JP6215023B2 - Method for manufacturing vehicle interior material - Google Patents

Description

  The present invention relates to a method for manufacturing a vehicle interior material such as a door trim or an instrument panel.

  2. Description of the Related Art Conventionally, vehicle interior materials are known in which a panel-like base material surface is covered with a skin material. For example, in Patent Document 1, a skin material body having a texture pattern on the surface is molded with a resin. In addition, after the skin material is stitched (embroidered) with a thread, the skin material is obtained, and then the base material injection-molded in another process is attached to the back surface side of the skin material with an adhesive or the like. I have the material.

JP 2013-216242 A

  By the way, in patent document 1, after obtaining a skin material and a base material by a separate process, a base material is affixed with the adhesive agent etc. on the back surface of a skin material, and an interior material for vehicles is obtained, Therefore A manufacturing takes time. It is complicated.

  In order to cope with this, for example, after the skin material body is stitched to obtain the skin material, the skin material is set in one of the molds of the injection-molded mold that is opened, and the injection mold after the mold is closed A method of consolidating the skin material and the base material simultaneously with injection molding of the base material is conceivable by filling the cavity with a thermoplastic resin to obtain the base material.

  However, when the above-described method is adopted, since a large number of needle holes are formed in the skin material body when stitching with a sewing thread, the needle holes are used when filling the cavity of the injection mold with the thermoplastic resin. The resin leaks out to the surface side of the skin material from the wide gap between the peripheral edge and the sewing thread (for example, the needle hole of the stitch made in the corner portion with a small radius of curvature), and the interior of the vehicle interior material after injection molding There is a possibility that the designability is lowered.

  Furthermore, there is also a demand for maintaining a high design without causing the sewing thread to loosen even when used for a long period of time for a vehicular interior material that has been stitched as described above.

  The present invention has been made in view of such a point, and an object of the present invention is to provide a method for manufacturing a vehicle interior material that can maintain high designability for a long period of time and can be manufactured efficiently. There is to do.

  In order to achieve the above object, the present invention integrates the base material and the skin material when the base material is injection-molded, and the thermoplastic resin is made of the skin material through the needle holes of the skin material body. The feature is that it has been devised not to move to the surface side.

  Specifically, the following solution was taken in a method for manufacturing an interior material for a vehicle including a panel-like base material and a flexible skin material covering the surface side of the base material.

That is, in the first invention, after molding the skin material body made of thermoplastic resin with the skin material molding die, the skin material molding die is opened and the skin material body is taken out, and then the skin material body A first die for setting the skin material by stitching with a sewing thread, and a second mold having a molding surface corresponding to the shape on the back surface side of the base material, which is disposed opposite to the first mold. An injection mold having a mold is prepared, and in the state where the injection mold is opened, the skin material in which at least a part of the stitch forming portion on the back surface side of the skin material is covered with a liquid leakage preventing means is used as the liquid. After setting the first mold so that the leakage prevention means is directed to the second mold, or after setting the skin material to the first mold, at least a part of the stitch formation portion on the back side of the skin material is the above Cover with liquid leakage prevention means, and then The injection mold is closed and a thermoplastic resin is filled into a cavity formed between the back surface of the skin material set on the first mold and the molding surface of the second mold to obtain the substrate. It is characterized by that.

The second invention is characterized in that, in the first invention, only a part of the entire stitch forming portion on the back surface side of the skin material is covered with the liquid leakage preventing means.

In a third invention, in the first or second invention, the liquid leakage preventing means is a thermoplastic resin sheet material to be attached to a part of the stitch forming portion on the back surface side of the skin material. .

In the first and second inventions, since the base material is injection-molded in the injection mold and the skin material and the base material are integrated, the skin material and the base material are obtained in separate steps, and then the skin is obtained. It is possible to avoid a complicated operation of attaching a base material to the back surface of the material with an adhesive or the like, and to efficiently manufacture an interior material for a vehicle. In addition, when the base material is injection molded, the liquid leakage preventing means prevents the thermoplastic resin filling the cavity of the injection mold from passing through the needle hole and moving to the surface side of the skin material body. This prevents the thermoplastic resin from leaking to the surface side of the vehicle and the design of the molded vehicle interior material from being deteriorated. Furthermore, since the back surface side of the skin material of the stitches applied to the skin material body is fixed by the base material, the vehicle interior material can be used for a long period of time while maintaining a high design without loosening the sewing thread.

In the third invention, the work of covering the back side of the skin material body of the stitch can be performed quantitatively and easily, the quality of the interior material to be manufactured is less likely to vary, and the number of work steps of the operator is reduced. be able to.

It is the perspective view which looked at the door for vehicles from the vehicle interior side. (A) is sectional drawing in the AA of FIG. 1, (b) is the C section enlarged view of (a). (A) is sectional drawing in the BB line of FIG. 1, (b) is the D section enlarged view of (a), (c) is sectional drawing in the HH line of (b). It is. It is a block diagram which shows the procedure of the manufacturing method of the vehicle interior material which concerns on embodiment of this invention. It is sectional drawing of the vacuum forming die which shape | molds the skin material main body which concerns on embodiment of this invention, (a) is the state in the middle of vacuum forming, (b) is the E section enlarged view of (a). Indicates. It is sectional drawing of the injection mold which shape | molds the vehicle interior material which concerns on embodiment of this invention, (a) is the state immediately after setting a skin material to an injection mold, (b) is (a). The F section enlarged view of is shown. The state immediately after the injection mold is closed and the thermoplastic resin is injected into the cavity is shown. (A) shows the state immediately after injection-molding a base material with an injection mold, (b) shows the G section enlarged view of (a). The state immediately after opening the injection mold and taking out the vehicle interior material from the injection mold is shown.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiment is merely exemplary in nature.

  FIG. 1 shows a vehicle door W provided with a door trim 1 (vehicle interior material) manufactured by the manufacturing method of the embodiment of the present invention. The door trim 1 has a panel shape extending in the vehicle front-rear direction and is attached to an upper portion of the door panel (not shown) so as to face the vehicle interior side. An opening 1a for the door lever W2 is provided at the front side portion in the vehicle front-rear direction. Is formed. An armrest Y extending in the vehicle front-rear direction is disposed below the door trim 1 of the vehicle door W. A window switch Y1 is provided on the vehicle front side of the armrest Y, and a recess on the vehicle rear side of the armrest Y is provided. The portion Y2 is provided with a gripping portion Y3 that the occupant grips.

  The upper part of the door trim 1 is gently curved toward the vehicle exterior as the vehicle goes upward. As shown in FIGS. 2 and 3, a panel-shaped resin base material 2 and the surface of the base material 2 are provided. A flexible skin material 3 covering the side (vehicle interior side), and the base material 2 is integrated with the back surface side of the skin material 3.

  The skin material 3 includes a skin material body 30 made of a thermoplastic resin 9. The skin material body 30 includes a skin 3a constituting the surface of the skin material body 30 and a foam 3b covering the back side of the skin 3a. The skin 3a and the foam 3b are made of an adhesive or the like. It is united.

  A linear groove 3c extending in the vehicle front-rear direction is formed in the upper portion of the skin 3a. As shown in FIGS. 1 to 3, the groove 4c of the skin main body 30 is threaded into the groove 3c. The skin material 3 is obtained by applying the stitch 40.

  As shown in FIG. 4, the door trim 1 is subjected to a first molding step 10a for vacuum molding, a sewing step 10b for sewing, a processing step 10c for processing, and a second molding step 10d for injection molding in order. It has come to be manufactured.

  As shown in FIG. 5, the vacuum forming die 6 (skin material forming die) of the first forming step 10a includes an upper die 62 and a lower die 61 that face each other so as to be able to advance and retreat.

  The upper mold 62 has a molding surface 62a for molding the surface side of the skin material body 30, and the molding surface 62a has a protrusion for forming the concave groove 3c as shown in FIG. 5 (b). A strip 62c projects downward.

  The molding surface 62a is formed with fine irregularities corresponding to the embossed pattern formed on the surface of the skin material main body 30 and a number of holes (not shown).

  On the other hand, the lower mold 61 has a molding surface 61a for molding the back side of the skin material main body 30, and the molding surface 61a has a shape corresponding to the protrusion 62c, and the skin is closed when the mold is closed. An escape recess 61c that allows the material body 30 to escape is formed.

  Then, the sheet-shaped skin material body 30 softened by heating is set between the upper mold 62 and the lower mold 61, and the vacuum forming mold 6 is closed to form the molding surface 61a and the mold. The skin material main body 30 is sandwiched between the molding surface 62a and vacuuming is performed from a large number of holes (not shown) formed in the molding surface 62a of the upper mold 62 so that the surface has a texture pattern and the concave groove. The skin material main body 30 formed with 3c is molded.

  In the processing step 10c, an unnecessary portion of the skin material body 30 formed by the vacuum forming die 6 is cut, and as shown in FIG. 2, a part of the stitch 40 forming portion on the back surface side of the skin material 3, for example, A thermoplastic resin sheet material 5 (liquid leakage prevention means) is affixed to a stitch 40 forming portion formed at a corner portion having a small curvature radius.

  The injection molding die 7 (skin material molding die) in the second molding step 10d includes a fixed lower die 71 (second die) and advancing and retreating with respect to the lower die 71 as shown in FIGS. An upper mold 72 (first mold) is provided so as to face each other.

  The lower mold 71 has a molding surface 71a corresponding to the shape of the back surface side (the back surface side of the base material 2) of the door trim 1, and a split surface 71b continuous with the molding surface 71a.

  On the other hand, the upper mold 72 corresponds to the shape of the surface side of the door trim 1 (the surface side of the skin material 3), a set surface 72a for setting the skin material 3, and a divided surface continuous to the set surface 72a. 72b, and the split surface 72b is adapted to be matched with the molding surface 71a of the lower mold 71 in the closed state of the injection mold 7 (see FIGS. 7 and 8).

  When the skin material 3 is set on the set surface 72a with the back surface side of the skin material 3 facing the lower mold 71, the surface of the skin material 3 excluding the stitch 40 forming portion and the set surface 72a come into contact with each other. Yes.

  As shown in FIG. 7, with the injection mold 7 closed, a cavity is formed between the back surface of the skin material 3 set on the set surface 72a of the upper mold 72 and the molding surface 71a of the lower mold 71. 8 is formed, and the base material 2 is formed by filling the cavity 8 with the thermoplastic resin 9.

  Next, a method for manufacturing the door trim 1 will be described.

  First, the vacuum forming die 6 is prepared, and the sheet-like skin material body 30 softened by heating is set between the upper die 62 and the lower die 61 in the opened vacuum forming die 6.

  Next, as shown in FIG. 5, the vacuum forming die 6 is closed, the skin material body 30 is sandwiched between the forming surface 62a of the upper die 62 and the forming surface 61a of the lower die 61, and the upper Vacuuming is performed from a large number of holes (not shown) formed on the molding surface 62a of the mold 62, and the skin material body 30 having a texture pattern and the groove 3c formed on the surface is molded.

  Thereafter, the skin material body 30 is removed from the vacuum forming die 6 and unnecessary portions of the skin material body 30 are cut, and then stitches 40 are formed on the concave grooves 3c of the skin material body 30 with the sewing thread 4. The skin material 3 is obtained.

  Thereafter, the thermoplastic resin sheet material 5 is affixed to a part of the stitch 40 forming portion on the back surface of the skin material 3.

  Next, the injection mold 7 is prepared. As shown in FIG. 6, the thermoplastic resin sheet material 5 faces the lower mold 71 side of the skin material 3 with the injection mold 7 opened. In this way, the upper mold 72 is set on the set surface 72a. Note that after setting the skin material 3 on the set surface 72 a of the upper mold 72, the thermoplastic resin sheet material 5 may be attached to a part of the stitch 40 forming portion on the back surface side of the skin material 3.

  Next, as shown in FIG. 7, after the injection mold 7 is closed, the thermoplastic resin 9 is injected into the cavity 8 formed between the back surface side of the skin material 3 and the molding surface 71 a of the lower mold 71. As shown in FIG. 8, the cavity 8 is filled with a thermoplastic resin 9 without a gap to obtain the base material 2. At that time, the portion covered with the thermoplastic resin sheet material 5 in the stitch 40 forming portion on the back surface side of the skin material 3 is thermoplastic from the needle hole 4a (see FIG. 7 (b)) to the surface side of the skin material 3. The resin 9 does not leak (see FIG. 2). On the other hand, in the portion where the stitch 40 is formed on the back surface side of the skin material 3, the sewing thread 4 is fixed to the back surface of the skin material 3 by the injected thermoplastic resin 9 in the portion not covered with the thermoplastic resin sheet material 5 (FIG. 3). (See (b) and (c)).

  Thereafter, as shown in FIG. 9, the upper mold 72 is retracted from the lower mold 71 to open the injection mold 7, and the door trim 1 in which the base material 2 is integrated with the skin material 3 is removed.

  As described above, according to the embodiment of the present invention, since the base material 2 is injection-molded in the injection mold 7 and the skin material 3 and the base material 2 are integrated, the skin material 3 and the base material 2 are separately provided. After being obtained in this step, it is possible to avoid a troublesome operation of attaching the base material 2 to the back surface of the skin material 3 with an adhesive or the like, and the door trim 1 can be manufactured efficiently. Further, when the base material 2 is injection-molded, it is the resin sheet material 5 that the thermoplastic resin 9 filling the cavity 8 of the injection mold 7 passes through the needle holes 4a and moves to the surface side of the skin material body 30. This prevents the thermoplastic resin 9 from leaking to the surface side of the skin material body 30, and the design of the door trim 1 after molding does not deteriorate. Furthermore, since the back surface side of the skin material 3 of the stitch 40 applied to the skin material body 30 is fixed by the base material 2, the door trim 1 can be used for a long period of time while maintaining high design without the sewing thread 4 loosening.

  Further, since a part of the stitch 40 forming portion on the back surface side of the skin material 3 is covered by attaching the thermoplastic resin sheet material 5, the work of covering the back surface side of the skin material body 30 of the stitch 40 is quantitatively performed, and As a result, the quality of the door trim 1 to be manufactured is less likely to vary, and the number of man-hours for the operator can be reduced.

  In the embodiment of the present invention, in order to prevent the thermoplastic resin 9 from leaking to the surface side of the skin material 3 at the time of injection molding, the thermoplastic resin sheet material 5 is applied to the stitch 40 forming portion on the back surface side of the skin material 3. However, the present invention is not limited to this. For example, a liquid or powdery resin material may be applied to prevent liquid leakage.

  In the embodiment of the present invention, there is only one stitch 40. However, the manufacturing method according to the embodiment of the present invention can be applied to manufacturing the door trim 1 having a plurality of stitches 40.

  In the embodiment of the present invention, the stitch 40 is applied to the concave groove 3c formed in the skin material body 30 with the sewing thread 4, but the stitch 40 is applied to the portion where the concave groove 3c is not formed. May be.

  Furthermore, in the embodiment of the present invention, the present invention is applied to the manufacture of the door trim 1, but the manufacturing method of the present invention can be applied to the manufacture of other vehicle interior materials such as instrument panels.

  In addition, in the present invention, the skin material body 30 is formed by vacuum forming, but may be formed by injection molding, transfer molding, or the like.

  In the embodiment of the present invention, the skin material 3 is set on the upper mold 72 of the injection mold 7. However, the skin material 3 may be set on the lower mold 71.

  The present invention is suitable for a method for manufacturing a vehicle interior material such as a door trim or an instrument panel.

1 Door trim (vehicle interior material)
2 Base material 3 Skin material 4 Sewing thread 5 Resin sheet material (Liquid leakage prevention means)
6 Vacuum mold (skin material mold)
7 Injection mold 8 Cavity 9 Thermoplastic resin 30 Skin body 40 Stitch 71 Lower mold (second mold)
71a Molding surface 72 Upper mold (first mold)

Claims (3)

A method for producing a vehicle interior material comprising a panel-shaped base material and a flexible skin material covering the surface side of the base material,
After the skin material body made of thermoplastic resin is molded with the skin material molding die, the skin material molding die is opened and the skin material body is taken out, and then the skin material body is stitched with a sewing thread and then the skin Material,
Next, an injection mold comprising a first mold for setting the skin material and a second mold disposed opposite to the first mold and having a molding surface corresponding to the shape of the back side of the base material is prepared. In the state where the injection mold is opened, the liquid leakage preventing means faces the second mold with the skin material covering at least a part of the stitch forming portion on the back surface side of the skin material with the liquid leakage preventing means. After setting the first mold, or after setting the skin material to the first mold, cover at least part of the stitch formation portion on the back side of the skin material with the liquid leakage prevention means,
Thereafter, the injection mold is closed and a thermoplastic resin is filled into a cavity formed between the back surface of the skin material set in the first mold and the molding surface of the second mold, and the base is formed. A method for producing an interior material for a vehicle, characterized in that the material is obtained. In the manufacturing method of the interior material for vehicles according to claim 1,
A method for manufacturing a vehicular interior material, characterized in that only a part of the entire stitch formation portion on the back side of the skin material is covered with a liquid leakage prevention means. In the manufacturing method of the interior material for vehicles according to claim 1 or 2 ,
The method for manufacturing an interior material for a vehicle, wherein the liquid leakage preventing means is a thermoplastic resin sheet material to be attached to a part of a stitch forming portion on the back surface side of the skin material.

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