JPH07100837A - Manufacture of automotive interior material - Google Patents

Abstract

PURPOSE:To provide a method of manufacturing an automotive interior material with a skin layer formed integrally using a resin in a mold with advantages of a presentable appearance due to an appropriate skin layer terminal process and a low cost mass production of automotive interior material. CONSTITUTION:A skin material 21 is set in a female die force 1 for vacuum suction with a slide die 3 and a clamp mechanism 6 both for folding the end provided on a terminal peripheral edge, in such a manner that the peripheral edge of the skin material 21 is retained by the clamp mechanism. In addition, the skin material 21 is pressed tightly onto the recessed part of the die which is almost equivalent to the thickness of a core material and formed on the female die force 1 by causing a suction pressure to work on the skin material. Next, the end part of the skin material is trimmed using a cutter 8 by causing the female die force 1 to move forward, and at the same time, the end part of the skin material 21 is bent inwardly by moving the slide die 3 forward. After that, a molten synthetic resin material is injected into a cavity part formed between a male die force 11 and the female die force 1 by causing the male die force to advance until its die surface is flush with the support surface of the skin material 21 of the slide die 3 to form a core plate. Simultaneously, the skin material is bonded, in an integrated form, to the entire peripheral edge from the front to the rear of the core plate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an automobile interior material by resin-in-skin molding.

[0002]

2. Description of the Related Art There are many methods for manufacturing an automobile interior material by molding a resin integrated with a skin, but the terminal treatment is difficult to perform accurately, so that the appearance may be impaired. Further, as disclosed in Japanese Patent Application Laid-Open No. 2-203891, it is also practiced that a skin is preliminarily formed into a predetermined shape, the end is cut, and then the core is set in a core plate molding die to mold the core plate. The productivity is poor because the manufacturing process is complicated and a positioning system is required. Furthermore, problems such as the exudation of resin at the terminals occur.

[0003]

The problem to be solved by the present invention is to solve the above-mentioned problems and to provide a low-priced automobile interior material by a skin-integrated resin molding which is appropriately subjected to a skin end treatment and has a good appearance. Another object of the present invention is to provide a method for manufacturing an automobile interior material by skin-integrated resin molding that can be mass-produced.

[0004]

A method for manufacturing an automobile interior material according to the present invention, which has solved the above-mentioned problems, is a vacuum suction device in which a slide die for bending an end portion and a clamp member are provided on the peripheral edge of the end portion. The skin material is set in the female mold for use with its peripheral edge held by the clamp member, and suction pressure is applied to bring the skin material into close contact with the mold recess corresponding to the thickness of the core material formed in the female mold. Then, the female die is advanced to trim the skin material end portion by the cutter, and the slide die is advanced to bend the skin material end portion inwardly, and then the male die is moved so that its die surface is the slide die. The synthetic resin material is injected into the cavity formed between the male mold and the female mold by advancing until the surface is substantially flush with the skin supporting surface, and the skin is formed on the core plate simultaneously with the molding of the core plate. It is necessary to bond and integrate from the front surface to the back edge. It is an butterfly.

[0005]

Next, the present invention will be described in detail with reference to the drawings. In FIG. 1, reference numeral 1 denotes a vertically movable vacuum suction female die having a die recess 1a communicating with a suction source 1c through a suction fine hole 1b and having a peripheral edge portion of the female die 1. A slide die 3 is provided which is moved back and forth by the cylinder 2 and bends the end portion of the skin material inwardly when it is moved forward.
Reference numeral 4 denotes a support plate mounted on the lower surface of the rear portion of the slide die 3 via a spring 5. The support plate 4 has a clamp member 6 suspended downward by a drive mechanism 7 and a support plate 4 which is horizontally stretched inward. The slide die 3 is provided so as to take two forms, and a trimming cutter 8 is provided on the lower surface of the intermediate portion of the slide die 3.

Reference numeral 9 denotes a clamp receiving member which is erected on the base so as to be positioned directly below the slide die 3,
The clamp receiving member 9 is always springed upward by a spring 10. Reference numeral 11 denotes a male die which is erected on the base inside the clump receiving material 9, and the male die 11 is a skin whose die surface is the upper surface of the slide die 3 when the female die 1 descends in the forward state. It rises until it becomes substantially flush with the material support surface, and a cavity is formed between it and the female die 1.

In order to manufacture an automobile interior material using the apparatus thus constructed, first, as shown in FIG.
Clamp member 6 attached to slide mold 3 as a step
When the skin material 21 is set so that the peripheral edge is clamped, and the suction source 1c is driven to apply suction pressure to the mold concave portion 1a of the female mold 1, the skin material 21 is moved as shown in FIG. The second step, in which the inner surface of the mold recess 1a of the mold 1 is suction-adhered and held, and is molded into a predetermined shape corresponding to the mold recess 1a, is completed. Next, as shown in FIG. When the clamp member 6 on the lower surface of the lower slide die 3 lowers the clamp receiving material 9 against the elastic force of the spring 10 until it is pushed down, the end of the skin material 1 is attached to the slide die 3. The third step, in which the cutter 8 is cut and trimmed to a predetermined size, and the clamp is released, is completed.

Therefore, as shown in FIG. 4, when the cylinder 2 is operated and the slide die 8 is moved forward as a fourth step, the end of the trimmed skin material 21 is released by releasing the clamp of the end portion by the clamp member 6. Since the portion is bent inward, thereafter, as shown in FIG. 5, the male die 11 is raised until its die surface is substantially flush with the skin material supporting surface of the slide die 3 and If the fifth step of injecting the molten synthetic resin material through a material supply hole (not shown) provided in a required portion of the male die 11 in the cavity portion formed between the female die 1 and the female die 1, the core plate 31 is provided in the cavity portion. At the same time that the core material 21 is molded, the entire surface is bonded and integrated from the front surface of the molded core plate to the peripheral edge of the back surface. The skin material 21 is So that the products 31 which are appropriately bonded and integrated to the core plate made of resin is obtained.

The clearance between the slide die 3 and the male die 11 is set to about 5/100 mm so that the molten synthetic resin material supplied does not flow out, and even a maximum of 10/10
It is preferable to set it to 0 mm or less. Further, the molten synthetic resin material may be supplied from the male mold 11 as well as a supplying means used for this kind of molding method such as directly supplying to the cavity by an extruder or the like. The sucking female die 1 may be formed of a porous body, and the slide die 3 for bending the end portion of the skin material may also be formed of a porous body.

[0010]

As is apparent from the above description, the present invention is as follows.
By skillfully using the slide type, the skin end treatment is appropriately performed, and the automobile interior material made of the skin-integrated resin molding having a good appearance can be mass-produced at low cost. Further, since there is no breakage such as a folded-back portion of the end portion of the skin material and no bleeding or bleeding of the molten synthetic resin material to be the core plate, quality and product value can be improved and yield can be improved. Furthermore, since a series of steps can be continuously performed, complicated manual work can be eliminated and productivity can be remarkably improved. Therefore, the present invention is extremely large in that it contributes to the development of the industry as a solution to the problems of the conventional method for manufacturing an automobile interior material by resin molding for skin.

[Brief description of drawings]

FIG. 1 is a partially cutaway front view of a main part for explaining a first step of an embodiment of the method of the present invention.

FIG. 2 is a cross-sectional view of an essential part explaining a second step of the embodiment of the method of the present invention.

FIG. 3 is a cross-sectional view of an essential part explaining a third step of the embodiment of the method of the present invention.

FIG. 4 is a cross-sectional view of a main part for explaining a fourth step of the embodiment of the method of the present invention.

FIG. 5 is a cross-sectional view of an essential part explaining a fifth step of the embodiment of the method of the present invention.

FIG. 6 is a sectional view of a main part of an automobile interior plate manufactured by the method of the present invention.

[Explanation of symbols]

 1 Female mold 1a Mold recess 1b Suction hole 1c Suction source 3 Slide type 6 Clamping member 8 Cutter 9 Clamp receiving material 11 Male type 21 Skin material

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Claims (1)

[Claims] 1. A skin material is set in a female die for vacuum suction having a slide die for bending the end portion and a clamp member on the periphery of the end portion, with the periphery held by the clamp member, and then suctioned. By applying pressure, the skin material is brought into close contact with the mold recess formed in the female mold and having a thickness substantially corresponding to the core material, and then the female mold is advanced to trim the edge of the skin material by the cutter and advance the slide mold. Then, the end portion of the skin material is bent inward, and then the male mold is advanced until its mold surface is substantially flush with the skin material supporting surface of the slide mold, and between the male mold and the female mold. A method for manufacturing an automobile interior material, comprising injecting a molten synthetic resin material into a cavity portion to be formed, molding the core plate, and simultaneously adhering and integrating the skin material from the front surface of the core plate to the peripheral edge of the back surface.