JP6857009B2 - Manufacturing method of interior materials for vehicles - Google Patents

Description

The present invention relates to a method for manufacturing an interior material for a vehicle, which adheres a three-dimensionally shaped base material and a skin material.

Conventionally, as a method for manufacturing an interior material for a vehicle of this type, a method of setting a base material and a skin material on an upper mold and a lower mold of a molding mold and closing the mold to bond the base material and the skin material is known. (See, for example, Patent Document 1). Further, a method is also known in which a vacuum pressure-bonding mold is used as a molding mold, and the skin material is vacuum-sucked so that the skin material adheres to the base material when the mold is closed.

Japanese Unexamined Patent Publication No. 2001-121613 (paragraphs [0021] to [0023], FIG. 5)

However, in the method for manufacturing an interior material for a vehicle using a vacuum pressure bonding type, if the suction of the skin material is insufficient, the skin material may be lifted and wrinkles may be formed on the skin material adhered to the base material. there were.

An object of the present invention is to provide a method for manufacturing an interior material for a vehicle capable of suppressing the formation of wrinkles on the skin material.

In the invention of claim 1, the three-dimensional base material and the skin material having a shape corresponding to the base material are set in the first type and the second type of the vacuum pressure bonding type, and the skin material is vacuum-sucked. It is a method of manufacturing an interior material for a vehicle in which the mold is closed and the skin material is adhered to the base material. When the skin material is set in the second mold, the outer edge portion of the skin material is the second mold. The mating surface is overlapped with the mating surface, and the mating surface and the outer edge portion of the skin material are sealed with a sealing material.

The invention of claim 2 is the method for manufacturing an interior material for a vehicle according to claim 1, wherein the size of the skin material when viewed from the opening / closing direction of the vacuum crimping type is spread over the entire circumferential direction. The size is set so as to protrude from the base material, and the sealing material is arranged so as to overlap the portion of the skin material that protrudes from the base material.

The invention of claim 3 is the method for manufacturing an interior material for a vehicle according to claim 1, wherein each of the skin material and the base material has a product area to be a product and a non-product surrounding the product area. A region is provided, and the sealing material is arranged so as to overlap the non-product region of the skin material and the non-product region of the base material.

The invention of claim 4 is the method for manufacturing an interior material for a vehicle according to any one of claims 1 to 3, wherein the seal is used before the skin material is set in the second type. The material is fixed to the second mold.

The invention of claim 5 is the method for manufacturing an interior material for a vehicle according to any one of claims 1 to 4, wherein the sealing material is a material having substantially the same hardness as the skin material or a material having substantially the same hardness as the skin material. A material made of a material softer than the skin material is used.

The invention of claim 6 is the method for manufacturing an interior material for a vehicle according to any one of claims 1 to 5, wherein the skin material includes a surface layer made of a thermoplastic resin and a surface material layer. It has a laminated structure with a lining layer made of a resin foam.

The invention of claim 7 is the method for manufacturing an interior material for a vehicle according to claim 6, wherein a decorative stitch is formed as the skin material.

[Invention of claims 1, 6 and 7]
In the invention of claim 1, since the space between the skin material and the mating surface of the second type is sealed by the sealing material, it is possible to sufficiently suck the skin material and suppress the lifting of the skin material. As a result, the formation of wrinkles on the skin material adhered to the base material is suppressed.

The skin material has a laminated structure having an outer material layer made of a thermoplastic resin and a lining layer made of a resin foam, so that the shape retention and flexibility of the skin material can be achieved at the same time. It is preferable from the viewpoint (the invention of claim 6). Moreover, when decorative stitches are formed on the skin material, the manufacturing method of the present invention in which the laminated sheet in which the outer material layer and the lining layer are bonded to each other is formed into a three-dimensional shape and then bonded to the base material is effective. ..

[Invention of claim 2]
In the invention of claim 2, since the sealing material is overlapped on the portion of the skin material that protrudes from the base material, the sealing material is pressed against the sealing material by removing the protruding portion of the skin material or wrapping it around the back side of the base material. It is possible to remove the unevenness formed on the skin material from the product or make it inconspicuous.

[Invention of claim 3]
In the invention of claim 3, since the sealing material is arranged so as to overlap the non-product region of the skin material and the non-product region of the base material, after the base material and the skin material are adhered, the base material and the skin material are not formed. By removing the product area, it is possible to remove from the product the unevenness formed on the skin material by pressing against the sealing material.

[Invention of claim 4]
According to the invention of claim 4, the misalignment of the sealing material is suppressed, and the skin material can be sucked stably.

[Invention of claim 5]
According to the invention of claim 5, it is possible to improve the adhesion between the sealing material and the skin material and improve the sealing property of the sealing material.

(A) Partially broken perspective view and (B) side sectional view of the instrument panel according to the first embodiment. Perspective view of base material and skin material before bonding Sectional view of vacuum crimping type Cross-sectional view of the vacuum crimping mold with the skin material set in the lower mold Cross-sectional view of the vacuum crimping mold before closing the mold Cross-sectional view of the vacuum crimping mold after closing the mold Cross-sectional view of the vacuum pressure bonding type in which the base material and the skin material according to the second embodiment are set. Cross-sectional view of the vacuum crimping mold after closing the mold

[First Embodiment]
Hereinafter, the first embodiment of the present invention will be described with reference to the drawings. The vehicle interior material in the present invention is intended for an instrument panel, a floor console, a door trim, a pillar garnish, etc. arranged in a passenger compartment of a vehicle, but in the present embodiment, the instrument panel will be described as an example. ..

As shown in FIGS. 1A and 1B, the instrument panel 10 has a three-dimensional base material 11 and a shape corresponding to the base material 11 on the surface of the base material 11. It is composed of the bonded skin material 21 and. The skin material 21 constitutes the design surface of the instrument panel 10, and the skin material 21 is formed with decorative stitches S. In the example shown in FIG. 1A, the base material 11 has a substantially L-shape in the side view, and the skin material 21 also has a substantially L-shape in the side view corresponding to the shape of the base material 11.

The base material 11 is made of a thermoplastic resin such as polypropylene (PP), polyethylene (PE), acrylonitrile / butadiene / styrene resin (ABS), polycarbonate / acrylonitrile / butadiene / styrene resin (PC / ABS). The skin material 21 is composed of a laminated sheet 24 in which a surface layer 22 made of a thermoplastic resin and a lining layer 23 made of a resin foam are bonded together (see FIG. 1 (B)). The outer layer 22 is preferably made of a thermoplastic elastomer (for example, an olefin-based thermoplastic elastomer (TPO), a polyvinyl chloride-based thermoplastic elastomer (TPVC), etc.) or a polyvinyl chloride resin (PVC). Since the thermoplastic elastomer (TPO, TPVC, etc.) has elasticity like rubber as compared with the polyvinyl chloride resin (PVC), the feel when the user touches the skin material 21 is improved, which is more preferable. Furthermore, since the olefin-based thermoplastic elastomer (TPO) does not contain vinyl chloride resin, it is possible to reduce the environmental load (due to its excellent recyclability and the absence of a phthalate ester-based plasticizer). Yes, especially preferred. The lining layer 23 is made of a resin foam having an appropriate cushioning property (for example, PP foam, PE foam, urethane foam, etc.). In drawings other than FIG. 1B, the laminated structure of the skin material 21 is omitted.

In order to manufacture the instrument panel 10, first, a base material 11 shaped into a three-dimensional shape and a skin material 21 are prepared. The base material 11 is obtained by injection molding of a thermoplastic resin. The skin material 21 is obtained by vacuum forming the laminated sheet 24 to shape it into a three-dimensional shape, and then forming a decorative stitch S with a sewing machine. FIG. 2 shows the skin material 21 before being adhered to the base material 11. As shown in the figure, the skin material 21 includes a three-dimensional shape portion 21A shaped into a three-dimensional shape, a flat portion 21B surrounding the three-dimensional shape portion 21A and forming an outer edge portion of the skin material 21. Consists of. The three-dimensional shape portion 21A has a shape corresponding to the base material 11, and when the base material 11 is superposed on the three-dimensional shape portion 21A, the flat portion 21B protrudes to the outside of the base material 11. ..

After the base material 11 and the skin material 21 are prepared, the base material 11 and the skin material 21 are adhered to each other. The vacuum pressure bonding mold 30 shown in FIG. 3 is used for adhering the base material 11 and the skin material 21. The vacuum crimping die 30 includes an upper die 31 and a lower die 32. A convex protrusion 31T corresponding to the base material 11 is formed on the portion of the upper mold 31 facing the lower mold 32. A concave recess 32A corresponding to the skin material 21 (specifically, the three-dimensional shape portion 21A of the skin material 21) is formed in the portion of the lower mold 32 facing the protrusion 31T. Further, the lower mold 32 is provided with a plurality of suction holes 33 opened on the inner surface of the recess 32A. The mating surfaces 31M and 32M of the molds 31 and 32 are formed on the outside of the protrusion 31T in the upper mold 31 and the outside of the recess 32A in the lower mold 32.

In order to bond the base material 11 and the skin material 21 using the vacuum pressure bonding mold 30, first, the three-dimensional shape portion 21A of the skin material 21 is set in the recess 32A of the lower mold 32 (see FIG. 4), and then the base material 21 is bonded. The material 11 is set on the protrusion 31T of the upper mold 31 (see FIG. 5). At this time, the flat portion 21B of the skin material 21 is overlapped with the mating surface 32M of the lower mold 32. When the skin material 21 is set in the lower mold 32, air is sucked between the skin material 21 and the inner surface of the recess 32A through the suction hole 33, and the three-dimensional shape portion 21A of the skin material 21 is brought into close contact with the inner surface of the recess 32A. Let me. When the base material 11 is set on the protrusion 31T, an adhesive (not shown) is applied to the surface of the base material 11 (the surface facing the skin material 21 side).

When the base material 11 and the skin material 21 are set in the vacuum crimping mold 30, the vacuum crimping mold 30 is closed as shown in FIG. Then, the base material 11 and the skin material 21 are adhered to each other by the adhesive applied to the surface of the base material 11.

Next, the base material 11 adhered to the skin material 21 is removed from the vacuum pressure bonding mold 30. Then, the unnecessary portions of the skin material 21 and the base material 11 are trimmed, and the flat portion 21B of the skin material 21 is wound around the back side of the base material 11 as needed. As a result, the instrument panel 10 shown in FIG. 1 (A) is completed.

Here, as described above, the skin material 21 is composed of a laminated sheet 24 in which a surface layer 22 made of a thermoplastic resin and a lining layer 23 made of a resin foam are bonded to each other to some extent. Has shape retention. Therefore, if the flat portion 21B of the skin material 21 has irregularities or bends, a gap is formed between the flat portion 21B and the mating surface 32M of the lower mold 32, and the suction of the skin material 21 becomes insufficient. Then, when the suction of the skin material 21 is insufficient, the skin material 21 and the base material 11 are adhered to each other in a state where the skin material 21 (specifically, the three-dimensional shape portion 21A) is lifted from the inner surface of the recess 32A, and the base is formed. There arises a problem that wrinkles are formed on the skin material 21 adhered to the material 11.

In order to prevent the formation of wrinkles in the skin material 21, the sealing material 40 is fixed to the mating surface 32M of the lower mold 32 as shown in FIG. 3 in the manufacturing method of the instrument panel 10 according to the present embodiment. ing. The sealing material 40 is fixed to the mating surface 32M with an adhesive, double-sided tape, or the like. The sealing material 40 is made of a material having low air permeability and elasticity. Further, the sealing material 40 is made of a material having substantially the same hardness as the skin material 21 or a material softer than the skin material 21. The material constituting the sealing material 40 is, for example, a rubber sponge having a closed cell structure, a PE foam having a closed cell structure, a urethane foam having a low air permeability, or the like.

As shown in FIG. 4, when the skin material 21 is set on the lower mold 32, the flat portion 21B of the skin material 21 is superposed on the sealing material 40. Here, as described above, since the sealing material 40 has elasticity and is made of a material having substantially the same hardness as the skin material 21 or a material softer than the skin material 21, the skin material 21 and the lower mold The space between the 32 mating surfaces 32M and the 32M mating surface can be filled with the sealing material 40 without any gap. As a result, it is possible to improve the adhesion between the skin material 21 and the inner surface of the recess 32A when the skin material 21 is sucked, and it is possible to suppress the formation of wrinkles in the skin material 21.

As shown in FIG. 6, when the vacuum crimping mold 30 is closed, the flat portion 21B of the skin material 21 is pushed against the mating surface 31M of the upper mold 31, and the sealing material 40 is pushed in the opening / closing direction of the vacuum crimping mold 30. It is compressed. At this time, unevenness is formed on the flat portion 21B of the skin material 21 due to pressing against the sealing material 40, and the uneven portion is removed by trimming or the base material 11 is formed. Get caught up in the back of. Therefore, even if the unevenness caused by the sealing material 40 is formed on the skin material 21 in the manufacturing process, the unevenness is not noticeable to the user.

This concludes the description of the manufacturing method of the instrument panel 10. In the present embodiment, the upper mold 31 corresponds to the "first type" of the present invention, and the lower mold 32 corresponds to the "second type" of the present invention. Further, the flat portion 21B of the skin material 21 corresponds to the "outer edge portion of the skin material" in the present invention.

Next, the operation and effect of the method for manufacturing the instrument panel 10 will be described. In the method for manufacturing the instrument panel 10 of the present embodiment, the sealing material 40 seals between the mating surface 32M of the lower mold 32 and the skin material 21, so that the skin material 21 is sufficiently sucked to form the skin material 21. It is possible to suppress the lifting. As a result, it is possible to improve the adhesion between the skin material 21 and the inner surface of the recess 32A, and it is possible to suppress the formation of wrinkles on the skin material 21.

Further, in the present embodiment, since the sealing material 40 is overlapped with the flat portion 21B of the skin material 21 protruding from the base material 11, the flat portion 21B of the skin material 21 is trimmed or rolled up on the back side of the base material 11. As a result, the unevenness formed on the skin material 21 by pressing against the sealing material 40 can be removed from the product or made inconspicuous.

Further, in the present embodiment, since the sealing material 40 is fixed to the lower mold 32, the misalignment of the sealing material 40 is suppressed, and the skin material 21 can be stably sucked.

[Second Embodiment]
Hereinafter, the second embodiment of the present invention will be described. This embodiment is a modification of the first embodiment, and the structure of the base material 11 and the arrangement of the sealing material 40 are different. In the present embodiment, similarly to the skin material 21, the base material 11 is flat, surrounding the three-dimensional shape portion 11A shaped into a three-dimensional shape and the three-dimensional shape portion 11A to form the outer edge portion of the base material 11. It is composed of a part 11B (see FIG. 7). The three-dimensional shape portion 11A of the base material 11 remains as a product, but the flat portion 11B of the base material 11 is removed from the base material 11 and does not remain as a product. Further, the three-dimensional shape portion 21A of the skin material 21 remains as a product, but the flat portion 21B of the skin material 21 is removed from the skin material 21 and does not remain as a product.

As shown in FIG. 7, in the present embodiment, the sealing material 40 is overlapped with the flat portion 11B of the base material 11 and the flat portion 21B of the skin material 21 when viewed from the opening / closing direction of the vacuum pressure bonding mold 30. As shown in FIG. 8, when the vacuum crimping die 30 is closed, the sealing material 40 is compressed in the opening / closing direction of the vacuum crimping die 30. At this time, unevenness is formed on the flat portion 21B of the skin material 21 by pressing against the sealing material 40. Here, the flat portion 11B of the base material 11 and the flat portion 21B of the skin material 21 are removed by trimming. Therefore, even if the skin material 21 is formed with irregularities due to the sealing material 40 in the manufacturing process, the irregularities are not noticeable to the user.

Since the other points of this embodiment are the same as those of the first embodiment, the description thereof will be omitted. In the present embodiment, the three-dimensional shape portion 11A and the flat portion 11B of the base material 11 form a "product region" and a "non-product region" of the base material 11, respectively, and the three-dimensional shape portion of the skin material 21. The 21A and the flat portion 21B form a "product area" and a "non-product area" in the skin material 21, respectively.

According to the method for manufacturing the instrument panel 10 of the present embodiment, it is possible to obtain the same effect as that of the first embodiment. Further, in the present embodiment, the sealing material 40 is arranged so as to overlap the flat portion 21B of the skin material 21 and the flat portion 11B of the base material 11. Therefore, after adhering the base material 11 and the skin material 21, the flat portions 11B and 21B of the base material 11 and the skin material 21 are removed, so that the unevenness formed on the skin material 21 by being pressed against the sealing material 40 is formed. It can be removed from the product.

[Other Embodiments]
The present invention is not limited to the above embodiments, and for example, embodiments as described below are also included in the technical scope of the present invention, and various other than the following, as long as the gist is not deviated. It can be changed and implemented.

(1) In the above embodiment, the skin material 21 may be set on the upper mold 31 and the base material 11 may be set on the lower mold 32. In this case, the lower mold 32 is formed with a protrusion corresponding to the shape of the base material 11, and the upper mold 31 is formed with a recess corresponding to the three-dimensional shape portion 21A of the skin material 21. Then, the skin material 21 is vacuum-sucked into the upper mold 31.

(2) In the above embodiment, the vacuum crimping mold 30 is configured to open and close in the vertical direction, but it may be configured to open and close in the horizontal direction, or it may be configured to open and close diagonally in the vertical direction. May be good. Even in this case, the sealing material 40 is fixed to the mold in which the skin material 21 is set, and the sealing material 40 is used between the skin material 21 (specifically, the flat portion 21B) and the mating surface of the mold. Should be sealed.

(3) In the above embodiment, the sealing material 40 may not be fixed to the lower mold 32. Even in this case, the adhesion between the skin material 21 and the inner surface of the recess 32A can be improved.

(4) In the above embodiment, the adhesive for adhering the base material 11 and the skin material 21 may be applied to the skin material 21.

(5) In the above embodiment, the decorative stitch S may not be formed on the skin material 21.

10 Instrument panel (vehicle interior material)
11 Base material 21 Skin material 22 Outer material layer 23 Lining layer 30 Vacuum crimping type 31 Upper type (1st type)
32 Lower type (2nd type)
40 Sealing material S Decorative stitch

Claims (8)

The three-dimensional base material and the skin material having a shape corresponding to the base material are set in the first type and the second type of the vacuum pressure bonding type, and the skin material is closed while vacuum sucking, and the skin is closed. A method for manufacturing an interior material for a vehicle in which the material is adhered to the base material.
When setting the skin material in the second mold, the outer edge portion of the skin material is overlapped with the mating surface of the second mold, and the mating surface and the outer edge portion of the skin material are sealed with a sealing material. .. The method for manufacturing an interior material for a vehicle according to claim 1.
The size of the skin material when viewed from the opening / closing direction of the vacuum pressure bonding type is set to a size that protrudes from the base material over the entire circumferential direction.
The sealing material is arranged so as to overlap the portion of the skin material that protrudes from the base material. The method for manufacturing an interior material for a vehicle according to claim 1.
Each of the skin material and the base material is provided with a product area to be a product and a non-product area surrounding the product area.
The sealing material is arranged so as to overlap the non-product region of the skin material and the non-product region of the base material. The method for manufacturing an interior material for a vehicle according to any one of claims 1 to 3.
Before setting the skin material in the second mold, the sealing material is fixed in the second mold. The method for manufacturing an interior material for a vehicle according to any one of claims 1 to 4.
As the sealing material, a material having substantially the same hardness as the skin material or a material softer than the skin material is used. The method for manufacturing an interior material for a vehicle according to any one of claims 1 to 5.
The skin material has a laminated structure including an outer layer made of a thermoplastic resin and a lining layer made of a resin foam. The method for manufacturing an interior material for a vehicle according to claim 6.
As the skin material, a material having decorative stitches formed is used. The method for manufacturing an interior material for a vehicle according to any one of claims 1 to 7, wherein when the first mold and the second mold are closed, the outer edge portion of the skin material is used. Among them, the outer edge portion of the skin material and the sealing material are compressed so that the unevenness caused by the sealing material is formed in the portion where the sealing material overlaps.

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