JP4302072B2 - Vacuum forming machine and vacuum forming method for interior parts - Google Patents

Description

  The present invention sets a clamping device attached with a heater that clamps the periphery so as to flatly support a thermoplastic skin material with a foam layer and softens the skin material, and a base material on which air intake passages are dispersedly formed. As described above, the vacuum suction mold for the base material provided on one side of the upper and lower sides with respect to the clamping tool, and the skin material to be shaped and provided on the other side so as to face the vacuum suction mold for the base material An undercut part which has a vacuum suction mold for skin material having a mold surface corresponding to the surface shape, and which becomes deeper via a base material corner part which bends at a negative angle from a base material region which is positive with respect to the demolding direction The present invention relates to a vacuum forming machine and a vacuum forming method for an interior product for producing an interior product by adhering a skin material in a state of being sucked by vacuum suction to a base material on which is formed.

  In Document 1, the skin material is flattened with a support and is tension-supported, and a base material that can be ventilated is assembled to a vacuum-adhesive convex surface, and the fabric material is partially bonded to the vacuum-adhesive convex surface. It is assembled to the mold surface of the receiving mold similar to the above, and the vacuum adhesive mold of the base material and the receiving mold assembled with the fabric material are moved from both sides toward the heated and softened skin material with a support tool. There is disclosed a method for manufacturing a partly-distributed vehicle interior member in which a fabric material is pressed and bonded to a predetermined part of a skin material in a vacuum bonding type by vacuum drawing and bonding to a surface of a substrate. According to this method, the fabric material is not only partially distributed on the skin material, but is also bonded to the surface of the substrate in a softened state without being molded in advance. However, when an undercut portion that makes it difficult to remove the mold is formed on the base material, it is necessary to provide a slide core by an ordinary method.

  Therefore, for the purpose of eliminating such a movable mold, according to Patent Document 2, an adhesive is applied to adhere the skin material in a close contact state without leaving a hollow portion in the core material or base material having the undercut portion. The core material is set in the male mold, and the skin stretched between the male mold and the female mold is brought into contact with the core material by moving relatively to the female mold side, and vacuum suction is performed from the female mold side, Next, a vacuum forming method is proposed in which the vacuum suction is stopped and then vacuum suction is performed from the male mold side.

According to this integrated molding method, the three-layer instrument panel 9 in which the skin material with the foam layer is bonded to the plate-like base material on the skin as shown in FIG. 2 forms the undercut portion on the back side of the upper wall. When the meter hood 7 is provided, the process is as follows. That is, as shown in FIG. 6, a vacuum suction mold 5 which is a male mold is provided with a base 4 which is provided with a notch 4c and an undercut 4b for mounting a meter, and which is freely ventilated, with an adhesive interposed therebetween. A skin material 3 in which a foam layer 2 is joined is overlapped on a warmed and softened skin 1 and clamped with a vacuum suction die 6 which is a female die. Next, vacuum suction is performed with this vacuum suction mold to shape the surface of the skin material 3 (A in the same figure), and then the vacuum suction is stopped and the vacuum suction mold 5 is vacuum suctioned to remove the skin material 3. At the same time as adsorbing and adhering to the base material 4, it is adsorbed by being sucked and moved along the undercut portion 4b (B in the same figure).
Japanese Patent Laid-Open No. 10-34741 JP-A-6-34433

  According to this vacuum forming, the undercut part of the base material can be shaped and bonded without a slide core by sucking in order from both molds, but the skin material with the foam layer attached to the skin is softened by heating. Assuming that it adheres to the substrate in the state, in the process of vacuum suction on the male mold side after vacuum suction from the female mold side to shape the surface of the skin material, the temperature drop due to mold contact between them As a result, the degree of softening is reduced, making it difficult to shape the undercut portion, particularly the corner portion, and the suction time to the epidermis side cannot be lengthened. Furthermore, when hot-melt type adhesion is used, peeling is likely to occur due to an adhesion failure due to a decrease in temperature or an increase in residual stress due to a decrease in the softness of the substrate. Therefore, as shown in FIG. 7A, the negative angle β of the undercut region 4h of the base material is included regardless of the positive angle α (including α = 0) with respect to the releasing direction of the base material region 4g that can be removed. Is gradually increased, particularly, it is difficult to faithfully shape the corner portion 4f, and as shown in FIG. 7B, even when a negative-angle curved corner portion 4k is interposed in the undercut region 4h, the radius of curvature thereof is increased. When becomes smaller, sharp shaping becomes difficult.

  Meanwhile, according to Japanese Patent Application No. 2004-56312, the applicant of the present application sets a breathable base material to a vacuum suction type, sets a skin material with a foam layer on the surface of the base material, and uses the skin material as a base material by vacuum suction. In order to produce an interior product by adhering in the sucked state, the vacuum suction mold for the base material is formed on one side of the upper and lower sides of the thermoplastic skin material supported in a flat shape, and the other in a flat shape. On the other hand, in a state where the skin material is softened by the heating treatment by the vacuum forming machine provided with the vacuum suction mold for the skin material having the mold surface corresponding to the surface shape of the entire surface material to be shaped, The vacuum suction mold for the base material and the vacuum suction mold for the skin material are clamped, and these vacuum suction molds are simultaneously vacuum-sucked in the clamped state, thereby compressing or expanding the foam layer to the base material, Forming the skin material along the surface of the vacuum suction mold for the skin material That was proposed interior trim vacuum molding method.

  As a result, the foam layer is sucked and adhered to the base material set in the vacuum suction mold for the base material with an adhesive by vacuum suction, and the skin material is adsorbed to the mold surface of the vacuum suction mold material for the skin material by vacuum suction. To be shaped. However, in this simultaneous vacuum suction, the adhesion of the base material to the deep undercut portion still has a problem on the assumption that there is no slide core.

  In view of such points, the present invention provides a vacuum suction mold for a base material on which a base material is set and a vacuum suction for a skin material having a mold surface corresponding to the surface shape of the skin material with a foam layer to be shaped. A small curvature that can be attached to the skin along the undercut part of the base material and begins to become negative when the mold is clamped in a state where the skin material is softened by heating treatment and vacuum suction is performed simultaneously. It is an object of the present invention to provide a vacuum forming machine and a vacuum forming method for an interior product that can sharply shape and bond a base material corner portion of a radius to a similar shape.

  In order to achieve this object, the present invention provides, according to claim 1, a clamping device attached with a heater for clamping the periphery so as to flatly support the thermoplastic skin material with a foam layer and softening the skin material. A base material vacuum suction mold provided on one of the upper and lower sides of the clamp so as to set a base material in which the intake passages are dispersedly formed, and the other so as to face the base material vacuum suction mold A vacuum suction mold for a skin material provided on the side and having a mold surface corresponding to the surface shape of the skin material to be shaped, and a base that bends at a negative angle from a base material region of a positive angle with respect to the demolding direction In a vacuum forming machine for interior parts for manufacturing interior parts by bonding the skin material in a state of being sucked by vacuum suction to a base material formed with an undercut part that becomes deeper via a material corner part, By vacuum compression mold for skin material, compression of foam layer A mold corner projecting in a similar shape to the base corner to the extent that the mold is allowed, and a non-similar shape that is continuous with this mold corner and can be removed from the similar shape to the undercut And a non-breathable mold receding portion that is receded into the upper surface.

  With the skin material being softened, the vacuum suction mold for the base material and the vacuum suction mold for the skin material are clamped and vacuum suctioned respectively, so that the back surface of the foam layer is made into a vacuum suction mold for the base material with an adhesive. While being adhered to the set substrate by vacuum suction, the skin material is adsorbed and shaped by vacuum suction on the mold surface of the vacuum suction mold material for the skin material due to expansion or contraction of the foam layer or both. The At that time, the skin material of the base material corner portion is shaped along the mold corner portion that can be vacuum-sucked, and the skin material positioned by the mold retraction portion is sucked and moved along the remaining remaining undercut region. Glued.

  As a form to which the present invention is effectively applied, according to claim 2, the undercut portion cuts deeper at a negative angle via a negative-angled curved surface corner portion having a curvature radius of 2 mm or less, and a mold The amount of protrusion of the corner corresponds to a similar shape to the curved base material corner.

  As a vacuum forming method using such a vacuum forming machine, according to claim 3, the base material is set in a vacuum suction mold, and the skin material is softened by a heating process. The vacuum suction mold for the skin material is clamped, and vacuum suction is simultaneously performed by these vacuum suction molds, thereby compressing or expanding the foam layer and shaping the skin material along the surface of the vacuum suction mold for the skin material. At the same time, the foam layer is adhered to the base material, and the skin material along the mold retreating portion is moved to the undercut portion by suction to be adhered.

  According to the present invention, the simultaneous suction eliminates the need for a vacuum forming process for the skin material and improves the surface quality as well as reducing the design restrictions and making the shape non-similar to the substrate surface. It can also be formed. The corner portion having a small curvature radius of the undercut portion is also securely bonded to the base material, and the surface of the skin material is sharply shaped into a similar shape along the surface of the vacuum suction mold for the skin material. Further, the base material in the deep part is reliably bonded and shaped by positioning the skin material by the mold retreating part.

  An interior product vacuum forming machine according to an embodiment of the present invention will be described with reference to FIGS. The plate-like interior product to be vacuum-bonded is an instrument panel 9 having a meter hood 7 with an undercut portion on the back side of the upper wall of the opening 7a as described above with reference to FIG. Three layers in which a thermoplastic skin material 10 in which a foam layer 12 made of PP foam (polypropylene foam) having a thickness of 3 mm is welded to a skin 11 made of TPO (thermoplastic olefin) is bonded to a base material 4 made of PP, for example. It is manufactured as a soft type. The same or equivalent parts as those described above will be described with the same reference numerals.

  As shown in FIG. 3, the vacuum forming machine for integral molding has a male mold on one side in the vertical direction of a clamp tool 18 that clamps the periphery of the thermoplastic skin material 10 with a foam layer so as to be pulled and supported in a flat state. The vacuum suction mold 5 for the substrate is provided, and the vacuum suction mold 16 for the porous skin material by electroforming which is the female mold is provided on the other side so as to face each other. These molds are moved up and down toward the clamp tool 18 by an attached lifting device (not shown), and both the coupling tools 17 and 17a are connected in a concavo-convex manner to perform mold clamping. Heaters 19 for heating the skin material 10 from both sides are arranged on both sides of the clamp tool 18, and can be moved to a side escape position during mold clamping. The suction path (not shown) of the convex mold 5a of the vacuum suction mold 5 for the substrate and the suction port 16d of the vacuum suction mold 16 are respectively connected to a vacuum pump to constitute suction means for simultaneously performing vacuum suction. Yes.

  The mold surface 16b of the concave mold 16a of the vacuum suction mold 16 for the skin material corresponds to the surface shape of the skin 11 to be shaped from a flat shape, and with respect to the mold surface 5b of the convex mold 5a or the surface of the base material 4, Most of the general surfaces excluding the area such as the meter hood 7 are similar in shape, and a cavity is formed with a separation distance capable of being pressed against or substantially in contact with the skin material 10 in a clamped state. The base material 4 set on the convex portion 5a includes a dispersed intake passage (not shown) communicating with the intake passage of the convex portion 5a, and as shown in an enlarged view in FIG. It is injection-molded so as to have a recess 5c that forms the portion 7a. Further, the mold surface 16b is formed with a convex portion 16c that enters the concave portion 5c.

  In the hood upper wall portion 21 of the base hood portion 20 set in the region of the recess 5c, the flat base region 21a having a positive angle with respect to the demolding direction has a negative angle, that is, in a crossing direction in which demolding is impossible. An undercut portion 4b having a base material recess 23 that digs deeper through a curved base material corner portion 22 having a curvature radius of 1 mm is formed. A notch portion 4c for attaching the meter is formed between the undercut portion and the removable hood lower wall portion 29.

  Correspondingly, the convex portion 16c of the skin vacuum suction mold 16 has a shape similar to that of the base material corner portion 22 and protrudes about 1 mm in a direction orthogonal to the demolding direction corresponding to the negative angle range. The mold corner portion 30 and the non-breathable portion that is formed continuously with the mold corner portion 30 and recedes from the similar shape to the non-similar shape so as to face the substrate recess 23 in the remaining region at a regular angle. A mold retraction part 31 and a mold similarity part 32 that forms a cavity corresponding to the thickness of the skin material 10 with respect to the mold surface 5c of the notch part 4c are formed. The mold retreating portion 31 has its pores abolished by sticking a tape on its surface, filling with a filler, and the like, and is incapable of suction in a region facing the non-similar shape to the mold surface 5b.

  In the case of integral molding, as shown in FIG. 3, a foam layer 12 made of PP foam is welded to a skin 11 made of TPO, and a hot-melt olefin adhesive 13 is applied to the back surface of the foam layer 12 and wound in a roll shape. The thermoplastic skin material 10 that has been stored is cut into a required size and supported flat by the clamp tool 18, and the substrate 4 of the vacuum surface 5 of the mold surface shape along its back surface is provided. Set to convex mold 5a. As shown in FIG. 4, the general surface of the base material 4 adjacent to the meter hood 7 and not having a notch is continuously in contact with the convex mold 5a over the top surface, front surface, and bottom surface of the instrument panel 9. Facing. Next, the skin material 10 is heated by the attached heater 19 to be softened, and then the heater is released and the vacuum suction mold 5 and the vacuum suction mold 16 are moved up and down to be clamped, and the suction port 16d and the convex Vacuum suction is performed almost simultaneously from both sides by the intake passage of the mold 5a.

  Thereby, as shown partially in FIG. 1, the foamed layer 12 is adhered to the base material 4 by the hot melt type olefin adhesive 13 and the skin 11 is formed of a porous concave mold 16a. It is closely adsorbed on the surface 16b, and is shaped along the mold surface 16b while compressing or expanding the foamed layer 12 in a thermally softened state. At that time, in the undercut part 4b, the skin material 10 is securely bonded to the base material corner part 22 in a sufficiently softened state by vacuum suction from both sides of the base material corner part 22 and the mold corner part 30, The surface is faithfully shaped into a similar curved surface along the mold corner 30. In addition, the skin material 10 (shown by a two-dot chain line in the figure) that is positioned in contact with the die retreating portion 31 without being attracted moves the space portion 23a to the opposing base material recess 23. Slightly stretches and sucks and adheres. A region of the cutout portion 4c facing the mold similarity portion 32 is shaped by a cavity therebetween.

  At the time of demolding after cooling, the mold corner portion 30 demolds by slightly compressing the foamed layer 12 of the base material corner portion 22 and does not deform or damage the skin 11. The skin material 10 is suppressed by the simultaneous vacuum suction to suppress the temperature drop at the time of mold contact, and is securely bonded to the substrate 4 and is faithfully shaped on the surface of the mold surface 16b, and has a fine shape such as wrinkles. Is also reliably transferred. As a result, a high-quality all-olefin three-layer instrument panel 9 is manufactured. The skin material 10 of the notch 4c is cut off when the meter is attached.

  The undercut portion 4b described above is continuous with the base material recess portion 23 by being deepened at about 45 ° along the tangential direction of the base material corner portion 22 with respect to the demolding direction. The range can be further increased to about 90 ° and deepened in the tangential direction. In some cases, the substrate corner portion 22 can be made deeper and deepened in the non-tangential direction. At this time, the protrusion amount of the mold corner portion 30 is set in correspondence with the curved surface shape similar to the foamed layer having a negative angle within a range in which the mold can be removed without impairing the surface quality.

  As shown in FIG. 5, the present invention is also applied to the case where a base material corner portion 22 a having a small radius of curvature is provided above and below the concave undercut portion 4 k of the base material. Similar curved surface corner portions 30a are formed on the upper and lower sides. The mold retreating part 31a is opposed to the concave undercut part 4k so that it can be removed from a mold by placing a space wider than the molding cavity without being deeper than the mold corner part 30a. Further, the present invention is not limited to the instrument panel, and is applied to various plate-shaped interior products having three layers including a foam layer having an undercut portion formed through a curved undercut corner portion having a small curvature. The

It is principal part sectional drawing of the mold clamping state of the vacuum forming machine for integration with respect to the base material of the skin material of the instrument panel by embodiment of this invention. It is a perspective view of the instrument panel integrally molded with the vacuum forming machine. It is sectional drawing explaining the structure of the vacuum forming machine. It is sectional drawing explaining the set state of the general surface of the base material of the vacuum forming machine. It is a fragmentary sectional view of another plate-shaped interior goods provided with the undercut part to which this invention is applied. It is sectional drawing explaining the integral formation process of the plate-shaped interior goods provided with the undercut part by the conventional vacuum forming machine. It is sectional drawing of the undercut part for demonstrating the principle of this invention.

Explanation of symbols

4 Substrate 4b Undercut 5 Substrate vacuum suction type
5b, 16b Mold surface 7 Meter hood 9 Instrument panel 10 Skin material 11 Skin 12 Foamed layer 13 Olefin adhesive 16 Vacuum suction type 18 for skin material 21 Clamp tool 21 Hood upper wall part 22 Base corner part 23 Base part concave part 30 Mold corner 31 Mold receding part

Claims (3)

Clamp the surroundings so that the thermoplastic skin material with foam layer is supported flat, and clamps attached with a heater that softens the skin material, and the base material on which the intake passages are dispersedly formed Corresponds to the vacuum shape for the base material provided on one side above and below the tool, and the surface shape of the skin material provided on the other side so as to face the vacuum suction type for the base material And a vacuum suction mold for the skin material having a mold surface to be formed, and an undercut portion that is further deepened is formed via a base material corner portion that bends at a negative angle from a base material region that is a positive angle with respect to the demolding direction. In a vacuum molding machine for interior parts for producing interior parts by adhering the skin material to the base material in a state of being sucked by vacuum suction,
In the vacuum suction mold for the skin material, a mold corner portion that projects in a similar shape to the base corner portion to the extent that demolding is allowed by compression of the foam layer, and an undercut portion that is continuous with this mold corner portion On the other hand, a vacuum forming machine for interior parts, characterized in that a non-breathable mold retreating part that has been retreated to a non-similar shape from its similar shape is formed.   The undercut portion digs deeper at a negative angle via a curved corner of the curved base having a radius of curvature of 2 mm or less, and the protruding amount of the mold corner is similar to that of the curved corner. The vacuum forming machine for interior parts according to claim 1, which corresponds to the vacuum forming machine. A vacuum forming method for interior parts using the vacuum forming machine for interior parts according to claim 1,
With the base material set in a vacuum suction mold and the skin material softened by heating, the vacuum suction mold for the base material and the vacuum suction mold for the skin material are clamped,
By simultaneously vacuuming with these vacuum suction molds, the foam layer is compressed or expanded to shape the skin material along the mold surface of the vacuum suction mold for the skin material, and the foam layer is A vacuum forming method for an interior product, wherein the skin material along the mold retreating part is adhered to a base material by being moved to an undercut part by suction.

Images