JPH08156141A - Surface material equipped with speaker grille and apparatus for manufacturing the same - Google Patents

Abstract

PURPOSE: To provide a surface material equipped with a speaker grille which is produced at a low manufacturing cost and still keeps a high-quality feeling. CONSTITUTION: This surface material equipped with a speaker grille is composed of a rigid base material 1 and a flexible synthetic resin skin 15 which is fixed on the surface of the base material 1 to cover the surface. Numbers of lower holes 12 are formed in the base material 1 at positions for making the speaker grille, notch recess parts 13 are formed in a range including all the lower holes in the back of the base material, the synthetic resin making the skin covers integrally the surface of the base material 11, the inside surfaces of the lower holes 12, and the recess parts 13, and numbers of through holes 16 for passing voice from a speaker are formed concentrically with the lower holes 12. An apparatus for manufacturing the surface material consists of a base material side mold 20 and a skin side mold 15, and a lot of pins 26 for making the through holes 16 are formed to protrude from the skin side mold.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface material provided with a speaker grill such as a door trim or an interior material of a vehicle and an exterior material of an audio device, and a manufacturing apparatus thereof.

[0002]

2. Description of the Related Art FIG. 4 and FIG. 5 show a separate speaker grill 5
1 shows an example of a conventional automobile door trim 1 equipped with a door trim 1. The door trim 1 is made by covering a surface of a base material 1a made of a rigid wooden aggregate or synthetic resin with a relatively flexible synthetic resin such as polypropylene. is there. The body 6 of the speaker grill 5 made of a relatively hard synthetic resin is formed with a large number of through holes 6a for allowing sound to pass therethrough, and the surface thereof is covered with a decorative body 6b made of woven fabric or the like. Is attached by locking a hook 6c to one side of the opening 2a formed in the recess 2 of the door trim 1 and screwing a mounting screw 8 into an insert fitting 7 provided on the other side. The speaker 3 is fixed to the frame inside the door, and the cushion material 4 made of urethane foam or the like adhered to the frame portion 3a of the speaker 3 is in contact with the peripheral portion of the inner surface of the grill body 6.

[0003]

The door trim provided with the above-described speaker grill of the prior art has a soft touch and is luxurious and has a high-class feeling, but since the speaker grill is a separate entity and has a complicated structure, it is costly for each part and mounting process. Cost is required, and the manufacturing cost is increased. SUMMARY OF THE INVENTION It is an object of the present invention to solve the above problems and provide a surface material such as a door trim provided with a speaker grill which is low in manufacturing cost and which does not lose a high-class feeling.

[0004]

A surface material provided with a speaker grill according to the present invention comprises a rigid base material and a soft synthetic resin skin adhered to and covering the surface of the base material. is there. A large number of pilot holes are formed in the base material at positions corresponding to the speaker grilles, and notch relief portions are formed in a range including all the pilot holes on the back surface of the base material. The skin integrally covers the surface of the base material, the inner surface of each pilot hole, and the notch relief portion, and has a large number of through holes corresponding to each pilot hole.

Further, in the apparatus for manufacturing a surface material provided with the speaker grill according to the present invention, a large number of pilot holes are formed at the positions to be the speaker grill, and the notch escape portions are formed in the range including all the pilot holes on the back surface. A base material is used, and a base material side molding die having a support surface for positioning and supporting the base material by abutting on the back surface of the base material, and a base material side molding die that can be moved toward and away from the base material side molding die. The thickness of the skin between the skin-side mold and the surface of the base material supported by the base-side mold, which is formed on the skin-side mold in the closest state of both molds. And a molding surface that forms a gap corresponding to each of the pilot holes and is provided so as to project from the molding surface toward the base-side mold corresponding to each pilot hole. With a large number of pins that are smaller in diameter than the pilot holes that come into contact with the support surface of the material side mold A.

[0006]

In the surface material provided with the speaker grill according to the present invention, since the speaker grill is formed integrally with the surface material, the cost for each part and the mounting processing cost are unnecessary. In addition, since the surface of the rigid base material is covered with a soft skin, the feel is soft, and the lower hole of the base material is covered with synthetic resin around the inner surface and the back surface, so that the voice Rough skin of the base material is not exposed on the inner surfaces of a large number of through-holes to be passed, and the inner surface shape of the through-holes for passing sound is not broken by peeling off the back surface side of the synthetic resin covering the inside of the lower hole.

Further, in the apparatus for manufacturing a surface material provided with a speaker grill according to the present invention, a pin that passes through the prepared hole of the base material is brought into contact with the support surface of the base material side molding die so that the base material is brought into contact with the base material. With a gap formed between the surface of the base and the molding surface of the skin-side mold, the molten synthetic resin is placed in the space formed between the base, the base-side mold, the skin-side mold, and the pin. By filling, a surface material integrally formed with a speaker grill having many through holes is formed.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which a surface material having a speaker grill and a manufacturing apparatus therefor according to the present invention is applied to a door trim of an automobile will be described below with reference to FIGS. The surface material 10 of the present embodiment is a laminated body composed of a rigid base material 11 and a flexible skin 15, and the base material 11 is made by adding and mixing a thermosetting resin such as phenol resin as a binder to wood chips or fibers. The obtained product was hot-press molded so as to be porous. The synthetic resin forming the skin 15 is a polypropylene resin which is a relatively flexible thermoplastic resin, and as described later, the molten synthetic resin 32 supplied onto the base material 11 is spread on the surface of the base material 11. It has been fixed firmly.

As shown in FIG. 1, a part of the surface material 10 has a large number of through holes 16 through which sound from a speaker (not shown; see reference numeral 3 of the prior art shown in FIG. 5) provided on the back surface is passed. Is integrally formed with the speaker grill B. As best shown in the partially enlarged cross-sectional view of the speaker grill B portion shown in FIG. 3 (a), the through holes 16 (see FIGS. 3 (b) and (c)) to be formed are formed in the base material 11. Correspondingly, a large number of pilot holes 12 having a diameter slightly larger than that are formed, and the base material 1
On the back surface of No. 1, a notch escape portion 13 having a constant depth is formed over a range slightly wider than the portion including all the pilot holes 12. As shown in FIG. 3 (c), the entire surface of the base material 11 is covered with a skin 15, and the inner surface of the lower hole 12 is covered with a synthetic resin which is integral with the skin 15 and has a through hole 16 through which sound from a speaker passes. The inside of the notch escape portion 13 is formed and is covered with the synthetic resin that is integral with the outer skin 15, and the lower surface of this portion is the base material 1.
It matches the back of 1. These synthetic resins are integrally fixed to the base material 11 by an adhesive applied to the base material 11 in advance or by an anchor connection in which the synthetic resin enters the fine gaps on the outer surface of the base material 11. For convenience of drawing, the thickness of the synthetic resin covering the skin 15, the inner surface of the lower hole 12 and the synthetic resin of the notch escape portion 13 is shown thicker than it actually is.

As shown mainly in FIG. 2, the manufacturing apparatus used for carrying out the present embodiment includes a lower mold (base material molding mold) 20 attached to a fixed mold supporting member (not shown) under the molding device. An upper mold (skin side molding mold) 25 attached to a movable mold supporting member (not shown) above the molding device, and a resin supply device 30 for discharging the synthetic resin in a molten state. On the upper surface of the lower die 20, a support surface 20a having a shape that matches the basic back surface shape of the base material 11 is formed.
The base material 11 is positioned and supported by the whole 0a. In this positioning and supporting state, as shown in FIG. 3, a space corresponding to the notch escape portion 13 is formed between the supporting surface 20a of the lower die 20 and the base material 11 (not shown in FIG. 2).

Upper mold 2 attached to the movable mold supporting member
5 is capable of approaching and separating from the lower mold 20 from above.
3 (a) shows the separated state, and FIG. 3 (b) shows the closest state. A molding surface 25a having a shape corresponding to the surface of the skin 15 covering the surface of the base material 11 is formed on the lower surface of the upper die 25, and each molding hole 25 of the base material 11 is formed on the molding surface 25a.
Corresponding to, a large number of pins 26 smaller than this,
It is provided so as to project toward the lower die 20 along the moving direction of. In the closest state shown in FIG. 3 (b), the surface of the base material 11 supported by the lower mold 20 and the molding surface 2 of the upper mold 25.
The distance from the surface 5 a is the skin 15 formed on the surface of the base material 11.
A space having the same thickness as that of the pin 26 is formed, and the tip of each pin 26 is in contact with the supporting surface 20a of the lower die 20. Lower mold 20
An outer step portion 20b and an inward step portion 25b are formed on the outer peripheral portion of the upper mold 25 along the planar contour shape of the skin 15, and these two step portions 20b, 25b have a slight gap in the closest state. Are fitted together.

A resin supply device 30 for supplying a synthetic resin in a molten state to form the skin 15 has a nozzle 31 at the tip and has a movable supply pipe 30a. Resin supply device 3
0 is a synthetic resin 3 in a molten state while moving the nozzle 31.
2 is supplied in a strip shape on the base material 11. The supply pipe 30a and the nozzle 31 are moved from the upper side of the lower mold 20 to the side and retracted before lowering the upper mold 25.

Next, the operation of this embodiment will be described using the manufacturing apparatus shown in FIGS. Lower mold 20 and upper mold 25
Is adjusted to a temperature of 50 to 80 ° C. in advance, and
As shown in (a), with the upper die 25 separated from the lower die 20, the substrate 11 is positioned on the lower die 20 by contacting the back surface of the substrate 11 excluding the notch escape portions 13 with the supporting surface 20a of the lower die 20. Supported. Next, while the supply pipe 30a and the nozzle 31 of the resin supply device 30 move between the lower mold 20 and the upper mold 25, the synthetic resin 32 in a molten state (180 to 200 ° C.) is supplied to the base material 11 in a strip shape. The discharge amount of the synthetic resin is controlled to be equal to or slightly larger than the volume of the skin 15 to be molded. After this discharge is completed, the supply pipe 30a
The nozzle 31 is retracted from the lower mold 20, and the upper mold 25 is lowered toward the lower mold 20.

As a result of this lowering, first the lower mold 20 and the upper mold 2
5. The outer step portion 20b and the inner step portion 25b of the outer peripheral portion are fitted to each other, and the molten synthetic resin discharged in a strip shape on the base material 11 moves in front of and behind the surface of the base material 11 and the upper mold 25. It is spread between the molding surfaces 25a. As shown in FIG. 3 (b), the upper mold 25 is lowered to the closest position where the distance between the surface of the base material 11 and the molding surface 25a becomes a value corresponding to the thickness of the skin 15 to be molded on the base material 11. When approaching the mold 20, the synthetic resin in a molten state will be exposed on the surface of the base material 11 and the molding surface 25 of the upper mold 25.
a, a space between the inner surface of the pilot hole 12 and the pin 26, and a space between the notch escape portion 13 and the support surface 20a are compression-filled to form a skin 15 integrally coupled to the base material 11. To be done. A small amount of extra synthetic resin is attached to the step 2
It is discharged as a thin burr from the gap between 0b and 25b.

As a result, the entire surface of the base material 11 is covered with the skin 15.
The inner surface of the lower hole 12 is covered with a synthetic resin that is integral with the outer skin 15, the through hole 16 is formed with the pin 26, and the inside of the notch escape portion 13 is also covered with the synthetic resin that is integral with the outer skin 15 so that a door trim A is formed. Molded. Then, when the temperature of the formed skin 15 is below a predetermined temperature at which it is hardened to a manageable level, the upper mold 25 is raised and the completed door trim A is taken out.

According to the above-described embodiment, the speaker grill B is molded at the same time as the door trim A, and no separate parts cost or installation processing cost is required, so that the manufacturing cost of the door trim having the speaker grill can be reduced. . Moreover, the door trim A of the present embodiment has a soft outer skin 15 that is soft to the touch, and has a large number of through holes 16 that allow sound to pass through. The inner surface of the through holes 16 is covered with a synthetic resin to form the base material 11. Of the synthetic resin on the inner surface of the through hole 16 without exposing the rough skin of
The shape is maintained by the synthetic resin filled in 3 and the shape is not deformed such as being deformed inward, so that the high-class feeling is not impaired.

In the above embodiment, a simple round hole is used as each through hole 16, but each through hole 16 may be a slit-like one arranged vertically and horizontally, and each through hole 16 is formed on the surface of the skin 15. You may provide the pattern by a convex line or a concave line in connection with this.

Although the above embodiment is an example in which the skin 15 is molded by compression molding, the skin 15 may be molded by injection molding. In this case, after closing the lower mold 20 and the upper mold 25 at the closest position, the molten synthetic resin from the resin supply device is applied under high pressure (100 to 300 kg / cm ² ) to the surface of the base material 11 and the upper mold. Between the molding surfaces 25a of the 25, the pilot hole 12 and the pin 2
6 and the space between the notch escape portion 13 and the support surface 20a of the lower mold 20. In this case, the synthetic resin in a molten state may be supplied from either side of the upper mold 25 and the lower mold 20.

In the above embodiment, polypropylene resin was used as the material for the skin 15, but thermoplastic resins such as vinyl chloride resin, polyethylene resin, polyamide resin, ABS resin, etc. may be used alone or in combination of two or more. May be. Further, although the wood-based porous molded article is used as the base material 11, a porous resin molded article such as hard urethane foam may be used, or a thermosetting resin such as phenol resin, epoxy resin, polyester resin or the like. Any material such as a polypropylene resin, a thermoplastic resin such as an ABS resin, or a composite material obtained by reinforcing these with a fiber or a metal can be used. When the heat welding property of the skin 15 to the base material 11 is poor, the base material 11 is made porous as described above,
The material of the skin 15 may be impregnated into a large number of gaps on the surface of the base material 11 to enhance the bondability between the base material 11 and the skin 15 by an anchor effect, or a surface modifier such as a modified olefin may be used as the base material. It may be applied to the surface of No. 11 to improve the wettability with the surface skin 15 to enhance the bondability, or may be combined to enhance the bondability.

[0020]

As described above, according to the surface material provided with the speaker grill of the present invention, the speaker grill is formed integrally with the surface material, and the cost of each part and the mounting processing cost are not required, so that the speaker grill is not required. It is possible to reduce the manufacturing cost of the surface material equipped with, and the soft skin makes it soft to the touch, and a large number of through holes that allow sound to pass through give it a functional beauty. Since it is not exposed or the shape is not broken, the high-class feeling is not impaired.

Further, according to the apparatus for manufacturing a surface material having a speaker grill of the present invention, since the surface material integrally formed with the speaker grill as described in the above item is molded, the surface material of the surface material is the same as in the above item. The manufacturing cost can be reduced, and the high-class feeling is not impaired.

[Brief description of drawings]

FIG. 1 is a plan view showing an embodiment of a surface material provided with a speaker grill according to the present invention.

2 is an overall cross-sectional view showing an apparatus for manufacturing a surface material of the embodiment of FIG. 1, which is a cross-section taken along line XX of FIG.

3 is a diagram showing the structure and manufacturing process of the surface material of the embodiment of FIG. 1 shown in the partially enlarged sectional view of FIG.

FIG. 4 is a plan view showing an example of a surface material provided with a speaker grill according to a conventional technique.

5 is an enlarged sectional view taken along line 5-5 of FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... Surface material, 11 ... Base material, 12 ... Under hole, 13 ... Notch escape part, 15 ... Skin, 16 ... Through hole, 20 ... Base material side mold (lower mold), 20a ... Support surface, 25 ... Skin Side mold (upper mold), 25a ... Molding surface, 26 ... Pin, B ... Speaker grill.

Continuation of the front page (51) Int.Cl. ⁶ Identification number Internal reference number in the agency FI Technical display location B29C 59/00 F 9446-4F H04R 1/02 104 Z // B29L 9:00 31:58 (72) Inventor Komada Kaneyoshi 25, Kamifujiike, Yoshiwara-cho, Toyota-shi, Aichi Araco Co., Ltd.

Claims (2)

[Claims] 1. A surface material having a speaker grill having a large number of through-holes through which sound from a speaker is provided on the back surface, and a rigid base material and a surface fixed to the surface of the base material to cover the surface. Made of flexible synthetic resin skin,
A large number of pilot holes are formed in the base material at a position to be a speaker grill, and a notch escape portion is formed in a range including all the pilot holes on the back surface of the base material, and the skin is formed on the front surface of the base material and the front surface of the base material. A surface material provided with a speaker grill, characterized in that an inner surface of each pilot hole and the notch escape portion are integrally covered and a large number of through holes corresponding to the pilot holes are formed. 2. A rigid base material and a soft synthetic resin skin fixed to the surface of the base material and covering the surface of the base material, and a large number of through-holes formed on the back surface for allowing sound from a speaker to pass therethrough are formed. In the manufacturing apparatus for a surface material including the speaker grill, the back surface of the base material, in which a large number of pilot holes are formed at positions to serve as the speaker grill, and notch escape portions are formed in a range including all the pilot holes on the back surface. A base material side molding die having a supporting surface that abuts against the base material and positions and supports the base material, a skin side molding die provided so as to be able to approach and separate from the base material side molding die, and the base material side molding die Is formed in the outer skin side molding die so as to face the surface of the base material supported by the base material, and a gap corresponding to the thickness of the outer skin is formed between the surface of the base material in the closest state of both molds. The molding surface and the molding surface corresponding to each pilot hole And a diameter smaller than that of the pilot hole that is provided so as to project toward the base-material side molding die and that concentrically passes through each of the pilot holes in the closest state and a tip of the tip abuts the supporting surface of the base-material-side molding die. An apparatus for manufacturing a surface material having a speaker grill, characterized by comprising a large number of pins.