JPH0334460B2 - - Google Patents

Description

Detailed Description of the Invention A. Purpose of the Invention [Field of Application of the Invention] The present invention provides a patterned surface decorative molded article, that is, two or more surface portions whose surfaces are different in color tone, pattern, material, feel, etc. The present invention relates to a method for manufacturing a molded article which is patterned and decoratively treated.

[Conventional technology]

For example, when it comes to door trim boards, which are interior parts for vehicles, those with the above-mentioned surface decoration specifications have come to be frequently used for reasons such as design.
As a specific example, Fig. 1a shows the outer surface of a door trim board A, with a first pattern surface portion 1 on the upper 1/3 area, and a second pattern surface portion 2 on the lower 2/3 area. The pattern is divided into two parts, and the color, pattern,
Shown below are surface decorations made of different materials. 3 is the first and second pattern surface portions 1 and 2
This is a mutual boundary.

Conventionally, such a patterned surface decorative molded product A is produced by manufacturing a molded base or a molded base with a surface skin, dividing the outer surface of the molded base into predetermined patterns 1 and 2, and applying a coating treatment in a desired color, respectively. By performing post-processing such as printing a desired pattern and applying a skin material of a desired material, a surface decorative molded body with a desired pattern is manufactured. The ground skin material and patterned skin material are, for example, woven fabrics, knitted fabrics, non-woven fabrics, synthetic resin sheets, natural or synthetic leathers, etc., and other intermediate materials such as a cushion material layer are laminated on the back side thereof.

[Problem that the invention seeks to solve]

Pattern-divided surface cosmetic treatment by painting or printing requires accurate masking of each pattern surface portion 1 and 2, which is time-consuming. When the pattern surface is a large curved surface or uneven surface, it may be difficult or even impossible to paint or print the pattern uniformly and beautifully on each part without uneven coating or printing on the curved or uneven surface. It required sophisticated processing technology and had a poor yield.

Furthermore, in the case of pattern-separated surface decoration treatment by applying skin material, it is time-consuming because the application process is done manually for each pattern surface portion. When the pattern surface is a large curved surface or uneven surface, it is difficult or impossible to adhere the skin material to each part closely without any raised or wrinkled parts and to create a beautiful appearance. There is also. Furthermore, it is difficult to position the mutually meeting edges of the skin materials of each pattern surface portion 1 and 2 along the predetermined boundary line 3 positions on the molded body and perform the tensioning process of the skin materials.
Therefore, the boundary line 3 tends to become an irregular line, and in order to hide it and improve the appearance, it is necessary to perform high-frequency contact treatment on the decorative molding member 4 along the boundary line 3.

The present invention has been proposed in view of the above, and is a practical method that can easily, efficiently, and mass-produce high-grade, high-quality patterned surface decorative molded products in desired shapes and with good yield without the above-mentioned problems. The purpose is to provide a method for

B. Structure of the Invention [Means for Solving Problems] The present invention provides a molded article whose surface is decoratively treated by dividing the surface into two or more surface portions having different colors, patterns, materials, etc. During manufacturing, a vacuum forming mold, a pressure-forming mold, or a vacuum-pressure molding mold having a molding surface approximately corresponding to the external shape of the target molded product, and the mutual boundary line between each surface decorative pattern surface portion of the target molded product. Using a bar member for holding the patterned skin material, the shape of which approximately corresponds to the outer surface shape of the molded article,
Positioning and holding the back side portion of the skin material along the mutual boundary line of each pattern surface portion of the patterned surface decorative skin material of the target molded body by the above-mentioned bar member,
The bar member holding the above-mentioned skin material is positioned at a mold surface position that approximately corresponds to the mutual boundary line position of each surface decorative pattern surface portion of the target molded object, and the skin material is applied to the mold and vacuum formed. Alternatively, perform air pressure forming or vacuum pressure forming treatment, remove the bar member with the molded skin material held on the surface of the mold, and fit the preformed molded body base into the mold to integrate it with the molded skin material. The object of the present invention is to provide a method for manufacturing a decorative molded article with a patterned surface, which is characterized by forming a molded article base material by applying a molded body material to form a molded article base material, and integrating the molded article with a molded skin material.

[Effect]

In the above, positioning and holding of the back surface side part of the skin material along the mutual boundary line of each pattern surface part of the skin material by the bar member can be done, for example, by providing a skin material puncturing needle along the length of the bar member, or by vacuum suction. The puncturing can be performed by providing a puncturing section or both, and by using a puncturing force using a puncturing needle, a vacuum suction force, or both.

The means for forming the molded body by applying the molded base material to the mold holding the molded skin material may be any suitable method such as press molding, injection molding, resin bead foam molding, or pour molding.

In the above method, the decorative skin material for the patterned surface of the target molded body is used in a mold having a molding surface approximately corresponding to the external shape of the target molded body, and each patterned surface portion of the skin material is Positioning the mutual boundary line position of the mold surface at a predetermined position on the mold surface using a bar member, that is, the mold surface position approximately corresponding to the mutual boundary line position of each surface decorative pattern surface portion of the target molded object,
Vacuum forming or pressure forming or vacuum pressure forming treatment,
The bar member is removed while the molded skin material is held on the surface of the mold, and the molded body base is inserted into the mold, or the molded body base is shaped using the mold and integrated with the molded skin material. Therefore, in the patterned surface decorative molded product obtained, the boundary line between each pattern surface portion is a regular line, and the line is always positioned at a predetermined position on the molded product surface. Even if the outer surface shape is complex, each part of the patterned surface decorative skin material conforms to the outer surface shape of the molded body base and adheres well, resulting in a patterned surface decorative molded product with a desired shape and high quality. It is possible to mass-produce easily and efficiently without variation.

〔Example〕

In this embodiment, the molded body A of the door trim board shown in FIG. The pattern is divided into two parts, a surface part 2, where the first pattern surface part 1 represents a desired printed pattern and an electrostatic flocking pattern of pile of an appropriate length applied thereto, and the second pattern surface part 2 is a plain surface. This is an example of manufacturing a cosmetic product.

5 (Fig. 2) is a patterned surface decorative skin material to be used, and this example has an outer skin sheet material 5a made of a synthetic resin sheet such as vinyl chloride, and a cushioning backing material such as foamed vinyl chloride or foamed polyethylene. It is a laminated material with a sheet material 5b, and the upper 1/3 area surface of the outer surface of the outer skin sheet material 5a is the area surface that becomes the first pattern surface portion 1 of the objective molded object A, and a desired pattern is printed. And electrostatic flocking has been applied over it. This surface portion is referred to as a print portion surface 1a. Approximately 2/3 of the lower area is the second pattern surface part 2
It is an area surface that becomes , and is a plain surface. This surface portion is referred to as a plain portion surface 1b. 3a is the boundary line between the printed portion surface 1a and the plain portion surface 1b.

In FIG. 3, reference numeral 10 denotes a vacuum forming mold having a forming surface 11 having a shape substantially corresponding to the outer surface shape of the target molded object A. Reference numeral 12 denotes small vacuum holes opened in various parts of the molding surface 11, and when a valve 13 leading to a vacuum pump VP is opened, a vacuum suction state is created.
14 is a cooling water pipe buried within the wall thickness of the mold.

Reference numeral 20 denotes a bar member for holding a patterned skin material, which has a shape that approximately corresponds to the shape of the outer surface of the molded object along the boundary line 3 between the surface decorative pattern surfaces 1 and 2 of the target molded object A, and the bar member has a longitudinal axis. A large number of skin material puncture needles 21 are provided to protrude downward at appropriate intervals along the line. The bar member is a hollow body with both ends closed, and a large number of vacuum suction holes 22 are provided at appropriate intervals along the length of the tube wall, as shown in a partially enlarged view in FIG. The vacuum suction hole 22 enters a vacuum suction state when a valve 23 communicating with the vacuum pump VP is opened.

30 is a frame for clamping the peripheral edge of the skin material, which is separate from or integrated with the bar member 20, and 40 is a vertically movable push rod device for pressing the bar member. 50 is the bar member 20
This is an auxiliary bar member having a shape corresponding to that of the auxiliary bar member, and has a large number of skin material puncturing needles 51 protruding along its length at appropriate intervals. The protruding length of each needle 51 is made somewhat longer than the thickness of the skin material 5.

The manufacturing procedure will be explained below.

(1) The printed part on the front side of the skin material 5 and the flocked surface 1a
The auxiliary bar member 50 is positioned at the boundary line 3a between the auxiliary bar member 50 and the plain portion surface 1b, and the puncture needle 51 on the auxiliary bar member 50 side is sequentially inserted and penetrated into the skin material along the boundary line 3a. The boundary line 3a of the skin material 5 is closely held along the longitudinal shape of the member 50, and the entire skin material is attached to the backing sheet material 5b of the skin material 5 as shown in the fourth figure.
Turn it over with the side facing up. Note that the boundary line 3 where the puncture needle 51 of the auxiliary bar member 50 can be easily inserted
By preparing a jig having the shape of part a and attaching the skin material 5 with the printed or flocked side facing up, the puncture needle 51 of the auxiliary bar member 50 can be accurately inserted and set at the boundary line 3a. can. The tips of the puncture needles 51 of the holding bar member 50 protrude from the surface of the backing sheet material 5b facing upward, and the line of protruding tips of the puncture needles 51 faces downward on the surface of the skin material. This corresponds to the boundary line 3a between the printed portion surface 1a and the plain portion surface 1b in .

(2) Next, the bar member 20 is placed in a position opposite to the row line position of each of the protruding tips of the puncture needles on the side of the skin lining sheet material 5b and pressed. As a result, each downward puncture needle 21 on the bar member 20 side is brought into a state of being inserted into the skin material 5 (FIGS. 5 and 6). The bar member 2
The position at which each puncture needle 21 on the 0 side penetrates the skin material is at the boundary line 3 between the printed part surface 1a and the plain part surface 1b on the downward facing front side of the skin material 5.
It corresponds to a. Note that the protruding tip of each puncture needle 51 on the auxiliary bar member 50 side that penetrates the skin material has a sixth hole in the corresponding vacuum suction hole/escape hole 22 on the bar member 20 side.
As shown in the figure, the structure is such that the bar member 20 does not interfere with the bar member 20 by entering therein.

The valve 23 is opened to bring each vacuum suction hole 22 along the length of the bar member 20 into a vacuum suction state. Further, the peripheral edge of the skin material 5 is clamped with a clamp frame 30.

(3) Removing the auxiliary bar member 50 on the downward facing front side of the skin material 5 (Fig. 7) Even if this auxiliary bar member 50 is removed, the boundary line 3a between the printed portion surface 1a and the plain portion surface 1b of the skin material 5 The portion follows the longitudinal shape of the bar member 20 and is stably and continuously held by the holding force of each puncture needle 21 of the bar member 20 on the back side of the skin material and the suction force of the vacuum suction hole 22. If the bar member 20 can stably hold the skin material during the skin material heating and softening treatment in the next step, the bar member 20 can hold the skin material only by the holding force of the puncture needle 21.
Alternatively, it may be performed only by the vacuum suction holding force of the vacuum suction hole 22.

(4) As described above, the skin material 5, which is held at a predetermined portion by the bar member 20 and whose peripheral edge is clamped by the clamp frame 30, is heat-treated on one side or both sides to be heated and softened so that it can be vacuum-formed.

(5) The bar member 20 holding the skin material 5 is attached to each surface decorative pattern surface portion 1, 2 of the target molded object A.
The skin material 5 is placed in the mold 1 with the skin material 5 positioned at a mold surface position that approximately corresponds to the mutual boundary line 3 position.
For 0, the method is applied by lowering the skin material or raising the mold. As shown in FIG. 8, a push rod device 40 presses the bar member 20 positioned at the predetermined position on the mold surface.
By lowering the bar member 20 onto the bar member 20, each longitudinal portion of the bar member 20 is pressed into the mold surface via the skin material 5. As a result, the boundary line 3a between the printed portion 1a and the plain portion surface 1b on the downward facing front side of the skin material 5 is located at a predetermined surface position on the mold surface 11, that is, at the mutual boundary between the surface decorative pattern portions 1 and 2 of the target molded object A. The mold is positioned and set at a mold surface position that approximately corresponds to the line 3 position.

Note that if the downward tip of each puncture needle 21 on the bar member 20 side penetrates the skin material 5 and interferes with the mold surface 11 due to the pressing of the bar member 20 by the thrust rod device 40, the puncture needle tip is placed on the mold surface 21 side. A small intrusion hole 17 (FIG. 12) may be provided, and if necessary, a design uneven pattern may be carved on the surface of the mold to hide the transfer of the small hole to the surface of the skin material. If the bar member 20 holds the skin material 5 only through the vacuum suction holes 22, the above-mentioned treatment is not necessary.

(6) Next, the applied skin material 5 is vacuum-formed using a mold 10. As a result, the skin material 5 is molded into a shape corresponding to the external shape of the target molding A. By etching a concavo-convex pattern on the entire surface of the mold surface 11 or partially on a desired surface portion, the concavo-convex pattern is transferred and formed on the surface of the skin material simultaneously with the vacuum forming of the skin material 5. Moreover, the puncture needle insertion mark along the boundary line 3a between the printed part surface 1a and the plain part surface 1b on the surface of the skin material can be camouflaged and hidden by the transferred uneven pattern.

The molding of the skin material 5 using the mold 10 may be performed by air pressure forming or by vacuum pressure forming. In FIG. 8, reference numeral 15 indicates a sealed box for the mold 10 in the case of air pressure molding.

(7) Cooling water is poured into the cooling water pipe 14 of the mold 10 to cool the mold 10 and the molded skin material 5 to a predetermined temperature, and the pressing of the bar member 20 by the thrust rod device 40 is released, and the bar member 20 is remove
The molded skin material 5 is continuously held in the mold 10.

(8) A molded body base 6 pre-molded as shown in FIG. 9 in a mold 10 holding the molded skin material 5.
is inserted and pressed to bond and integrate with the molded skin material 5. The adhesive is applied in advance to one or both of the joint surfaces of the molded body base 6 and the molded skin material 5.

The molded body base 6 can also be formed by molding the base material into a mold 10 holding the molded skin material 5 by a method such as press molding, injection molding, resin bead foam molding, or pour molding.

(9) The bonded body of the molded body base 6 and the molded skin material 5 is removed from the mold, and the ineffective molding material portion 5c around the effective molded part of the molded skin material 5 is trimmed along the periphery of the molded body base 6. Processing c1-c1 (10th
(Fig.), or trimming process c2-c2 with an appropriate width W, and trimming the skin material portion 5c of the width W portion.
The desired molded product A is obtained by folding it back to the back side of the molded body base 6 and rolling it up and fixing it with an adhesive or a stopper to finish the edges. The above-mentioned trimming process c1-c1 or c2-c2 around the molded skin material 5 may be performed on the automobile in the same process as the vacuum forming process of the skin material 5.

In the patterned surface decorative molded body A manufactured above, the boundary line 3 between each pattern surface portion 1 and 2 is a straight line, and its position is approximately accurately positioned at a predetermined position on the molded body surface. . Furthermore, even if the molded body A has a complex external shape, each part of the patterned surface decorative skin material 5 follows the external shape of the molded body base 6 and is in good contact with the molded body A.

In this way, it is possible to easily produce a patterned surface decorative molded article A having a desired shape and high quality with no variation and with a high yield. By preparing a plurality of bar members 20 and performing the setting of the skin material 5 on the bar members 20 (FIGS. 4 to 7) as a preparatory work, it is possible to mass-produce the target molded product A efficiently.

Furthermore, it is also possible to easily manufacture a molded body in which each surface decorative pattern surface portion is made of different materials. That is,
For example, in the case of manufacturing the molded body A shown in FIG. 1a, the first pattern surface portion 1 is cloth and the second pattern surface is a resin sheet, the puncture needle of the bar member 20 is used as shown in FIG. 11. The bar member 20 is formed by holding each edge of the room-temperature extensible or heat-extensible cloth skin material 5d, which will become the first pattern surface portion, and the resin theta skin material 5e, which will become the second pattern surface portion, in the row 21. Then, both the skin materials 5d and 5e are set. In this case, there is no need to use the auxiliary bar member 50 to mark the boundary between the two skin material parts (FIGS. 2 and 3).

Thereafter, the molded body A may be manufactured in accordance with the procedure described in Section 4 and below. Skin material used 5d, 5e
If the material is air permeable and difficult to vacuum form as it is, a non-air permeable backing layer such as a thermoplastic resin may be formed on the back surface of the material in advance.

The cloth 5d was temporarily fixed on the skin material 5e, and a thin wall 16 (FIG. 12) made of a steel plate or the like was provided where the edge of the cloth of the mold 10 touched, avoiding the needle 21 of the bar member 20, and molding was performed. If a thin groove is formed on the surface of the molded article and the end of the cloth 5d is pressed into the groove, a cloth with no irregular edges can be manufactured. It is better to apply adhesive to the outer material to the back of the fabric edge in advance.

C. Effect of the invention As described above, according to the present invention, the desired design and
It is possible to easily and efficiently mass-produce patterned surface decorative molded bodies A with high-grade and high-quality shapes, and the intended purpose is well achieved.

[Brief explanation of drawings]

Fig. 1a is a front view of an example of a patterned surface decorative molded product, Fig. 1b is a sectional view taken along the line b-b of Fig.
Figure a is a plan view of the skin material used, Figure b is a cross-sectional view showing the layer structure, Figure 3 is an explanatory diagram of the configuration of the mold, bar member, and thrust rod device, and Figure 4 is a top view of the skin material used on the auxiliary bar member. Figure 5 is a diagram of the set state, Figure 5 is a diagram of the bar member matched to it, Figure 6 is an enlarged vertical sectional view of a part of it, Figure 7 is the bar member and the skin material held by the clamp frame. Fig. 8 is a cross-sectional view of the vacuum-formed state, Fig. 9 is a cross-sectional view of the molded body fitted with the molded body, and Fig. 10 is a cross-sectional view of the molded body after it has been removed from the mold. Cross section, 11th
12 are explanatory diagrams of other examples, respectively. 10 is a mold, 20 is a bar member, 30 is a frame for clamping the skin material periphery, 40 is a push rod device, 50 is an auxiliary bar member, A is a patterned surface decorative molded body,
5 is a skin material, and 6 is a molded body base.

Claims (1)

[Scope of Claims] 1. In manufacturing a molded object whose surface is decoratively treated by dividing the surface into two or more surface portions with different colors, patterns, materials, etc., the external shape of the desired molded object. A vacuum forming mold, a pressure-air forming mold, or a vacuum-pressure forming mold having a molding surface having a shape that substantially corresponds to the shape of the molded product, and a shape that roughly corresponds to the outer surface shape of the molded product along the boundary line between each surface decorative pattern surface portion of the target molded product. Using the bar member for holding the patterned skin material, the bar member positions and holds the back side portion of the skin material along the mutual boundary line of each pattern surface portion of the patterned surface decorative skin material of the target molded object, and the above-mentioned skin material is The bar member holding the material is positioned at a mold surface position that approximately corresponds to the mutual boundary line position of each surface decorative pattern surface portion of the target molded object, and the skin material is applied to the mold and then vacuum formed or compressed. Molding or vacuum-pressure forming is performed, the bar member is removed while the molded skin material is held on the surface of the mold, and a pre-formed molded body base is fitted into the mold to integrate with the molded skin material. Alternatively, a method for producing a patterned surface decorative molded article, comprising: applying a molded body base material to shape the molded body base and integrating it with a molded skin material. 2 The pattern skin material is held by the bar member by providing a skin material puncture needle along the length of the bar member, a vacuum suction section, or both, and applying the puncture holding force of the puncture needle or vacuum suction. A method for producing a patterned surface decorative molded article according to claim 1, which is carried out by force or both.