JPH0363937B2 - - Google Patents

Description

[Detailed description of the invention]

B. Object of the Invention [Industrial Application Field] The present invention relates to a method for manufacturing a molded article provided with a so-called ornamental skin part (decorative skin part/inlay part). More specifically, the present invention relates to a method for producing a molded article in which substantially the entire back surface of an ornamental skin material is provided in a non-adhesive, so-called floating state on the ground skin surface of the molded article body. [Prior Art] For example, due to the design of a vehicle door trim board, the outer surface of the ground skin of the molded board body is made of a material different from that of the ground skin.
Many of them are made by partially pasting ornamental skin materials of different colors and patterns in a desired design pattern. FIG. 5 is an external perspective view of an example of a door trim board having such an ornamental skin part.
1 is a door trim board body which is a molded body; 2 is an ornamental skin part which is provided by partially pasting a desired design pattern on the outer surface of the ground skin 13 of the board body;・Woven and knitted fabrics with different colors and patterns・
Nonwoven fabrics, carpets, natural leather, synthetic leather, resin sheet materials, etc. The conventional ornament skin part 2 has a configuration in which the entire back surface thereof is completely adhered to the outer surface of the ground skin 13 of the molded body 1. However, in recent years, in vehicle door trim boards, etc., the outer peripheral edge of the ornamental skin material is firmly fixed to the ground skin side of the board body 1, which is the molded body, from the viewpoint of the feel and texture of the ornamental skin part 2. Approximately the entire area of the back side is provided with a non-adhesive, so-called floating pasting form to the ground skin surface, so that the decorative drape wrinkles are consciously expressed on the ornament skin surface, or the fine wrinkles are created when touched. has come to be liked. Conventionally, for such items, as shown in the example in FIG. 6, an ornament skin material 2 is attached to a plate material 22 or a frame material (hereinafter referred to as an ornament core material) formed into an outer shape corresponding to a desired ornament pattern.
1, the peripheral edge 21c was folded back to the back side of the core material 22, and the ornament skin material 21 was folded back as described above while consciously creating fine drape wrinkles 21a on the surface of the ornament skin material 21, or by stretching the skin material 21 loosely. The skin material peripheral part 21c is locked 21b on the back side along the outer periphery of the core material 22 with adhesive or a locking needle, etc., to prevent fine wrinkles 2.
An ornamental skin patch member A with 1a attached or with a skin material loosely stretched is manufactured. The patch member A is applied to a predetermined portion of the surface of the molded body 1, and the core material 22 is subsequently attached using means such as a locking needle 23, a clip, or an adhesive. The molded body 1 in this example is a three-layer composite consisting of a hard or semi-hard solid or porous base layer 11 having appropriate strength and rigidity, a soft intermediate cushion material layer 12, and a ground skin material layer 13. It consists of layers. [Problems to be Solved by the Invention] However, the above conventional manufacturing method is inefficient because both the production of the ornamental skin material patch A and the attachment of the patch A to the molded body 1 are completely manual. In addition, it is difficult to mass produce, is expensive, and requires skilled work to maintain a high level of quality without variations in the position and external shape of the ornament. In view of the above, the present invention provides a rational manufacturing method that can efficiently mass-produce a molded article with an ornamental skin part in a floating state while maintaining a high level of quality without variation. The purpose is to provide B. Structure of the Invention [Means for Solving Problems] The present invention provides that the base of the molded body is molded into a predetermined shape by any method separately from the ground skin material covering the outer surface of the base, and The skin material shall be vacuum formed into a shape that approximately conforms to the outer surface shape of the molded substrate using a vacuum mold, and the vacuum mold has a mold surface portion corresponding to the position of the ornament skin portion to be provided on the surface of the desired completed molded product. A parting frame is provided separated from the mold surface, and the ornament skin material is placed within the parting frame of the vacuum forming mold, and the outer peripheral edge of the skin material is placed along the inner peripheral wall surface of the parting frame, or along the convex part of the parting frame. The ground skin material is set by being hooked to the edge, and then the ground skin material is subjected to vacuum forming processing using the vacuum forming mold, and the above-mentioned separate molding process is carried out on top of the vacuum formed ground skin material while it is held in the vacuum forming mold as it is. The molded substrates that have been molded are stacked together with an adhesive and pressed between the vacuum mold and the vacuum mold by a pressure mold to integrate the molded surface material and the molded base, and in this case, the vacuum mold and the pressure mold are Regardless of the mold clamping pressure, within the parting frame of the vacuum forming mold, the back side of the ornament skin material corresponds to the mold surface within the frame,
The mold surface level within the parting frame of the vacuum forming mold or the protrusion of the outer surface corresponding to this portion of the molding base so as not to substantially press contact with the outer surface portion of the ground skin material corresponding to the back surface portion. The gist of the present invention is a method for manufacturing a molded article having an ornament part with a preset level. [Function] That is, by the above process, the outer peripheral edge of the ornamental skin material set in the parting frame of the vacuum forming mold is aligned with the inner peripheral wall surface or hooked onto the convex edge. Due to the clamping force of the vacuum molding die and the crimping die, the parting frame bites into the wall thickness of the ground skin material in a thermally softened state, so that the outer periphery of the ornament skin material also falls within the wall thickness of the ground skin material. It bites into the ground and adheres to the thermally softened ground skin material, resulting in a locked state. On the other hand, regarding the back surface of the ornamental skin material excluding this biting outer periphery, there is virtually no mutual pressure contact with the outer surface of the ground skin material in a thermally softened state, regardless of the clamping between the vacuum forming mold and the crimping mold. As a result, the material does not adhere to the outer surface of the ground skin material, and is in a so-called floating state with respect to the outer surface of the ground skin material. After that, when the mold is opened and the molded body is removed from the vacuum mold, the parting frame will come out from within the thickness of the ground skin material on the molded body side where it penetrates and bites, but the outer periphery of the ornament skin remains intact as it is in the ground skin material. It bites into the wall thickness and is held in a locked state. Therefore, at the same time as the molded base of the molded body and the molded ground skin material are crimped and integrated, the ornamental skin material is attached to a predetermined surface position of the ground skin material defined by the parting frame, with its outer peripheral edge facing the ground skin material side. The material can be fixed and the back surface can be applied in a non-adhesive, raised form, making it possible to efficiently mass-produce this type of molded product while maintaining a high level of quality without variation. If the ornament skin material is something like moquette, it also has the effect of preventing so-called hair from falling. [Example] (1) Molded substrate 11 of the molded body body For example, various hard or semi-hard solid or porous fleshy resins, resin felt, polystyrene bead foam, rigid corrugated cardboard structures made of resin or paper, etc. , cardboard, hardened plant debris, metal plates, etc. are used as raw materials, and the characteristics of the materials used include vacuum forming, pressure forming, hot press forming, press forming, injection molding, and cast molding. The desired molded body 1 is molded into the desired shape as the base body 11 by a suitable molding method. Also included are molded substrates that are themselves in a laminate configuration. (2) Surface skin material 13 of the body of the molded body, for example, various woven fabrics, knitted fabrics, non-woven fabrics, carpets, soft resin sheets such as vinyl chloride, natural leather, synthetic leather, etc., and a suitable back-up material on the back side thereof. Items that can be entirely vacuum formed, such as those lined with a cushion material layer 12 such as wood or soft foam resin such as polypropylene or felt. (3) Ornament skin material 21 For example, various woven fabrics, knitted fabrics, non-woven fabrics, carpets, soft resin sheets, natural leather, synthetic leather, etc., or those lined with a suitable backing material on the back side, etc. Highly flexible with bendability and stretch. (4) Vacuum forming mold Figure 2 shows a cross-sectional view of an example of a vacuum forming mold. 50 is a mold body, 51 is a molding surface, 52 is a vacuum hole opened in each required part of the molding surface, 53 is a vacuum chamber, and 54 is a vacuum pump. Reference numeral 55 indicates a molding area corresponding to the position of the ornament skin of the desired completed molded product, and 56 indicates a parting frame that partitions the molding surface area. In the mold of this example, the surface of the molding surface region 55 is an uneven surface corresponding to the design fine wrinkles to be expressed on the surface of the ornament skin. The wall thickness of the parting frame 56 may be made as thin as possible. (5) Manufacturing process (Fig. 1) a Setting of the ornamental skin material 21 (Fig. 1 a) The molding surface area 55 in the parting frame 56 of the vacuum forming mold 50 is shaped into an outer shape that approximately corresponds to the outline of the area. The cut ornament skin material 21 is inserted and set. In this example, we use urethane-based synthetic leather with a total thickness of 0.8 mm that is flexible and stretchable by backing cloth. The outer peripheral edge 21c of the ornament skin material 21 is aligned along the inner peripheral wall surface of the parting frame 56, or as shown in FIG. Hook members 25 made of resin, metal, etc. are integrally provided in advance at key points by welding, gluing, sewing, etc., and the hook members 25 are hooked and locked onto the convex edge of the parting frame 56. Or, as shown in Fig. 3b, the oment skin material 21
25a, the periphery thereof is made hard or textured by heat pressing or the like in advance at key points, either all around or at intervals, to form a hook shape 25a
However, the hook portion 25a may be hooked and locked onto the convex edge of the parting frame 56.
Further, the convex edge of the parting frame 56 is made into a sawtooth shape, and the outer peripheral edge 21 of the ornament skin material is attached to the sawtooth portion.
c may be hooked and locked in a thrusting manner. By hooking the outer peripheral edge of the ornament skin material 21 to the parting frame 56, displacement of the set ornament skin material 21 is strictly prevented. Adhesive may be applied in advance to the back surface along the outer peripheral edge 21c of the ornament skin material 21 or to the outer surface of the hook portions 25, 25a. In addition, as mentioned above, the ornament skin material 21 to be set inside the parting frame 56 is vacuum formed and molded in advance.
It is also good to preform by press molding or the like. b. Vacuum forming of the surface skin material of the molded body body (Fig. 1 b) The ground skin material 13 of the molded body body is placed in the vacuum forming mold 50 in which the above-mentioned ornament skin material 21 is set.
After being heated and softened, it is covered and vacuum formed according to a conventional method. The ground skin material 13 in this example has a thickness of
It is a 0.3 mm soft vinyl chloride sheet, with a 2 mm thick cushion material layer 12 on the back side.
It uses a composite material made of 25x foamed polypropylene flexible foam sheets that are bonded together in advance. 57 indicates a seal clamp. Ground skin material 1 with this cushion material layer 12
3, a portion corresponding to the molding surface region 51 outside the parting frame 56 of the mold 50 is well vacuum-formed into a predetermined shape along the outer molding surface. On the other hand, in the parting frame 56, an ornament skin material 21 is set in the frame 56, and in this example, since the skin material 21 is non-air permeable, only the skin material 21 is set in the parting frame 56.
The molding surface 55 inside is vacuum-suctioned and brought into close contact, and the ground skin material portion corresponding to the parting frame 56 is not actually drawn into the upper frame 56. When the oment skin material 21 to be used is breathable, a vacuum suction hole 52 is provided in the molding surface 55 in the parting frame 56 as a vacuum molding mold 50.
It should be in a form that does not include the following. Or even if it is provided, the ornament skin material 21 is formed on the molding surface 5.
5, but the surface skin material part has a weak suction force that is not enough to attract it to the back surface of the ornament skin material 21 and bring it into close contact. c Pressing of the molded base 11 of the molded body body (Fig. 1c, d) While the vacuum-formed ground skin material 13 with the cushion material layer 12 is held in the vacuum mold as it is, a The molded substrates 11 that have been molded and manufactured are stacked together via a hot melt type adhesive, a solvent type adhesive, etc., and then molded into a vacuum mold 5 using a pressure mold (press mold) 60.
0 to integrate both layers. The adhesive may be applied in advance to one or both of the mutually opposing surfaces of the molded base 11 and the cushion material layer 12. The entire outer surface of the molded substrate 11 may be heated and softened or melted in advance to impart adhesive properties. The compression mold 60 of this example is designed to hold the molded substrate 11 by vacuum suction, and 61 is a molded substrate holding surface of the compression mold, 62 is a vacuum suction hole, 63 is a vacuum chamber, and 64 is a vacuum pump. The crimping process of the molded base 11 is performed on the ground skin material 1.
The vacuum forming steps 3 and 12 may be performed at the same time, or with some delay in operation. When the vacuum forming mold 50 and the crimping mold 60 are clamped to a predetermined position, the cushion material layered ground skin material 12, 13 corresponding to the inside of the parting frame 56 is pressed by the corresponding outer surface portion of the molding base 11 side. It is press-molded into the parting frame 56 (FIG. 1d). As a result, the outer peripheral edge 21c of the ornament skin material 21 set in the parting frame 56 is aligned with the inner peripheral wall surface or hooked onto the convex edge of the parting frame 5.
6 is a ground skin material 12 in a thermosetting state due to the clamping pressure of the vacuum forming mold 50 and the pressure bonding mold 60;
13 (Fig. 1 d), the outer peripheral edge 21c of the ornament skin material is also cut into the inside wall thickness of the ground skin materials 12 and 13, and is covered with the thermoset ground skin material. The outer peripheral edge 21c of the ornament skin material 21 is
If an adhesive is applied to the back side of the holder, the adhesive will hold the holder in place. On the other hand, the back surface of the ornament skin material excluding this biting outer peripheral edge is in substantially mutual pressure contact with the outer surface of the ground skin material portion pressed into the parting frame 56 regardless of the mold clamping with the molds 50 and 60. Vacuum forming mold 5 to prevent this from occurring.
0 molding surface level l ₁ (second
(Fig.) Alternatively, by setting the protrusion level _l2 (Fig. 1c) of the outer surface corresponding to the portion of the molded base 11 in advance, the back surface of the ornament skin material and the outer surface of the ground skin material are substantially pressed against each other. No contact occurs. Therefore, even if the outer surface of the ground skin material is thermally softened and adhesive at that point, the back surface of the augment skin material 21 will not adhere to the outer surface of the ground skin material and will not adhere to the outer surface of the ground skin materials 12 and 13. This results in a so-called floating tension state. When the molded skin materials 12, 13 and the molded base 11 are bonded together, the skin material 12, which corresponds to the parting frame 56, prevents the formation of so-called air pockets due to air entrainment between the two.
For the purpose of actively suctioning and adhering the back surface of the portion 13 to the outer surface portion of the molded base 11 to which the back surface portion corresponds, thick through holes are provided in advance at key points of the molded base 11, Molding base holding surface 6 of the crimping mold 60 corresponding to the through hole
By opening a vent hole in one portion, the air between the molded skin materials 12, 13 and the molded base 11 can be actively vented through the vent hole and the thick through hole. d Opening the mold, taking out the molded product, and processing the ends After the predetermined cooling time has elapsed, the compression mold 60 is pulled up (mold opening), and the molded product is removed from the vacuum mold 50. The parting frame 56 on the side of the mold 50 comes out of the cushion material layered ground skin material 12, 13 of the molded body into which it bites, but the peripheral edge of the ornament skin material 21 is held in the biting state, and the adhesive Alternatively, it is firmly fixed by the adhesion force caused by the heat applied to the ground skin material during vacuum forming (Fig. 1e). If hook edges 25, 25a are provided on the periphery of the ornamental skin material 21 as shown in Fig. 3a and Fig. 3b, Fig. 3c
This serves as an anchor member to ensure that the peripheral edge of the ornamental skin material 21 is prevented from slipping out from within the thickness of the ground skin material. Next, the unnecessary outer edges 13a (Fig. 1 e) of the ground skin materials 12 and 13 of the molded body are trimmed c-c, or rolled onto the back side of the molded base 11 as shown by the two-dot chain line (same). Then process the terminals such as fixing them with adhesive to create a finished product. In addition, the ornament skin part 212 is then heated.
By compressing, kneading, etc., the wrinkled state becomes more natural and it can be made to have a good texture. Due to the design, the ornament skin part 2 may be applied in a form that hangs over the edge of the molded body as shown in the example in FIG. can be manufactured. C. Effects of the Invention In this way, this type of molded body in which substantially the entire area of the back surface of the ornamental skin material 21 is provided in a non-adhesive, so-called floating state on the surface of the ground skin material 13 of the molded body body can be efficiently manufactured. It is possible to mass-produce at a low cost while maintaining a high level of quality without variation, and it does not require an ornament core material, so it has the advantage of being able to obtain a lighter product. , the intended purpose is well achieved.

[Brief explanation of drawings]

Figures 1a to 3e are process explanatory diagrams of the embodiment, Figure 2 is a sectional view of the vacuum forming mold, Figures 3a and 3b.
3 shows an example in which a positioning and locking hook member is provided on the edge of the ornament skin material, and FIG. 4 and 5 are external oblique views of an example of a vehicle door trim board provided with an ornamental skin part, and Fig. 6 shows a conventional example in which the ornamental skin part is provided in a floating form. Cross-sectional view. 1 is the molded body body, 13 is the ground skin material layer, 2, 21
is the ornamental skin part or the same skin material.

Claims (1)

[Claims] 1. The base 11 of the molded body 1 is molded into a predetermined shape by any method separately from the ground skin materials 12, 13 that cover the outer surface of the base, and the ground skin materials 12, 13 are The vacuum forming mold 50 is used to vacuum form a shape that approximately matches the outer surface shape of the molded base 11, and the vacuum forming mold has a mold surface portion corresponding to the position of the ornament skin portion 2 to be provided on the surface of the desired completed molded product. A parting frame 56 is provided separated from the mold surface, the ornament skin material 21 is placed within the parting frame 56 of the vacuum forming mold 50, and the outer peripheral edge 21c of the skin material is aligned along the inner peripheral wall surface of the parting frame 56. Alternatively, it is set by being hooked onto the convex edge of the parting frame 56, and then the ground skin materials 12, 13 are formed using the vacuum forming mold.
are subjected to vacuum forming treatment, and while the vacuum formed surface skin materials 12 and 13 are held as they are in the vacuum forming mold, the separately formed molded substrate 11 is superimposed thereon via an adhesive. The molded surface skin materials 12 and 13 are pressed between the pressure mold 60 and the vacuum mold 50.
and the molding base 11 are integrated, and in this case, regardless of the mold clamping force between the vacuum mold 50 and the crimping mold 60, an ornament corresponding to the mold surface within the frame is formed within the parting frame of the vacuum mold 50. The back surface portion of the skin material and the outer surface portion of the ground skin material corresponding to the back surface portion are arranged at the mold surface level within the parting frame of the vacuum forming mold 50 or on the molding base 11 so that there is no substantial pressure contact with each other. A method for manufacturing a molded article equipped with an ornament part, characterized in that a protrusion level of an outer surface corresponding to the part is set in advance.