JP5894441B2 - Mold manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a mold for molding a member on which a stitch pattern is formed.

  Vehicle interior members such as instrument panels and floor consoles are installed in the passenger compartment of automobiles. Since such a vehicle interior member greatly contributes to the passenger compartment atmosphere, the surface of the synthetic resin base material formed in a required shape is covered with a skin material to improve the texture. For example, the skin material is made of genuine leather. Genuine leather skin material has a good texture and high quality, but the material is expensive and expensive to manufacture. Therefore, on the surface of the synthetic resin skin material, by reproducing the texture pattern resembling the surface pattern of genuine leather and the shape of stitches formed when sewing multiple genuine leather pieces with thread, synthetic resin The skin material is closer to the texture of the leather surface material.

  Synthetic resin skin material is molded from resin sheet material to the required shape based on vacuum molding technology, molded from resin powder to required shape based on powder slush molding technology, polyurethane based on spray molding technology, etc. What was shape | molded by various shaping | molding methods, such as what was shape | molded in the required shape, is put into practical use. In these molding methods, a so-called “electroforming mold” manufactured by electroforming is generally used.

  In order to manufacture an electroforming mold, first, an original model is manufactured by attaching a skin sheet and thread such as genuine leather or synthetic resin to a wooden model formed in the same outer shape as the base material of the vehicle interior member. Next, using a silicone resin or the like, an inverted model having a transfer surface onto which the shape of a stitch composed of a skin sheet and yarn of the original model is transferred is manufactured. Then, using an epoxy resin or the like, a tank model having a mold surface on which the shape of the transfer surface of the inverted model is transferred is manufactured. An electroforming mold having a skin molding surface to which the shape of the mold forming surface of the bathing model is transferred is produced by electroforming based on the bathing model. Thus, the electroforming mold is manufactured by sequentially transferring the shape of the skin sheet and the stitch in the original model to the transfer surface of the reversal model, the mold forming surface of the basin model, and the skin forming surface of the electroforming mold (for example, , See Patent Document 1).

JP-A-3-169606

  As illustrated in FIGS. 8A and 8B, the yarn 60 forming the stitch 66 in the prototype model 68 is formed by twisting three thin yarns 62, 62, 62 of equal thickness. Yes. On the surface of the thread 60, a twisted line 64 that is recessed spirally along the twisted fine thread 62 is formed (see FIG. 8C). However, since the yarn 60 itself is small and the twist 64 formed on the surface of the yarn 60 is shallow, even if the original model 68 is transferred to the inverted model, the shape of the twist 64 of the yarn 60 is difficult to be transferred. In addition, since the electroforming mold is manufactured by transferring the prototype model 68 a plurality of times, the shape of the knot 64 may be crushed. Therefore, it is difficult to reproduce the twist 64 in the stitch pattern of the skin material formed with the obtained electroforming mold.

  That is, the present invention has been proposed to solve these problems inherently in the prior art, and provides a method for manufacturing a mold that can form a member having a stitch pattern with a high texture. The purpose is to do.

In order to overcome the above-mentioned problems and achieve the intended purpose, a manufacturing method of a mold according to claim 1 of the present application is
Based prototype model denoted by the stitch Iriso model obtained through a step of transferring a plurality of times, in the method of manufacturing the mold for forming a mold by electroforming,
The step of fabricating the prototype model, sticking a skin sheet to the mounting surface of the wooden model, a yarn thin yarn of at least one is twisted plurality of fine yarns which are set to the thickness that is different from the other fine yarns The gist is to form the stitches on the surface of the skin sheet attached to the wooden model by sequentially inserting it into a plurality of through holes provided on the mounting surface of the wooden model .
According to the first aspect of the present invention, at least one fine yarn is formed by twisting a plurality of fine yarns set to different thicknesses from the other fine yarns, so that the fine yarns having different thicknesses are formed. A large step occurs on the surface of the yarn where the yarn is adjacent. Since the uneven shape of the yarn twist is emphasized by this step, the shape of the yarn twist can be clearly transferred to a forming die formed by transferring the original model. Therefore, the member molded with the obtained molding die reproduces the yarn twist and improves the texture. Then, since the uneven shape of the yarn twist is emphasized in the original model, even if the forming die is formed based on the inlet model obtained by transferring the original model a plurality of times, the uneven shape of the yarn twist is difficult to be crushed.

The gist of the invention according to claim 2 is that the yarn is formed by twisting one fine yarn and two or more fine yarns set to be thinner than the fine yarn and having the same thickness. .
According to the invention of claim 2 , since the yarn is formed by twisting one fine yarn and two or more fine yarns having the same thickness set thinner than the fine yarn, Since two or more thin yarns having the same width can be used to increase the spacing between the adjacent twisted yarns with different thicknesses, and the uneven shape of the yarn can be increased even if the original model is transferred. It is hard to be crushed.

  According to the manufacturing method of the shaping | molding die concerning this invention, the shaping | molding die which can shape | mold the member which has a highly textured stitch pattern can be manufactured.

It is explanatory drawing which shows the process of producing the original model which concerns on an Example, (a) shows the state which affixed the skin sheet to the wooden model, (b) forms a stitch with a thread | yarn on a skin sheet, (C) is a schematic sectional drawing of the original model which concerns on an Example. (a) is explanatory drawing which shows the process of manufacturing the inversion model which concerns on an Example, (b) is a schematic sectional drawing of the inversion model which concerns on an Example. It is explanatory drawing which shows the process of manufacturing the tank model which concerns on an Example. It is explanatory drawing which shows the process of manufacturing the electroforming mold which concerns on an Example. It is explanatory drawing which shows the stitch in the original model of an Example, (a) is A arrow directional view of FIG.1 (c), (b) is ZZ sectional drawing of the thread | yarn in (a). (C) is the W section enlarged view of (a). It is a schematic enlarged view of the thread | yarn which concerns on the example of a change. It is a schematic perspective view which represents the instrument panel which equips a design surface with the skin material shape | molded using the electroforming mold manufactured with the manufacturing method which concerns on an Example, and is represented partially. It is a schematic explanatory drawing which shows the thread | yarn which forms the stitch in the conventional original model, Comprising: (a) is a top view, (b) is XX sectional drawing of the thread | yarn in (a), (c) FIG. 4 is an enlarged view of a Y part in (a).

  A method for manufacturing a mold according to the present invention will be described below with reference to the accompanying drawings by way of preferred examples. In the embodiment, a case where an electroforming mold (molding die) 10 for molding a synthetic resin skin material 52 constituting a design surface of an instrument panel IP disposed in a passenger compartment of a vehicle is illustrated. explain. As illustrated in FIG. 7, the instrument panel IP includes a base material 54 formed in a required shape and a synthetic resin skin material 52 that covers the surface of the base material 54. On the surface of the skin material 52, a stitch pattern SD in which a stitch is reproduced in a pseudo manner is formed. In the following description, the skin material 52 is illustrated with a simple shape.

  The method for manufacturing the electroforming mold 10 according to the embodiment includes a step of manufacturing a prototype model 14 with a stitch S attached to the surface by a thread 26, and a reversal model 32 having a transfer surface 34 to which the shape of the surface of the prototype model 14 is transferred. A step of manufacturing, a step of manufacturing a tank model 44 having a molding surface 46 to which the shape of the transfer surface 34 of the reversal model 32 is transferred, and skin molding in which the shape of the mold surface 46 of the tank model 44 is transferred. And the step of manufacturing the electroforming mold 10 having the surface 12.

  In order to produce the prototype model 14, the wooden model 18 formed from the wood or artificial wood or the like in the same outer shape as the base material 54, and the skin sheet 24 made of synthetic resin or genuine leather with a wrinkle pattern. And prepare. Then, the skin sheet 24 is attached to the mounting surface 20 of the wooden model 18 using an adhesive or the like (see FIG. 1A). Next, a stitch S is formed with a thread 26 on the surface of the skin sheet 24 attached to the wooden model 18. At this time, the stitch S is formed by sequentially inserting the thread 26 into a plurality of through holes 22 corresponding to each thread of the stitch S provided on the mounting surface 20 of the wooden model 18 (FIG. 1B). reference). As a result, the prototype model 14 in which the stitch S is attached to the skin sheet surface 16 that is the surface with the thread 26 is manufactured (see FIGS. 1C and 5A). The yarn 26 forming the stitch S is composed of one fine yarn 28a (in the embodiment, a diameter of 0.95 mm) and two fine yarns 28b and 28b (in the embodiment, a diameter that is set narrower than the fine yarn 28a). 0.5 mm) (see FIG. 5B). The yarn 26 of the embodiment is obtained by twisting three thin yarns 28a, 28b, and 28b in a spiral shape, and in the portion where the thin yarns 28a and 28b having different thicknesses are adjacent to each other, the surface of the yarn 26 is large. A step is formed, and the uneven shape of the twist 30 of the yarn 26 is emphasized by this step (see FIG. 5C).

  As shown in FIG. 2 (a), the inversion model 32 includes a prototype model 14 and a base mold having a molding surface that holds a required distance from the skin sheet surface 16 when the prototype model 14 is closed. 36. In order to manufacture the reversal model 32, silicone 40 is injected into a cavity 38 defined between the skin sheet surface 16 of the original model 14 and the molding surface of the base mold 36 and cured. Then, the inversion model 32 in which the silicone layer 42 is formed on the molding surface of the base mold 36 is obtained by opening the prototype model 14 and the base mold 36 (see FIG. 2B). The outer surface of the silicone layer 42 is a transfer surface 34 onto which the shape of the skin sheet surface 16 of the prototype model 14 is transferred. That is, the shape of the skin sheet surface 16 such as the shape corresponding to the pattern of the skin sheet surface 16 and the shape corresponding to the stitch S is transferred to the transfer surface 34.

  As shown in FIG. 3, the tank model 44 is manufactured using the reversal model 32, and a thermosetting or thermoplastic resin is poured into the recess 48 facing the transfer surface 34 of the reversal model 32. Is molded while being in close contact with the transfer surface 34. A mold forming surface 46 on which the shape of the transfer surface 34 of the reversal model 32 is transferred is formed in the inlet tank model 44. That is, the same shape as the skin sheet surface 16 of the prototype model 14 is reproduced on the mold forming surface 46 of the tank model 44. In the embodiment, an epoxy resin is employed as the resin.

  As shown in FIG. 4, the electroforming mold 10 is manufactured by using a bathing model 44. Conductive treatment is performed on the molding surface 46 of the tank model 44 by applying a conductive film by a silver mirror reaction. Next, the tank model 44 subjected to the conductive treatment is loaded into the electroforming tank 50, and the electroforming 10 having a required thickness is formed on the mold forming surface 46 of the tank model 44 by electroforming. In the embodiment, the mold forming surface 46 of the tank model 44 is electroformed with nickel. The electroforming mold 10 is formed with a skin forming surface 12 to which the shape of the mold forming surface 46 of the tank model 44 is transferred. That is, the same shape as the transfer surface 34 of the inversion model 32 is reproduced on the skin molding surface 12 of the electroforming mold 10.

  In the manufacturing method of the electroforming mold 10 of the embodiment, on the skin sheet surface 16 of the prototype model 14, three fine yarns 28 a, in which one thin yarn 28 a is set to have a different thickness from the other fine yarns 28 b, 28 b, A stitch S is formed by a thread 26 in which 28b and 28b are twisted. Therefore, as shown in FIG. 5C, the surface of the thread 26 is adjacent to the portions where the thin yarns 28a and 28b having different thicknesses are in contact with the thin yarns 62 and 62 in the conventional yarn 60 (FIG. 8). Compared with (c), a large step is formed. The uneven shape of the thread 30 of the yarn 26 on the surface of the yarn 26 is emphasized by the large step formed in the adjacent portions of the thin yarns 28a and 28b having different thicknesses. Therefore, the uneven shape of the twist 30 of the yarn 26 forming the stitch S can be clearly transferred to the transfer surface 34 of the reverse model 32 to which the shape of the skin sheet surface 16 of the prototype model 14 is transferred. Therefore, the shape of the twist 30 of the yarn 26 can be transferred to the electroforming mold 10 formed based on the transfer surface 34 of the reversal model 32 to which the uneven shape of the twist 30 of the yarn 26 is clearly transferred. In addition, in the method for manufacturing the electroforming mold 10 of the example, one thin yarn 28a and two fine yarns 28b and 28b set to be thinner than the thin yarn 28a and having the same thickness are twisted. Since the stitch S is formed by the yarn 26, the knitted stitch 30 in which the uneven shape is emphasized in the adjacent portion of the fine yarns 28a and 28b having different thicknesses by the two fine yarns 28b and 28b having the same thickness. The interval can be increased. Therefore, when the shape of the skin sheet surface 16 of the prototype model 14 is transferred, the concavo-convex shape of the knot 30 is not easily crushed.

  The electroforming mold 10 of the example transfers the shape of the skin sheet surface 16 of the prototype model 14 to the transfer surface 34 of the inversion model 32, and transfers the shape of the transfer surface 34 to the mold forming surface 46 of the inlet model 44. It is manufactured by transferring the shape of the molding surface 46 to the skin molding surface 12. Even when the prototype model 14 is manufactured by repeating the transfer operation a plurality of times as described above, the concavo-convex shape of the thread 30 of the yarn 26 forming the stitch S in the prototype model 14 is emphasized. The uneven shape is difficult to collapse during the manufacturing process. Therefore, the uneven shape of the twist line 30 of the yarn 26 can be clearly transferred to the skin forming surface 12 of the electroforming mold 10.

  A thread 26 forming a stitch S is formed on the surface of the skin material 52 formed by using the electroforming mold 10 manufactured by the manufacturing method of the embodiment based on a vacuum forming technique, a powder slush forming technique, a spray forming technique, or the like. The shape of the skin sheet surface 16 including the shape of the twist line 30 is reproduced. Therefore, by forming the skin material 52 using the electroforming mold 10, the skin material 52 on which a high-quality stitch pattern SD in which the shape of the twist 30 of the yarn 26 is reproduced is formed.

(Change example)
The present invention is not limited to the above-described embodiment, and can be modified as follows.
(1) The yarn may be constituted by twisting two or three or more fine yarns. Further, the yarn only needs to be formed by twisting a plurality of fine yarns having at least one fine yarn set to a different thickness from the other fine yarns, and all the thicknesses are different as shown in FIG. The yarn 70 may be composed of three fine yarns 72a, 72b, 72c. By forming stitches with the yarns 70 made of the fine yarns 72a, 72b, and 72c having different thicknesses, a step is generated between all the adjacent fine yarns 72a, 72b, and 72c, and the uneven shape of the knot 76 can be emphasized. .
(2) The stitches attached to the skin surface of the original model may be formed by sewing the skin sheet with a thread. Therefore, the original model may be manufactured by attaching a skin sheet stitched to the mounting surface of the wooden model.
(3) The mold targeted by the present invention is not limited to an electromold, but may be any mold that can be manufactured through a process of transferring an original model with stitches. It may be a mold manufactured by manufacturing a mold and pouring molten metal into the mold.
(4) The member to be molded with the molding die targeted by the present invention is not limited to the skin material of the instrument panel, but may be a skin material of a vehicle interior member such as a floor console, a door trim, a pillar garnish, or a hard base material. It may also be a member constituting a furniture product such as a sofa or chair, or a member constituting daily necessities such as shoes or a bag.

10 Electric mold (molding die), 12 Skin molding surface, 14 Prototype model, 20 Mounting surface, 22 Through hole
24 skin sheet, 26 threads, 28a, 28b fine thread, 44 tank model, S stitch

Claims (2)

Based prototype model denoted by the stitch Iriso model obtained through a step of transferring a plurality of times, in the method of manufacturing the mold for forming a mold by electroforming,
The step of fabricating the prototype model, sticking a skin sheet to the mounting surface of the wooden model, a yarn thin yarn of at least one is twisted plurality of fine yarns which are set to the thickness that is different from the other fine yarns The stitches are formed on the surface of the skin sheet attached to the wooden model by sequentially inserting into a plurality of through holes provided on the mounting surface of the wooden model. A method for manufacturing a mold. The yarns are one and fine yarn production method of the mold of the fine yarns than narrower set is two or more fine yarns and the twisted configuration of equal thickness claims 1 Symbol placement.

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