JPH0542942B2 - - Google Patents

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention is directed to a good-looking automobile interior in which the surface of a base material is covered with an ornamental material such as moquette or carpet material and a synthetic resin skin material. The present invention relates to a manufacturing method and manufacturing apparatus for automobile interior materials that can be easily mass-produced.

(Prior art) A synthetic resin skin material is completely coated on the surface of a base material to which a raised ornament member such as carpet material is partially attached, and this is welded to the periphery of the ornament member. A method of manufacturing an automobile interior material in which a portion of the synthetic resin skin material covering the ornament member is removed along the welding line is widely known, such as in Japanese Patent Publication No. 59-24008.

(Problem to be Solved by the Invention) However, in this type of conventionally known method, in order to cover the surface of a base material partially attached with an ornamental member with a synthetic resin skin material, a synthetic resin skin material is required. The skin material is heated and set on the front side of the base material, and then vacuum formed using negative pressure applied from the back side of the base material so as to completely cover the surface of the base material on which the ornament member is attached. During vacuum forming, the heated synthetic resin skin material is pressed onto the surface of the ornament member, causing hair to fall and causing partial color changes, making it difficult to obtain a good-quality product with good appearance. In the case of a molded base material with unevenness, this tendency is remarkable in the convex portions. Furthermore, when vacuum-formed synthetic resin skin material is cooled, residual stress is generated, and during the subsequent welding process with ornament parts, the synthetic resin skin material at the welded area may cause defects such as cracks, tears, and welding. To prevent plastic deformation, the part of the synthetic resin skin material that covers the ornament member may be cut out immediately after vacuum forming, or the heating temperature of the synthetic resin skin material may be raised to prevent residual stress. Therefore, in the former case, complicated means were required, and in the latter case, there were problems such as the design being impaired due to overheating.

(Means for Solving the Problems) The present invention solves the above-mentioned problems and provides a manufacturing method and manufacturing apparatus for automobile interior materials that can vacuum-form a synthetic resin skin material without causing a color change phenomenon in an ornament member. It was completed for the purpose of coating a synthetic resin skin material on the surface of a base material partially attached with an ornament member, and welding this to the periphery of the ornament member. In a manufacturing method for an automobile interior material in which the part covering the ornament member is removed along the welding line, a synthetic resin skin material is coated on the surface of the base material partially attached to the outside of the raised ornament part. When mounting, the part of the synthetic resin skin material that covers the ornament member is slightly raised above the surface of the ornament member, and the heated synthetic resin skin material and the raised part of the ornament member are cut off from contact and vacuum is applied. The first invention is a method for manufacturing an automobile interior material characterized by molding, which includes a receiving mold for placing a base material provided with a vacuum suction hole and a mold that can be freely matched with the receiving mold. In an automobile interior material manufacturing apparatus that vacuum-forms a synthetic resin skin material onto the surface of the base material placed on the receiving mold by setting a synthetic resin skin material between the presser mold and the mold surface. A soft sealing material is provided corresponding to the outer shape of the ornament member on the surface of the base material, and an air blowing pipe whose tip is communicated with a part of the mold surface surrounded by the soft sealing material, while the A second invention provides an apparatus for manufacturing an automobile interior material, characterized in that a pressing protrusion is provided at a position corresponding to the soft sealing material, and a vent hole is provided for opening a portion surrounded by the pressing protrusion to the atmosphere. It is something.

The base material used in the present invention may be of any material such as synthetic resin board or hard fiber board, and may have a flat structure or a molded base material with uneven structure, but in particular, The effect is remarkable when a molded base material with unevenness is used. next,
The ornamental member to be covered on the surface of the base material may be any fiber fabric woven or knitted with chemical fibers, natural fibers, or any other fibers, but in particular, moquette fabric with a nap length of approximately 0.5 to 10 mm may be used. The effect is remarkable when the fabric has relatively long naps, such as raised fabrics such as carpet fabrics and flocked fabrics. On the other hand, the synthetic resin skin material may be of any material as long as it can be welded by high frequency welding or other means, but generally it is a solid type made of thermoplastic synthetic resin or a laminated type sheet with a foam layer. Depending on the material, a synthetic resin adhesive layer for welding, such as a hot melt adhesive, may be previously formed on the back surface of the part to be welded. Further, the welding means for welding the synthetic resin skin material to the peripheral edge of the ornament member may be performed using any welder such as an ultrasonic welder in addition to a high frequency welder.

(Example) Next, an example of the present invention will be described in detail with reference to the drawings.

1 is a receiving mold with a vacuum box 2 at the bottom, and the mold surface is formed into a concave-convex surface with vacuum suction holes 3 arranged therein, and a part of this mold surface is connected to an air supply source. The connected air blowing pipe 4 is in communication. Reference numeral 5 denotes an assist mold as a presser die which is arranged to be freely matched with the receiving mold 1, and most of the mold surface of the assist mold corresponds to the mold surface of the receiving mold 1. , only a part of the receiving mold 1 facing the part where the ornament member is set has a concave surface sufficient to form the required cavity 6 between the mold surface of the receiving mold 1 during mold matching. be. 7 is set on the mold surface of the receiving mold 1 so that it slightly protrudes from the mold surface of the receiving mold 1 in order to maintain the balance of the base material and enhance the sealing effect when setting the base material on the mold surface of the receiving mold 1. soft sealing material partially buried in 8
10 is a pressing protrusion provided on the mold surface of the presser die 5 so as to correspond to the outer shape of the ornament member; 10 is a hollow portion 6 of the presser die 5 whose open end is surrounded by the presser protrusion 8;
This is a vent that opens the air to the atmosphere. Reference numeral 11 denotes a base material that is set on the mold surface of the receiving mold 1, and the base material 11 is made of a synthetic resin board or hard fiberboard and is preformed into a textured material, and is provided with a large number of small holes for suction. A part of the surface of the base material 11 has a raised length.
Carpet fabric or moquette fabric made of polyester or polyamide fibers with a diameter of 0.5 to 10 mm and a softening point of 70 to 120°C is added and then cut into the desired shape, or pre-cut into the desired shape and then added. An ornament member 21 is attached, and reference numeral 31 is a synthetic resin skin material with a foam layer laminated on the back side as required. It is made of vacuum-formed thermoplastic synthetic resin such as plastic polyester resin and weldable leather or film material, and is heated to an optimal temperature of, for example, 10 to 200 degrees Celsius, so that it is not melted but sufficiently softened. It is designed to be set between the receiving mold 1 and the presser mold 5 in a state in which the mold is held in place.

Next, to show a specific example of manufacturing an automobile interior material using the above-mentioned apparatus and materials, first, a hard wood fiberboard is formed on the surface of a base material 11 which is three-dimensionally formed into a door trim shape using a well-known forming apparatus. A fabric piece made of a polyester fiber with a nap of 2 mm in length and a softening point of 90°C is attached partially around the convex portion formed on the surface of the base material, and this is trimmed into the desired shape. As a result, the ornament member 21 is partially attached to the surface of the base material 11. Then, this is set on the mold surface of the receiving mold 1 with the presser mold 5 opened, and a vinyl chloride resin sheet having a foam layer above it as a synthetic resin skin material 31 is heated and softened at 150°C. , and clamp the presser die 5 and receiving die 1 together. At this time, at the same time or just before the pressing protrusion 8 of the presser mold 5 comes into contact with the base material 11, the air blowing pipe 4 communicating with the mold surface of the receiving mold 1 is blown at a pressure higher than atmospheric pressure, preferably 2 to 6 kg/cm. ² blows air to lift the part of the synthetic resin skin material 31 above the ornament member 21 toward the cavity 6 formed between the holding mold 5 and the receiving mold 1, while connecting it to a vacuum source. When the synthetic resin skin material 31, which has been heated and softened, is vacuum-formed on the surface of the base material through the vacuum box 2 and the vacuum suction hole 3 provided in the receiving mold 1, the ornament is formed on the mold surface of the presser mold 5. Member 21
Since the pressing protrusion 8 is provided so as to correspond to the outer shape of the pressing protrusion 8, the pressing protrusion 8 presses the peripheral portion of the ornament member 21 together with a part of the synthetic resin skin material 31 against the base material 11 on the mold 1. However, the synthetic resin skin material 31 is divided into a part that covers the ornament member 21 and a part that covers the base material 11 with the peripheral edge of the ornament member 21 as a boundary, and the part that covers the ornament member 21 is raised due to air blowing, etc. The synthetic resin skin material 31 and the ornament member 21 are heated during vacuum forming to maintain airtightness so that the vacuum forming can be performed properly.
The contact with the raised part of the base material is cut off, and therefore, it is possible to completely prevent the color change phenomenon caused by the hair falling down when the ornament member 21 is pressed against the heated synthetic resin skin material 31 during vacuum forming. When the material 1 has an uneven curved surface, the synthetic resin skin material 31 has a low development rate due to partial lifting, and therefore it is not necessary to take the trouble of cutting out a part immediately after vacuum forming or to increase the heating temperature. It is possible to reduce residual stress without increasing it. Note that even if a part of the synthetic resin skin material is welded to the periphery of the ornament member 21 by using the pressing protrusion 8 as a welding electrode of a high-frequency welder or the like, the welding process may be performed using another welding device in the next step. However, if the part of the synthetic resin skin material 31 that covers the ornament member 21 is lifted up during welding, the part adjacent to the weld line forming part when pressed by the welding electrode Since the part can be prevented from coming into contact with the raised nap of the ornament member 21, whitening of the ornament member 21 that tends to occur along the welding line can also be prevented. Furthermore, in the above description, air is blown as a means of lifting the portion of the synthetic resin skin material 31 that covers the ornament member 21, but even if the vent hole 10 is connected to a vacuum source (not shown), the purpose is not It can be achieved. Further, as in the other implementation device shown in FIG. A part of the resin skin material 31 may be lifted up while being pressed against the periphery of the ornament member 21 with the pressing protrusions 8 at the leg ends of the frame-shaped presser mold 5 described above. A cushion material may be added in advance to the surface of the ornament member attached to the surface of the ornament member without directly covering it with the synthetic resin skin material 31, or the receiving mold 1 and the assist mold 5 may be placed upside down and facing each other, or may be placed horizontally or horizontally. Detailed changes such as making them face each other are optional. After welding, the part of the synthetic resin skin material 31 that covers the ornament member 21 is cut off using a fusing blade attached to the welding electrode, or the part is thinned until it is easy to remove, and then the ornament member is removed. 21 should be exposed.

(Effects of the Invention) As is clear from the above description, the present invention is characterized in that when vacuum forming a synthetic resin skin material, the part covering the ornament member is slightly raised, and the synthetic resin is heated against the nap of the ornament member. By simply applying a process to eliminate contact between the decorative skin materials, it is possible to prevent the hair from falling and the color change caused by the heat and pressure applied during vacuum forming of the ornamental material. In order to remove the residual stress caused by temperature changes in the synthetic resin skin material or to remove the tension applied to the part covering the ornament component, the part of the synthetic resin skin material that covers the ornament member is cut out, or the synthetic resin skin material is removed. Since there is no need for conventionally complicated measures such as raising the heating temperature, the manufacturing process can be simplified and the design will not be impaired due to overheating. has the advantage of being able to easily carry out the manufacturing method of automobile interior materials with these features, and because of its simple structure, it can be provided at low cost. There are some solutions that will greatly contribute to the development of the industry.

[Brief explanation of the drawing]

FIG. 1 is a partially cutaway front view showing an embodiment of the present invention apparatus in a mold open state, FIG. 2 is a partially cutaway front view showing the same in a mold closed state, and FIG. FIG. 2 is a partially cutaway front view of an example device. 1: Receiving mold, 4: Air blowing pipe, 5: Holding mold, 6:
Hollow part, 7: Soft sealing material, 8: Pressing projection, 1
0: Vent hole, 11: Base material, 21: Ornament member, 31: Synthetic resin skin material.

Claims (1)

[Scope of Claims] 1. A synthetic resin skin material is coated on the surface of a base material partially attached with an ornament member, and this is welded to the periphery of the ornament member. In a manufacturing method for automobile interior materials in which the part covering the ornament member is removed along the welding line, when covering the surface of the base material partially attached with the ornament member with a synthetic resin skin material, the synthetic resin The part of the synthetic resin skin material that covers the ornament member is raised slightly above the surface of the ornament member, and vacuum forming is performed while cutting off contact between the heated synthetic resin skin material and the raised part of the ornament member. A manufacturing method for automobile interior materials. 2. A synthetic resin skin material is set between a receiving mold 1 for placing a base material provided with a vacuum suction hole 3 and a presser mold 5 arranged to be freely matched with the receiving mold 1. In an automobile interior material manufacturing apparatus in which a synthetic resin skin material is vacuum-formed on the surface of a base material placed on a receiving mold 1, the receiving mold 1 is provided with ornamental members on the surface of the base material on the mold surface. A soft sealing material 7 is provided corresponding to the outer shape, and an air blowing pipe 4 whose tip communicates with a part of the mold surface surrounded by the soft sealing material 7 is provided, while the presser mold 5 is provided with the soft sealing material 7. 7. A manufacturing apparatus for automobile interior materials, characterized in that a pressing projection 8 is provided at a position corresponding to the pressing projection 7, and a ventilation hole 10 is provided for opening a portion surrounded by the pressing projection 8 to the atmosphere.