skin material are provided at the bottom of the molding surface of the skin-side mold according to the invention of the preceding paragraph. In this way, the surface of the skin material is formed with pleats that become gathers at the same time as molding.
[0009]
Further, the barrier material of the inventions of the preceding two paragraphs may be placed on the skin material via a flexible sheet-like cover pad whose outer peripheral portion is not substantially restrained by the outer peripheral surface and the contact surface. Alternatively, the barrier material may be a closed cell or semi-closed cell foamed resin sheet that is not substantially impregnated with the foam material but can be bonded.
[0010]
Further, the method for manufacturing an ornament assembly according to the present invention is a method in which a flat outer peripheral surface is formed in the peripheral portion of one side surface, a molding surface is formed in the central portion that is dug out of the outer peripheral surface, and the molding surface of the outer peripheral surface is surrounded. A sheet-shaped skin material that is superposed on one side of the skin-side mold that forms a shallow concave step on the side surface and is bonded to the outside of the molding surface in an integrated manner. A sheet-like barrier material that is flexible and substantially non-breathable is placed, and the outer surface of the skin material and the barrier material are lightly pressed against the outer peripheral surface. The molding surface is provided in the skin-side mold. The skin material is brought into close contact with the molding surface while drawing the peripheral part of the skin material and the barrier material into the molding surface by sucking the air between the skin material and the molding surface through a suction passage having a large number of intake holes opened in The outer periphery of the contact surface on one side of the back side mold And the foam material which is brought into contact with the outer peripheral surface of the skin side mold through the barrier material and foamed from the foam raw material supplied between the barrier material and the contact surface and filled between the contact surface and the barrier material. It is characterized by forming.
[0011]
When the foam raw material is foamed and filled between the contact surface and the barrier material, and the foamed foam raw material finishes the reaction and the foam is formed, the molding of the ornament assembly is completed. When the skin material and the barrier material are sucked into close contact with the molding surface, the peripheral portion is drawn into the molding surface, so that the skin material is compressed in the tangential direction at the rising portion around the molding surface. The tensile stress generated in the outer skin material is slight. The heat-meltable barrier material melts the surface with the heat of reaction during foaming of the foam material and is integrated with the foam. Therefore, the skin material and the barrier material are integrally formed outside the rising part around the molding surface. In the bonded part, the skin material and the foam are also integrated with each other, but in the part where the skin material and the barrier material are not integrally bonded inside, the skin material is not integrated with the foam, and the foam It is not impregnated with the raw material.
[0012]
It is preferable that a plurality of ridges for forming pleats for forming gathers on the skin material are provided at the bottom of the molding surface of the skin-side mold according to the invention of the preceding paragraph. In this way, the surface of the skin material is formed with pleats that become gathers at the same time as molding.
[0013]
In the inventions of the preceding two items, a flexible sheet-like cover pad may be provided between the skin material and the barrier material in a range that is inside the vicinity of the contour of the molding surface. Alternatively, the barrier material is made of a closed-cell or semi-closed-cell resin foam sheet that is located in a range that is inside the vicinity of the contour of the molding surface and that is not substantially impregnated with the foam material but can be bonded. It is good also as what consists of a thin sheet-like heat-meltable 2nd barrier material which consists of a 1st barrier material, the part adhere | attached on the skin material, and the part which covers the peripheral part of a 1st barrier material.
[0014]
In addition, the method for manufacturing an ornament assembly according to the present invention includes a plurality of moldings for forming a pleat that forms a flat outer peripheral surface at a peripheral portion of one side surface and is dug out of the outer peripheral surface at a central portion and forms a gather at the bottom portion. A sheet-shaped skin material is placed on one side surface of a skin-side molding die in which a shallow concave step is formed in a portion surrounding the molding surface of the outer peripheral surface while forming a molding surface provided with a ridge. The peripheral part is abutted lightly to the outer peripheral surface, and air between the skin material and the molding surface is sucked through a suction pipe provided in the skin side molding die and having a large number of intake holes opened to the molding surface. The skin material is closely attached to the molding surface while the peripheral portion of the skin material is drawn into the molding surface, and one side surface of the skin material is in close contact with the molding surface through at least one top of the plurality of protrusions. Plugged so that the entire outer periphery is substantially in contact with the skin material , The peripheral part of the contact surface on one side of the back side mold is brought into contact with the outer peripheral surface of the skin side mold through the skin material, and the foam material supplied between the contact surface and the insertion plate is foamed. To form a foam filled between the abutment surface, the insertion plate, and the outer skin material outside the insertion plate, and the insertion plate is not substantially deformed by the foaming pressure of the foam raw material and The insertion plate is characterized in that it is pulled out to the outside from the cut formed in the foam after the foam is formed.
[0015]
The foam material is foamed and filled between the contact surface, the insertion plate, and the outer skin material outside the insertion plate. After the foam material finishes the reaction and the foam is formed, the insertion plate is exposed to the outside. If pulled out, the molding of the ornament assembly is completed. When the skin material is sucked into close contact with the molding surface, its peripheral part is drawn into the molding surface, so that the skin material is compressed in the tangential direction at the rising part around the molding surface, resulting in the skin material within the molding surface. The resulting tensile stress is negligible. The part of the skin material corresponding to the peripheral rising part and the concave step part adjacent to the outside is outside the insertion plate, and the foam material is in direct contact with the back surface of these parts of the skin material. Since the skin material and the foam are integrated because they are impregnated, the foam material is blocked by the insertion plate on the inner side, and the foam is between the back surface of the skin material on the bottom side of the molding surface. Therefore, if the insertion plate is pulled out, a gap is formed between the foam and the skin material.
[0016]
In the invention of the preceding paragraph, a flexible cover pad having the same contour shape as the insertion plate is provided between the insertion plate and the skin material, and one side surface of the insertion plate is provided on the top of at least one of the plurality of protrusions and the cover material. It is preferable that the contact is made through the pad. If it does in this way, in the state which pulled out the insertion board and completed the ornament assembly, the surface of the foam used as the space side will be covered with a cover pad.
[0017]
In addition, the method for manufacturing an ornament assembly according to the present invention includes a plurality of moldings for forming a pleat that forms a flat outer peripheral surface at a peripheral portion of one side surface and is dug out of the outer peripheral surface at a central portion and forms a gather at the bottom portion. A sheet-shaped skin material is placed on one side surface of a skin-side molding die in which a shallow concave step is formed in a portion surrounding the molding surface of the outer peripheral surface while forming a molding surface provided with a ridge. The peripheral part is abutted lightly to the outer peripheral surface, and air between the skin material and the molding surface is sucked through a suction pipe provided in the skin side molding die and having a large number of intake holes opened to the molding surface. The skin material is closely attached to the molding surface while the peripheral portion of the skin material is drawn into the molding surface, and one side surface of the skin material is in close contact with the molding surface through at least one top of the plurality of protrusions. Plugged so that the entire outer periphery is substantially in contact with the skin material The peripheral portion of the contact surface on one side of the back side mold is brought into contact with the outer peripheral surface of the skin side molding die through the skin material, and the outer peripheral portion is substantially made by the outer peripheral surface and the contact surface. The sheet material placed on the insertion plate so as not to be restrained is foamed with the foam material supplied between the contact material and the barrier material having a contour shape larger than the insertion plate, and the contact surface, the barrier material, and the barrier material. A foam filled between the outer skin materials is formed, and the insertion plate is an elastic plate material that is not substantially deformed by the foaming pressure of the foam material. This insertion plate is foamed after the foam is formed. It is characterized by being pulled out from the cut formed in the body.
[0018]
The foam material is foamed and filled between the contact surface, the barrier material, and the outer skin material outside the barrier material, and after the foam material finishes the reaction and the foam is formed, the insert plate is pulled out. In this case, the molding of the ornament assembly is finished. When the skin material is sucked into close contact with the molding surface, its peripheral part is drawn into the molding surface, so that the skin material is compressed in the tangential direction at the rising part around the molding surface, resulting in the skin material within the molding surface. The resulting tensile stress is negligible. The part of the skin material corresponding to the peripheral rising part and the recessed step adjacent to the outside is outside the barrier material, and the foamed foam material directly contacts the back surface of these parts of the skin material. Since the surface material and the foam are integrated because they are impregnated, the foam material is blocked by the barrier material and the insertion plate inside and between the back surface of the skin material that is the bottom side of the molding surface from the insertion plate. Is not filled with foam, so if the insertion plate is pulled out, a gap is formed between the foam and the skin material.
[0019]
In the invention of the preceding paragraph, a flexible cover pad having the same contour shape as the insertion plate is provided between the insertion plate and the skin material, and one side surface of the insertion plate is provided on the top of at least one of the plurality of protrusions and the cover material. It is preferable that the contact is made through the pad. If it does in this way, in the state which pulled out the insertion board and completed the ornament assembly, the surface of the foam used as the space side will be covered with a cover pad.
[0020]
DETAILED DESCRIPTION OF THE INVENTION
First, a first embodiment of a method for manufacturing an ornament assembly according to the present invention will be described with reference to FIGS. The ornament assembly 40 molded according to the first embodiment includes a skin material 41 shaped to rise from the outermost flange portion 40a, as shown in a partially enlarged sectional view in FIG. The cover pad 43 that is in contact with the inner surface of the skin material 41 except for the rising part, and the barrier material that covers the lower side of the cover pad 43 and the peripheral part is in contact with the rising part of the skin material 41 42 and a foam 44 filled inside the skin material 41, the barrier material 42 and the cover pad 43.
[0021]
The skin material 41 is a flexible sheet made of genuine leather, woven fabric, synthetic leather, or the like. In the case of a woven fabric having high air permeability, a backing is provided to reduce or eliminate the air permeability. Backing with a flexible foam sheet or the like is optional. The foam 44 is a urethane foam obtained by foaming a urethane foam raw material. The barrier material 42 is for preventing the foam material from coming into contact with the back surface of the skin material 41 and impregnating it, and is a material that is substantially non-breathable so that the foam material does not pass through (for example, heat A thin flexible sheet made of a plastic polyurethane sheet or a thermoplastic polyester sheet. The barrier material 42 may be bonded integrally with the foam material 44a when foamed, or may not be bonded. The cover pad 43 is a thin sheet made of a flexible synthetic resin foam such as a flexible urethane foam.
[0022]
A molding apparatus used in the first embodiment includes a lower mold (skin-side molding mold) 20 attached to a lower fixed-side mold support member (not shown), as shown in FIG. The upper mold (back mold) 30 attached to the upper movable mold support member (not shown) and the presser frame 32 are provided. A flat outer peripheral surface 22 extending outward is formed in the upper peripheral portion of the lower mold 20, and a molding surface 21 having a shape corresponding to the surface of the skin material 41 of the ornament assembly 40 is dug inside thereof, A concave step portion 22a having a shallow constant width is formed in a portion surrounding the molding surface 21 of the outer peripheral surface 22. A plurality of protrusions 21a for forming a large number of pleats 40b (see FIG. 14) for forming gathers on the skin material 41 are provided on the bottom of the molding surface 21 in all or part of the width in the direction perpendicular to the figure. ing. The lower mold 20 has a cavity 26 formed therein, a plurality of intake holes 27 having both ends opened in the cavity 26 and the molding surface 21, and a suction passage 25 including an intake port 28 opened in the cavity 26. The intake port 28 is connected to a vacuum source 29 comprising a vacuum pump, a vacuum tank, and an on-off valve.
[0023]
The upper mold 30 can approach and separate from the lower mold 20 from above, and FIGS. 1, 2 (a) and 2 (b) show the state where the upper mold 30 is separated upward, and FIG. 2 (c). Indicates the closest state. On the lower surface of the upper mold 30, a contact surface 31 that is flat as a whole and whose peripheral portion can contact the outer peripheral surface 22 of the lower mold 20 is formed. The presser frame 32 lightly presses the peripheral portion of the skin material 41 placed on the outer peripheral surface 22 against the outer peripheral surface 22, and the rod 33 for operating the presser frame 32 is separated from the upper mold 30 by a lifting device. It may be moved, or may be supported by the upper mold 30 via a spring. A cutout 31 a for avoiding the presser frame 32 is formed on the outer peripheral portion of the contact surface 31 of the upper mold 30.
[0024]
In the manufacturing process of the first embodiment, first, as shown in FIG. 2 (a), a skin material 41 having a contour shape larger than the contour shape of the outer peripheral surface 22 of the lower mold 20 is placed on the outer peripheral surface 22, The cover pad 43 is placed thereon, and the barrier material 42 is further stacked thereon, and then the presser frame body 32 is lowered by the rod 33 to lightly press the peripheral portion of the skin material 41 against the outer peripheral surface 22 of the lower mold 20. . The contour shape of the barrier material 42 is set to be slightly larger than the contour shape of the molding surface 21, and the barrier material 42 is formed by the outer peripheral surface 22 of the lower die 20 and the abutment surface 31 of the upper die 30 that abuts the skin material 41. The outer peripheral portion is not substantially restrained, and the contour shape of the cover pad 43 is slightly smaller than the contour shape of the barrier material 42 so that the outer peripheral portion is not substantially restrained as described above. Next, the open / close valve of the vacuum source 29 is opened, and the air between the skin material 41 and the molding surface 21 is sucked through the suction passage 25, so that the skin material 41 is molded into the molding surface 21 as shown in FIG. At this time, a part of the peripheral portion of the skin material 41 slides between the outer peripheral surface 22 and the presser frame 32 and is drawn into the molding surface 21. As a result, the skin material 41 is compressed in the tangential direction of the outer periphery at the rising portion around the molding surface 21, but the tensile stress generated in the skin material 41 in the molding surface 21 is slight.
[0025]
Next, a predetermined amount of urethane foam raw material 44a composed of a polyol component and an isocyanate component is supplied onto the barrier material 42 by a urethane injection gun (not shown) (see FIG. 2 (b)), and then the upper mold 30 is lowered. When the peripheral portion of the contact surface 31 is brought into contact with the outer peripheral surface 22 through the skin material 41, the supplied urethane foam raw material 44a is foamed, and the contact surface 31, the barrier material 42, and the outside thereof. A urethane foam 44 filled between the outer skin materials 41 is formed. The back surface of the skin material 41 between the outer edge of the barrier material 42 and the outer edge of the recessed step portion 22a is impregnated with the foam raw material 44a and bonded to the urethane foam 44, but the other portion of the skin material 41 is foamed. The body material 44a is not impregnated. When the barrier material 42 is heat-meltable, the foam material 44a partially melted by the reaction heat of the foam material 44a and bonded to the urethane foam 44 has finished the reaction, and the foam 44 is formed. By the way, if the ornament assembly 40 formed by raising the upper die 30 is taken out from the lower die 20 and is cut at the position 45 shown in FIG. 2 (d) to remove the unnecessary portion 46, the concave step portion 22a. The molding of the ornament assembly 40 in which the flange portion 40a corresponding to is formed on the entire circumference is completed. The foam raw material 44 a may be injected between the contact surface 31 and the barrier material 42 from an injection passage that opens to the contact surface 31 after the upper mold 30 is closed.
[0026]
The skin material 41 which is sucked and adhered to the molding surface 21 and the concave step portion 22a and formed into the shape thereof is impregnated with the urethane foam raw material 44a on the back surface between the outer edge of the barrier material 42 and the outer edge of the concave step portion 22a. The foam 44 integrated with the foam 44 is elastically hardened, and particularly the thin-walled foam 44 corresponding to the concave step portion 22a is quickly cooled by the upper mold 30 to reduce the foaming rate. The part 40a becomes difficult to expand and contract. Further, as described above, the tensile stress generated in the skin material 41 in the molding surface 21 is slight. Therefore, even if the skin material 41 of the molded ornament assembly 40 is taken out from the lower mold 20, the shape when it is in close contact with the molding surface 21 is maintained. As a result, the skin material 41 of the ornament assembly 40 is maintained in a desired cross-sectional shape at the peripheral rising portion, and does not come into contact with adjacent parts such as a door trim upper and an armrest. Can be given.
[0027]
Further, since the skin material 41 is not impregnated with the foam raw material 44a in the portion inside the rising portion around the molding surface 21, sufficient flexibility is maintained in this portion. Furthermore, in this embodiment, since the folds 40b that are gathers are formed simultaneously with the molding by the lower mold 20, labor is not required to form the gathers, so that the manufacturing cost can be reduced, and the quality of the gathers is also stabilized. It will be a thing. In addition, although the part used as the pleat 40b of the skin material 41 in which the gather was formed is not integrated with the foam body 44, the skin material 41 of this part is in the state attracted | sucked by the molding surface 21 as mentioned above. Since the generated tensile stress is slight, even if the tensile stress is taken out from the lower mold 20, the shape is maintained along the foam 44, and the pleat 40b does not disappear. In this embodiment, since the flexible sheet-like cover pad 43 is provided between the skin material 41 and the barrier material 42, the tactile sensation on the surface of the ornament assembly 40 can be adjusted.
[0028]
This first embodiment may be carried out with the cover pad 43 omitted, and FIG. 5 shows a partially enlarged sectional view of a modification of the ornament assembly 40 obtained in that case. In this modification, a thin sheet having no air permeability is used as the barrier material 42. However, closed cells or semi-closed cells that are not substantially impregnated with the foam raw material 44a but can be bonded (small number of bubbles are continuous). However, the resin foam sheet may be used as the barrier material 42 as a whole. FIG. 6 shows a partially enlarged sectional view of a modified example of the ornament assembly 40 obtained in that case. Also in this case, the feel of the surface of the ornament assembly 40 can be adjusted by adjusting the flexibility of the resin foam sheet.
[0029]
Next, a second embodiment will be described with reference to FIG. In this embodiment, the barrier material 42 is a flexible sheet (for example, a polyurethane-based hot-melt sheet having a melting point of 80) made of a material having substantially no air permeability and heat-melting property so that the urethane foam raw material does not pass therethrough. ˜120 ° C.), and the skin material 41 and the barrier material 42 have substantially the same contour shape, and are integrally bonded to the outside of the vicinity of the contour of the molding surface 21, and the skin material 41 and the barrier material 42 are Is different from the first embodiment only in that a cover pad 43 is provided in a range inside the vicinity of the contour of the molding surface 21. Bonding of the skin material 41 and the barrier material 42 may be performed using the heat melting property of the barrier material 42. In addition, it is not necessary to give the skin material 41 a backing for reducing or eliminating air permeability. The molding apparatus used in the second embodiment is the same as that used in the first embodiment.
[0030]
In the second embodiment, the skin material 41, the barrier material 42, and the cover pad 43 that are integrally joined to each other are first formed with the skin material 41 side down as shown in FIG. 3 (a). The outer peripheral surface 22 of the lower mold 20 is lightly pressed on the outer peripheral surface 22 of the lower mold 20 by lowering the presser frame body 32 and lowering the presser frame 32. Next, the vacuum source 29 sucks the air between the skin material 41 and the molding surface 21 through the suction passage 25, and as shown in FIG. 3 (b), the skin material 41, the cover pad 43, and the barrier material 42. Is closely attached to the molding surface 21. As in the case of the first embodiment, at this time, a part of the peripheral portion of the skin material 41 and the barrier material 42 is drawn into the molding surface 21, and the skin material 41 and the barrier material are raised at the rising portion around the molding surface 21. The material 42 is compressed in the tangential direction of the outer periphery, but the tensile stress generated in the skin material 41, the barrier material 42 and the cover pad 43 in the molding surface 21 is slight.
[0031]
Next, after supplying a predetermined amount of urethane foam raw material 44a onto the barrier material 42 by a urethane injection gun (see FIG. 2 (b)), the upper mold 30 is lowered and applied through the skin material 41 and the barrier material 42. When the contact surface 31 is brought into contact with the outer peripheral surface 22, the supplied urethane foam raw material 44 a is foamed to form a foam 44 filled between the contact surface 31 and the barrier material 42. The heat-meltable barrier material 42 is bonded to the urethane foam 44 by melting the surface by reaction heat when foaming the foam material 44 a. As a result, in the portion between the portion corresponding to the outer edge of the concave step portion 22a and the outer edge of the cover pad 43, the skin material 41 and the foam 44 are integrated with each other via the barrier material 42, but the inner side of the inner surface is further increased. Thus, the skin material 41 and the foam 44 are not integrated with each other at the portion where the skin material 41 and the barrier material 42 are not integrally bonded. When the foamed foam raw material 44a finishes the reaction and the foam 44 is formed, the ornament assembly 40 formed by raising the upper mold 30 is taken out from the lower mold 20, and the reference numeral shown in FIG. If the unnecessary portion 46 is removed by cutting at the position 45, the molding of the ornament assembly 40 in which the flange portion 40a corresponding to the concave step portion 22a is formed on the entire circumference is completed.
[0032]
The skin material 41 that is sucked and adhered to the molding surface 21 and the concave step portion 22a and formed into the shape thereof is integrated with the foam 44 through the barrier material 42 between the outer edge of the cover pad 43 and the outer edge of the concave step portion 22a. In particular, the thin-walled foam 44 corresponding to the concave step portion 22a is quickly cooled by the upper mold 30 to reduce the foaming rate, so that the flange portion 40a serving as this portion expands and contracts. It becomes difficult to do. Further, as described above, the tensile stress generated in the skin material 41, the barrier material 42, and the cover pad 43 in the molding surface 21 is slight. Therefore, even when the ornament assembly 40 is taken out from the lower mold 20, the shape when it is in close contact with the molding surface 21 is maintained. Therefore, as in the first embodiment, the skin material 41 of the ornament assembly 40 has a desired cross-sectional shape at the peripheral rising portion, and therefore, a mating portion with an adjacent part such as a door trim upper or an armrest is leaked. Because it is not, it can give a tight feeling.
[0033]
Further, since the skin material 41 is not integrated with the foam material 44a via the barrier material 42 in the portion inside the outer edge of the cover pad 43, sufficient flexibility is maintained in this portion. Further, in this embodiment, the folds 40b that are gathers are formed simultaneously with the molding by the lower mold 20, so that labor is not required to form the gathers, the manufacturing cost can be reduced, and the gather quality is also stable. It will be a thing. Although the skin material 41 of the part used as a gather is not integrated with the foam 44, the pleat 40b of the skin material 41 does not have a possibility of disappearing as mentioned above. In this embodiment, since the flexible sheet-like cover pad 43 is provided between the skin material 41 and the barrier material 42, the tactile sensation on the surface of the ornament assembly 40 can be adjusted.
[0034]
This second embodiment may be carried out with the cover pad 43 omitted, and FIG. 7 shows a partially enlarged sectional view of a modified example of the ornament assembly 40 obtained in that case. The adhesion of the skin material 41 and the barrier material 42 in the modification of FIG. 7 is preferably performed only at the peripheral portion as in the second embodiment, but may be performed over the entire surface. Further, in this modification, one thin heat-meltable sheet having no air permeability is used as the barrier material 42. However, as shown in FIG. The first barrier material 42a made of a closed cell or semi-closed cell foamed resin sheet that is not substantially impregnated with the foam material 44a but can be bonded, the portion bonded to the skin material 41, and the first barrier material You may use the barrier material 42 which consists of the thin sheet-like heat-meltable 2nd barrier material 42b which consists of a part which covers the peripheral part of 42a. Also in this case, the feel of the surface of the ornament assembly 40 can be adjusted by adjusting the flexibility of the first barrier material 42a.
[0035]
Next, a third embodiment will be described with reference to FIG. Although this embodiment is similar to the second embodiment, the cover pad 43 is widened to cover the entire back surface of the rising portion around the skin material 41 and the entire circumference of the cover pad 43 is covered with the skin material. 41 is different in that it is previously adhered to the back surface of 41, and this difference will be mainly described.
[0036]
In this embodiment, the cover pad 43 is contoured so that the outer edge of the cover pad 43 is substantially coincident with the outer edge of the molding surface 21 in the state of being in close contact with the molding surface 21 as shown in FIG. The shape is determined, and the outer peripheral range W (see FIG. 4 (a)) is previously bonded to the skin material 41 with a hot melt sheet or an adhesive. Then, the portion of the barrier material 42 placed on the outer side of the cover pad 43 is bonded to the skin material 41. The skin material 41, the barrier material 42, and the cover pad 43, which are integrally joined to each other in this way, are placed on the lower mold 20 (see FIG. 4 (a)) as in the second embodiment, and the molding surface 21 is placed. The foam material 44a supplied between the upper mold 30 and the skin material 41 and the barrier material 42 is foamed to form a urethane foam 44 (see FIG. 4 (b)). An ornament assembly 40 as shown in FIG. 4 (d) is obtained.
[0037]
In this embodiment, since the outer peripheral portion of the cover pad 43 is bonded to the skin material 41, the position relative to the skin material 41 does not shift when the skin material 41 is drawn into the molding surface 21 by vacuum adhesion. The entire back surface of the rising portion around the skin material 41 is continuously covered with the cover pad 43. Therefore, no troublesome highlight line is generated on the outer surface of the rising portion. Other functions and effects are the same as those of the second embodiment.
[0038]
Next, a fourth embodiment will be described with reference to FIG. In this embodiment, when the foam 44 is formed, a thin insertion plate 47 is used, and after the foam 44 is formed, the insertion plate 47 is pulled out, so that a gap is formed between the skin material 41 and the foam 44. 48 is formed. The molding apparatus used in the fourth embodiment is also the same as that used in the first embodiment.
[0039]
In the fourth embodiment, first, a skin material 41 having a contour shape larger than the contour shape of the outer peripheral surface 22 of the lower mold 20 is placed on the outer peripheral surface 22 as indicated by a two-dot chain line in FIG. Then, the presser frame body 32 is lowered to lightly press the peripheral portion of the skin material 41 against the outer peripheral surface 22 of the lower mold 20. Next, the opening / closing valve of the vacuum source 29 is opened, and the air between the skin material 41 and the molding surface 21 is sucked through the suction passage 25, thereby forming the skin material 41 as shown by the solid line in FIG. 9 (a). Close contact with the surface 21. As in the case of each of the above-described embodiments, at this time, a part of the peripheral portion of the skin material 41 slides between the outer peripheral surface 22 and the presser frame body 32 and is drawn into the molding surface 21. As a result, the skin material 41 is compressed in the tangential direction of the outer periphery at the rising portion around the molding surface 21, but the tensile stress generated in the skin material 41 in the molding surface 21 is slight.
[0040]
As shown in FIG. 9 (b), the cover pad 43 and the insertion plate 47 are overlapped in the skin material 41 in close contact with the molding surface 21 so that the former is on the lower side (skin material 41 side). Place. The insertion plate 47 is elastic to such an extent that it is not substantially deformed by the foaming pressure of the foam raw material 44a forming the foam 44, and is not integrally bonded to the foam raw material 44a when foaming. It is a thin plate material (for example, a plate material made of polyethylene having a thickness of 1 mm), and at least one of the protrusions 21a of the molding surface 21 through the skin material 41 and the compressed cover pad 43 by applying the foaming pressure of the foam raw material 44a. When it abuts on the top (see FIG. 9 (c) described below), the outer peripheral edge is of a contour shape that abuts on the inner surface of the skin material 41 substantially without a gap. The cover pad 43 has a slightly smaller contour shape than the insertion plate 47. The cover pad 43 may have a slightly larger outline shape than the insertion plate 47, and the outer peripheral edge of the insertion plate 47 may be in contact with the inner surface of the skin material 41 through the compressed cover pad 43 with substantially no gap.
Next, a predetermined amount of urethane foam raw material 44a mainly composed of polyol and isocyanate is supplied onto the insertion plate 47 by a urethane injection gun (not shown) (see FIG. 2 (b)), and then the upper mold 30 is lowered. If the contact surface 31 is brought into contact with the outer peripheral surface 22 through the skin material 41, the supplied urethane foam raw material 44a is foamed and becomes the contact surface 31, the insertion plate 47, and the outside thereof. A foam 44 filled between the skin materials 41 is formed. The back surface of the skin material 41 between the outer edge of the insertion plate 47 and the outer edge of the recessed step portion 22a is impregnated with the foam raw material 44a and integrated with the urethane foam 44. On the inner side, the foam raw material 44a is A gap 48 is formed between the cover pad 43 and the skin material 41 by being blocked by the insertion plate 47 that is not substantially deformed by the foaming pressure. When the foamed foam raw material 44a finishes the reaction and the foam 44 is formed, the ornament assembly 40 formed by raising the upper mold 30 is taken out from the lower mold 20, and the reference numeral shown in FIG. If the insertion plate 47 is extracted to the outside from a cut 44b formed in a part of the foam 44 by a knife or the like over the entire width in the direction orthogonal to the figure, the concave step portion Molding of the ornament assembly 40 in which the flange portion 40a corresponding to 22a is formed on the entire circumference is completed. The insertion plate 47 may be extracted by bending the ornament assembly 40.
[0041]
As in each of the above-described embodiments, the skin material 41 that is sucked and adhered to the molding surface 21 and the concave step portion 22a and formed into the shape thereof is a back surface that is between the outer edge of the barrier material 42 and the outer edge of the concave step portion 22a. Is impregnated with the foam raw material 44a, integrated with the foam 44, and elastically hardened. In particular, the flange portion 40a is difficult to expand and contract. Therefore, even if the skin material 41 of the molded ornament assembly 40 is taken out from the lower mold 20, the shape when it is in close contact with the molding surface 21 is maintained. That is, the cross-sectional shape of the rising portion around the skin material 41 is maintained in a desired shape, and the mating portion with the adjacent parts such as the door trim upper and the armrest does not fall, so that a tight feeling can be given. In addition, in the portion inside the peripheral rising portion, a gap 48 is formed between the skin material 41 and the foam 44, so that the gathers formed by the skin material 41 have a very flexible feel in a free state, In addition, since the tensile stress generated in the skin material 41 is slight in this portion, the gathers formed in this portion are not lost even if the tensile stress is taken out from the lower mold 20.
[0042]
Further, in this embodiment, since the flexible sheet-like cover pad 43 is provided on the surface of the foam 44 on the skin material 41 side, the tactile sensation on the surface of the ornament assembly 40 when the gathers are pressed is adjusted. can do.
[0043]
This fourth embodiment may be carried out by providing a barrier material 42 between the foam 44 and the insertion plate 47, and FIG. 10 shows the last part of the manufacturing process in that case. In the state where the foam raw material 44a has finished the reaction and the foam 44 is formed and taken out from the lower mold 20, as shown in FIG. 10 (a), a barrier material 42, between the foam 44 and the skin material 41, The insertion plate 47, the cover pad 43, and the gap 48 are interposed. If the insertion plate 47 is pulled out from the cut 44b formed in the foam 44, the ornament assembly 40 as shown in FIG. It becomes. The insertion plate 47 of the modified example of FIG. 10 may be bonded integrally with the foam material 44a when foaming. Further, the fourth embodiment may be carried out by omitting the cover pad 43, and FIG. 11 shows a partially enlarged sectional view of a modified example of the ornament assembly 40 obtained in that case.
[0044]
As shown in FIGS. 12 and 13, the ornament assembly 40 formed as described above sandwiches the upper flange portion 40 a between the door trim base 11 and the lower edge 12 a of the door trim upper 12, and lower flange portion. The door trim 10 is assembled to the door trim 10 by sandwiching 40a between the door trim base 11 and the inner edge 6b of the armrest 6. Alternatively, this ornament assembly 40 is also provided with a V-cut portion a similar to the case of the skin 5 of the prior art shown in FIG. 15 in the peripheral flange portion 40a, and a core plate 3 similar to that in FIG. 14 is applied from the back side. The flange portion 40a may be wound around the back side of the core plate 3 and bonded to the door trim or the like via the core plate 3.
[0045]
In each of the above embodiments, the presser frame 32 separate from the upper mold 30 is used to lightly press the outer peripheral portion of the skin material 41 against the outer peripheral surface 22 of the lower mold 20, but the outer peripheral surface of the lower mold 20 is used. The abutting surface 31 of the upper mold 30 is lightly abutted against and pressed against the skin material 41 placed on the surface 22, and the pressing force of the abutting surface 31 is increased after the skin material 41 is drawn in and brought into suction contact with the molding surface 21. The presser frame 32 can be omitted so as to withstand the foaming pressure of the urethane foam raw material 44a. In this case, instead of supplying the urethane foam raw material 44a onto the barrier material 42 by the urethane injection gun with the upper mold 30 opened, the injection is made to open to the contact surface 31 with the upper mold 30 closed. What is necessary is just to make it inject | pour the urethane foam raw material 44a from a channel | path.
[0046]
【The invention's effect】
According to the present invention using the barrier material placed on the skin material so that the outer peripheral portion is not constrained by the outer peripheral surface of the skin-side molding die and the contact surface of the back-side molding die, The skin material that has been sucked into close contact and molded into that shape has the back surface impregnated with the foam raw material at the portion corresponding to the recessed step portion and the rising portion around the molding surface, and is integrated with the foam. Since the tensile stress generated in the outer skin material is slight, even when taken out from the outer skin side mold, it is kept in the shape when it is in close contact with the molding surface. Therefore, the skin material of the ornament assembly can give a tight feeling to the mating part with the adjacent part with the peripheral rising part as a desired shape. Further, since the skin material is not impregnated with the foam material in the portion inside the rising portion around the molding surface, sufficient flexibility is maintained in this portion.
[0047]
In the invention of the preceding paragraph, according to what is provided with a plurality of protrusions for forming the pleats forming the gathers at the bottom of the molding surface of the skin side molding die, the skin material is molded by the skin side molding die. At the same time, since the pleats that become gathers are formed, in addition to the effect of the invention of the preceding paragraph, the gathers are formed on the skin material, so labor is not required and the manufacturing cost can be reduced, and the gather quality is also stable. Will be.
[0048]
In the inventions of the preceding two paragraphs, a barrier material placed on the skin material via a flexible sheet-like cover pad, and the barrier material are not substantially impregnated with the foam material, but can be bonded. According to the closed cell or semi-closed cell foamed resin foam sheet, since the cover pad or the foamed resin sheet is interposed between the skin material and the foam, in addition to the effects of the inventions in the preceding two paragraphs, The tactile feel of the surface of the ornament assembly can be adjusted.
[0049]
Further, according to the present invention using the skin material and the heat-meltable barrier material that are integrally bonded to the outer side of the contour side of the molding surface of the skin-side molding die, the skin-side molding die is used. In the skin material molded into the shape by suction and adhesion to the molding surface and the outer peripheral surface of the mold, the portions corresponding to the recessed step portion and the rising portion around the molding surface are integrated with the foam through the barrier material. Since the tensile stress generated in the inner skin material and the barrier material is slight, even when it is taken out from the skin side molding die, it is kept in the shape when it is in close contact with the molding surface. Therefore, the skin material of the ornament assembly can give a tight feeling to the mating part with the adjacent part with the peripheral rising part as a desired shape. Further, since the skin material is not integrated with the foam or impregnated with the foam material in the portion inside the rising portion around the molding surface, sufficient flexibility is maintained in this portion.
[0050]
In the invention of the preceding paragraph, according to what is provided with a plurality of protrusions for forming the pleats forming the gathers at the bottom of the molding surface of the skin side mold, the skin material depends on the skin side mold Because the pleats that become gathers are formed at the same time as the molding, in addition to the effect of the invention of the preceding paragraph, the gathers are formed on the skin material, so labor is not required and the manufacturing cost can be reduced. It will be stable.
[0051]
In the inventions of the preceding two paragraphs, a soft sheet-like cover pad is provided between the skin material and the barrier material in a range that is inside the vicinity of the contour of the molding surface, and the barrier material is near the contour of the molding surface A first barrier material made of a closed cell or semi-closed cell foamed resin sheet that is not impregnated with the foam material and is not substantially impregnated, but is bonded to the skin material. According to a thin sheet-like heat-meltable second barrier material consisting of a portion and a portion covering the periphery of the first barrier material, a cover pad or a resin foam sheet between the skin material and the foam Therefore, in addition to the effects of the inventions of the preceding two items, the tactile sensation on the surface of the ornament assembly can be adjusted.
[0052]
In addition, according to the present invention using an insertion plate that is pulled out after molding, the skin material that is suction-contacted to the molding surface and the concave step portion and molded into that shape is formed on the rising portion around the concave step portion and the molding surface. The corresponding part is impregnated with the foam raw material on the back side and integrated with the foam, so the skin material of the ornament assembly has a feeling that the peripheral rising part is in the desired shape and tightened to the mating part with the adjacent part Can be given. In addition, in the part inside the rising part around the molding surface, a gap is formed between the skin material and the foam, so the gathers formed by the skin material have a very soft feel in the free state. Since the tensile stress generated in the skin material is very small in the portion, the gathers formed in this portion are not lost even when taken out from the skin side mold.
[0053]
In the invention of the preceding paragraph, an ornament assembly is completed according to one aspect of the insertion plate being brought into contact with at least one top of the plurality of protrusions via a skin material and a cover pad Then, since the surface of the foam on the gap portion side is covered with the cover pad, in addition to the effect of the invention of the preceding item, the gathers formed by the skin material can adjust the tactile sensation in the pressed state.
[0054]
Further, according to the present invention in which a barrier material is used in addition to the insertion plate pulled out after molding, in addition to the effects of the invention of the preceding paragraph, a larger barrier material is placed on the insertion plate. Therefore, even if a slight gap is generated between the outer peripheral edge of the insertion plate and the skin material due to manufacturing errors, etc., it is formed between the skin material and the foam on the bottom side of the molding surface of the skin side molding die. Intrusion of the foam raw material into the gap is reliably prevented, and the desired effect can be obtained with certainty.
[0055]
In the invention of the preceding paragraph, an ornament assembly is completed according to one aspect of the insertion plate being brought into contact with at least one top of the plurality of protrusions via a skin material and a cover pad Then, since the surface of the foam on the gap portion side is covered with the cover pad, in addition to the effect of the invention of the preceding item, the gathers formed by the skin material can adjust the tactile sensation in the pressed state.
[Brief description of the drawings]
FIG. 1 is an overall longitudinal sectional view of an apparatus used in a first embodiment of a method for manufacturing an ornament assembly according to the present invention.
FIG. 2 is a partial enlarged cross-sectional view showing each step of the first embodiment shown in FIG. 1;
FIG. 3 is a partially enlarged sectional view showing each step of a second embodiment of the method for manufacturing an ornament assembly according to the present invention.
FIG. 4 is a partially enlarged sectional view showing each step of a third embodiment of the method for manufacturing an ornament assembly according to the present invention.
FIG. 5 is a partially enlarged cross-sectional view of an ornament assembly manufactured according to a modification of the first embodiment.
FIG. 6 is a partially enlarged cross-sectional view of an ornament assembly manufactured according to a different modification of the first embodiment.
FIG. 7 is a partially enlarged cross-sectional view of an ornament assembly manufactured according to a modification of the second embodiment.
FIG. 8 is a partially enlarged cross-sectional view of an ornament assembly manufactured according to a different modification of the second embodiment.
FIG. 9 is a partially enlarged sectional view showing each step of a fourth embodiment of a method for manufacturing an ornament assembly according to the present invention.
FIG. 10 is a partially enlarged cross-sectional view of a part of a process of a modified example of the fourth embodiment and an ornament assembly manufactured thereby.
FIG. 11 is a partially enlarged cross-sectional view of an ornament assembly manufactured according to a different modification of the fourth embodiment.
FIG. 12 is an overall front view of a door trim to which an ornament assembly manufactured according to each embodiment of the present invention is attached.
13 is an enlarged cross-sectional view taken along line 12-12 of FIG.
FIG. 14 is a plan view of a core plate of an ornament assembly according to the prior art.
15 is a plan view of the skin of the ornament according to the prior art shown in FIG.
16 is an enlarged cross-sectional view corresponding to FIG. 13 of the door trim to which the ornament assembly according to the prior art shown in FIGS. 14 and 15 is attached.
FIG. 17 is an enlarged cross-sectional view corresponding to FIG. 13 of a door trim to which an ornament assembly according to a different prior art is attached.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 20 ... Skin side shaping | molding die (lower die), 21 ... Molding surface, 21a ... Projection, 22 ... Outer peripheral surface, 22a ... Recessed step part, 25 ... Suction passage, 27 ... Air intake hole, 30 ... Back side molding die (Upper) Mold), 31 ... contact surface, 40 ... ornament assembly, 40b ... pleats, 41 ... skin material, 42 ... barrier material, 42a ... first barrier material, 42b ... second barrier material, 43 ... cover pad, 44 ... Foam, 44a ... foam material, 44b ... cut, 47 ... insert.

Claims (12)

A flat outer peripheral surface is formed in the peripheral portion of one side surface, a molding surface is formed in the central portion that is dug out of the outer peripheral surface, and a shallow concave step portion is formed in a portion surrounding the molding surface of the outer peripheral surface. On the one side of the skin-side molding die to be placed, a sheet-like skin material is placed and its peripheral part is lightly pressed against the outer peripheral surface,
The peripheral portion of the skin material is removed by sucking air between the skin material and the molding surface through a suction passage provided in the skin-side molding die and having a number of intake holes that open to the molding surface. Adhering the same skin material to the molding surface while drawing into the molding surface,
The peripheral part of the contact surface on one side of the back surface side mold is brought into contact with the outer peripheral surface of the skin side mold through the skin material,
Supplied between the contact surface and a flexible, substantially non-breathable sheet-like barrier material placed on the skin material so that the outer peripheral portion is not substantially restrained by the outer peripheral surface and the contact surface A foam manufacturing method is provided, wherein the foam material is foamed to form a foam filled between the contact surface, the barrier material, and a skin material outside the barrier material. The method for manufacturing an ornament assembly according to claim 1, wherein a plurality of protrusions for forming pleats for forming gathers on the skin material are provided at the bottom of the molding surface of the skin-side mold. The said barrier material is mounted on the said skin material through the flexible sheet-like cover pad by which the outer peripheral part is not substantially restrained by the said outer peripheral surface and contact surface. 3. A method for manufacturing an ornament assembly according to 2. 3. The method for manufacturing an ornament assembly according to claim 1, wherein the barrier material is a closed cell or semi-closed cell foamed resin sheet that is not substantially impregnated with the foam material but can be bonded. . A flat outer peripheral surface is formed in the peripheral portion of one side surface, a molding surface is formed in the central portion that is dug out of the outer peripheral surface, and a shallow concave step portion is formed in a portion surrounding the molding surface of the outer peripheral surface. On the one side of the skin-side mold, a sheet-like skin material that is superposed on each other and is integrally bonded to the outside of the vicinity of the contour of the molding surface is heat-meltable, flexible, and substantially A non-breathable sheet-like barrier material is placed on the outer peripheral surface of the skin material and the barrier material, and lightly pressed against the outer peripheral surface,
Periphery of the skin material and the barrier material by sucking air between the skin material and the molding surface through a suction passage provided in the skin side molding die and having a number of intake holes that open to the molding surface Adhering the same skin material to the molding surface while drawing the part into the molding surface,
A peripheral portion of the contact surface on one side of the back side mold is brought into contact with the outer peripheral surface of the skin side mold through the skin material and the barrier material,
A method of manufacturing an ornament assembly, comprising: foaming a foam material supplied between the barrier material and the contact surface to form a foam filled between the contact surface and the barrier material. 6. The method for manufacturing an ornament assembly according to claim 5, wherein a plurality of protrusions for forming pleats for forming gathers on the skin material are provided at the bottom of the molding surface of the skin side mold. The method for manufacturing an ornament assembly according to claim 5 or 6, wherein a flexible sheet-like cover pad is provided between the skin material and the barrier material in a range inward of the vicinity of the contour of the molding surface. The barrier material is
A first barrier material made of a closed-cell or semi-closed-cell resin foam sheet that is located in a range inward of the vicinity of the contour of the molding surface and is not substantially impregnated with the foam material but can be bonded; ,
The ornament assembly according to claim 5 or 6, comprising a thin sheet-like heat-meltable second barrier material comprising a portion bonded to the skin material and a portion covering the periphery of the first barrier material. Production method. A flat outer peripheral surface is formed on the peripheral portion of one side surface, and a molding surface is formed with a plurality of protrusions for forming pleats that are dug into the central portion and form gathers at the bottom portion thereof. In addition, a sheet-like skin material is placed on the one side surface of the skin-side molding die formed by forming a shallow concave step portion in a portion surrounding the molding surface of the outer peripheral surface, and the peripheral portion is placed on the outer peripheral surface. Lightly touching the
A peripheral portion of the skin material is drawn by sucking air between the skin material and the molding surface through a suction pipe provided in the skin side molding die and having a number of intake holes that open to the molding surface. Adhering the same skin material to the molding surface while drawing into the molding surface,
In the skin material in close contact with the molding surface, one side is in contact with at least one top of the plurality of protrusions via the skin material, and the entire outer periphery is substantially in contact with the skin material. Place the insertion plate,
The peripheral part of the contact surface on one side of the back surface side mold is brought into contact with the outer peripheral surface of the skin side mold through the skin material,
Foaming the foam material supplied between the contact surface and the insertion plate to form a foam filled between the contact surface and the insertion plate and the skin material outside the insertion plate,
The insertion plate is an elastic plate material that is not substantially deformed by the foaming pressure of the foam raw material and is not fixed to the foam during foaming. The insertion plate was formed in the foam after the foam was formed. A method for manufacturing an ornament assembly, wherein the ornament assembly is pulled out from the cut. A flexible cover pad having the same contour shape as the insertion plate is provided between the insertion plate and the skin material, and one side surface of the insertion plate is provided on the top of at least one of the plurality of protrusions. The method of manufacturing an ornament assembly according to claim 9, wherein the ornament assembly is in contact with the pad. A flat outer peripheral surface is formed on the peripheral portion of one side surface, and a molding surface is formed with a plurality of protrusions for forming pleats that are dug into the central portion and form gathers at the bottom portion thereof. In addition, a sheet-like skin material is placed on the one side surface of the skin-side molding die formed by forming a shallow concave step portion in a portion surrounding the molding surface of the outer peripheral surface, and the peripheral portion is placed on the outer peripheral surface. Lightly touching the
A peripheral portion of the skin material is drawn by sucking air between the skin material and the molding surface through a suction pipe provided in the skin side molding die and having a number of intake holes that open to the molding surface. The skin material is brought into intimate contact with the molding surface while being drawn into the molding surface, and one side surface is placed on the top of at least one of the plurality of protrusions with the skin material in the skin material in close contact with the molding surface. Placing an insertion plate whose entire outer peripheral edge is substantially in contact with the skin material,
The peripheral part of the contact surface on one side of the back surface side mold is brought into contact with the outer peripheral surface of the skin side mold through the skin material,
A sheet-like sheet placed on the insertion plate is supplied between the contact surface and a barrier material having a contour shape larger than the insertion plate so that the outer peripheral portion is not substantially restrained by the outer peripheral surface and the contact surface. Foam material is formed to form a foam filled between the contact surface, the barrier material, and the skin material outside the barrier material;
The insertion plate is an elastic plate material that is not substantially deformed by the foaming pressure of the foam material, and the insertion plate is pulled out from a cut formed in the foam after the foam is formed. Solid manufacturing method. A flexible cover pad having the same contour shape as the insertion plate is provided between the insertion plate and the skin material, and one side surface of the insertion plate is provided on the top of at least one of the plurality of protrusions. The method of manufacturing an ornament assembly according to claim 11, wherein the ornament assembly is in contact with the pad.

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