JP7393676B2 - Decorative member manufacturing method - Google Patents

Description

The present invention relates to a decorative member manufacturing method for manufacturing a decorative member in which a decorative material is bonded to the surface of a base material.

For vehicle interior parts such as door trims and instrument panels, decorative materials, including natural wood veneers, are partially laminated onto the surface of a base material made of thermoplastic resin, etc., to give a sense of luxury. It is being said.

For example, in Patent Document 1, with a decorative material placed at the boundary between the two housings, the two housings are butted against each other to create a lower space sealed by the lower housing and the decorative material, and a lower space sealed by the lower housing and the upper housing. A step of forming an upper space sealed by the body and the decorative material, a step of forming the decorative material into a predetermined shape while the lower space has a lower pressure than the upper space, and a step of molding the decorative material into a base material. A method for manufacturing a decorative panel is disclosed, which includes the step of laminating the decorative panel onto the surface of the decorative panel.

International Publication No. 2017/217416

In the decorative panel manufacturing method described in Patent Document 1, in order to make the decorative material follow the shape of the base material in the step of molding the decorative material into a predetermined shape, a thermoplastic film or the like is molded onto the adhesive layer. Sometimes parts were used. In the prior art, by using a molded member for the adhesive layer, the weight and thickness of the decorative member increased.

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to enable the decorative material to follow the shape of the base material when laminating the decorative material to the base material, and to It is an object of the present invention to provide a method for manufacturing a decorative member in which an increase in the weight of the member is suppressed.

The above-mentioned problem is a method for manufacturing a decorative member that includes a decorating material on the surface of a base material, which includes a step of arranging the decorating material at a position facing the surface of the base material, and a step of disposing the decorating material at a position facing the surface of the base material, and a step of disposing the decorating material at a position facing the surface of the base material. A flexible molded member is placed at the boundary between one housing and a second housing that is open on the side of the first housing, and the first housing and the second housing are butted against each other. , forming a first space sealed by the first casing and the molded member, and a second space sealed by the second casing and the molded member; and the first space. a step of molding the decorative material provided in the first space into a predetermined shape via the molding member in a state where the pressure is lower than that of the second space; laminating on the surface of a base material, wherein the decorating member includes an elastic layer between the decorating material and the base material , and the first space and the second space are separated from each other. In the forming step, the decorating material and the molded member are arranged with a gap between them without contacting each other in the butting direction of the first casing and the second casing, and the decorating material is placed at a predetermined distance. The problem is solved by a decorative member manufacturing method characterized in that in the step of molding into the shape, the decorative member is pressed against the molded member by a movable mechanism .
According to the above-described decorative member manufacturing method, when laminating the decorative material to the base material, it is possible to make the decorative material follow the shape of the base material using the flexible molded member, and the molding Since the member is separate from the decorating member, an increase in the weight of the decorating member is suppressed.
In addition, in the above structure, by having an elastic layer between the decorative material and the base material, the shape of the decorative material after being laminated to the base material becomes appropriate, so that the design property is improved. .

The above-mentioned problem is also a method for manufacturing a decorative member that includes a decorative material on the surface of a base material, which includes a step of arranging the decorative material at a position facing the surface of the base material, and a step of disposing the decorative material at a position facing the surface of the base material; A flexible molded member is arranged at the boundary between the first casing and a second casing having an opening on the side of the first casing, and the first casing and the second casing are butted together. forming a first space sealed by the first casing and the molded member, and a second space sealed by the second casing and the molded member; molding the decorative material provided in the first space into a predetermined shape via the molding member in a state where the pressure in the space is lower than that in the second space; laminating on the surface of the base material, the base material and the decorative material are supported by a support jig, at least a part of the support jig has flexibility, and the first In the step of forming the space and the second space, the decorating material and the molded member are spaced apart from each other without coming into contact with each other in the direction in which the first casing and the second casing are brought into contact with each other. The problem is solved by a method for manufacturing a decorative member , characterized in that in the step of arranging and molding the decorative material into a predetermined shape, the decorative material is pressed against the molded member by a movable mechanism .
In the above configuration, since the base material and the decorative material are appropriately supported, it becomes possible to efficiently bond the decorative material to the base material.
In addition, in the above configuration, since the supporting jig is deflected, the followability when the molded member is deformed is improved, so that the decorative material can better follow the surface shape of the base material.

Moreover, in the above-described decorative member manufacturing method, the decorative material is preferably bonded to the surface of the base material using an air-permeable adhesive.
In the above configuration, since air is prevented from remaining between the decorating material and the base material, the generation of air pockets is suppressed.

Moreover, in the above-mentioned decorative member manufacturing method, the molded member is preferably an elastic body.
In the above configuration, since the molded member is an elastic body, it is easy to extend, so that it is possible to efficiently make the decorative material follow the shape of the base material.

Moreover, in the above-mentioned decorative member manufacturing method, the molded member is preferably formed of silicone rubber.
In the above configuration, since the molded member is made of silicone rubber, it does not harden even when heat is applied, so it can be used repeatedly.

Further, in the above method for manufacturing a decorative member, the decorating material includes a resin-impregnated veneer, a breathable layer, and an adhesive layer that adheres to the base material, and the breathable layer is formed of the resin-containing veneer. and the base material.
In the above configuration, by arranging the breathable layer between the resin-containing veneer and the base material, generation of air pockets is suppressed.

Moreover, in the above-described decorative member manufacturing method, it is preferable that the decorative material and the elastic layer have a larger surface area than the base material.
With the above configuration, it is possible to efficiently bond the decorative material and the elastic layer to the base material.

Moreover, in the above-described decorative member manufacturing method, the decorative material is preferably formed thinner than the elastic layer.
In the above configuration, since the decorative material is formed thinner than the elastic layer, it is possible to deform the decorative material by reducing pressure while retaining the elasticity of the elastic layer.

Further, in the above-mentioned method for manufacturing a decorative member, before the step of arranging the decorative material at a position facing the surface of the base material, the step of applying a surface protective layer to the surface of the decorative material may be further performed. Good to have.
In the above configuration, a surface protective layer is coated on the surface of the decorative material before the decorative material is formed into a predetermined shape. The coating work of the surface protective layer becomes easier than when applying the surface protective layer. As a result, it leads to a reduction in manufacturing man-hours.

Moreover, in the above-described decorative member manufacturing method, the decorative member further includes a surface protective layer on the surface of the decorative material, and the surface protective layer has a glass transition temperature of 66° C. or higher and 135° C. or lower. The surface protective layer has a thickness of 10 μm or more and 40 μm or less, and the total thickness of the decorating material and the surface protective layer is 0.3 mm or more. It is preferable that the thickness is 1.5 mm or less.
In the above configuration, by optimizing the resin material that is the main component of the surface protection layer, the glass transition temperature of the resin material, and the thickness of the surface protection layer, the followability of the surface protection layer can be improved in manufacturing the decorative member. It is possible to achieve both weather resistance and improve moldability.

Further, in the above-mentioned method for manufacturing a decorative member, the decorative member has a three-dimensional structure, and the corner portion of the decorative material bonded to the surface of the base material has a corner portion. It is preferable that a rounded corner R portion is formed and the radius of curvature of the corner R portion is 0.5 mm or more.
In the above configuration, since a corner R portion with a radius of curvature of 0.5 mm or more is formed at the corner of the decorative member, the moldability of the decorative member can be improved (cracking during molding can be suppressed).

Further, in the above method for manufacturing a decorative member, the surface protective layer contains the acrylic resin and a pigment, and the content of the acrylic resin is 50 to 50% based on the total mass of the surface protective layer. It is preferable that the content of the pigment is 90% by mass and the content of the pigment is 1 to 15% by mass.
Further, the surface protection layer further contains a weather resistance improver for improving the weather resistance of the decorative member, and the content of the weather resistance improver is 1% relative to the total mass of the surface protection layer. It is preferable that the amount is 10% by mass.
With the above configuration, by optimizing the content of the acrylic resin, pigment, and/or weather resistance improver, it is possible to manufacture a decorative member with improved appearance and improved weather resistance. .

According to the decorative member manufacturing method of the present invention, when laminating the decorative material to the base material, it is possible to make the decorative material follow the shape of the base material using the flexible molded member, and Since the molded member is separate from the decorative member, an increase in the weight of the decorative member is suppressed.
Furthermore, according to the decorative member manufacturing method of the present invention, air remains between the decorative material and the base material, and thus the generation of air pockets is suppressed.
Further, according to the method for manufacturing a decorative member of the present invention, since the molded member is an elastic body, it is easy to extend, so that it is possible to efficiently make the decorative material follow the shape of the base material.
Further, according to the method for manufacturing a decorative member of the present invention, since the molded member is made of silicone rubber, it does not harden even when heated, so it can be used repeatedly.
Moreover, according to the decorative member manufacturing method of the present invention, the formation of air pockets is suppressed by arranging the breathable layer between the resin-containing veneer and the base material.
Further, according to the method for manufacturing a decorative member of the present invention, by having an elastic layer between the decorative material and the base material, the shape of the decorative material after being laminated to the base material is appropriate. Therefore, the design quality is improved.
Moreover, according to the decorative member manufacturing method of the present invention, it becomes possible to efficiently bond the decorative material and the elastic layer to the base material.
Furthermore, according to the method for manufacturing a decorative member of the present invention, since the decorative material is formed thinner than the elastic layer, it is possible to deform the decorative material by reducing pressure while retaining the elasticity of the elastic layer. Become.
Moreover, according to the decorative member manufacturing method of the present invention, the base material and the decorative material are appropriately supported, so that it becomes possible to efficiently bond the decorative material to the base material.
Furthermore, according to the method for manufacturing a decorative member of the present invention, the support jig is bent, which improves the followability when the molded member is deformed, so that the decorative material can more appropriately follow the shape of the base material. Become something.
Furthermore, according to the method for manufacturing a decorative member of the present invention, the work of applying a surface protective layer becomes easier than when a surface protective layer is applied to the surface of a decorative material having a predetermined shape. As a result, it leads to a reduction in manufacturing man-hours.
In addition, according to the method for manufacturing a decorative member of the present invention, by optimizing the resin material that is the main component of the surface protective layer, the glass transition temperature of the resin material, and the thickness of the surface protective layer, the decorative member can be manufactured. In manufacturing, it is possible to achieve both conformability and weather resistance of the surface protective layer, and improve moldability.
Further, according to the method for manufacturing a decorative member of the present invention, since a corner R portion with a radius of curvature of 0.5 mm or more is formed at the corner of the decorative member, it is possible to improve the moldability of the decorative member. (Cracking during molding can be suppressed).
Furthermore, according to the method for manufacturing a decorative member of the present invention, by optimizing the content of the acrylic resin, pigment, and/or weather resistance improver, the appearance is further ensured and the weather resistance is improved. Decorative members can be manufactured.

It is a figure showing an example of the door trim provided with the decoration panel manufactured by the decoration member manufacturing method concerning this embodiment. It is a perspective view showing the composition of a decoration panel. 3 is a sectional view taken along line AA in FIG. 2. FIG. 4 is a sectional view taken along line BB in FIG. 3. FIG. It is a flow diagram of a decorative panel manufacturing method concerning this embodiment. It is a figure explaining a decorative panel manufacturing method. It is a figure explaining a decorative panel manufacturing method. It is a figure explaining a decorative panel manufacturing method. It is a figure explaining a decorative panel manufacturing method. It is a figure explaining a decorative panel manufacturing method. It is a figure explaining a decorative panel manufacturing method. It is a figure explaining a decorative panel manufacturing method. It is a figure explaining a decorative panel manufacturing method. It is a figure explaining the support jig concerning the 1st modification. It is a figure explaining the support jig concerning the 1st modification. It is a figure explaining the support jig concerning the 2nd modification. It is a figure explaining the support jig concerning the 3rd modification. It is a figure explaining the support jig concerning the 4th modification. It is a figure explaining the support jig concerning the 5th modification. It is a typical sectional view showing the composition of the decoration panel concerning a modification. It is a typical sectional view showing the composition of the decoration panel concerning a 2nd embodiment. 22 is a sectional view taken along the line CC in FIG. 21. FIG. It is a flow chart of a decorative panel manufacturing method concerning a 2nd embodiment.

Hereinafter, with reference to FIGS. 1 to 23, a method for manufacturing a decorative member according to an embodiment of the present invention (hereinafter referred to as the present embodiment) will be described by exemplifying a method for manufacturing a decorative panel. In this embodiment, the decorative panel is a member used as a part of interior parts such as a door trim or an instrument panel of a vehicle, for example.

Note that the embodiments described below are merely examples for facilitating understanding of the present invention, and do not limit the present invention. That is, the shapes, dimensions, arrangement, etc. of the members described below may be changed and improved without departing from the spirit of the present invention, and it goes without saying that the present invention includes equivalents thereof.

<Decorative panel P>
1 to 4 show a decorative panel P as an example of a decorative member manufactured by the decorative panel manufacturing method according to the present embodiment. As shown in FIG. 1, which shows a door trim D provided on the indoor side surface of a door of a passenger car, the decorative panel P is a decorative member provided at the upper trim portion of the door trim D. The door trim D decorates the inside of the vehicle door, and is composed of a group of parts attached to a door inner panel (not shown).

As shown in FIGS. 2 to 4, the decorative panel P has a curved cross section. The decorative panel P is constructed by laminating, on the panel base material 1, a decorative material 2 including a resin-impregnated veneer 2A obtained by processing a veneer, which is a board material obtained by thinly slicing wood. According to the decorative panel manufacturing method according to the present embodiment, the decorative panel P is produced by laminating the decorative material 2 including a veneer suitably to the panel base material 1 having such a curved three-dimensional shape. can be manufactured.

As shown in FIGS. 3 and 4, the decorative panel P is a decorative member that includes a decorative material 2 on the surface of a panel base material 1. The panel base material 1 may be, for example, a member made of resin manufactured by injection molding or the like.

The decorative material 2 includes a resin-impregnated veneer 2A, a breathable layer 2B, and an adhesive layer 2C that adheres to the panel base material 1. The resin-impregnated veneer 2A is a member obtained by impregnating a veneer (for example, a thin board of natural wood) with a resin (for example, a synthetic resin). In this way, by containing the resin in the conduits and fibers inside the veneer, stress concentration inside the veneer can be alleviated.

The breathable layer 2B is a breathable backing material made of a nonwoven fabric, a cotton sheet, or the like and placed between the resin-impregnated veneer 2A and the panel base material 1. The breathable layer 2B prevents air from remaining between the resin-impregnated veneer 2A and the panel base material 1, thereby suppressing the formation of air pockets.

The adhesive layer 2C is a layer that adheres to the panel base material 1. For example, by using a thermosetting resin that hardens when heated or a thermoplastic resin that softens when heated for the adhesive layer 2C, the panel base material 1 and the decorative material 2 can be bonded together through a heating process. When the adhesive layer 2C is made of a breathable adhesive, it is preferable because it prevents air from remaining between the decorative material 2 and the panel base material 1, thereby suppressing the formation of air pockets. be.

The decorative panel manufacturing method according to the present embodiment is capable of decompressing a sealed space formed by butting a first casing with an open end and a second casing with an open end on the first casing side. This is a method of manufacturing a decorative panel in which a decorative material including a veneer is laminated onto the surface of a panel base material using a vacuum forming machine.

<Summary of decorative panel manufacturing method>
FIG. 5 is a flow diagram of the decorative panel manufacturing method according to this embodiment. The decorative panel manufacturing method according to the present embodiment is a manufacturing method of a decorative panel P that includes a decorative material 2 on the surface of a panel base material 1, in which the decorative material is provided at a position facing the surface of the panel base material 1. 2 (step ST1), a flexible molded member 40 is placed at the boundary between the lower casing 21, which is open on one side, and the upper casing 11, where the lower casing 21 side is open; The casing 21 and the upper casing 11 are butted against each other to form a lower space 20A sealed by the lower casing 21 and the molded member 40, and an upper space 10A sealed by the upper casing 11 and the molded member 40. a process (step ST2), a process (step ST3) of molding the decorative material 2 into a predetermined shape via the molding member 40 in a state where the pressure in the lower space 20A is lower than that in the upper space 10A; 2 on the surface of the panel base material 1 (step ST4).

An overview of the decorative panel manufacturing method according to this embodiment will be described below. Specifically, the decorative panel manufacturing method according to the present embodiment includes the following steps (1) to (11).
(1) The panel base material 1 is placed on a vertically movable table 22A provided in the lower casing 21 as the first casing, and the decorative material 2 is placed at a position facing the surface of the panel base material 1. (2) Step of arranging the flexible molded member 40 at the boundary between the lower casing 21 and the upper casing 11 as the second casing (3) The upper casing 11 and the lower casing A lower space 20A as a first space sealed by the lower casing 21 and the molded member 40 and a second space sealed by the upper casing 11 and the molded member 40 when the bodies 21 are butted against each other. Step of forming upper space 10A (4) Step of reducing the pressure of lower space 20A and upper space 10A, respectively (5) Step of heating with heater 12 provided in upper housing 11 (6) Predetermined decoration material 2 Step (7) of heating the decorative material 2 with heating steam S prior to molding it into the shape of (8) A step of releasing the reduced pressure in the upper space 10A and molding the decorative material 2 into a predetermined shape via the molding member 40 (9) Pasting the decorative material 2 on the surface of the panel base material 1 (10) Taking out the decorative panel P from the vacuum forming machine (11) Trimming the end of the decorative material 2

Hereinafter, details of each of the above steps will be explained with reference to the drawings.

<Vacuum forming machine VF>
An overview of the configuration of the vacuum forming machine VF used in the decorative panel manufacturing method according to the present embodiment will be described with reference to FIG. 6. Note that FIGS. 6 to 12 schematically show a cross section of the vacuum forming machine VF. As shown in FIG. 6, the vacuum forming machine VF includes an upper unit 10 and a lower unit 20.

The upper unit 10 includes an upper housing 11 as a second housing and a heater 12 disposed inside the upper housing 11. In this embodiment, the heater 12 is attached to the upper surface of the inner wall of the upper housing 11, and may be composed of, for example, a plurality of heating elements.

The upper housing 11 is a box-shaped chamber member with one side open. Specifically, a portion of the lower surface of the upper housing 11 is open. The upper housing 11 is movable up and down, and can seal the internal space of the upper housing 11 by abutting against a lower housing 21, which will be described later. As shown in FIG. 6, a pipe 14, a pipe 16, and a pipe 19 are connected to the inner wall of the upper housing 11.

Piping 14 is a pipe that supplies heated steam from steam supply device 13 to the inside of upper housing 11 . Further, an on-off valve 15 is provided in a part of the pipe 14 that connects the upper housing 11 and the steam supply device 13. The heated steam is supplied to the inside of the upper housing 11 only while the on-off valve 15 is open.

A part of the pipe 16 is provided with an on-off valve 17, and the on-off valve 17 is closed when the internal space of the upper housing 11 is closed to reduce pressure. Thereafter, by opening the on-off valve 17, the reduced pressure in the internal space of the upper housing 11 can be returned to atmospheric pressure.

The pipe 19 is connected to a suction pump 24 via an on-off valve 18 and a pipe 25. After the internal space of the upper housing 11 is sealed, the internal space of the upper housing 11 can be brought into a reduced pressure state (vacuum state) by sucking air with the suction pump 24 while the on-off valve 18 is open. .

Next, the lower unit 20 will be explained. As shown in FIG. 6, the lower unit 20 includes a lower housing 21 as a first housing, a stand 22A disposed inside the lower housing 21, and a movable unit that allows the stand 22A to move up and down. A mechanism 22 is provided.

The lower housing 21 is a box-shaped chamber member that is open on the upper housing 11 side. Specifically, a portion of the upper surface of the lower housing 21 is open. Note that the openings of the upper housing 11 and the lower housing 21 are provided at opposing positions, respectively. Further, as described above, by abutting the lower housing 21 against the upper housing 11, the internal space of the lower housing 21 can be sealed. That is, the space formed by abutting the upper housing 11 and the lower housing 21 becomes a sealed space.

As shown in FIG. 6, a pipe 25 is connected to the inner wall of the lower housing 21. The pipe 25 is a pipe that connects the lower housing 21 and the suction pump 24, and an on-off valve 26 is provided between the pipe 25 and the suction pump 24. After the internal space of the lower housing 21 is sealed, air is sucked by the suction pump 24 with the on-off valve 26 open, thereby bringing the internal space of the lower housing 21 into a reduced pressure state (vacuum state). I can do it.

<Description of decorative panel manufacturing method>
Next, based on FIGS. 6 to 13, details of the process of manufacturing the decorative panel P by laminating the decorative material 2 to the panel base material 1 will be described using an example performed using the vacuum forming machine VF. I will explain. In addition, in the initial state, the on-off valve 15, the on-off valve 17, the on-off valve 18, and the on-off valve 26 are all closed.

[Step (1)]
First, as shown in FIG. 6, the panel base material 1 is placed on the stand 22A. Specifically, a support jig 30 having a receiving portion 30a that conforms to the shape of the lower surface of the panel base material 1 is installed on the stand 22A. Place them in contact with each other. Thereby, the position of the panel base material 1 with respect to the movable mechanism 22 is fixed. Then, the decoration material 2 is arranged at a position facing the surface of the panel base material 1.

Further, as shown in FIG. 6, a flexible molded member 40 is placed to cover the opening of the upper housing 11. That is, the molded member 40 is arranged so that the internal space of the upper housing 11 is sealed by the molded member 40 . The molding member 40 is a member for molding the decorative material 2 into a predetermined shape along the surface of the panel base material 1.

The molded member 40 is a flexible sheet-like or film-like member (sheet member or film member), and is an elastic body. If the molding member 40 is an elastic body such as an elastic sheet or an elastic film, it will easily stretch when force is applied, so that the decorative material 2 can be made to efficiently follow the shape of the panel base material 1. Further, the molded member 40 may be made of a heat-resistant thermoplastic resin (for example, olefin-based or urethane-based) or silicone rubber. When the molded member 40 is a thermoplastic sheet or thermoplastic film made of a thermoplastic resin, it tends to stretch when heated, so it is difficult to make the decorative material 2 efficiently follow the shape of the panel base material 1. It becomes possible. Furthermore, if the molded member 40 is a silicone rubber sheet made of silicone rubber, it will not harden even when heated, so it can be repeatedly used in the process of laminating the decorative material 2 to the panel base material 1. Become.

[Step (2), Step (3)]
Next, as shown in FIG. 7, the lower casing 21 is moved upward until it comes into contact with the molded member 40, and the upper casing 11 and the lower casing 21 move the molded member 40 (Step (2)). In other words, by abutting the upper housing 11 and the lower housing 21, the molded member 40 is sandwiched between the upper housing 11 and the lower housing 21.

Through this step, an upper space 10A sealed by the upper housing 11 and the molded member 40 and a lower space 20A sealed by the lower housing 21 and the molded member 40 are formed (step (3)). Note that during this step, heating may be started by turning on the switch of the heater 12. Thereafter, heating by the heater 12 continues until the end of the process. Further, in the drawings, the state in which the heater 12 is ON is represented by painting the heater 12 black.

[Steps (4), (5)]
Next, after opening the on-off valve 18 and the on-off valve 26, the suction pump 24 starts reducing the pressure in the upper space 10A and the lower space 20A to reduce the pressure in each to a vacuum state (step (4)). FIG. 8 shows the state of the upper space 10A and the lower space 20A that are reduced in pressure to a vacuum state. In this embodiment, a vacuum state is represented by filling the inside with dots. Note that after the pressure is reduced to a vacuum state, the on-off valve 18 and the on-off valve 26 may be closed again. Further, even when the pressure in the upper space 10A and the lower space 20A is reduced, heating by the heater 12 is performed (step (5)).

[Step (6)]
Next, the stand 22A is raised to the position shown in FIG. Then, as shown in FIG. 10, before the decorating material 2 is deformed along the panel base material 1, heated steam S from the steam supply device 13 is injected into the upper space 10A. This makes it easier to deform the decorative material 2 including the resin-impregnated veneer 2A.

[Step (7)]
Next, as shown in FIG. 11, the movable mechanism 22 moves the stand 22A upward and presses the panel base material 1 and the decorative material 2 against the molded member 40. In this way, the surface of the panel base material 1 comes into contact with the adhesive layer 2C of the decorative material 2 via the molded member 40.

[Steps (8), (9)]
Next, as shown in FIG. 11, the pressure in the upper space 10A is returned from the reduced pressure state to atmospheric pressure by opening the on-off valve 17 (that is, the reduced pressure is released), and the pressure is heated by the steam supply device 13. The steam switches to a pressurized state.

In addition, the movable mechanism 22 moves the table 22A further upward, and strongly presses the panel base material 1 and the decorative material 2 against the molded member 40, so that the decorative material 2 is moved along the surface of the panel base material 1. Form into the desired shape. In this way, the decorative material 2 is molded into a predetermined shape along the surface of the panel base material 1 (step (8)). At this time, the decoration material 2 is brought closer to the heater 12 to further heat the decoration material 2.

In this step, the upper space 10A is pressurized while the lower space 20A is maintained in a vacuum state. Due to the pressure difference between the upper space 10A and the lower space 20A caused by this, the decorative material 2 is strongly attached to the panel base material 1 from above via the molded member 40, and at the same time, the panel base material 2 is supported by the base 22A. The material 1 is also strongly pressed against the decorative material 2 from below.

At this time, the resin-impregnated veneer 2A of the decorative material 2 is easily deformed flexibly by heating by the heated steam S and the heater 12. Thereby, cracking of the resin-impregnated veneer 2A is suppressed. Furthermore, since the resin-impregnated veneer 2A is impregnated with resin, stress concentration is alleviated in this respect as well, making it more difficult to break. Then, in this step, the decorative material 2 is bonded to the surface of the panel base material 1 (step (9)).

In this way, the decorative material 2 is molded into a predetermined shape via the flexible molded member 40 and the decorative material 2 is bonded to the surface of the panel base material 1. It becomes possible to make the material 2 follow the shape of the panel base material 1. Moreover, since the molded member 40 is separate from the decorative panel P, an increase in the weight of the decorative panel P is suppressed.

[Steps (10), (11)]
Next, after the above step (9), after cooling the decorative panel P as necessary, the upper housing 11 is moved upward (FIG. 12), and the decorative panel P is removed from the support jig 30. It is removed and taken out from the vacuum forming machine VF (step (10)). Then, as shown in FIG. 13, the end portion of the decorating material 2 is trimmed (step (11)), and the decorative panel P is completed (FIG. 13). For trimming, a physical cutter or a laser may be used.

<Modified example>
The present invention is not limited to the embodiments described above. In the above embodiment, the first casing (lower casing 21) and the second casing (upper casing 11) are arranged vertically, but the first casing and the second casing are It may also be arranged horizontally.

Modifications of the support jig 30 will be described below with reference to FIGS. 14 to 19. As shown in FIGS. 14 and 15 (first modification), the support jig 30 may include an upright portion 31 that protrudes upward around the receiving portion 30a. At this time, it is preferable that the upright portion 31 has a notched recess 32 for supporting the decorative material 2.

According to such a configuration, since the panel base material 1 and the decorative material 2 are supported by the support jig 30 in an appropriate arrangement, the decorative material 2 can be laminated to the panel base material 1 efficiently. It becomes possible. Specifically, by deforming the molded member 40 from the state shown in FIG. 14 to the state shown in FIG. Since the decorative material 2 is deformed and crimped in a sequential manner, it is possible to efficiently bond the decorative material 2 to the panel base material 1.

Note that, as shown in FIG. 16 (second modification), it is also possible to provide an upright portion 31 that does not have a recess cut out to support the decorative material 2. Further, as shown in FIGS. 17 to 19, it is also possible to form the upright portion separately from the main body of the support jig 30.

The height of the standing portion 31X in FIG. 17 (third modification) is configured to be higher than the upper end portion of the panel base material 1 held in the receiving portion 30a. Further, the height of the upright portion 31Y in FIG. 18 (fourth modification) is configured to substantially match the upper end portion of the panel base material 1 held in the receiving portion 30a. Further, the height of the upright portion 31Z in FIG. 19 (fifth modification) is configured to be lower than the upper end portion of the panel base material 1 held by the receiving portion 30a.

The receiving portion 30a of the support jig 30 is preferably formed of a material with high hardness from the viewpoint of stable holding. Further, the upright portions shown in FIGS. 14 to 19 may be made of the same material as the main body of the support jig 30, but may also be made of a flexible material. By bending a part of the support jig 30, specifically, the upright part arranged around the receiving part 30a, the followability when the molded member 40 is deformed is improved. can better follow the surface shape of the panel base material 1.

FIG. 20 is a schematic cross-sectional view showing the configuration of a decorative panel PX according to a modification. The decorative panel PX has an elastic layer 2X between the decorative material 2 and the panel base material 1. The elastic layer 2X can be made of an elastic material such as urethane, and may be exemplified by a thin layer of urethane pad, but is not limited thereto. When the elastic layer 2X is arranged, the shape of the decorative material 2 after being bonded to the panel base material 1 becomes appropriate, so that the design is improved.

At this time, if the decorative material 2 and the elastic layer 2X have a larger surface area than the panel base material 1, it becomes possible to efficiently bond the decorative material 2 and the elastic layer 2X to the panel base material 1. . Moreover, the decoration material 2 is preferably formed thinner than the elastic layer 2X. Since the decorative material 2 is formed thinner than the elastic layer 2X, it is possible to deform the decorative material 2 by reducing pressure while retaining the elasticity of the elastic layer 2X.

Furthermore, it is also possible to protect the surface of the decorative material 2 by providing a surface protection layer (not shown) made of clear coating or a transparent film on the resin-impregnated veneer 2A.

The decorative member manufacturing method according to the present embodiment has been described above by exemplifying the decorative panel manufacturing method, but the decorative member manufacturing method according to the present embodiment is not limited to the decorative panel manufacturing method. It is also possible to apply it to decorative members other than decorative panels. Furthermore, the decorative member is not limited to vehicle interior parts such as vehicle door trims and instrument panels, and may be decorative parts other than vehicles.

<Decorative panel P of second embodiment>
Next, the decoration panel P2 of the second embodiment will be described based on FIGS. 21 to 23.
Note that the description of contents that overlap with those of the decorative panel P described above will be omitted.
The decorative panel P2 of the second embodiment is a decorative member that includes a decorative material 102 on the surface of a panel base material 101 and a surface protective layer 103 on the surface of the decorative material 102, and is a three-dimensional It has a structure.

The decorative material 102 includes a resin-impregnated veneer 102A, a breathable layer 102B, and an adhesive layer 102C that adheres to the surface of the panel base material 101.
An uneven pattern 104 is previously formed on the surface of the decorative material 102 (resin-impregnated veneer 102A) by a known method. Therefore, for example, by expressing the appearance of real wood grain (open porous), the design of the decorative panel P2 can be improved.
Furthermore, a corner R portion 105 is formed by rounding the corner portion of the decorative material 102, and the radius of curvature of the corner R portion 105 is 0.5 mm or more. Therefore, the moldability of the decorative panel P2 can be improved, that is, cracking of the decorative material 102 during molding can be suppressed.

The surface protective layer 103 is configured as a protective layer containing an "acrylic resin" as a main component, a "pigment", a "matting agent", and a "weather resistance improver".
The thickness of the surface protective layer 103 is preferably 10 μm or more and 40 μm or less.
This is because it has been confirmed that if the thickness of the surface protection layer 103 is less than 10 μm, the surface protection layer 103 will crack or break when forming the decorative panel P2. Furthermore, it has been confirmed that when the thickness of the surface protective layer 103 exceeds 40 μm, the glossiness of the surface protective layer 103 becomes high and the appearance and merchantability of the decorative panel P2 cannot be ensured.
In the above case, when the total thickness of the decorative material 102 and the surface protection layer 103 is 0.3 mm or more and 1.5 mm or less, moldability and appearance merchantability can be further improved.

In the surface protective layer 103, the content of "acrylic resin" is 50 to 90% by mass with respect to the total mass, the content of "pigment" is 1 to 15% by mass, and the content of "matting agent" is 50 to 90% by mass. It is preferable that the content of ``weather resistance improver'' is 1 to 5% by weight, and the content of ``weather resistance improver'' is 1 to 10% by weight.
Further, the "acrylic resin" is preferably an acrylic resin having a glass transition temperature of 66°C or higher and 135°C or lower, more preferably a glass transition temperature of 82°C or higher and 135°C or lower. An acrylic resin having a glass transition temperature of 100° C. is more preferable.
Further, the "acrylic resin" is preferably a TX-free acrylic resin. TX-free means that it does not contain toluene or xylene, which are regulated as substances that induce sick building syndrome.
Moreover, the "weather resistance improver" is an additive for improving the weather resistance of the decorative panel P2, and is preferably an ultraviolet absorber or a light stabilizer.

In the above, it has been confirmed that when the content of the "acrylic resin" is less than 50% by mass, the overall physical properties (particularly the weather resistance) of the decorative panel P2 deteriorate. Furthermore, it has been confirmed that when the content of the "acrylic resin" exceeds 90% by mass, it becomes difficult to adjust the gloss and color tone of the decorative panel P2.
Moreover, in the above, it has been confirmed that when the glass transition temperature of the "acrylic resin" is less than 66° C., the heat resistance of the decorative panel P2 is poor. Furthermore, it has been confirmed that if the glass transition temperature of the "acrylic resin" exceeds 135° C., the decorative material 102 will break during molding of the decorative panel P2.

Furthermore, in the above, it has been confirmed that when the content of the "pigment" is less than 1% by mass, the appearance and merchantability of the decorative panel P2 deteriorates. Furthermore, it has been confirmed that when the content of the "pigment" exceeds 15% by mass, the adhesion of the surface protective layer 103 decreases and the decorative material 102 cracks during molding.
Furthermore, in the above, it has been confirmed that when the content of the "matting agent" is less than 1% by mass, the color gloss (gloss value) of the decorative panel P2 becomes high, and the appearance and merchantability deteriorate. Furthermore, it has been confirmed that when the content of the "matting agent" exceeds 5% by mass, the coatability of the surface protective layer 103 decreases, resulting in a decrease in appearance and merchantability.

Moreover, in the above, it has been confirmed that when the content of the "weather resistance improver" is less than 1% by mass, the weather resistance of the decorative panel P2 is reduced. Moreover, if the content of the "weather resistance improver" exceeds 10% by mass, the cost will increase.
Further, in the above, when the "weather resistance improver" is an ultraviolet absorber, the weather resistance of the surface protective layer 103 can be efficiently improved by absorbing ultraviolet rays of a certain wavelength.
Further, in the above, when the "weather resistance improver" is a light stabilizer, the progression of deterioration of the surface protective layer 103 when exposed to ultraviolet rays can be suppressed, and weather resistance can be efficiently improved.

Next, the decorative panel manufacturing method (steps ST1-1 to ST4) of the second embodiment will be described based on FIG. 23.
The decorative panel manufacturing method of the second embodiment includes a step of applying a surface protective layer 103 to the surface of the decorative material 102 (step ST1-1), and a step of applying the decorative layer 103 to the surface of the panel base material 101 at a position facing the surface of the panel base material 101. 102 (step ST1-2), and as shown in FIG. (step ST2), and in a state where the pressure in the lower space 20A is lower than that of the upper space 10A, the decorative material 102 provided in the lower space 20A is inserted through the molded member 40. It includes a step of molding into a predetermined shape (step ST3) and a step of pasting the decorative material 102 on the surface of the panel base material 101 (step ST4).
More specifically, in step ST1-1, the surface protective layer 103 is applied to the surface of the decorative material 102 to a uniform thickness using, for example, a roll coater. Dry thoroughly after application.
By including the above step ST1-1, it becomes easier to apply the surface protective layer 103, compared to, for example, the case where the surface protective layer 103 is applied to the surface of the decorative material 102 after molding. For example, compared to spray coating, the thickness of the surface protective layer 103 can be made more uniform.

D Door trim P, PX, P2 Decorative panel (decorative member)
1,101 Panel base material (base material)
2,102 Decorating material 2A, 102A Resin-impregnated veneer 2B, 102B Breathable layer 2C, 102C Adhesive layer 2X Elastic layer 103 Surface protective layer 104 Uneven pattern 105 Corner R portion VF Vacuum forming machine 10 Upper unit 10A Upper space (second space)
11 Upper case (second case)
12 Heater 13 Steam supply device 14 Piping 15 On-off valve 16 Piping 17 On-off valve 18 On-off valve 19 Piping 20 Lower unit 20A Lower space (first space)
21 Lower case (first case)
22 Movable mechanism 22A stand 24 Suction pump 25 Piping 26 Opening/closing valve 30 Support jig 30a Receiving section 31, 31X, 31Y, 31Z Upright section 32 Recessed section 40 Molded member S Heated steam

Claims (13)

A method for manufacturing a decorative member comprising a decorating material on the surface of a base material, the method comprising:
arranging the decorative material at a position facing the surface of the base material;
A flexible molded member is arranged at the boundary between a first casing that is open on one side and a second casing that is open on the first casing side, and the first casing and the second casing are forming a first space sealed by the first casing and the molded member, and a second space sealed by the second casing and the molded member;
molding the decorating material provided in the first space into a predetermined shape via the molding member in a state where the pressure in the first space is lower than that in the second space;
a step of laminating the decorative material on the surface of the base material,
The decorating member includes an elastic layer between the decorating material and the base material ,
In the step of forming the first space and the second space, the decorating material and the molded member are not brought into contact with each other in the direction in which the first casing and the second casing are brought into contact with each other. Place it with a space between
A method for manufacturing a decorative member, characterized in that in the step of molding the decorative material into a predetermined shape, the decorative material is pressed against the molded member by a movable mechanism . A method for manufacturing a decorative member comprising a decorating material on the surface of a base material, the method comprising:
arranging the decorative material at a position facing the surface of the base material;
A flexible molded member is arranged at the boundary between a first casing that is open on one side and a second casing that is open on the first casing side, and the first casing and the second casing are forming a first space sealed by the first casing and the molded member, and a second space sealed by the second casing and the molded member;
molding the decorating material provided in the first space into a predetermined shape via the molding member in a state where the pressure in the first space is lower than that in the second space;
a step of laminating the decorative material on the surface of the base material,
The base material and the decorative material are supported by a support jig,
At least a portion of the support jig has flexibility,
In the step of forming the first space and the second space, the decorating material and the molded member are not brought into contact with each other in the direction in which the first casing and the second casing are brought into contact with each other. Place it with a space between
A method for manufacturing a decorative member, characterized in that in the step of molding the decorative material into a predetermined shape, the decorative material is pressed against the molded member by a movable mechanism . 3. The method for manufacturing a decorative member according to claim 1, wherein the decorative material is bonded to the surface of the base material using an air-permeable adhesive. 3. The decorative member manufacturing method according to claim 1, wherein the molded member is an elastic body. 3. The method for manufacturing a decorative member according to claim 1, wherein the molded member is made of silicone rubber. The decorative material has a resin-impregnated veneer, a breathable layer, and an adhesive layer that adheres to the base material,
3. The decorative member manufacturing method according to claim 1, wherein the breathable layer is disposed between the resin-impregnated veneer and the base material. The method for manufacturing a decorative member according to claim 1, wherein the decorative material and the elastic layer have a larger surface area than the base material. The method for manufacturing a decorative member according to claim 1, wherein the decorative material is formed thinner than the elastic layer. Claim 1 or 2, further comprising the step of applying a surface protective layer to the surface of the decorating material before the step of arranging the decorating material at a position facing the surface of the base material. The decorative member manufacturing method described in . The decorating member further includes a surface protection layer on the surface of the decorating material,
The surface protective layer contains as a main component an acrylic resin having a glass transition temperature of 66° C. or higher and 135° C. or lower,
The thickness of the surface protective layer is 10 μm or more and 40 μm or less,
The method for manufacturing a decorative member according to claim 1 or 2, wherein the total thickness of the decorative material and the surface protection layer is 0.3 mm or more and 1.5 mm or less. The decorative member has a three-dimensional structure,
A corner R portion formed by rounding the corner is formed at a corner of the decorative material bonded to the surface of the base material,
11. The method for manufacturing a decorative member according to claim 10, wherein the radius of curvature of the corner R portion is 0.5 mm or more. The surface protective layer contains the acrylic resin and a pigment,
Claim 10, wherein the content of the acrylic resin is 50 to 90% by mass and the content of the pigment is 1 to 15% by mass with respect to the total mass of the surface protective layer. The decorative member manufacturing method described. The surface protective layer further contains a weather resistance improver for improving the weather resistance of the decorative member,
13. The method for producing a decorative member according to claim 12, wherein the content of the weather resistance improver is 1 to 10% by mass based on the total mass of the surface protective layer.

Images