JP4962241B2 - Vacuum forming method for interior parts - Google Patents

Description

  The present invention relates to a vacuum forming method for interior parts such as automobile interior parts, for example. Specifically, the surface shape is formed by sucking the skin with a skin side vacuum suction mold, and further using the substrate side vacuum suction mold. The present invention relates to a vacuum forming method for an interior product in which the skin is sucked through an air passage of a base material and the skin is adhered to the surface of the base material.

2. Description of the Related Art Conventionally, an instrument panel, which is one of interior parts for automobiles, is attached to a position facing a driver's seat and a passenger seat along the windshield of the automobile with the vehicle width direction as a longitudinal direction. Such an instrument panel attaches the skin along the surface of a part of the base material, and the base material and the skin are separated by the base material side vacuum suction type and the skin side vacuum suction type by a vacuum forming method. It is sandwiched and formed integrally.
In the instrument panel, around the glove box on the passenger side and around the cockpit on the driver's seat, when these parts are viewed from the vehicle width direction, the shape is directed from the front of the car toward the interior space. It has a curved shape that is swollen. In such a curved panel bending portion, the shape of the base material in this portion is substantially in line with the shape of the panel bending portion.

Such an instrument panel is manufactured by, for example, the vacuum forming method disclosed in Patent Document 1. The vacuum forming method described in Patent Document 1 will be briefly described with reference to FIG. In addition, FIG. 11 is explanatory drawing explaining the method of coat | covering a skin on a base material in the vacuum forming method of patent document 1. FIG.
In the vacuum forming method of Patent Document 1, the substrate 10 is attached to the substrate-side suction die 51 in an arrangement form in which the top of the curved portion is directed upward in the mold opening / closing direction VL (vertical direction in FIG. 11). ing. On the other hand, the skin 20 is disposed between the base-side suction mold 51 (base-side vacuum suction type) and the skin-side suction mold 52 (skin-side vacuum suction type) while being held horizontally by the clamp tool 55. It is installed.
And at the time of shaping | molding, the base material side suction type | mold 51 is raised with the skin 20 in a horizontal attitude | position, and a part of skin 20 is coat | covered by a part of base material 11. FIG. Next, after the skin-side suction mold 52 is lowered and a part of the remaining skin 20 is covered with the remaining portion of the base material 10, the base-side suction mold 51 and the skin-side suction mold 52 are clamped. . After clamping, the surface shape of the skin 20 is formed by vacuuming the skin 20 from the skin-side suction mold 52 side in the molding space of the substrate-side suction mold 51 and the skin-side suction mold 52, and the substrate-side suction is performed. The skin 20 is adhered to the base material 10 by sucking the skin 20 from the mold 51 side through the ventilation portion of the base material 10.
JP 2007-160604 A

However, when the base material is coated on the base material in a horizontal posture, the thickness of the skin material varies at each part of the panel bending portion, and due to this variation, the base material side vacuum suction type and the skin side vacuum suction type cause When sandwiched, there is a problem that the outer skin is damaged such as tearing.
Hereinafter, the reason will be described with reference to FIG. FIG. 12 is an explanatory diagram for explaining a state in which a base material is covered with a skin disposed in a horizontal posture and clamped with a base material side vacuum suction type and a skin side vacuum suction type.

In the instrument panel, as shown in FIG. 12, in the panel bending portion, the entire surface of the bending portion 11 of the base material 10 (between the bending first portion Z1 and the bending third portion Z3 in FIG. 12) is epidermis. For example, some of the bending portions 11 cover the epidermis 20 only between the curved first portion Z1 and the curved second portion Z2.
In such an instrument panel, if the height of the bending portion 11 in the mold opening / closing direction VL (vertical direction in FIG. 12) is the bending portion height H, the bending portion height is determined when the instrument panel is molded. It is desirable to clamp the substrate-side vacuum suction mold 51 and the skin-side vacuum suction mold 52 with a curved portion intermediate line FC that crosses the curved portion 11 in the horizontal direction at a substantially intermediate position of H.
The reason for this is that the top portion of the bending portion 11 that is higher than the bending portion intermediate line FC is covered with the skin 20 by the rising of the substrate-side vacuum suction mold 51, while the lower portion is lower than the bending portion intermediate line FC. The skin 20 is covered by the lowering of the skin-side vacuum suction die 52 on the bottom side portion. That is, the skin 20 is in contact with the curved portion 11 of the base material 10 in a horizontal posture, and the shape according to the shape of the curved portion 11 is raised by raising the base material side vacuum suction die 51 and lowering the skin side vacuum suction die 52. And is stretched in the surface direction.
At this time, with respect to the mold opening / closing direction VL, the distance until the epidermis 20 covers the apex side portion of the curving portion 11 and the epidermis 20 are curving, with respect to the mold opening / closing direction VL. The difference from the distance to cover the bottom side portion of the portion 11 is relatively small. For this reason, when the skin 20 is deformed along the curved portion 11 due to the rise of the substrate-side vacuum suction die 51 and the lowering of the skin-side vacuum suction die 52, the amount of stretching in the surface direction of the skin 20 is the top side portion. This is because the side and bottom side portions can have the same degree.

On the other hand, the epidermis 20 is also covered between the curved second portion Z2 and the curved third portion Z3 of the bending portion 11 (see FIG. 12). That is, as shown in FIG. 11 to be referred to, when clamping is performed with the epidermis 20 kept in a horizontal posture, the horizontal length of the epidermis 20 is the second curved portion Z2—the third curved portion of the curved portion 11. An extra portion is necessary for covering the space between Z3, and the skin 20 is wasted, resulting in an increase in cost.
For this reason, the horizontal length of the epidermis 20 is shortened so that the unnecessary epidermis 20 is not covered between the curved second portion Z2 and the curved third portion Z3 of the bending portion 11, and the base-side vacuum suction die 51 and the epidermis are separated. The clamping reference line FX when the side vacuum suction die 52 clamps is set higher than the bending portion intermediate line FC, and the skin 20 is between the seventh portion Z1 and the eighth portion Z2 of the bending portion 11 that is required. Is covered.

However, when the skin 20 is disposed in a horizontal posture, the base material-side vacuum suction mold 51 and the skin-side vacuum suction mold 52 are clamped by the clamping reference line FX, and the skin 20 is coated on the base material 10, Depending on the shape of the bending portion 11 (for example, the size of the curvature diameter, the position of the inflection point where the different curvature diameters are connected to each other, etc.) The difference from the downward movement amount when the mold 52 is lowered may be relatively large.
That is, with respect to the mold opening / closing direction VL, the distance H1 until the skin 20 covers the top portion of the bending portion 11 and the distance H2 until the skin 20 covers the bottom portion of the bending portion 11 (H2> H1). (H2−H1) may be larger than the case where the mold clamping position is the bending portion intermediate line FC.
Then, when the skin 20 is deformed along the curved portion 11 due to the rising of the substrate-side vacuum suction mold 51 and the lowering of the skin-side vacuum suction mold 52, the amount of stretching in the surface direction of the skin 20 is the top side portion side. And the bottom side portion side is greatly different from each other, and the difference in the relative stretch amount on both sides is also relatively large.

When the skin 20 is stretched in the surface direction, the thickness of the skin 20 becomes small according to the stretch amount when stretched. For this reason, if the extending amount of the skin 20 is greatly different between the top side portion side and the bottom side portion side, the thickness of the skin 20 is also greatly different on both sides of the top side portion side and the bottom side portion side. . That is, the thickness of the epidermis 20 on the top side portion side and the bottom side portion side of the bending portion 11 is covered with the epidermis 20 covered between the bending first portion Z1 and the bending second portion Z2 of the bending portion 11. Variations occur.
Due to the variation in the thickness of the skin 20 thus generated, there arises a problem that the skin 20 is broken or damaged when sandwiched by the substrate-side vacuum suction mold 51 and the skin-side vacuum suction mold 52.

  The present invention has been made in order to solve the above-described problems, and an object of the present invention is to provide a vacuum forming method for an interior product in which variation in the thickness of the skin is suppressed in the skin coated on the curved portion of the base material. And

The vacuum forming method for interior parts according to the present invention, which is a means for solving the problem, has the following characteristics.
(1) The injection-molded base material is set in the base material side vacuum suction mold, and the base material side vacuum suction mold and the skin side vacuum suction mold are previously clamped by the base material side vacuum suction mold and the skin side vacuum suction mold. In a state where the molds are separated from each other, the skin arranged between the vacuum suction molds in a planar shape and the peripheral part fixed with a clamp are brought into contact with the base material, and along the inner surface of the skin side vacuum suction mold, In this state, the skin is vacuum-sucked by the skin-side vacuum suction mold to form the skin. Next, after the vacuum suction by the skin-side vacuum suction mold is stopped, the base-side vacuum suction mold is used to pass through the ventilation part of the base. The vacuum forming method of the interior product in which the skin is vacuum-sucked to the base material side and the skin is bonded to the base material, and when the base-side vacuum suction mold and the skin-side vacuum suction mold are clamped, The amount of interference with both vacuum suction types is small, and the amount of interference varies in the front-rear and left-right directions. Tilting hold the skin to the scan angle.

  (2) In the vacuum forming method for interior parts according to (1), the base material has at least a curved portion that curves in the thickness direction, and at least a portion of the surface of the curved portion. A skin covering planned portion for covering the skin, and inclining the skin in a direction parallel to a tangent at a contact reference point with the skin covering planned portion of the substrate.

  (3) In the vacuum forming method for interior parts according to (1) or (2), among the surface directions connecting the peripheral portions of the skin, the skin width direction that is one direction fixed by the clamp, The epidermis is rotated and inclined with an axis passing through the center between the peripheral edges as an axis.

  (4) In the vacuum forming method for an interior product according to (2) or (3), the skin coating planned portion of the base material with respect to the mold opening / closing direction of the base material side vacuum suction mold and the skin side vacuum suction mold When the horizontal axis that intersects near the center and crosses the planned skin covering portion is used as a clamping reference line, the substrate-side vacuum suction mold moves to the clamping clamping reference line, so that at least the skin coating planned A first covering step of covering a part of the skin on a top side covering planned portion on the skin side vacuum suction die side of the mold clamping reference line, and the skin covering portion following the first covering step, A second covering step of covering the remaining portion of the skin with the remaining side covering planned portion excluding the top side covering planned portion of the skin covering planned portion by moving the side vacuum suction mold to the mold clamping reference line And providing.

The present invention has the following operations and effects due to its configuration.
In general, when an interior product is manufactured by a vacuum forming method, when the skin is covered on the curved portion of the base material by pressing with the base-side vacuum suction mold and the skin-side vacuum suction mold, the skin is It deforms along the shape of the curved portion of the material and extends along the surface direction. And the thickness of the skin becomes smaller than the state before stretching according to the amount stretched by stretching at this time.
On the other hand, in the vacuum forming method of the interior product of the present invention, the amount of interference between the vacuum suction mold of the skin and the vacuum suction mold of the base material side is small and the interference amount when clamping the base material side vacuum suction mold and the skin side vacuum suction mold. Since the skin is tilted and held at an angle that balances in the front-rear and left-right directions, when covering the skin to the curved part of the base material, the distance between the skin and the curved part of the base material, the base material in a horizontal posture Compared with the case of the conventional vacuum forming method coated on, it can be made relatively small. As a result, when the skin is deformed along the shape of the curved portion of the base material, the amount of stretching in the surface direction of the skin can be reduced, and the change in the thickness of the skin according to the amount of stretching is suppressed to be small.
At the time of covering the skin, the thickness change from the thickness of the skin before coating (before stretching) to the thickness of the skin after coating (after stretching) is also suppressed to a small extent. In each part, the variation in the thickness of the epidermis is relatively small in each part.
Therefore, in each part of the epidermis coated with the base material, the stretching of the epidermis is suppressed during coating, and the variation in the thickness of the epidermis is kept relatively small. It is possible to prevent the skin from being damaged such as tearing when sandwiched by the suction mold and the skin-side vacuum suction mold.

  Further, in the vacuum forming method of the interior product of the present invention, the base material has at least a curved portion that curves in the thickness direction thereof, and at least a part of the surface of the curved portion covers the skin. Because it has a planned coating part and the skin is inclined in a direction parallel to the tangent at the reference point of contact with the planned skin coating part of the substrate, when a part of the skin comes into contact with the planned skin coating part The distance between the epidermis and the epidermis covering part on both the top side of the curved part and the bottom side of the curved part across the contact reference point can be made the same size, and the stretch amount of the epidermis Can be made to the same size.

  Further, in the vacuum forming method of the interior product of the present invention, the axis passing through the center between the peripheral portions is the axis of the skin width direction which is one direction fixed by the clamp among the surface directions connecting the peripheral portions of the skin. Since the skin is rotated and tilted in the heart, the stroke of each molding die required from the fully open position to the clamping position when raising and lowering the base-side vacuum suction mold and the skin-side vacuum suction mold is approximately the same. Can be For this reason, it can suppress that a difference arises in the thickness of an epidermis in each site | part of the epidermis coated on the base material due to the movement amount of the base-side vacuum suction type and the epidermis side vacuum suction type.

  Further, in the vacuum forming method for an interior product according to the present invention, the skin opening and closing directions of the base material side vacuum suction mold and the skin side vacuum suction mold intersect in the vicinity of the center of the skin covering planned portion of the base material, When the horizontal axis line that crosses the planned coating portion is used as a clamping reference line, the base clamping vacuum line moves to the clamping reference line, so that at least the above-mentioned skin coating planned portion among the planned skin coating portion A first covering step for covering a part of the skin on the top side covering planned portion on the skin side vacuum suction mold side with respect to the line, and following the first coating step, the skin side vacuum suction die is clamped By moving to the reference line, among the planned skin covering portion, the remaining portion covering planned portion excluding the top side covering planned portion is provided with a second covering step for covering the remaining portion of the skin, In the first coating process, the substrate side vacuum suction At least, a part of the epidermis is applied to the top portion of the base skin covering planned portion of the base material, and in the second coating step, the epidermis is applied to the remaining side covering target portion of the target skin covering portion by the skin side vacuum suction mold. In the epidermis, the remaining part is covered separately, and in the epidermis, the stretching in the surface direction that occurs along the curved shape of the epidermis covering portion covers the epidermis over the entire epidermis covering portion in which the epidermis is covered with the epidermis covering portion. Compared to the case where the entire covered skin portion is covered at once, it is kept small.

The reason for this is that in the first covering step, a part of the skin is covered on at least the top side covering planned part on the skin side vacuum suction mold side of the mold clamping reference line located near the center in the mold opening and closing direction. Therefore, at this time, the range in which the skin is stretched is smaller than the case where the entire skin covering planned portion is covered at once. In the second coating step, the remaining portion of the epidermis is covered on the remaining portion of the planned covering portion excluding the top portion of the covering portion, and at this time, the range in which the skin is stretched is once in all the planned covering portions of the skin. It is smaller than the case where it covers.
In this second coating step, the remaining part of the epidermis is covered along the curved shape with the top side covering planned part of the skin covering planned part, and the remaining part of the skin is planned to be covered on the remaining side of the planned skin covering part. Cover along the curved shape. For this reason, when the remaining part of the skin is coated on the remaining part side covering planned part, even if the skin side vacuum suction type presses the top side covering planned part with the remaining part of the skin sandwiched between the base material side vacuum suction type This is because, in a part of the skin coated along the shape of the top side covered portion, it is difficult for the skin to stretch.
Therefore, it is divided into the first coating step and the second coating step, and the skin is divided into the top side coating planned portion and the remaining side coating planned portion of the skin coating planned portion, respectively, and coating the skin, Compared to the case where the entire surface of the planned portion is covered with the entire surface of the planned covering portion, the surface can be kept small.

Hereinafter, a vacuum forming method for an interior product according to the present embodiment will be described with reference to the drawings.
The interior product according to the present embodiment is an instrument panel that is one of automotive interior components. Therefore, hereinafter, a vacuum forming method of the instrument panel will be described with reference to FIGS.

First, the instrument panel according to the present embodiment will be briefly described with reference to FIGS. 6 to 10, and then the vacuum forming method will be described.
FIG. 6 is a plan view of the instrument panel 1. FIG. 7 is a cross-sectional view of the instrument panel 1 shown in FIG. FIG. 8 is a cross-sectional view of the instrument panel 1 shown in FIG. FIG. 9 is a cross-sectional view of the instrument panel 1 shown in FIG. Note that the left-right direction in FIG. 6 is the longitudinal direction PL of the instrument panel 1, and the left-right direction in FIGS. 7 to 9 is the width direction PW of the instrument panel 1.

As shown in FIG. 6, the instrument panel 1 is located on the vehicle interior side from a windshield of an unillustrated RV (Recreation Vechicle) vehicle, with the longitudinal direction PL along the vehicle width direction and the width direction PW along the vehicle front-rear direction. The left side in FIG. 6 is the passenger seat side and the right side in FIG. 6 is the driver seat side.
The instrument panel 1 includes a base material 10 and a skin 20. The instrument panel 1 has an outer skin 20 (dot hatched portion) attached to a part of the base material 10 along the surface 10a, and sandwiches the base material 10 and the outer skin 20 by a vacuum forming method to be described later. It is put on and molded integrally. In the instrument panel 1, the parts around the glove box on the passenger side and around the cockpit on the driver's seat side, when viewed from the vehicle width direction (longitudinal direction PL), the shape of the instrument panel 1 The panel bending portion swells in a curved shape from the front side toward the vehicle interior space.

Specifically, in the instrument panel 1 shown in FIG. 6, the panel bending portion is formed, for example, in the place shown in FIGS. 7 to 9, and as will be described later, the skin covering of the bending portion 11 of the base material 10. It is the skin covering portion 15 in which the planned portion 12 is covered with the skin 20.
In the portion of the skin covering portion 15 shown in FIG. 7, the bending portion 11 is formed between the first portion P1 and the fifth portion P5, and the skin 20 is composed of the second portion P2 to the fourth portion P4 (skin covering). The planned portion 12) is covered.
Further, in the portion of the skin covering portion 15 shown in FIG. 8, the bending portion 11 is formed between the sixth portion Q1 and the tenth portion Q5, and the skin 20 is composed of the seventh portion Q2 to the ninth portion Q4 ( It is covered with a skin covering planned portion 12).
Similarly, in the portion of the skin covering portion 15 shown in FIG. 9, the bending portion 11 is formed between the eleventh portion R1 and the fourteenth portion R4 (skin covering planned portion 12), and the skin 20 is also entirely covered during this time. ing.
7 and 8, the portion of the epidermis 20 indicated by the two-dot chain line between the third part P3 and the fourth part P4 and between the eighth part Q3 and the ninth part Q4 is It is cut after vacuum forming.

  The base material 10 is a plate-like member obtained by injection-molding a resin such as polypropylene (PP), for example, and as shown in FIGS. A curved portion 11 curved in the thickness direction TH of the base material 10 is formed substantially along the shape. This base material 10 is provided with a plurality of minute air passages (not shown) having a minute diameter and penetrating in the thickness direction TH. The curved portion 11 has a skin coating planned portion 12 that covers the skin 20 on a part of the surface 11a.

On the other hand, the skin 20 has flexibility and covers a part of the surface 10 a of the substrate 10. As shown in FIG. 10, the skin 20 has, for example, a sheet-like surface member 21 such as thermoplastic olefin (TPO), and the surface member 21 on the back side (downward in FIG. 10) of the surface member 21. It consists of the foam layer 22 welded together. The surface of the surface member 21 (the surface 20a of the skin 20) is a design surface of the instrument panel 1 (dot hatched portion in FIG. 6). On the other hand, although not shown, an adhesive such as a hot-melt olefin adhesive is applied to the back surface side of the foam layer 22 (the back surface 20b of the skin 20). The skin 20 and the substrate 10 are bonded by hot melt using an adhesive applied to the foam layer 22.
In this embodiment, the thickness t of the skin 20 is 1 (mm) for the surface member 21 and 4 (mm) for the foamed layer 22 before the surface 20 is coated on the substrate 10. The thickness of the entire skin 20 is t = 5 (mm).

Next, a vacuum forming method for the instrument panel will be described.
A vacuum forming apparatus 50 is used for vacuum forming of the instrument panel 1. First, the vacuum forming apparatus 50 will be briefly described.
The vacuum forming apparatus 50 is an apparatus for forming the instrument panel 1 by bringing the base material 10 and the sheet-shaped skin 20 that have been preliminarily formed into a predetermined shape into close contact with each other by a vacuum forming method.
The vacuum forming apparatus 50 includes a base-side vacuum suction mold 51 and a skin-side vacuum suction mold 52 that can be moved up and down in the mold opening / closing direction VL (vertical direction in FIGS. 1 to 5), and a plurality of clamps 55. Have. The clamp tool 55 is in a state where tension is applied to the skin width direction HW (upper left-lower direction in the skin 20 shown in FIG. 1), which is one of the surface directions connecting the peripheral portions of the skin 20. The peripheral edge of the epidermis 20 is fixed and held. Although not shown, the vacuum forming apparatus 50 is a frame in which the skin 20 is configured to be rotatable about the axis O passing through the center between the peripheral edges of the skin 20 with respect to the skin width direction HW of the skin 20. It has a body and a heater.

  As shown in FIG. 1, the substrate-side vacuum suction mold 51 is formed in a convex shape that can be set with a preformed substrate 10 in advance, and the surface 11 a of the curved portion 11 is formed on the skin-side vacuum suction mold 52 side. The base material 10 can be held by the support surface 51a in the arrangement form facing the head. The base-side vacuum suction mold 51 has a plurality of vent holes (not shown) that communicate with the inside and outside of the base-side vacuum suction mold 51 on the support surface 51a. The vent hole is airtightly connected to a suction device (not shown), and is configured so that the skin 20 can be sucked through the vent passage of the base material 10 by the suction device.

  The skin-side vacuum suction mold 52 is formed in a concave shape that follows the shape of the base material 10, and has a molding surface 52 a that covers the skin 20 on the surface 10 a of the base material 10. The skin-side vacuum suction mold 52 has a small diameter and has a plurality of micro-holes (not shown) that communicate with the inside and outside of the skin-side molding mold 52. These micro-holes are also connected to a suction device (not shown) in an airtight manner. The epidermis 20 can be sucked by this suction device.

The substrate-side vacuum suction mold 51 and the skin-side vacuum suction mold 52 are mounted on the lifting mechanism of the vacuum forming apparatus 50, and the mold is positioned between the mold opening position shown in FIG. 1 and the mold clamping position shown in FIG. It is movable in the opening / closing direction VL.
When the base material side vacuum suction mold 51 and the skin side vacuum suction mold 52 are clamped, the base material 10 and the skin 20 are accommodated inside the base material side vacuum suction mold 51 and the skin side vacuum suction mold 52. A forming space 50S is formed (see FIG. 4).

  The heater heats and softens the skin 20 held by the clamps 55 from both the front surface 20a side and the back surface 20b side of the skin 20. This heater is positioned along the skin 20 only when the base-side vacuum suction mold 51 and the skin-side vacuum suction mold 52 are opened, but before the base-side vacuum suction mold 51 and the like are moved up and down, It can move to a standby position (not shown) that avoids interference with the material-side vacuum suction mold 51 and the skin-side vacuum suction mold 52.

Next, a vacuum forming method for the instrument panel 1 will be described with reference to FIGS.
In the instrument panel 1, a plurality of panel bending portions are formed over the longitudinal direction PL as in the panel bending portion (skin covering portion 15) illustrated in FIG. 7 to FIG. The shape differs slightly depending on the position where it exists.
Therefore, in the following description, when the base material 10 is covered with the skin 20, the curved portion 11 of the base material 10 is schematically shown in the shape shown in FIG. A case where the surface 11a between the second part M2 and the fourth part M4 shown in FIG.

In the panel bending portion shown in FIG. 7, one end side portion M1 of the bending portion 11 corresponds to the fifth portion P5, and the other end side portion M4 corresponds to the first portion P1.
In the panel bending portion shown in FIG. 8, one end side portion M1 corresponds to the tenth portion Q5, and the other end side portion M4 corresponds to the sixth portion Q1.
Similarly, in the panel bending portion shown in FIG. 9, the other end side portion M4 corresponds to the eleventh portion R1, and the one end side portion M1 does not exist in FIG. The one end side portion M1 is located on the vehicle front side (upward in FIG. 6) of the instrument panel 1 in the width direction PW, while the other end side portion M4 is located below the glove box or cockpit in the vehicle height direction.

  In the vacuum forming of the instrument panel 1, the base material 10 is primarily formed into a predetermined shape in advance. As shown in FIGS. 1 and 3, the base material 10 is arranged in such a manner that the one end side portion M1 of the bending portion 11 is lower than the other end side portion M4 of the bending portion 11, and is opposite to the surface 10a. The back surface of the substrate 10 is placed on the support surface 51 a and set in the substrate-side vacuum suction die 51.

  On the other hand, the skin 20 is cut into a predetermined size as shown in FIG. As shown in FIG. 1, the skin 20 is clamped and fixed by a clamp 55 with the back surface 20 b facing the curved portion 11 of the substrate 10 and the surface 20 a facing the skin-side vacuum suction die 52. Next, both surfaces (front surface 20a, back surface 20b) of the skin 20 are heated with a heater, and when the skin 20 is in a softened state, the heater is moved to a standby position. Next, as shown in FIG. 1, the frame body is rotated about the axis O, and the softened skin 20 is fixed with the clamp tool 55, and the skin 20 is clamped with a clamping reference line parallel to the horizontal direction, which will be described later. The angle between FX and the surface 20a of the skin 20 is inclined at an inclination angle θ.

Here, in inclining the skin 20 to the inclination angle θ, the substrate-side vacuum suction mold 51 is raised, and the skin 20 is curved within a range in which the skin 20 is covered with the skin coating planned portion 12 of the curved portion 11 of the substrate 10. A contact reference point T at a predetermined position on the surface 11a of the portion 11 is determined in advance. The position of the contact reference point T is determined in consideration of the shape of the surface 11a of the bending portion 11, but in the present embodiment, it is positioned near the top of the bending portion 11.
Then, the skin 20 is inclined so that the direction parallel to the tangent line SX at the contact reference point T, that is, the tangent line SX and the mold clamping reference line FX become the inclination angle θ.

Next, the first coating step of the present invention was performed, and as shown in FIG. 2, the base-side vacuum suction mold 51 was raised, and the top side of the planned skin covering portion 12 in the curved portion 11 of the base 10 was inclined. The skin 20 is brought into contact.
That is, it intersects with the mold opening / closing direction VL of the base-side vacuum suction mold 51 and the skin-side vacuum suction mold 52 in the vicinity of the center of the planned skin covering portion 12 of the base material 10 and is horizontal across the planned skin covering portion 12. When the axis line is the mold clamping reference line FX, in the first coating step, the base-side vacuum suction mold 51 moves to the mold clamping reference line FX, so that as shown in FIG. A part of the skin 20 is covered on the top side covering planned portion 12T located on the skin side vacuum suction die 52 side of the mold clamping reference line FX.

Specifically, here, the height of the mold opening / closing direction VL (the size in the vertical direction in FIG. 3) in the bending portion 11 of the base material 10 is defined as the bending portion height H, which is substantially in the middle of the bending portion height H. When the position (about H / 2 in FIG. 3) is the planned curve intermediate line WX that crosses the mold clamping reference line FX in parallel, the third part M3 shown in FIG. A position where the planned portion intermediate line WX and the planned skin covering portion 12 intersect.
In the first covering step, when the base-side vacuum suction mold 51 is moved to the clamping reference line FX, and the base-side vacuum suction mold 51 is raised while contacting a part of the skin 20, the base-side side A part of the skin 20 with which the vacuum suction mold 51 abuts is deformed along the shape of the substrate-side vacuum suction mold 51 by the pressing by the substrate-side vacuum suction mold 51. Thereby, a part of the epidermis 20 is part of the epidermis coating planned portion 12 between the other end side part M4 and the third part M3, that is, the top side of the epidermis coating planned part 12 above the third part M3. The covering portion 12T is covered (see FIG. 2).

Following the first coating step, the second coating step is performed, and as shown in FIG. 4, the skin side vacuum suction die 52 is lowered, and the bottom side of the skin coating planned portion 12 in the curved portion 11 is coated on the top side. The remaining part of the skin 20 is brought into contact.
That is, as shown in FIGS. 3 and 4, in the second covering step, the skin side vacuum suction die 52 moves to the mold clamping reference line FX, so that the top side covered planned portion 12 </ b> T among the planned skin covered portions 12. The remaining portion of the epidermis 20 is coated on the remaining portion-side covering planned portion 12R except for.

  Specifically, as shown in FIGS. 3 and 4, when the skin-side vacuum suction mold 52 is lowered to the mold clamping reference line FX, a part of the remaining skin 20 is pressed by the skin-side vacuum suction mold 52. Then, it deforms along the shape of the skin-side vacuum suction mold 52 while contacting the skin-side vacuum suction mold 52. Accordingly, a part of the remaining epidermis 20 is between the third part M3 and the second part M2 (about H / 2 in FIG. 3 to be referred to) in the planned skin covering portion 12, that is, the third part. The remaining covering side covering portion 12R of the covering skin covering portion 12 below M3 is covered.

Next, the substrate-side vacuum suction mold 51 and the skin-side vacuum suction mold 52 are clamped. In this embodiment, when clamping the mold, the skin 20 is inclined at an inclination angle θ with respect to the mold clamping reference line FX. The substrate-side vacuum suction mold 51 and the skin-side vacuum suction mold 52 are moved to the mold clamping reference line FX, respectively, and the substrate-side vacuum suction mold 51 and the skin-side vacuum suction mold 52 are moved along the mold clamping reference line FX. Are matched.
That is, in the vacuum forming method for interior parts according to the present embodiment, when the base-side vacuum suction mold 51 and the skin-side vacuum suction mold 52 are clamped, the amount of interference between the vacuum suction molds 51 and 52 of the skin 20 is small. The skin 20 is inclined and held at an angle where the amount of interference is small and the amount of interference balances in the width direction PW of the instrument panel 1.

Next, when the substrate-side vacuum suction die 51 and the skin-side vacuum suction die 52 are clamped, the back surface 20b of the skin 20 is covered with the skin of the curved portion 11 of the substrate 10 in the molding space 50S as shown in FIG. It is clamped to the planned portion 12.
Next, the skin 20 is sucked from the surface 20a side through a vent hole (not shown) of the skin-side vacuum suction mold 52 at a predetermined vacuum pressure value for a predetermined time. Thereby, the inside of the molding space 50S becomes negative pressure, the surface 20a of the skin 20 is attracted to the molding surface 52a, and the skin 20 is molded into a predetermined surface shape (texture transfer, detail shape, etc.).
After the suction device completely stops the suction from the skin-side vacuum suction mold 52, the skin 20 is moved from the fixing surface 20b side to the ventilation hole of the substrate-side vacuum suction mold 51 and the minute ventilation path ( Neither is shown), and suction is performed at a predetermined vacuum pressure value for a predetermined time. As a result, the fixing surface 20b of the skin 20 is adsorbed to the surface 11a (skin coating target portion 12) of the curved portion 11 of the base material 10, and the skin 20 and the base material 10 are bonded by the adhesive applied to the fixing surface 20b side. And adhere.

After the bonding, the instrument panel 1 in which the base material side vacuum suction mold 51 and the skin side vacuum suction mold 52 are opened to bring the skin 20 and the base material 10 into close contact with each other is removed from the base material side vacuum suction mold 51. Remove. And as above-mentioned, the unnecessary part which is not coat | covered with the base material 10 among the skin 20 is trimmed.
Thus, the skin covering portion 15 of the instrument panel 1 in which the base material 10 and the skin 20 are integrally formed is obtained (see FIG. 1).

  By the way, in general, when manufacturing the instrument panel 1 by the vacuum forming method, when the skin 20 is coated on the curved portion 11 of the base material 10 by pressing with the base-side vacuum suction mold 51 and the skin-side vacuum suction mold 52, The skin 20 is deformed along the curved portion 11 of the base material 10 in the thickness direction and stretched along the surface direction. Then, the thickness t1 of the epidermis becomes smaller than the state before stretching according to the amount stretched by stretching at this time.

  On the other hand, in the vacuum forming method of the instrument panel 1 of the present embodiment, when the base material side vacuum suction mold 51 and the skin side vacuum suction mold 52 are clamped, the vacuum suction molds 51 and 52 of the skin 20 Since the skin 20 is inclined and held at an angle where the amount of interference is small and the amount of interference is balanced in the width direction PW of the instrument panel 1, the skin 20 is covered when the curved portion 11 of the substrate 10 is covered with the skin 20. However, when deform | transforming along the shape of the curved part 11 of the base material 10, the extending | stretching amount to the surface direction of the skin 20 can also be made small, and the change of the thickness of the skin according to this extending | stretching amount is also suppressed small.

The reason is that, in the conventional vacuum forming method in which the skin 20 is coated on the substrate in a horizontal posture, the substrate-side vacuum suction die 51 and the skin-side vacuum suction die 52 are located at a clamping position higher than the curved intermediate line FC. Is clamped in the mold opening / closing direction VL, the distance H1 until the skin 20 covers the top side portion of the bending portion 11 and the distance H2 until the skin 20 covers the bottom side portion of the bending portion 11 ( The difference (H2−H1) from H2> H1) was relatively large.
On the other hand, in the vacuum forming method of the instrument panel 1 of the present embodiment, the distance (about H / 2) until the skin 20 covers the top side covering planned portion 12T of the bending portion 11, and the skin 20 is the bending portion. The difference (about H / 2 to about H / 2) from the distance (about H / 2) to cover the remaining remaining side covering portion 12R of 11 is made relatively small as compared with the conventional vacuum forming method. Because you can.

In the vacuum forming method of the instrument panel 1 of the present embodiment, when the skin 20 is coated, the thickness changed from the thickness t of the skin 20 before coating (before stretching) to the thickness t1 of the skin after coating (after stretching). Since the amount of change (t−t1) is also suppressed to a small value, when the curved portion 11 of the base material 20 is covered with the epidermis 20, the thickness variation of the epidermis 20 is relatively small in each part. Yes.
Therefore, in each part of the epidermis 20 coated with the base material 10, the stretching of the epidermis 20 is suppressed at the time of coating, and the variation in the thickness t1 of the epidermis 20 is kept relatively small, resulting in the variation in the thickness t1 of the epidermis 20 Thus, it is possible to prevent the skin 20 from being damaged such as tearing when sandwiched by the substrate-side vacuum suction mold 51 and the skin-side vacuum suction mold 52.

  Moreover, in the vacuum forming method of the instrument panel 1 of the present embodiment, the base material 10 has, in part, the curved portion 11 that curves in the thickness direction TH, and one of the surfaces 11 a of the curved portion 11. Since it has a skin covering planned part 12 that covers the skin 20 at the part, and the skin 20 is inclined in a direction parallel to the tangent line SX at the contact reference point T with the skin covering planned part 12 of the base material 10, When a part of the skin 20 is in contact with the planned skin covering portion 12, the top side of the bending portion 11 (M4 side in FIG. 1 and the like) and the bottom side of the bending portion (FIG. 1 etc.) sandwiching the contact reference point T. The distance between the epidermis 20 and the epidermis covering portion 12 can be made approximately the same on both sides (middle, M1 side), and the stretching amount of the epidermis 20 should also be made the same size respectively. Will be able to.

  Moreover, in the vacuum forming method of the instrument panel 1 of the present embodiment, between the peripheral portions with respect to the skin width direction HW which is one direction fixed by the clamp tool 55 among the surface directions connecting the peripheral portions of the skin 20. Since the skin 20 is rotated and tilted with the axis passing through the center of the shaft center O as the axis O, each of the steps required from the fully open position to the mold clamping position when the substrate side vacuum suction mold 51 and the skin side vacuum suction mold 52 are raised and lowered. The strokes of the vacuum suction dies 51 and 52 can be set to the same size. For this reason, the occurrence of a difference in the thickness t1 of the epidermis 20 in each part of the epidermis 20 coated on the base material 10 due to the movement amount of the base-side vacuum suction die 51 and the skin-side vacuum suction die 52 is suppressed. can do.

  Moreover, in the vacuum forming method of the instrument panel 1 of the present embodiment, the base-side vacuum suction mold 51 moves to the mold clamping reference line FX, so that the skin coating planned portion 12 is closer than the mold clamping reference line FX. Following the first coating step for covering a part of the skin 20 on the top-side coating planned portion 12T on the skin-side vacuum suction die 52 side, and the first coating step, the skin-side vacuum suction die 52 is connected to the mold clamping reference line FX. A second covering step of covering a part of the remaining skin 20 on the remaining side covered planned part 12R excluding the top side covered planned part 12T of the covered skin covered part 12 by moving to Therefore, in the first coating step, the base-side vacuum suction die 51 is used to apply a part of the epidermis 20 to the top-side coating planned portion 12 of the skin-covering planned portion 12 of the base material 10, and the skin-side vacuum in the second coating step. This skin cover will be covered by suction mold 52 In the skin 20, the stretching in the surface direction that occurs when the remaining portion of the remaining skin 20 is partially covered with the remaining portion 12 of the covering portion 12 R along the curved shape of the skin covering planned portion 12. The entire skin covering portion 12 in which the skin 20 is covered with the skin covering planned portion 12 is suppressed as compared with the case where the skin 20 is covered with the entire skin covering planned portion 12 all at once.

The reason is that in the first covering step, a part of the skin 20 is covered at least on the top side covering planned portion 12T on the skin side vacuum suction die 52 side of the clamping reference line FX. The range in which the skin 20 is stretched is smaller than the case where the entire skin covering planned portion 12 is covered at once. Further, in the second coating step, since the remaining side covered planned portion 12R excluding the top side covered planned portion 12T is covered with a part of the remaining skin 20, the range in which the skin 20 is stretched at this time, It is smaller than the case where the entire skin covering planned portion 12 is covered at once.
In this second covering step, a part of the epidermis 20 is covered along the curved shape with the top side covering planned part 12T of the planned skin covering part 12, and the remaining part of the epidermis 20 is covered with the skin. The remaining portion side covering planned portion 12R of the planned portion 12 is covered along the curved shape. For this reason, when a part of the remaining skin 20 is coated on the remaining part side covering planned portion 12 </ b> R, the skin side vacuum suction mold 52 sandwiches a part of the remaining skin 20 between the base side vacuum suction mold 51. This is because even if the top side covered planned portion 12R is pressed, the skin 20 hardly stretches in a part of the skin 20 covered along the shape of the top side covered planned portion 12T.
Therefore, the skin 20 is divided into the first coating step and the second coating step, and the skin 20 is divided into the top side covered planned portion 12T and the remaining side covered planned portion 12R of the skin covered planned portion 12, respectively. Stretching can be suppressed to be small compared to the case where the entire surface 20 is covered with the entire surface 20 planned to cover the entire surface 20 to be covered.

Here, it investigated about the effect of the vacuum forming method of the instrument panel 1 which concerns on this embodiment compared with the vacuum forming method of the conventional instrument panel.
In this investigation, the instrument panel 1 shown in FIG. 6 was formed by the vacuum forming method of this embodiment and the conventional vacuum forming method, respectively. About both instrument panels 1, among the panel bending parts (skin covering part 15), between 2nd site | part P2- 3rd site | part P3 (refer FIG. 7), 7th site | part Q2- 8th site | part Q3 (refer FIG. 8). And thickness t1 of the skin 20 in windshield vicinity, such as 12th site | part R2-13th site | part R3 (refer FIG. 9), was measured.
This is because, in the vicinity of the windshield, through the manufacture of the instrument panel 1 so far, the thickness t of the epidermis 20 becomes the smallest, which causes a variation in the thickness t1 of the entire epidermis 20.

  The investigation conditions are the same for both the present embodiment and the conventional vacuum forming method, and the thickness of the skin 20 before coating is t = 5 (mm). In the vacuum forming method of the present embodiment, the inclination angle θ between the axis parallel to the skin width direction HW and the mold clamping reference line FX is set to θ = 18 °. On the other hand, in the conventional vacuum forming method, the skin 20 is held by the clamp in a horizontal posture, and is sandwiched between the substrate-side vacuum suction die 51 and the skin-side vacuum suction die 52 in the same posture.

The survey results were as follows. In the conventional vacuum forming method, the thickness t1 of the skin 20 was t1 = 0.4 (mm). On the other hand, in the vacuum forming method of this embodiment, the thickness t1 of the skin 20 is t1 = 0.5 (mm).
In the vacuum forming method of the present embodiment and the conventional vacuum forming method, the difference in the thickness t1 of the skin 20 is 0.1 (mm), but the difference in the thickness 0.1 (mm) It was confirmed that the occurrence of breakage or the like in the skin 20 was greatly improved when sandwiched by the side vacuum suction mold 51 and the skin side vacuum suction mold 52.

In addition, this invention is not limited to the thing of the said embodiment, A various change is possible in the range which does not deviate from the meaning.
For example, the boundary position between the top side covered planned portion 12T and the remaining side covered planned portion 12R is positioned approximately in the middle of the curved portion height H of the skin covered planned portion 12 (about H / 2 in FIG. 3). It was set as the site | part M3. However, the boundary position between the top-side covered planned portion and the remaining-side covered planned portion is not limited to the embodiment. For example, the shape of the base skin-covered portion, the base-side vacuum suction type, and the skin-side vacuum suction This can be done appropriately in consideration of the operating conditions of the mold.

It is explanatory drawing explaining the vacuum forming method of the instrument panel which concerns on this embodiment, and is a figure which shows a mold open state. It is explanatory drawing explaining the vacuum forming method of the instrument panel which concerns on this embodiment, and is explanatory drawing explaining a 1st coating | coated process. It is explanatory drawing explaining the vacuum forming method of the instrument panel which concerns on this embodiment, and is explanatory drawing explaining the mode after a 1st coating | coated process. It is explanatory drawing explaining the vacuum forming method of the instrument panel which concerns on this embodiment, and is explanatory drawing explaining a 2nd coating | covering process. It is explanatory drawing explaining the vacuum forming method of the instrument panel which concerns on this embodiment, and is sectional drawing which shows a mode when a skin and a base material are clamped. It is a top view of the instrument panel which concerns on this embodiment. It is AA arrow sectional drawing of the instrument panel shown in FIG. It is BB arrow sectional drawing of the instrument panel shown in FIG. It is CC sectional view taken on the line of the instrument panel 1 shown in FIG. It is a figure which shows the skin of the instrument panel which concerns on this embodiment, and is sectional drawing which shows the mode before shaping | molding. It is explanatory drawing explaining the method of coat | covering a skin with a base material by the vacuum forming method of patent document 1. FIG. It is explanatory drawing explaining a mode when a base material is coat | covered with the skin arrange | positioned in the horizontal attitude | position.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Instrument panel PL (Instrument panel) longitudinal direction PW (Instrument panel) width direction 10 Base material TH Thickness direction 10a (Base material) surface 11 Curved part 11a (of curved part) 12 Skin covering plan part 12T Plane side covering portion 12R Remaining portion covering portion 20 Skin HW Skin width direction O Axis center T Contact reference point SX Tangent line VL Mold opening / closing direction FX Mold clamping reference line 51 Substrate side vacuum suction type 51a Support surface 52 Skin side Vacuum suction type 52a Molding surface 55 Clamping tool

Claims (2)

Set the injection-molded base material on the base-side vacuum suction mold,
By clamping the base-side vacuum suction mold and the skin-side vacuum suction mold, the base-side vacuum suction mold and the skin-side vacuum suction mold are separated in advance and arranged in a plane between these vacuum suction molds. The skin whose peripheral part is fixed by a clamp is brought into contact with the base material, and along the inner surface of the skin-side vacuum suction mold, in this state, the skin is vacuum-sucked by the skin-side vacuum suction mold to form the skin,
Next, after the vacuum suction by the skin-side vacuum suction mold is stopped, the inner skin is vacuum-sucked to the base material side through the ventilation part of the base material by the base-side vacuum suction mold to adhere the skin to the base material. In the vacuum forming method of
When clamping the substrate-side vacuum suction mold and the skin-side vacuum suction mold, the amount of interference between the vacuum suction molds of the skin is small, and the skin is held at an angle that balances the amount of interference in the front-rear and left-right directions. Letting
The substrate has at least a curved portion that curves in the thickness direction at least partially,
Of the surface of the curved portion, at least a portion having a skin covering planned portion that covers the skin,
Inclining the skin in a direction parallel to a tangent at a reference point of contact with the skin coating planned portion of the substrate;
When a part of the skin comes into contact with the skin covering planned portion, the distance between the skin and the skin covering planned portion is the same on both the top side of the bending portion and the bottom side of the bending portion with respect to the contact reference point. Making it about the size,
The horizontal axis line intersecting the center of the planned skin covering portion of the base material with respect to the mold opening / closing direction of the base-side vacuum suction mold and the skin-side vacuum suction mold, and a horizontal axis line across the planned skin covering portion is a mold clamping reference line When
When the base-side vacuum suction mold moves to the mold clamping reference line, at least, among the skin coating planned parts, the top side coating planned part located on the skin side vacuum suction mold side with respect to the mold clamping reference line And a first coating step for coating a part of the epidermis;
Following the first coating step, the skin side vacuum suction mold moves to the mold clamping reference line, so that the remaining side covered planned portion excluding the top side covered planned portion of the skin covered planned portion, A second coating step for covering the remainder of the epidermis;
Providing
In the first coating step, at least a part of the epidermis is applied to the top-side covered planned portion of the base coat-covered portion of the base material by the base-side vacuum suction die, and in the second covering step, the skin-side vacuum suction die is used. A vacuum forming method for an interior product, characterized in that the remaining portion of the skin is separately coated on the remaining portion of the planned skin covering portion . In the vacuum forming method of the interior part according to claim 1,
Of the surface direction connecting the peripheral portions of the skin, the skin is rotated about the axis passing through the center between the peripheral portions with respect to the skin width direction which is one direction fixed by the clamp. A vacuum forming method of an interior product characterized by being inclined .

Images