JP7374773B2 - Decorative component manufacturing method - Google Patents

Description

The present invention relates to a method of manufacturing a decorative member, and more particularly to a method of manufacturing a decorative member by pressing a skin material having a cushion layer on the back side of the skin layer to a base material.

For various vehicles such as automobiles, ships, and aircraft, building materials for buildings such as houses, and furniture such as chairs and sofas, it is necessary to improve the decorativeness of the target parts and the texture such as texture. For this purpose, a decorative member is provided in which the surface of a resin base material is covered with a cushioning skin material. For example, in vehicles such as automobiles, instrument panels, floor consoles, door trims, pillar garnishes, and the like are widely used as decorative members for decorating the interior of the vehicle. Such decorative members are produced by molding a base material into a desired shape by injection molding or the like, and by molding a sheet-like skin material by vacuum forming or the like into a shape that matches the outer surface shape of the base material. , by holding the base material coated with adhesive in the first mold and holding the skin material in the second mold, and closing the first mold and the second mold so that the base material faces inside the skin material. It can be manufactured by crimping and bonding the two together (for example, see Patent Document 1).

Japanese Patent Application Publication No. 2001-121613

Incidentally, in recent years, the shape of the above-mentioned decorative member having a skin material on the surface of the base material has tended to become more complex in order to further enhance the decorativeness of the target member. However, in the configuration in which a decorative member is manufactured by crimping and pasting the base material and the skin material together while the first and second molds are closed together as described above, the base material faces the inside of the skin material. Due to this necessity, the shape of the skin material is limited. That is, for example, as shown in FIG. 6, from the lower end edge, which is the rear end edge in the crimping direction in which the skin material is crimped, to the wall portion of the side surface provided so as to be opposed, to the wall portion of the side surface facing the opposite side. If the base material is formed so that the wall part extends in a curved shape toward the direction of the base material, and a skin material is to be bonded to the side wall part and the curved wall part, the base material must be compatible with the base material. If the skin material is formed in a shape that . In this case, the skin material to be crimped to the side wall located on the front side of the base material in the crimping direction and the skin material to be crimped to the bent wall part located on the rear side of the base material in the crimping direction are separately separated. Although it is possible to form a decorative member by pressing each skin material onto the wall of the corresponding base material, there is a problem in that the appearance of the decorative member is deteriorated due to the formation of seams in the skin material. Furthermore, it has been pointed out that the presence of seams in the skin material makes it more susceptible to dirt and stains due to dust and the like.

That is, an object of the present invention is to provide a method for manufacturing a decorative member, which allows a skin material to be pressure-bonded to the surface of a base material formed into a complex shape with a good appearance.

In order to overcome the above problems and achieve the intended purpose, the first means is to:
A second wall having opposing first wall portions and extending from the rear end edge in the crimping direction for crimping the skin material on at least one of the first wall portions toward the other first wall portion. A method for producing a decorative member, the method comprising: pressing a skin material having a cushion layer on the back side of the skin layer onto a base material formed to have a cushion layer;
A laminated sheet in which a skin sheet forming the skin layer and a foam sheet forming the cushion layer are stacked is placed so that the foam sheet faces a first skin mold part and is relative to the first skin mold part. arranging the skin sheet so as to face a second skin mold part that can be opened and closed;
By closing the first skin mold part and the second skin mold part, the first skin part to be laminated on the first wall part of the base material and the second wall part of the base material The skin material having a second skin part to be laminated is located at a position where the second skin part does not interfere with the base material when the first skin part is crimped onto the first wall part. In addition to forming the
When molding the skin material, by compressing the foam sheet with a convex portion formed to protrude from the molding surfaces of the first skin part and the second skin part in the first skin mold part. , continuously or intermittently forming a thin-walled portion to be bent so as to extend along the boundary between the first skin portion and the second skin portion;
By closing the first crimping mold part that held the base material and the second crimping mold part that held the skin material, the crimping mold part holds the base material at the boundary between the first wall part and the second wall part of the base material. The first skin part of the skin material is crimped to the first wall part of the base material so that the planned bending part faces and the second skin part faces the outside of the second wall part. ,
Pressing the second skin part of the skin material with the first skin part crimped onto the first wall part of the base material toward the second wall part of the base material with a third crimping mold part. By doing so, the second skin part is bent at the planned bending part so as to be crimped to the second wall part.
In this way, the skin material is molded so that when the first skin part of the skin material is crimped onto the first wall part of the base material, the second skin part is located at a position that does not interfere with the base material. , the first skin part of the skin material can be crimped onto the first wall part of the base material without the second skin part getting in the way. In addition, when forming the skin material, by continuously or intermittently forming a thin-walled bent portion extending along the boundary between the first skin part and the second skin part, the first part of the base material can be bent. After the first skin part of the skin material is crimped to the wall part of the skin material, the second skin part can be crimped to the second wall part by bending it at the planned bending part. That is, the skin material formed integrally with each of the first wall part of the base material and the second wall part of the base material that has an undercut shape with respect to the direction in which the base material is pressed against the skin material. Since it can be crimped, decorative members with good appearance can be manufactured without creating seams on the surface. In addition, by bending the second skin part at the thin bending portion formed in the skin material, when the second skin part is crimped against the second wall part, the bending of the second skin part can be prevented. The position can be stabilized. Therefore, undulations and wrinkles are less likely to occur at the bent portions of the skin material, and the appearance of the decorative member can be improved.

The second means is
The foam sheet is compressed so that the thickness of the cushion layer at the position where the planned bending part is formed is 1/2 or less of the thickness of the cushion layer in the second skin part, thereby forming the planned bending part. The gist is that.
In this way, by setting the thickness of the cushion layer at the formation position of the planned bending part to 1/2 or less of the thickness of the cushion layer in the second skin part, the second skin part is pressed and the second side wall is formed. When crimping the parts, stress can be effectively concentrated on the parts to be bent, and the appearance of the decorative member can be improved by making it difficult to cause undulations, wrinkles, etc. at the bent parts of the skin material.

The third means is
At the boundary between the first skin part and the second skin part, a plurality of the bent parts are continuously or intermittently formed spaced apart in the direction in which the first skin part and the second skin part are lined up. The gist is to do so.
In this way, by forming a plurality of bent portions spaced apart in the direction in which the first skin part and the second skin part are lined up, the second skin part is pressed and crimped to the second side wall part. When doing so, the second skin part can be smoothly bent from the plurality of planned bending parts, so that undulations, wrinkles, etc. are less likely to occur in the bent parts of the skin material, and the appearance of the decorative member is improved. I can do it. In addition, by forming a plurality of bent portions, the first skin portion and the second wall portion can be connected to each other in a curved manner. The second skin part can be bent by aligning the boundary position of the second skin part with the curved shape of the base material, and the appearance of the decorative member is improved by making it difficult for waving or wrinkles to occur at the bent part of the skin material. It can be made good.

According to the present invention, a skin material can be pressure-bonded to the surface of a base material formed into a complicated shape with good appearance.

FIG. 2 is a schematic explanatory diagram illustrating a manufacturing process for manufacturing a decorative member in cross section, showing a state in which a laminated sheet is placed between a first skin mold part and a second skin mold part of an opened skin mold. . (a) is a schematic cross-sectional view showing the manufacturing process of the decorative member, in which the first skin molding mold part and the second skin molding part of the skin molding mold are closed to form a laminated sheet; , and (b) is a sectional view showing the skin material taken out from the skin mold. (a) is an enlarged view of part A in FIG. 2(b), (b) is a view taken along the line B in FIG. 2(b) is a view taken along line B in FIG. 2(b), showing a state in which concave portions are formed intermittently. FIG. 2 is a schematic explanatory diagram showing a manufacturing process of a decorative member in cross section, in which (a) shows a process in which a base material is attached to a first crimp molding part and a skin material is attached to a second crimp molding part with the crimp mold opened; (b) shows a state in which the first crimping mold part and the second crimping mold part of the crimping mold are closed, and the top skin part and the first side skin part of the skin material are placed on the base material. It shows a state in which it is crimped to the wall and the first side wall. (a) is a schematic explanatory diagram showing a manufacturing process of a decorative member in cross section, in which the first crimping mold part and the second crimping mold part of the crimping mold are closed, and the third crimping molding part is closed. (b) is a cross-sectional view showing the decorative member taken out from the crimping mold, showing a state in which the second side skin part of the skin material is pressed to the second side wall part of the base material by moving from the standby position to the pressing position. It is. FIG. 2 is a schematic perspective view showing a decorative member placed on a vehicle. (a) is a schematic explanatory diagram illustrating a manufacturing process of a decorative member according to a modified example in cross section, in which a second side skin part of a skin material in which a plurality of recessed parts are formed is connected to a second side wall part of a base material; (b) is an enlarged cross-sectional view of a main part of a decorative member in which a plurality of concave portions are formed to extend in a cross direction.

Next, a method for manufacturing a decorative member according to the present invention will be described below with reference to preferred embodiments and the accompanying drawings. In this embodiment, as shown in FIG. 6, a console box installed between front seats (driver's seat and passenger seat) S, S in the cabin at the front of the vehicle will be explained as an example of the decorative member 10. The decorative member 10 may be an instrument panel, a door trim, a pillar garnish, etc., and may be attached to various vehicles such as ships or aircraft, building materials for buildings such as houses, or furniture such as chairs and sofas. Good too. The decorative member 10 of this embodiment has an upper surface where accessories such as the shift lever SL and a storage box are arranged, a side surface located on the front seat side, and a rear surface on the rear seat side of the vehicle. The decorative member 10 is formed into a box shape, and the side surfaces of the decorative member 10 are formed in a design shape that extends to an instrument panel provided at the front of the vehicle compartment.

Further, as shown in FIGS. 5(b) and 6, the decorative member 10 includes a base material 12 forming a skeleton and a skin material 20 decorating the outer surface. are joined with adhesive or the like. This base material 12 includes an upper wall portion 14 forming an upper surface, side wall portions 16 and 18 connected to the side edges of the upper wall portion 14, and a rear wall portion (not shown) connected to the rear edge of the upper wall portion 14. It is formed into a box shape with a downward opening, and has fixing parts for fixing accessories such as the shift lever SL and storage box, and fixing parts for attaching to the vehicle body at required positions on each wall part 14, 16, 18. A fixing portion (none of which is shown) is formed. Note that, in FIG. 5(b), the decorative member 10 is shown upside down.

Here, the side wall parts 16 and 18 of the base material 12 include a first side wall part (first wall part) 16 continuous to the upper surface of the base material 12, and a side wall part facing from the lower end of the first side wall part 16. 16 (first side wall portion 16) side and a second side wall portion (second wall portion) 18 extending in a bent manner toward the side of the first side wall portion 16 (first side wall portion 16). That is, the base material 12 has a generally U-shaped cross section with the upper wall portion 14 and the side wall portions 16 and 18, and has second side walls extending from the lower end of each first side wall portion 16 so as to be close to each other. A portion 18 is provided (see FIG. 5(b) and FIG. 6).

Similarly, the skin material 20 includes a top skin part 22 that forms an upper surface and covers the top wall part 14 of the base material 12, and a top skin part 22 that extends to the side edges of the top skin part 22 and covers the side wall parts 16 and 18 of the base material 12. It includes side skin parts 24 and 26, and a rear skin part (not shown) that extends from the rear edge of the top skin part 22 and covers the rear wall part of the base material 12. More specifically, the side surface skin portions 24 and 26 of the skin material 20 are a first side surface skin portion (first skin portion) 24 that continues to the top surface skin portion 22 and covers the first side wall portion 16 of the base material 12. , a second side wall portion 18 extending from the lower end of the first side surface skin portion 24 so as to be bent toward the opposing side surface skin portion 24 (first side surface skin portion 24) side and covering the second side wall portion 18 of the base material 12; It is formed into a bent shape having a side skin part (second skin part) 26. That is, the entire outer surface of the base material 12 is covered with the skin material 20.

Here, the base material 12 is a relatively hard resin molded product having a rigidity capable of maintaining the shape of the decorative member 10, and is made of, for example, polypropylene (PP), polyethylene (PE), acrylonitrile-butadiene-styrene resin (ABS), etc. ), thermoplastic resin such as polycarbonate/acrylonitrile-butadiene-styrene resin (PC/ABS).

Further, the skin material 20 has a multilayer structure including a skin layer 28 constituting the front side of the decorative member 10 and a cushion layer 30 provided on the back side of the skin layer 28 and joined to the base material 12. There is. The skin layer 28 is made of a flexible solid synthetic resin, and the cushion layer 30 is made of an elastic foam. The skin layer 28 in the example is formed from a thermoplastic elastomer. Thermoplastic elastomers forming the skin layer 28 include olefin elastomers (TPO), vinyl chloride elastomers, and styrene elastomers, among which olefin resins such as polypropylene (PP) and ethylene-propylene rubber (EPDM) are used. Olefin elastomers obtained by dispersing rubber such as , EPM) are preferred. The cushion layer 30 may be made of foamed olefin materials such as polyethylene or polypropylene, polyurethane, or styrene, among which polyethylene foam (PEF) is preferred.

Next, a method for manufacturing the decorative member 10 will be explained. This decorative member 10 has a molding process of molding the base material 12, a skin molding process of molding the skin material 20, and a crimping process of crimping and joining the base material 12 and the skin material 20. . Here, in the molding process, the second side wall portion 18 described above is formed into a box shape with an undercut shape by a conventionally known molding method such as injection molding using an injection mold (not shown) having a slide core. The base material 12 can be integrally molded. Note that the molding method for the base material 12 does not necessarily have to be integral molding by injection molding, but after molding each part such as the top wall 14, side walls 16, 18, and rear wall separately, adhesives, clips, etc. It may be assembled using a fixture.

In the skin forming step, as shown in FIG. 1, the skin sheet 42 forming the skin layer 28 of the skin material 20 and the foam sheet 44 forming the cushion layer 30 are held by a holding means 46 in an overlapping state. The skin sheet 42 is a sheet-like member made of the above-mentioned thermoplastic elastomer, and the foam sheet 44 is a sheet-like member made of foam. Then, the laminated sheet 40 consisting of the skin sheet 42 and the foamed sheet 44 held by the holding means 46 is heated and softened by a heating means such as a heater (not shown).

Next, the softened skin material 20 is set in the opened skin mold 50. This skin mold 50 includes a first skin mold part 52 and a second skin mold part 58 that can be opened and closed relatively. The laminated sheet is held between the skin mold part 58 by the holding means 46 such that the foam sheet 44 faces the first skin mold part 52 and the skin sheet 42 faces the second skin mold part 58. 40 (see Figure 1).

This first skin mold part 52 has a first molding surface 54a for molding the top skin part 22, a second molding surface 54b for molding the first side skin part 24, and a second molding surface 54b for molding the second side skin part 26. The second skin mold part 58 is formed as a male mold with a convex molding part 54 having a third molding surface 54c, and when the mold is closed, each of the first skin mold parts 52 It is formed as a female mold having a concave molding surface 60 spaced apart from the molding surfaces 54a, 54b, 54c by the thickness of the skin material 20.

As shown in FIG. 2(a), with the laminated sheet 40 disposed between the first skin mold part 52 and the second skin mold part 58, the first skin mold part 52 and the second skin mold part By moving the skin mold part 58 relatively close to each other and closing the mold, the space between each molding surface 54a, 54b, 54c, 60 of the first skin mold part 52 and the second skin mold part 58 is The skin material 20 is formed by shaping the laminated sheet 40 into a shape that matches the cavity to be formed.

Here, an intake hole 62 is formed in the second skin mold part 58 so as to open at a predetermined position on the molding surface, and the molding surface of the second skin mold part 58 is opened through the intake hole 62. A suction device 64 is provided to suck air from the inner space. That is, when the first skin mold part 52 and the second skin mold part 58 are moved relatively close to each other and the molds are closed, the air intake device 64 is operated. While vacuuming the skin sheet 42 through the suction holes 62, the laminated sheet 40 is pressed from the foam sheet 44 side by the molding section 54 of the first skin mold section 52, thereby removing the vacuum-suctioned skin sheet. 42 is in close contact with the molding surface 60 of the second skin mold section 58, and the three-dimensional shape matches the shape of each molding surface 54a, 54b, 54c, 60 of the first skin mold section 52 and the second skin mold section 58. The laminated sheet 40 is shaped, and the softened skin sheet 42 and foamed sheet 44 are fused and bonded under pressure. Thereafter, after opening the first skin mold part 52 and the second skin mold part 58 and taking out the molded product in which the skin sheet 42 and the foamed sheet 44 are joined, the portion held by the holding means 46 is removed. The skin material 20 is obtained by removing unnecessary portions including the cutter using a cutting means such as a cutter (see FIG. 2(b)).

Further, as shown in FIG. 1, the second molding surface 54b and the third molding surface 54c of the first skin molding part 52 are formed to be located on the same plane. That is, the skin material 20 molded by the skin mold 50 is formed such that the first side surface skin portion 24 and the second side surface skin portion 26 are located on the same plane in the form of a flat plate, and the inside of the skin material 20 ( When the base material 12 faces the cushion layer 30 side), the upper wall part 14 and the first side wall part 16 of the base material 12 are in contact with the upper surface skin part 22 and the first side skin part 24 of the skin material 20. On the other hand, the second side surface skin part 26 of the skin material 20 is located on the outside of the second side wall part 18 of the base material 12 with a space therebetween (see FIG. 4(b)). In this way, when the skin material 20 is pressure-bonded to the base material 12, the skin material 20 is molded so that the second side surface skin portion 26 is located at a position that does not interfere with the base material 12.

Further, as shown in FIG. 1, at the boundary between the second molding surface 54b and the third molding surface 54c in the first skin mold part 52, there is a part that protrudes outward from the second molding surface 54b and the third molding surface 54c. A convex portion 56 is provided. That is, when molding the skin material 20 by closing the first skin mold part 52 and the second skin mold part 58, the foamed sheet 44 of the laminated sheet 40 is inserted into the convex part of the first skin mold part 52. 56, a thin concave portion (portion to be bent) 32 is formed at the boundary between the first side surface skin portion 24 and the second side surface skin portion 26 (FIG. 2(b)). reference). Here, in this embodiment, a convex part 56 having a triangular cross section is formed in the first skin mold part 52, and the foam sheet 44 is compressed by the convex part 56 to form a groove having a V-shaped cross section. A thin recessed portion 32 is formed.

Here, as shown in FIG. 3(a), the convex part 56 of the first skin mold part 52 has a thickness T1 of the cushion layer 30 at the formation position of the concave part 32 formed by the convex part 56. , it is preferable to form the first side surface skin part 24 and the second side surface skin part 26 with a protrusion height that is 1/2 or less of the thickness T2 of the cushion layer 30 forming the first side surface skin part 24 and the second side surface skin part 26. In this way, the thickness T1 of the cushion layer 30 at the position where the concave portion 32 is formed is equal to or less than 1/2 of the thickness T2 of the cushion layer 30 forming the first side surface skin portion 24 and the second side surface skin portion 26. By molding the skin material 20 in this way, the stress when pressing the second side surface skin part 26 in the crimping process can be effectively concentrated at the formation position of the recessed part 32, and the stress can be effectively concentrated at the formation position of the recessed part 32. Since the second side surface skin part 26 can be bent and the second side surface skin part 26 can be quickly bent, there is an advantage that manufacturing efficiency can be improved. On the other hand, when the skin material 20 is formed so that the thickness T1 exceeds 1/2 of the thickness T2, the stress when pressing the second side surface skin part 26 in the crimping process is easily dispersed, and the second side surface skin part 26 is easily dispersed. This tends to lead to a decrease in manufacturing efficiency, such as carefully bending the side surface skin portion 26 of the case.

Further, the convex portion 56 may be formed continuously along the boundary between the second molding surface 54b and the third molding surface 54c, or the convex portion 56 may be formed continuously along the boundary between the second molding surface 54b and the third molding surface 54c. It may be formed intermittently along. By forming the convex portions 56 continuously, the concave portions 32 are formed continuously along the boundary between the first side surface skin portion 24 and the second side surface skin portion 26, as shown in FIG. 3(b). By forming the convex portions 56 intermittently, as shown in FIG. Recessed portions 32 can be formed intermittently along the length. Here, when the recessed portions 32 are formed continuously, the second side skin portion 26 can be effectively bent at the formation position of the linearly extending recessed portions 32, and the recessed portions 32 can be bent. When formed intermittently, the cushion layer 30 remains at the bending position where the second side surface skin part 26 is bent with respect to the first side surface skin part 24, so that deterioration in the tactile sensation can be suppressed.

In the crimping process, as shown in FIGS. 4 and 5, the base material 12 molded in the molding process and the skin material 20 molded in the skin molding process are attached to an opened crimping mold 70. By closing the mold, the base material 12 and the skin material 20 are crimped and joined. Here, this crimping mold 70 is configured to be relatively openable and closable, and includes a first crimping part 72 that can hold the base material 12, a second crimping part 74 that can hold the skin material 20, and a second crimping part 74 that can hold the skin material 20. It includes a third compression molding section 76 that is movable in a direction intersecting the opening/closing direction (crimping direction) of the first compression molding section 72 and the second compression molding section 74 .

Then, as shown in FIG. 4(a), the base material 12 is coated with an adhesive on the joint surfaces (the surfaces of the upper wall part 14 and side walls 16 and 18) to which the skin material 20 is joined, and the joint surface is 2. Attach the skin material 20 to the first crimp molding part 72 so that it faces toward the crimp molding part 74, and attach the skin material 20 to the second crimp molding part 74 so that the cushion layer 30 faces the first crimp molding part 72. The base material 12 is attached so as to face above the opening formed between the side skin parts 24 and 26 (the first side skin part 24 and the second side skin part 26) of the skin material 20. Here, with the skin material 20 attached to the second pressure molded part 74, the third pressure molded part 76 is located outside the second side surface skin part 26 of the skin material 20. The third compression molded part 76 has a standby position located outside the second side surface skin part 26 (see FIG. 4(b)) and a position where it moves close to the second side skin part 26 from the standby position and moves to the base. It is movable to a pressing position (see FIG. 5(a)) where the second side skin portion 26 is pressed against the second side wall portion 18 of the material 12.

Then, as shown in FIG. 4(b), with the base material 12 attached to the first compression molding part 72 and the skin material 20 being attached to the second compression molding part 74, the first compression molding part 72 and The mold is closed by moving the second compression molding part 74 relatively close to each other. Here, since the skin material 20 is formed so that the second side surface skin part 26 is located at a position that does not interfere with the base material 12 when the skin material 20 is crimped onto the base material 12, the side surface of the skin material 20 is The base material 12 moves to the inside surrounded by the side skin parts 24 and 26 through the opening formed by the skin parts 24 and 26 (the first side skin part 24 and the second side skin part 26).

Thereby, the upper wall part 14 and the first side wall part 16 of the base material 12 to which the adhesive has been applied are pressed against the cushion layer 30 of the upper surface skin part 22 and the first side skin part 24 of the skin material 20, The top skin part 22 and the first side skin part 24 are crimped onto the top wall part 14 and the first side wall part 16 . In this state, the concave portion 32 of the skin material 20 faces the boundary between the first side wall portion 16 and the second side wall portion 18 of the base material 12, and the concave portion 32 of the skin material 20 faces the boundary between the first side wall portion 16 and the second side wall portion 18 of the base material 12. A second side skin portion 26 of the skin material 20 faces a position spaced apart from the outside (see FIG. 4(b)).

Then, as shown in FIG. 5(a), the first compression molded part 72 and the second compression molded part 74 are closed (the first side skin part 24 is attached to the first side wall part 16 of the base material 12). is pressed), move the third pressure forming part 76 from the standby position to the pressing position, and the third pressure forming part 76 presses the second side skin part 26 of the skin material 20 onto the second side skin part 26 of the base material 12. Press toward the side wall portion 18. At this time, the stress generated when the second side surface skin part 26 is pressed by the third compression molding part 76 is applied to the concave part 30 of the skin material 20 facing the boundary between the first side wall part 16 and the second side wall part 18. By concentrating on this, the second side surface skin portion 26 approaches the second side wall portion 18 of the base material 12 so as to be bent at the position where the concave portion 32 is formed, and the second side surface skin portion 26 It is crimped onto the side wall portion 18 of No. 2.

After the second side surface skin part 26 is crimped to the second side wall part 18, the third crimping part 76 is moved from the pressing position to the standby position, and the first crimping part 72 and the second crimping part 74 are moved. The decorative member 10 with the skin material 20 crimped onto the base material 12 is obtained by opening the mold.

In this way, by forming the first side skin part 24 and the second side skin part 26 to be located on the same plane when molding the skin material 20, the upper wall part 14 and the first side skin part of the base material 12 are formed. When the upper skin part 22 and the first side skin part 24 of the skin material 20 are crimped onto the side wall part 16, the second side skin part 26 can be positioned at a position where it does not interfere with the base material 12. By positioning the second side surface skin portion 26 at a position where it does not interfere with the base material 12 when the skin material 20 is crimped onto the base material 12, when the compression mold 70 is closed, the second side surface portion 26 The top skin part 22 and the first side skin part 24 of the skin material 20 can be crimped onto the top wall part 14 and the first side wall part 16 of the base material 12 without the skin part 26 getting in the way.

Further, when the skin material 20 is molded, a thin concave portion 32 is formed continuously or intermittently so as to extend along the boundary between the first side surface skin portion 24 and the second side surface skin portion 26. For this reason, after the upper wall portion 14 and first side wall portion 16 of the base material 12 are crimped to the upper surface skin portion 22 and the first side surface skin portion 24 of the skin material 20, the second side surface skin portion 26 is attached to the concave portion. It can be crimped to the second side wall portion 18 by bending it at 32 . For this reason, the side wall portions 16 and 18 of the base material 12 are connected to the first side wall portion 16 and a second side wall portion 16 that extends from the lower end of the first side wall portion 16 so as to be bent toward the opposing first side wall portion 16 side. Even when the side wall portion 18 is formed into a bent shape, the first side surface skin portion 24 is crimped to the first side wall portion 16 and an undercut is formed in the direction of crimping of the base material 12 to the skin material 20. By crimping the second side surface skin part 26 to the second side wall part 18 which becomes the shape, a skin material integrally formed on each of the first side wall part 16 and the second side wall part 18 is formed. Since the decorative member 10 can be crimped, the decorative member 10 can have a good appearance without any seams or the like on the surface.

Furthermore, by forming the thin concave portion 32 in the skin material 20 so as to be located at the boundary between the first side surface skin portion 24 and the second side surface skin portion 26, the second side surface skin portion 76 can be Stress generated when the skin portion 26 is pressed toward the second side wall portion 18 can be concentrated in the concave portion 32 . Therefore, the second side skin part 26 can be accurately bent at the boundary with the first side skin part 24, and the second side skin part 26 can be bent with respect to the second side wall part 18. The bending position of the second side surface skin portion 26 during crimping can be stabilized. That is, even if a bending line is formed in the skin material 20 due to the bending of the second side surface skin part 26, the bending line can be formed linearly in accordance with the formation position of the concave part 32, and the skin material Waving and wrinkles are less likely to occur in the bent portion of the decorative member 10, and the appearance of the decorative member 10 can be improved.

Further, by setting the thickness T1 of the cushion layer 30 at the formation position of the concave portion 32 to 1/2 or less of the thickness T2 of the cushion layer 30 at the first side surface skin portion 24 and the second side surface skin portion 26, When pressing the second side surface skin portion 26 to press the second side surface skin portion 26 to the second side wall portion 18, stress can be more effectively concentrated at the formation position of the recessed portion 32. For this reason, by setting the thickness T1 to 1/2 or less of the thickness T2, when the second side skin part 26 is pressed and crimped to the second side wall part 18, the waving at the bent part of the skin material 20 can be avoided. The appearance of the decorative member 10 can be improved by more effectively preventing the occurrence of wrinkles.

(Example of change)
The present invention is not limited to the embodiment described above, and can be modified as follows, for example.
(1) Although the second side wall portion 18 is formed to be bent with respect to the first side wall portion 16 of the base material 12, the second side wall portion 18 is curved with respect to the first side wall portion 16. The second side wall portion 18 itself may be formed in a curved shape.
(2) Also, although the second side wall portion 18 is provided on each of both first side wall portions 16 of the base material 12, the second side wall portion 18 is provided on at least one of the first side wall portions 16. You can do it like this. That is, it has first side wall portions 16 facing each other and extends from the rear end edge of at least one of the first side wall portions 16 in the crimping direction in which the skin material 20 is crimped toward the other first side wall portion 16 side. The integrally formed skin material 20 can be bonded by pressure bonding to each wall portion 14, 16, 18 of the base material 12 formed in a shape having the second side wall portion 18.
(3) Although the concave portion 32 as a planned bending portion is formed in the skin material 20 so as to form a V-shaped groove, the present invention is not limited to this. If the cushion layer 30 forming the first side surface skin part 24 and the second side surface skin part 26 is formed to be thinner, the recessed part 32 is formed in the form of a square groove or an arc groove. be able to. Note that, as in the embodiment, by forming the concave portion 32 to form a V-shaped groove, there is an advantage that stress when bending the second side surface skin portion 26 can be easily concentrated in one place. .
(4) In the embodiment, a single concave portion 32 (concave portion 32) is formed at the boundary between the first side surface skin portion 24 and the second side surface skin portion 26, but as shown in FIG. As shown in FIG. 7, a plurality of (two in FIG. 7(a)) concave portions 32 (concave portions 32) are provided at the boundary between the first side surface skin portion 24 and the second side surface skin portion 26. The side surface skin portion 24 and the second side surface skin portion 26 may be formed apart from each other in the direction in which they are lined up. Note that the plurality of concave portions 32 can be formed on the skin material 20 by forming a plurality of convex portions 56 on the first skin mold portion 52 .
That is, by forming a plurality of concave portions 32 spaced apart in the direction in which the first side surface skin portion 24 and the second side surface skin portion 26 are lined up, the second side surface skin portion 26 is pressed and the second side surface skin portion 26 is pressed. When crimping the side wall portion 18, the second side surface skin portion 26 can be smoothly bent starting from each concave portion 32, so that when the second side surface skin portion 26 is bent, the bent portion of the skin material 20 It is possible to improve the appearance of the decorative member 10 by making undulations and wrinkles less likely to occur. Furthermore, by forming a plurality of concave portions 32, the first side wall portion 16 and the second side wall portion 18 may be connected via the curved portion 80 as shown in FIG. 7(a), Even for a base material 12 in which the second side wall part 18 itself is formed into a curved surface shape, the second side skin part 26 can be bent along the curved shape of the base material 12, and the skin material 20 The appearance of the decorative member 10 can be improved by effectively preventing the occurrence of undulations and wrinkles at the bent portions of the decorative member 10.
(5) When forming a plurality of concave portions 32 in the skin material 20, each concave portion 32 may be formed with the same shape and depth, or the shape and depth of each concave portion 32 may be different. It may be possible to do so. That is, when the first side wall portion 16 and the second side wall portion 18 are formed so as to be connected via a curved portion, or when the second side wall portion 18 itself is formed into a curved surface shape, the curved surface portion By changing the shape and depth of each concave portion 32 according to the curvature, the bent portion of the skin material 20 when bending the second side surface skin portion 26 along the curved shape of the base material 12 It is possible to effectively prevent the occurrence of ripples and wrinkles.
(6) When forming a plurality of recessed portions 32 in the skin material 20, each recessed portion 32 may be formed to extend in parallel or may be formed to extend in a cross direction. . For example, as shown in FIG. 7(b), by forming a plurality of concave portions 32 to extend in the cross direction, the first side wall portion 16 and the second side wall portion 18 are connected to each other via the curved portion 80. In the case where the second side wall portion 18 itself is formed into a curved surface shape, the curved surface portion is formed into a conical shape with different curvatures in the longitudinal direction (the axial direction of the curved surface). Even in this case, it is possible to effectively prevent the occurrence of waving or wrinkles in the bent portion of the skin material 20 when the second side surface skin portion 26 is bent to follow the curved shape of the base material 12.
(7) In the embodiment, the skin sheet 42 and the foamed sheet 44 were shaped and fused together in the skin forming process, but the skin material 20 in which the skin sheet 42 and the foamed sheet 44 were bonded in advance was used. , a skin molding step may be performed.

12 base material, 16 first side wall part (first wall part), 18 second side wall part (second wall part)
20 Skin material, 24 First side surface skin part (first skin part)
26 second side skin part (second skin part), 28 skin layer, 30 cushion layer 32 concave part (planned bending part), 40 laminated sheet, 42 skin sheet, 44 foam sheet 52 first skin mold part, 56 convex part, 58 second skin mold part 72 first pressure molding part, 74 second pressure molding part, 76 third pressure molding part

Claims (3)

A second wall having opposing first wall portions and extending from the rear end edge in the crimping direction for crimping the skin material on at least one of the first wall portions toward the other first wall portion. A method for producing a decorative member, the method comprising: pressing a skin material having a cushion layer on the back side of the skin layer onto a base material formed to have a cushion layer;
A laminated sheet in which a skin sheet forming the skin layer and a foam sheet forming the cushion layer are stacked is placed so that the foam sheet faces a first skin mold part and is relative to the first skin mold part. arranging the skin sheet so as to face a second skin mold part that can be opened and closed;
By closing the first skin mold part and the second skin mold part, the first skin part to be laminated on the first wall part of the base material and the second wall part of the base material The skin material having a second skin part to be laminated is located at a position where the second skin part does not interfere with the base material when the first skin part is crimped onto the first wall part. In addition to forming the
When molding the skin material, by compressing the foam sheet with a convex portion formed to protrude from the molding surfaces of the first skin part and the second skin part in the first skin mold part. , continuously or intermittently forming a thin-walled portion to be bent so as to extend along the boundary between the first skin portion and the second skin portion;
By closing the first crimping mold part that held the base material and the second crimping mold part that held the skin material, the crimping mold part holds the base material at the boundary between the first wall part and the second wall part of the base material. The first skin part of the skin material is crimped to the first wall part of the base material so that the planned bending part faces and the second skin part faces the outside of the second wall part. ,
Pressing the second skin part of the skin material with the first skin part crimped onto the first wall part of the base material toward the second wall part of the base material with a third crimping mold part. By doing so, the second skin part is bent at the planned bending part and crimped to the second wall part.
A method for manufacturing a decorative member, characterized by: The foam sheet is compressed so that the thickness of the cushion layer at the position where the planned bending part is formed is 1/2 or less of the thickness of the cushion layer in the second skin part, thereby forming the planned bending part. 2. The method for manufacturing a decorative member according to claim 1. At the boundary between the first skin part and the second skin part, a plurality of the bent parts are continuously or intermittently formed spaced apart in the direction in which the first skin part and the second skin part are lined up. The method for manufacturing a decorative member according to claim 1 or 2, characterized in that:

Images