JPH0552244B2 - - Google Patents

Description

[Detailed Description of the Invention] (Industrial Application Field) This invention relates to a method for manufacturing an interior material for an automobile,
In particular, the present invention relates to a method of manufacturing an interior material in which an ornament made of woven fabric or the like is fixed to the surface of the interior material.

(Prior Art) In recent years, so-called integrally molded interior materials, in which interior components such as armrests are integrally molded into a part of the interior materials for automobiles, typified by door trims, have tended to be frequently used.

By the way, there are various methods for manufacturing such an integrally molded interior material, but one method is to set a vacuum-formed skin such as soft vinyl chloride resin in a mold, and then cover the back side with liquid foamed plastic such as hard urethane foam. There is a method of casting and lining the skin material with plastic material.

On the other hand, a door trim is required to have a good feel, and an ornament member having a surface material such as woven fabric is required to be attached near the armrest.

When manufacturing a door trim using the above-mentioned method for manufacturing an integrally molded interior material, the ornament member is usually attached in a later process, and the end portion of the ornament member is often hidden inside the trim skin material. If so, it is necessary to provide an undercut in the skin material. However, in this case, since the back surface of the skin material is lined with hard urethane foam or the like, there is a problem in that it is difficult to attach the ornament member.

Therefore, we fixed the ornament material to the skin material,
A method has also been proposed in which after setting this in a mold, a liquid plastic such as hard urethane foam is cast on the back side of the skin material. However, in this method, when the surface material of the ornament member is made of woven cloth, etc., the surface of the woven cloth is pressed against the mold by the foaming pressure when the liquid plastic is foamed, and the hairs on the surface are prevented from falling. It has been found that a so-called heat-set phenomenon occurs in which the hair fall is fixed due to the heat generated at that time and the heat retained by the mold.

(Problems to be Solved by the Invention) The present invention solves the above-mentioned problems and provides a method for manufacturing a novel interior material in which the lint of the woven fabric on the surface of an ornament member is less likely to fall. .

(Means for Solving the Problems) The gist of the present invention is to set the skin material to which the ornament member is fixed in a mold, and then to cast liquid foamed plastic on the back side of the skin material. A method of manufacturing an interior material in which a material is lined with a plastic material includes casting liquid foamed plastic while supporting the ornament material with needle-like protrusions.

An example in which the present invention is applied to the manufacture of an automobile door trim will be described below.

(Example) Fig. 1 is an enlarged sectional view of the skin material and mold in the support part of the ornament member shown in Fig. 2, and Fig. 2 is an overall sectional view showing the arrangement of the skin material and mold before setting the skin material. It is.

By closing the lower mold 10 and the upper mold 12, the mold forms a cavity that conforms to the surface shape of the door trim. At a predetermined position on the mold surface of the lower mold 10 is a needle-shaped projection 15 for supporting an ornament member 14, which will be described later.
Many have been erected. The needle-like protrusion 15 may have a sharp tip like a sword mount, or may be a thin rod with a small diameter. The former is suitable when the surface material 16 of the ornament member 14 has thin hair, and the latter is suitable when the hair is thick.

The ornament member 14 includes at least the surface material 1
6 and a backing material 18. The surface material 16 is woven fabric,
It is preferably made of a decorative material with excellent feel, such as a knitted fabric or a flocked layer, and is preferably brushed. Backing material 1
Reference numeral 8 is for holding the surface material 16 such as woven fabric in a predetermined shape, and is made of a material having appropriate rigidity such as a plastic sheet, hardboard, or metal plate. Note that a cushion material 20 such as soft polyurethane foam may be interposed between the two. The surface material 16, the backing material 18, and if necessary the cushion material 20 are laminated and crimped to reduce the thickness at the periphery.

The skin material 22 forms the surface layer of the door trim 30 shown in FIG. 7, and may be a vacuum-formable sheet material mainly made of soft vinyl chloride resin, or a layer of other materials that do not inhibit vacuum forming. For example, it is made of a vacuum-formed body of laminated foamed polyethylene sheets, etc., and an ornament member 14 is fixed at a predetermined position.

Next, a door trim manufacturing process based on the present invention using these will be explained.

First, the skin material 2 to which the ornament member 14 is fixed
Prepare 2.

The ornament member 14 is fixed to the skin material 22 by fitting the ornament member 14 after vacuum forming into the recess 24 shown in FIG. This may be carried out simultaneously with the vacuum forming of the sheet-like material. The latter fixation during vacuum forming is achieved by setting the ornament member 14 in a predetermined position of the vacuum forming mold 26 with the skin material 16 and the mold surface facing each other, and disposing it on the backing material 18 side, as shown in FIG. 5A. The sheet-like material 22a is attached to the ornament member 1 as shown in 5th B.
4. Vacuum forming is performed to surround the back and sides. Note that the vacuum forming mold 26 includes the lower mold 10.
A protrusion 28 similar to the upright needle-like protrusion 15 is provided, and the ornament member 14 is placed on the needle-like protrusion 28 in a state floating from the mold surface to perform vacuum forming of the sheet-like material 22a. Good. This prevents the surface of the ornament member 14 from coming into pressure contact with the mold surface during vacuum forming, and the nap of the surface material 16 from falling down. Further, it is also possible to use the lower die 10 and the vacuum forming die 26.

The skin material 22 is set on the surface of the lower mold 10 so that the ornament member 14 is located on the needle-shaped protrusion 15. At this time, the ornament member 14 is
As shown in FIG. 3, the surface material 16 is supported by the needle-like protrusions 15 and is slightly suspended from the mold surface of the mold 12.

Subsequently, a liquid foamed plastic, for example, a hard urethane foam raw material, is injected into the back surface of the skin material 22.
The lower mold 10 and upper mold 12 are closed. At this time, a reinforcing material such as glass fiber may be set on the upper mold 12 or on the back surface of the skin material 22, if necessary.

After the foaming of the foamed plastic is completed, the product is demolded. FIG. 6 shows a cross section of the ornament part when the foamed plastic is foamed, and FIG. 7 shows an example of the door trim obtained.

Next, the action during injection and foaming of foamed plastic in this invention will be explained.

(Function) The ornament member 14 of the skin material 22 set on the lower mold 10 is supported by the needle-like projections 15 in a slightly floating state of the lower mold 10 as shown in FIG. The ornament member 14 is pressed against the mold surface side of the lower mold 10 by the foaming pressure when the foamed plastic injected into the back surface of the skin material 22 is foamed. However, since the ornament member 14 is supported by the needle-like projections 15 as described above, it is prevented from moving toward the mold surface, and even if the needle-like projections 15 penetrate the surface material 16 of the ornament member. It abuts against and supports the back material 18, and the surface material 16
is not pressed against the mold surface. In other words, the needle-like protrusions serve to prevent hair from falling down, such as the piles of the surface material, and at the same time, the slight gap created between the surface material 16 and the mold surface of the lower mold 10 allows heat setting, etc. It also has the effect of cutting off heat conduction from the lower mold, which has an adverse effect.

(Effects) According to this invention, when foaming plastic is injected into the back surface of the skin material to which the ornament member is fixed, the ornament member is slightly suspended in the air from the mold surface by the needle-like protrusions provided upright in the foam molding mold. Since the ornament member surface is supported in a fixed state, the surface of the ornament member is not pressed against the mold surface of the mold, and the hairs do not fall. In addition, a slight gap created between the surface of the ornament member and the mold surface of the foam mold prevents the conduction of heat from the mold to the ornament member, and the surface of the ornament member may undergo thermal deformation such as heat set. There is no.

[Brief explanation of the drawing]

The drawings relate to an embodiment of the present invention; FIG. 1 is an enlarged sectional view of the ornament support portion of the lower mold and the skin material before the skin material is set, and FIG. 2 is an overall view showing the arrangement of the mold and the skin material before the skin material is set. 3 is an enlarged sectional view of the ornament support after setting the skin material, FIG. 4 is a sectional view illustrating the fixation of the ornament member after vacuum forming, and FIGS. 5 A and B show the ornament member during vacuum forming. FIG. 6 is an enlarged cross-sectional view of the ornament support when foamed, and FIG. 7 is a perspective view of a door trim obtained by the present invention. 14...Ornament member, 15...Acicular projection, 22...Skin material.

Claims (1)

[Claims] 1. In the method for producing an interior material, the method for manufacturing an interior material includes setting a skin material to which an ornament member is fixed in a mold, and then lining the skin material with a foamed plastic material by casting liquid foamed plastic on the back side of the skin material. A method for producing an interior material, characterized by casting liquid foamed plastic while supporting the member with needle-like protrusions.