JPH02227235A - Manufacture of trimming material - Google Patents

Abstract

PURPOSE:To eliminate garnishes and reduce the number of processes by folding and end section of base to form a non-product section to the opposite side of a skin material, simultaneously crushing locally an area close to a folded base section to form a thin wall section and cutting off and removing the non- product section from the thin wall section to form a terminal flange section on a product section. CONSTITUTION:A sheet-shaped base 2, a cushioning material 3 having a skin material 4 are stuck together preliminarily and pressurizing and heat molding in the three-dimensional shape to fold and form a section for forming a non- product section 15 eventually out of terminal sections of the base 2 by fold molding sections 11, 12 on the opposite side of the skin material, while a section close to a folded base section 16 is crushed locally by thin wall forming sections 13, 14 to form a thin wall section 17. Then, the non-product section 15 out of the base 2 is cut off and removed by a cut-off line l from the thin wall section 17 by the joint operation of a cutter 21 and a bottom force 20 of a trimming mold 18. As a result, a trimming material 1 having a terminal flange section 5 with its plate thickness gradually growing smaller is manufactured at the terminal of a product section 22.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to a method for manufacturing an interior material having a composite structure consisting of at least a base material and a skin material.

2. Description of the Related Art For example, as a roof interior material installed inside the roof of an automobile, there is a structure shown in FIGS. 4 and 5, for example. This is made by laminating a cover material 33 and a skin material 34 on a cardboard base material 32 in order and forming it into a predetermined three-dimensional shape.When the interior material 31 is in its original state, special end treatment is required. Roof rail 3 on the roof 35 side
6, and attach the terminal part of the interior material 31 to the garnish 3.
It was fixed by pressing at step 7. 38 is a window glass, and 39 is a tapping screw.

In such an interior material 31, a separate garnish 37 is required as a terminal treatment, which is unfavorable in terms of appearance, and it is desirable to eliminate unnecessary accessories to make the interior space of the vehicle as wide as possible (and make it look cleaner). This goes against the recent trend of

Therefore, instead of the terminal treatment using the garnish 37 shown in FIG. 5, the terminals of the cover material 43 and the skin material 44 are folded back to the back side of the corrugated cardboard base material 42 to perform the terminal treatment, as shown in FIG. 42 is not directly visible and is fixed to the roof rail 36 with tapping screws 39 (a similar structure is disclosed in, for example, Japanese Unexamined Patent Publication No. 159936/1983).
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Problems to be Solved by the Invention However, when looking at the manufacturing process of the interior material 41 shown in FIG. It is necessary to attach and trim, and also to fold back the end portions of the cushion material 43 and the skin material 44 to the back side of the base material 42.
In addition to the increase in the number of processing steps, which leads to an increase in cost, there is a problem in that the stiffness of the end portion of the interior material 41 is reduced due to the elimination of the nish 37 shown in FIG.

The present invention was made in view of the above problems.
The purpose of this is to maintain the basic beauty of making the end of the base material invisible from the outside, reduce the number of processing steps by eliminating the garnish, and create a sense of rigidity that is sufficient for the end of the base material alone. An object of the present invention is to provide a manufacturing method that allows an interior material having the following properties to be obtained.

Means for Solving the Problems The present invention is a method for manufacturing interior materials in which a skin material is bonded to the surface of a base material, in which a resin base material with a skin material bonded to one side is shaped into a predetermined three-dimensional shape. During pressure/heat molding, the end part of the base material that will become the non-product part is bent toward the side opposite to the skin material, and at the same time, the vicinity of the bent base near the non-product part is locally crushed to form a thin wall part. , forming an end flange portion at the end of the product portion by cutting and removing the non-product portion of the base material to which the skin material is attached from the thin wall portion.

Here, in the interior material described above, a cushion material may be interposed between the base material and the skin material, if necessary.

According to the method described above, the base material to which at least the skin material is bonded is pressurized and heat-molded using a predetermined mold, and then the non-product part at the periphery of the base material is cut and removed from the thin part along with the skin material. As a result, an end flange portion bent toward the side opposite to the skin material is formed at the end of the product portion.

When the interior material thus obtained is attached to the roof of a car, for example, as shown in FIG. 3, the terminal flange part serves to hide the base material from view from the outside.
No other terminal processing means are required. Moreover, since the base material itself is made of resin, the end portion of the interior material can have sufficient rigidity by itself.

Embodiment FIG. 3 shows the assembled state of an automobile roof interior material obtained by the method of the present invention, and parts common to FIGS. 5 and 6 are given the same reference numerals.

As shown in the figure, the interior material 1 has a cushion material 3 and a skin material 4 laminated in order on a resin-based base material 2, which have good affinity for each other. A terminal flange portion 5 is formed which is bent with a relatively large curvature. And the interior material 1 is a tapping screw 3
9 is fixed to the roof rail 36, and the end face of the terminal flange portion 5 faces the roof rail 36, and serves to prevent the base material 2 from being seen from the outside.

Next, an embodiment of the method for manufacturing the interior material 1 will be described with reference to FIGS. 1 and 2.

First, as shown in FIG. 2(A), the cushion material 3 and the skin material 4 are bonded to a sheet-like base material 2 in advance, and the base material 2 to which the cushion material 3 and the skin material 4 are bonded is bonded together. As shown in the figure, it is set in a mold 6 consisting of an upper mold 7 and a lower mold 8.

The upper mold 7 and the lower mold 8 have built-in heating means (not shown), and each mold 7, 8 has a molding surface 9.10 corresponding to the three-dimensional shape of the interior material 1, as well as molding surfaces 9 and 10 shown in FIG. As shown, a bent molded portion 11.12 and a thin molded portion 13.14 are formed.

Then, when the upper die 7 is lowered from the state shown in FIG. 2(A) and pressurized and heat-molded, the base material 2 is softened by heat and together with the cushion material 3 and the skin material 4 shown in FIGS. 1 and 2 ( As shown in B), it is molded into a predetermined three-dimensional shape. At this time, the part of the end portion of the base material 2 that will eventually become the non-product part I5 is bent and formed by the bending part 11.12 toward the side opposite to the skin material, while the part of the non-product part 15 A portion close to the base 16 is locally crushed by the thin-walled molded portion 13.14 to form a thin-walled portion 17.

Subsequently, after a predetermined pressure cooling time has elapsed under the condition shown in FIG. 2(B), the upper mold 7 is raised and the base material 2 is taken out from the mold 6. As shown in (C), it is transferred to a trim processing mold 18 for the purpose of trim processing. The trim processing die 18 is composed of an upper die 19 and a lower die 20, and the upper die 19 has a built-in cutter 21 driven by a mechanical cam that operates at the bottom dead center position of the upper die 19.

Then, from the state shown in FIG. 2(C), the retired emperor 19 is lowered, and by force, cooperation between the tar 21 and the lower die 20, the non-product part 15 of the base material 2 is cut along the cutting line a from the thin part 17. Cut and remove. As a result, as shown in FIGS. 1 and 3, an interior material 1 having an end flange portion 5 whose thickness gradually decreases at the end of the product portion 22 is obtained.

At the time of this cutting, since the thin wall portion 17 of the board that has been crushed and hardened in advance is cut, a clean cut surface with a so-called sharp cutting edge and no distortion or cracks can be obtained.

Effects of the Invention As described above, according to the present invention, when pressurizing and heat-molding a resin base material to which a skin material has been bonded in advance into a predetermined shape, the end portion of the base material, which will be a non-product part, is At the same time as bending to the skin material side, the vicinity of the bent base near the non-product part is locally crushed to form a thin wall part, and then the non-product part of the base material is cut and removed from the thin wall part to form the end of the product part. By adopting a construction method in which the end flange portion is formed at the end portion, an interior material having sufficient rigidity can be obtained by using only the end portion with fewer processing steps, and processing costs can be reduced.

In addition, since the terminal flange has a cosmetic function that prevents the base material from being seen from the outside when the interior material is assembled to the mating member, other terminal processing means such as garnishes etc. is not necessary at all, and this can also greatly contribute to the above-mentioned cost reduction.

[Brief explanation of the drawing]

FIG. 1 is a diagram showing an embodiment of the present invention, and b in FIG.
2 (A), (B), and (C) are process explanatory views of the manufacturing process showing one embodiment of the present invention, and FIG. 3 is an interior for an automobile roof obtained by the method of the present invention. The assembly of the materials is shown in an enlarged view of the main parts showing the condition. Figure 4 is a perspective view of the car, Figure 5
This figure and FIG. 6 are diagrams showing a conventional end treatment structure of an interior material, and are views corresponding to the cross section taken along the line ■-V in FIG. 4. ■...Interior material, 2...Base material, 3...Cushion material, 4...Skin material, 5...Terminal flange portion, 6...
Molding die, 15... Non-product part, 16... Bending base, 1
7... Thin wall part, 21... Cutter, Q... Cutting line. Figure 1 Figure (A) Figure 1 (B) Figure (C) Diagram of Deafness

Claims (1)

[Claims] (1) In a method for manufacturing interior materials in which a skin material is bonded to the surface of a base material, when pressurizing and heat-forming a resin base material with a skin material bonded to one side into a predetermined three-dimensional shape, A step of bending the end portion of the base material, which will become the non-product part, toward the side opposite to the skin material, and at the same time, locally crushing the vicinity of the bent base near the non-product part to form a thin part, and bonding the skin material together. forming an end flange part at the end of the product part by cutting and removing the non-product part of the base material from the thin wall part.