JPH10687A - Press-bonding method for decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce a mold expense by reducing a working man-hour, enhancing an external appearance show, and alleviating a restriction applied to a shape of a woodgrained groove by discontinuing a conventional adhesive in a method for press-bonding a decorative sheet for press-bonding the sheet to a surface predetermined position of a trim body. SOLUTION: A metal foil 31 and a hot-melt film 32 are laminated in this order on a rear surface of a decorative sheet 30. The sheet 30 is set at a surface predetermined position of a door trim body 20. Then, the foil 31 is heated by electromagnetic induction heating. The film 32 is melted. Thus, the sheet 30 is press-bonded to the surface predetermined position of the body 20 by a strong strength without using an adhesive.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to interior parts for automobiles such as door trims for automobiles, and more particularly to a method for crimping a decorative sheet which can easily and beautifully attach a decorative sheet to a trim main body.

[0002]

2. Description of the Related Art In recent years, in order to enhance the livability in a vehicle interior, as a material of a skin material used for interior parts such as an automobile door trim, a high grade material such as a high-quality cloth or a cloth such as cloth is used. Attempts have been made to attach a decorative sheet to a predetermined portion of the door trim surface.

FIG. 8 is a sectional view showing the structure of a conventional automobile door trim. A door trim 1 is formed by attaching a skin material 3 to a surface of a core material 2 formed into a required shape. The exterior appearance, such as the body 4 and a cloth or the like that further provides a decorative property to a predetermined portion of the surface of the door trim body 4
The decorative sheet 5 has an excellent surface feel.

In order to enhance the appearance of the peripheral portion of the decorative sheet 5, the peripheral end 5a of the decorative sheet 5 is provided with a wood-groove groove 4a (groove depth of about 9 m) formed in the door trim main body 4.
The graining process is performed in m).

By the way, as a conventional method of pressing the decorative sheet 5 to the door trim body 4, first, as shown in FIG. 9, a door trim is performed by using a masking jig 6 a so as to prevent uneven application of the adhesive 6 b. The adhesive 6b is applied to the surface of the main body 4 by the spray gun 6.

Although not shown, an adhesive is also applied to the back surface of the decorative sheet 5, and the adhesive applied to the door trim body 4 and the decorative sheet 5 is dried by hot air or the like.

Next, as shown in FIG. 10, the door trim main body 4 is set on the upper crimping die 7a, the decorative sheet 5 is set on the lower crimping die 7b, and the upper and lower crimping die 7a, 7b are clamped. Then, as shown in FIG. 11, the decorative sheet 5 is crimped to a predetermined position on the surface of the trim main body 4.

As shown in FIG. 12, the peripheral edge 5a of the decorative sheet 5 is pressed into the wood groove 4a of the trim main body 4 by the wood grain blade 8 in the next step.
The manufacture of the door trim 1 is completed.

[0009]

As described above, in the conventional method of crimping the decorative sheet 5 to the door trim main body 4, the process of applying the adhesive 6b to both the door trim main body 4 and the decorative sheet 5 and drying is performed. It has been pointed out that it is necessary, the number of steps is increased, the production cost is increased, and the working environment is deteriorated due to the use of the adhesive 6b.

Further, it is necessary to properly position the decorative sheet 5 with respect to the door trim main body 4. If the decorative sheet 5 is misaligned, the surface of the product is easily stained by the adhesive 6b on the door trim main body 4 side. Further, when a cloth is used for the decorative sheet 5, there is a problem that the cloth is deformed by heat in a drying step and a pressure bonding step of the adhesive, and the hair of the cloth is liable to fall down, thereby deteriorating the commercial value.

Further, since it is difficult to uniformly apply the adhesive 6b into the wood groove 4a, the peripheral edge 5a of the decorative sheet 5
It is difficult to keep the bonding strength of the door trim 5 good, and the terminal 5a is liable to float.
It is necessary to deeply set the groove depth of the wood groove 4a to be formed, and the molding of the molding die is troublesome, and the bonding of the skin material 3 of the door trim 1 also requires accuracy. There is a disadvantage that the sticking process of the skin material is troublesome.

The present invention has been made in view of such circumstances, and in a method of crimping a decorative sheet to be attached to a predetermined portion of the surface of a trim main body, the conventional adhesive is eliminated to reduce the number of steps. In addition to improving the working environment, it has various advantages such as the ability to reliably prevent the surface of the product from being stained by the adhesive, the appearance performance can be improved, and the mold processing for trim body molding can be simplified. An object of the present invention is to provide a method for crimping a decorative sheet.

[0013]

In order to achieve the above object, the present invention relates to a method for crimping a decorative sheet mounted on a predetermined surface of a trim main body. Are laminated and integrated in this order, and the decorative sheet is positioned by facing the hot melt film surface to a predetermined portion of the surface of the trim main body, and the metal foil is heated by electromagnetic induction heating to melt the hot melt film. The decorative sheet is pressure-fixed to a predetermined position on the surface of the trim body.

Here, examples of the trim parts include a door trim for an automobile installed in a door panel, a rear corner trim installed on a rear seat side of a two-door car, and the like.

The trim body has a laminated structure of a core material formed into a required shape and a skin material integrally adhered to the surface of the core material. The core material is a thermosetting resin. May be formed into a required shape by hot-pressing a wood fiber mat with a binder as a binder, and a thermoplastic resin or a thermoplastic resin mixed with a filler is formed into a required shape by stamping molding, injection molding or the like. You may.

When stamping molding is employed, the skin material can be integrally molded when the core material is molded.

On the other hand, decorative sheets are cloth, synthetic leather,
It may be appropriately selected from a synthetic resin sheet, a nonwoven fabric, or the like, and it is preferable to select a material having a surface appearance and a different feel from the skin material on the trim body side.

On the back surface of the decorative sheet, a metal foil and a hot melt film are laminated in this order. As the metal foil, aluminum foil is preferable in terms of formability and cost, but other metal foils are preferred. Can also be used.

As the hot melt film, a film based on a low melting point resin such as a polyethylene film is preferable.

Next, as the electromagnetic induction heating method, since the metal foil may be heated by electromagnetic induction, an electromagnetic induction coil may be installed at a predetermined position of the crimping lower die where the trim main body is set. After the trim body and decorative sheet are properly positioned on the lower crimping die provided with metal, the metal foil is heated by electromagnetic induction, and the hot melt film is melted. What is necessary is just to press with appropriate pressure.

As is apparent from the above configuration, according to the method of the present invention, a laminate of a metal foil and a hot melt film on the back surface of a decorative sheet in this order is positioned at a predetermined position on the front surface of the trim main body, and electromagnetic induction is performed. By heating the metal foil, the hot melt film is melted and the decorative sheet can be firmly fixed to the trim main body by pressure bonding.

Therefore, the conventional adhesive for bonding the trim main body and the decorative sheet can be eliminated, the steps of applying and drying the adhesive can be omitted, and the space for applying the adhesive can be saved.

Further, when cloth such as cloth is used for the decorative sheet, since there is no conventional drying step and pressure bonding step, the cloth is not heated and pressure-bonded, and there is no trouble such as hair falling of the cloth.

Furthermore, since the strong adhesive strength can be maintained over the entire surface of the decorative sheet, especially at the peripheral edge thereof, the peripheral edge does not float as in the conventional art, and the wood grain groove for hiding the peripheral edge is set deep. No need.

[0025]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for crimping a decorative sheet according to the present invention applied to an automobile door trim will be described in detail with reference to the accompanying drawings.

FIG. 1 is a front view showing an automobile door trim manufactured by applying the method of the present invention, FIG. 2 is a cross-sectional view showing the structure of the automobile door trim, and FIG. 3 shows a joining state of a peripheral edge portion of a decorative sheet. 4 to 6 are cross-sectional views showing steps in which the method of the present invention is applied to a manufacturing process of a door trim. FIG. 7 is a cross-sectional view showing another embodiment of a door trim for an automobile to which the method of the present invention is applied. FIG.

First, the structure of the door trim 10 for a vehicle will be described with reference to FIGS.

The door trim 10 for an automobile is generally constituted by a door trim main body 20 formed into a desired curved surface shape, and a decorative sheet 30 mounted on a predetermined portion of the surface of the door trim main body 20.

More specifically, the door trim body 20
Is obtained by hot-pressing a wood fiber mat impregnated with a thermosetting resin such as a phenol resin as a binder to form a core material 21 formed into a required shape;
Is provided with a breathable material, and is constituted by a skin material 22 integrally adhered to the surface of the core material 21 by vacuum molding, and the skin material 22 is constituted by a PVC sheet, a thermoplastic elastomer sheet, or the like. Have been.

When a deep drawing is required for the door trim 10 due to its shape, a thermoplastic resin material such as PP resin, PE resin, ABS resin or the like is used as the core material 21 and stamping molding and injection molding are performed. The core material 21 may be formed by, for example, stamping molding, and the skin material 22 can be integrally formed when the core material 21 is formed.

On the other hand, as the decorative sheet 30, a cloth of any specification such as velvet, jersey, tricot, moquette, etc. is used in the present embodiment. However, synthetic leather, non-woven cloth, etc. can be used. Door trim body 2
In order to emphasize the contrast effect with the skin material 22 of 0, a cloth having an appearance, feeling, and feel different from the skin material 22 is preferable. Therefore, a cloth is optimal.

The decorative sheet 30 used in the method of the present invention is characterized in that a metal foil 31 and a hot melt film 32 are laminated on the back surface in this order.

The metal foil 31 is preferably an aluminum foil in terms of formability and cost, and the hot melt film 32 is preferably a low melting point polyethylene film (softening temperature 110 ° C.).
To 130 ° C.) is used in this embodiment.

Further, as clearly shown in FIG. 3, the wood trimming groove 23 for wood graining the peripheral edge 30a of the decorative sheet 30 is formed in the door trim main body 20,
The grain depth of the wood grain groove 23 is reduced by half and the groove width is set to be relatively large (groove depth: 4 to 6 mm, groove width: 3 to 5 mm) as compared with the conventional wood grain groove.

Therefore, since the shape of the wood grain groove 23 is set gently, it can be formed by hot press molding using a wood fiber mat as the core material 21, and the material of the core material 21 can be any material. However, there is an advantage that the molding of the molding die can be simplified.

The reason why the groove depth of the wood grain groove 23 can be set to be shallow and the groove width can be set relatively wide is that the decorative sheet 30 can be securely placed at a predetermined position on the surface of the door trim main body 20.
This is because the adhesive can be securely adhered over the entire surface with a uniform strength, and the peripheral edge 30a can be adhered tightly without floating.

In FIGS. 2 and 3, the hot melt film 32 on the back surface of the metal foil 31 is melted by an electromagnetic induction heating method described later to form an adhesive layer 32a.

Next, a method of crimping the decorative sheet 30 to the door trim main body 20 will be sequentially described with reference to FIGS.

First, as shown in FIG. 4, the door trim main body 20 is set on the crimping lower mold 40. At this time, the coil 41 is provided on the crimping lower mold 40. 42 and is set to a shape substantially matching the peripheral shape of the decorative sheet 30.

Then, the door trim body 2 is attached to the crimping lower mold 40.
When setting 0, the door trim main body 20 is crimped so that the installation position of the decorative sheet 30 corresponds to the coil 41.
Set to 0.

Next, as shown in FIG. 5, the locating frame 43 is placed on the door trim main body 20 located at an appropriate position of the crimping lower die 40, and the locating frame 4
3, the decorative sheet 30 is set on the upper surface of the door trim main body 20.

Then, as shown in FIG.
Is lowered, the decorative sheet 30 is pressed against the surface of the door trim main body at a predetermined position with appropriate pressure, and a current of a predetermined value is supplied to the coil 41 through the AC generator 42, and the metal foil 31 is heated to 120 ° C. to 130 ° C. Then, since the hot melt film 32 is melted and functions as the adhesive layer 32a, the decorative sheet 30 is securely pressed on the surface of the door trim main body 20 with substantially uniform adhesive strength over the entirety.

The periphery of the upper crimping die 44 has a wood grain groove 2.
A ridge 44a for graining the peripheral edge 30a of the decorative sheet 30 is formed in the inside 3.

As described above, according to the method of the present invention, a current is applied to the coil 41 through the AC generator 42 to heat the metal foil 31 by electromagnetic induction, thereby melting the hot melt film 32 and trimming the decorative sheet 30 to the door trim. Since the pressure is applied to a predetermined portion of the surface of the main body 20 with a uniform adhesive strength and with high precision, compared to the conventional method using an adhesive, the use of the adhesive is eliminated, and the application step of the adhesive and the drying are performed. The process can be eliminated, shortening the number of processes, simplifying the equipment space on the production line, improving the working environment by eliminating the adhesive, and leaving the adhesive on the product surface, causing poor appearance. And the appearance can be improved.

Further, when a cloth is used as the decorative sheet 30, since the cloth is not fixed by pressing with a strong press pressure after the drying process as in the prior art, there is almost no hair fall and the decorative sheet has excellent appearance and feel. The seat 30 can be firmly integrated with a predetermined portion of the surface of the door trim main body 20.

As described above, in the method of the present invention, the peripheral terminal 30a of the decorative sheet 30 does not float at all due to uneven application of the adhesive or the like, so that the peripheral terminal 30a of the decorative sheet 30 has a good appearance. Thereby, the shape of the wood grain groove 23 can be formed shallowly, which has the advantage of simplifying the mold processing when forming the door trim main body 20 and widening the selection range of the construction method, as shown in FIG. , Can be applied to the door trim 10 having a shape in which the wood grain groove 23 is eliminated.
Since there is no need to form the wood groove 23 in the core material 2,
There is an advantage that the molding die 1 can be further simplified, and problems at the time of vacuum molding of the skin material 22 can be solved.

The embodiment described above relates to the method of crimping the decorative sheet 30 in the automobile door trim 10, but the application thereof such as the rear corner trim is not particularly limited.

[0048]

As described above, the present invention has the following special functions and effects.

(1) In the present invention, when a decorative sheet is pressure-bonded to a predetermined surface of a trim main body, a metal foil provided on a back surface of the decorative sheet is heated by electromagnetic induction heating, and a hot melt film laminated on the metal foil is heated. Since the decorative sheet is heated and melted and the decorative sheet is pressed and fixed to the trim main body side, the adhesive that has conventionally been used to bond and fix the trim main body and the decorative sheet can be eliminated. This has the effect of significantly reducing costs, such as shortening the manufacturing process due to the abolition and simplifying the space on the manufacturing line such as a space for applying an adhesive and a drying space.

(2) In the present invention, when a decorative sheet is pressed onto a predetermined portion of the surface of the trim body, the metal foil provided on the back surface of the decorative sheet is heated by electromagnetic induction heating to form a hot melt film laminated on the metal foil. Since the decorative sheet is heated and melted and the decorative sheet is pressed and fixed to the trim main body side, the adhesive used to bond and fix the decorative sheet to the trim main body can be eliminated, so the adhesive is abolished. Therefore, the working environment can be improved.

(3) According to the present invention, when a decorative sheet is pressure-bonded to a predetermined portion of the front surface of a trim body, the metal foil provided on the back surface of the decorative sheet is heated by electromagnetic induction heating to form a hot melt film laminated on the metal foil. Since the decorative sheet is heated and melted and the decorative sheet is pressed and fixed to the trim main body side, the problem of the hair falling of the cloth due to the application of the adhesive on the back side of the decorative sheet and drying is eliminated, as in the related art. When a cloth is used as a sheet, the external appearance and design can be maintained well, and a product with high commercial value can be provided.

(4) According to the present invention, when a decorative sheet is pressed on a predetermined portion of the surface of the trim body, the metal foil provided on the back surface of the decorative sheet is heated by electromagnetic induction heating to form a hot melt film laminated on the metal foil. Since the decorative sheet is pressed and fixed to the trim body side by heating and melting, conventionally, an adhesive is applied to both the trim body and the decorative sheet, and the two are bonded and fixed. Although the problem that the product surface is stained has occurred, there is no stain on the product surface due to the adhesive, and there is an effect that the appearance performance can be improved.

(5) According to the present invention, since the trim sheet can be securely bonded and fixed to the trim body over the entire surface of the decorative sheet including the peripheral edge portion, floating or peeling due to uneven application of the adhesive to the peripheral edge portion can be prevented. This has the effect that defects can be eliminated and the appearance of the peripheral portion of the decorative sheet can be greatly enhanced.

(6) According to the present invention, when a decorative sheet is pressure-bonded to a predetermined portion of the front surface of a trim body, a metal foil provided on the back surface of the decorative sheet is heated by electromagnetic induction heating to form a hot melt film laminated on the metal foil. Since the decorative sheet is heated and melted and pressure-fixed to the trim main body side, lifting and peeling of the peripheral end portion are eliminated, so that the shape restriction of the wood grain groove formed in the trim main body can be greatly eased, In addition, it is possible to simplify the processing of the molding die when molding the trim body, eliminate the problems during vacuum forming of the skin material, and use various methods as a molding method for the trim body side. Can be expanded.

[Brief description of the drawings]

FIG. 1 is a front view showing an automobile door trim manufactured by applying the method of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is an enlarged sectional view of a portion A in FIG. 2;

FIG. 4 is a sectional view showing a door trim main body setting step in the method of the present invention.

FIG. 5 is a sectional view showing a setting step of a decorative sheet in the method of the present invention.

FIG. 6 is a sectional view showing an electromagnetic induction heating step in the method of the present invention.

FIG. 7 is a sectional view showing another embodiment of a vehicle door trim to which the method of the present invention is applied.

FIG. 8 is a sectional view showing a configuration of a conventional automobile door trim.

FIG. 9 is an explanatory view showing a step of applying an adhesive in a conventional method of door trim.

FIG. 10 is a cross-sectional view showing a state in which a door trim main body and a decorative sheet are set to a crimping die in a conventional method of door trim.

FIG. 11 is a cross-sectional view showing a decorative sheet crimping step in the conventional method of door trim.

FIG. 12 is a cross-sectional view showing a wood graining step of a decorative sheet in a conventional door trim method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Automobile door trim 20 Door trim main body 21 Core material 22 Skin material 23 Groove groove 30 Decorative sheet 31 Metal foil 32 Hot melt film 40 Crimp lower mold 41 Coil 42 AC generator 43 Locating frame 44 Crimp upper mold

Claims (2)

[Claims] 1. A method for crimping a decorative sheet (30) mounted on a predetermined portion of a surface of a trim body (20), wherein a metal foil (3) is provided on the back of the decorative sheet (30).
1) The hot melt film (32) is laminated and integrated in this order, and the decorative sheet (30) is positioned with the hot melt film (32) facing a predetermined portion of the surface of the trim body (20). By heating the metal foil (31) by electromagnetic induction heating and melting the hot melt film (32), the decorative sheet (3) is heated.
A method for crimping a decorative sheet, characterized in that (0) is fixed to a predetermined portion of the surface of the trim body (20) by crimping. 2. A peripheral edge (3) of the decorative sheet (30).
2. The method for crimping a decorative sheet according to claim 1, wherein the step (a) is grained into a grained groove (23) formed in the trim body (20). 3.