JPS5931153A - Manufacture of shape with skin material layer - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a molded article with a skin layer, and in particular, to a method for manufacturing a molded article with a skin layer having a different material, hue pattern, etc. on the outer surface of the molded article. Relating to a method of manufacturing.

For example, vehicle interior parts such as door trim boards, front seat panels, ceiling lining boards, instrument panels, etc. generally have a hard or semi-hard base layer with appropriate strength and rigidity, and other desired materials such as a soft cushioning material and a cushioning material. A composite molded article is used which has a three-layer laminated structure including an intermediate material layer for properties and a skin material layer for decoration and surface protection. Some have a two-layer structure with only a base layer and a skin material layer, and others have a multi-layer structure with four or more layers. In addition to various interior products for vehicles, composite molded products having the above-mentioned layer structure are often used as various interior materials for buildings, furniture, exterior members for electrical appliances, and the like.

The means for industrial mass production of such composite molded bodies can be roughly divided into two types: a laminated board molding method for each layer, and a laminated sheet molding method for each layer.

For the former, a laminated flat plate is made by bonding each constituent layer together in advance,
This material is then molded into a desired shape using a hot pressure molding method (vacuum molding method, pressure molding method, plug molding method, hot press molding method, etc.), press molding method, etc.

The latter involves dividing the individual constituent layers or each constituent layer into groups of the molded body and applying the hot pressure forming method, press forming method, or
The product is obtained by molding layer by layer using injection (pressure feeding) molding method, resin bead foam molding method, etc., and finally stacking each molded layer by one layer as a whole. Various procedures and methods have been developed and proposed (for example, Japanese Patent Application Laid-open Nos. 55-73532 to 73536, Japanese Patent Application Laid-open Nos. 55-1
00133・118837・158037・15993
4/159938/159937, 56-10
8132・109133・111845φ111688
・154040φ157329 publication, patent application 1984-1
8+1030, 56-22107, 126873, etc.). This layer-by-layer molding and laminating method is recommended because it has various advantages over the former layer-by-layer single-laminate molding method, such as being able to manufacture molded bodies with complex uneven shapes almost as designed, and greatly reducing material loss.

By the way, regarding the above-mentioned composite molded product, there are 1. It is often necessary to design and manufacture molded bodies in which the outer surface of the molded body is made of different materials.

FIGS. 1(a) and 1(b) are examples of the base layer 3.
Regarding the vehicle door trim board A having a three-layer structure of intermediate material layer 2 and skin material layer 1, the outer skin material layer 1 is referred to as region 1a.
An example is shown in which the portion is made of a resin sheet-based skin material such as a thermoplastic elastomer sheet or a vinyl sheet, and the region 1b is made of a left-handed skin material such as a woven fabric, knitted fabric, or non-woven fabric. For convenience, the skin material layer in the area 1a is called the ground skin, and the skin material layer in the area 1b is called the pattern skin.

Conventionally, as described above, for the skin material layer 1, the outer surface "-material Φ
When manufacturing a composite molded body A having a partially different color, pattern, etc., the composite molded body A is first manufactured with the entire outer surface covered with the ground skin material layer 1a. −・Metal plate processed into an external shape that approximately matches the external shape of the square pattern skin region lb・／＼
- Cover the outer surface of the core plate 4 (Fig. 2 (a) and (b)) such as a board with a sheet material for pattern skin, and in this case, if necessary, cover the entire surface of the core plate outer surface and the back surface of the covered sheet material. A patterned skin material patch plate is produced in which the peripheral edge of the sheet material is folded back to the back side of the core plate 4 and fixed by adhering to the back side of the core plate. The patch plate is then adhered to a predetermined position on the outer surface of the molded body A or fixed with a fastener 7 such as a screw (FIG. 2(a)). In this case, if the overall wall thickness of the patch plate is quite thick, a molded body A having four parts 1C into which one patch plate fits into the outer surface as shown in Figure I2 (b) is manufactured. By fitting a patch plate into the recess IC and fixing it with adhesive, fasteners, etc., the surface of the ground skin material layer 1a and the surface of the patterned skin material 1b are made into a road surface.

However, this is a procedure in which the patterned skin material patch plate is attached after once manufacturing the composite molded body A whose entire outer surface is covered with the ground skin material layer 1a, which increases the number of man-hours and cannot be said to be efficient. As the pattern skin area lb becomes wider, the core plate 4 of the patch board becomes larger, and the amount of core plate material used increases accordingly.
Moreover, the weight of the entire molded body A also increases. Pattern skin material layer area 1
B has a drawback that the entire area is hard to hit due to the presence of the core plate 4 on the back side.

Therefore, in order to adhere the patterned skin material layer ib to a predetermined position on the outer surface of the molded body skin material layer 1a during the molding manufacturing process of the composite molded body A, the molding layer is formed on the surface of the molded body A on the skin material layer side. Vacuum molding molds, air pressure molding molds, plug molding molds, press molding molds, and injection molding molds that mold the surface of the skin material layer side of the molded product in a single-laminate molding method for each layer or a laminated molding method for each layer. In some cases, the composite molded body A may be manufactured by placing or temporarily attaching a sheet material for a pattern skin cut into a predetermined external shape at a predetermined position within the effective molding surface of a mold or the like. That is, in the molding layer on the side of the molded body skin material layer, the patterned skin material layer 1b is simultaneously adhered to the outer surface of the molded body ground skin material layer 1a during the molding process.

However, this method tends to cause misalignment and wrinkles in the patterned skin material layer 1b. Also, due to the difference in elongation of each part during molding of the ground skin material layer 1a and the patterned skin material layer 1b, the contour line of the patterned skin material layer 1b tends to become an irregular straight line or irregular curve, so that the contour line of the patterned skin material layer 1b is It is often necessary to perform post-processing such as welding a decorative molding material along the line to hide irregular lines and curves.

The present invention is a method in which a patterned skin material layer is arranged in advance on the mold surface as in the latter method, but the patterned skin material does not have the above-mentioned drawbacks, that is, does not cause misalignment or wrinkles in the patterned skin material layer 1b. It is an object of the present invention to provide a method for producing a molded article with a skin material layer, which has advantages such as not causing unsightly displacement of the contour line of the layer 1b, and therefore not requiring subsequent processing to attach a decorative molding material. It is something.

That is, as shown in the example in FIG. 3, a sheet material 1b' which becomes the patterned skin material layer 1b is stretched and held by a frame 5 whose outer shape substantially matches the pattern outer shape of the layer 1b. The frame 5 in the example shown in FIG. 3 is a thin metal plate punched frame, and a large number of elongated triangular cut-out needles 51 are formed along the frame on the back side of the frame.
The sheet material 1b' is stretched and held on the frame 5 by piercing the periphery of the rolled up sheet material to the back side of the frame with the cutting needle 51.

The means for securing the periphery of the sheet material rolled back to the back side of the frame may be an adhesive, a fastener such as a clip, a high frequency or ultrasonic welder, or the like. A piercing needle hole like the one described in item 2 is easy and quick. The frame 5 may be made of synthetic resin. If it is made of metal, apply anti-rust treatment as necessary. Sheet material 1b'
In order to eliminate material waste as much as possible, the material is cut into an outer shape that is thicker than the outer shape of the frame by the amount of rewind required.

Then, as shown in the fourth figure, the frame 5 holding the sheet material 1b' stretched is placed in a mold 6 for molding the surface of the molded body on the skin material layer side.
Position and set at a predetermined surface position within the effective molding surface. In this example, the mold 6 is a vacuum molding mold. 62 is a vacuum hole, 63 is a vacuum cavity, and P is a vacuum pump. In addition, the positioning set of the frame 5 with respect to the mold surface is such that when the frame 5 is placed on a predetermined surface position within the mold surface, a pin is placed in advance at the mold surface position corresponding to the cut hole 52 of the cutting needle 51 of the frame 5. The frame 5 is positioned by providing a protruding needle 61 and inserting the pin needle 61 into the needle cut-out hole 52 of the frame 5. It is sufficient to provide the pin needles 61 on the mold side only at four to five locations at appropriate intervals among the numerous needle cut holes 52 around the frame. If the frame 5 is made of a magnetic material such as iron, a magnet piece may be embedded in a predetermined surface position on the mold side and the frame 5 can be positioned and set on the mold surface by magnetic attraction. In addition, as shown in the example in FIG. 5, a surrounding frame 64 is provided at the frame body setting position on the molding die side with a contour shape that approximately corresponds to the external shape of the frame body, and protrudes from the molding surface, and the frame body is placed within the surrounding frame 64. By fitting 5 into the frame body 5
may be positioned and set on the six sides of the mold.

Next, this mold is used to mold and manufacture a molded body A having a skin material layer (la) as a base. The example in Figures 4 and 5 shows the base layer 3.
, the main part of a laminated flat plate made by bonding an intermediate material layer 2, such as a cushioning material, and a ground skin material layer 1a together, is heated and softened, and then vacuum-formed by covering it with a mold 5. (each layer is a single laminate molding method). Then, at the same time as this molded body is formed, the ground skin material layer 18 of the molded body is formed.
A sheet material lb', which is a patterned skin material layer and which is stretched and held by the frame 5 on the side of the mold, is integrally adhered to the frame 5, thereby partially covering the skin material layer 1a, which is the upper layer of the outer surface of the molded product. Accordingly, a molded article with a skin layer 1b of a different material having a desired pattern can be obtained.

Sea I, which is a patterned skin material layer stretched and held on the frame 5.
If the material tb' is breathable, the ground skin material layer 1a on the back side is sufficiently attracted to the back side of the sheet material lb' through the breathable sheet material 1b' and adheres tightly. The sheet material 1b is made by applying an adhesive to the back side of the sheet material 1b' to maintain the breathability of the material 1b' in advance.
'The adhesion of the ground skin material layer 1a becomes strong. When the sheet material 1b' and the ground skin material layer 1a are made of the same type of resin, they are adhered to each other by heat fusion. Even if the sheet material 1b' is a non-breathable material, in most cases the material 1b' and the ground skin material layer 1
It is possible to obtain a product in which a and (a) are well adhered to each other.

The above also applies when the skin material layer (ground skin) or the laminated material of the skin material layer and the intermediate material layer is hot-press molded in each layered lamination method, or when the skin material layer is injection molded. Similarly, by positioning and setting the frame 5 holding the sheet material 1b' which will become the patterned skin layer 1b in advance at a predetermined surface position of the mold for molding or molding the skin material layer, the above-mentioned surface material layer is finally formed. A molded article having the same skin material layer form is obtained.

FIGS. 6(a) and 6(b) show modified examples of the frame body 5,
The frame of this example also serves as a molding material (beading material) for decorating the periphery of the pattern skin material layer 1b.

That is, the frame side of the frame body 5 is made of a transparent resin such as butyral resin with aluminum foil 53 enclosed for decoration inside the wall thickness, and the cross-sectional outer shape is roughly formed with a hollow 54 inside along the length of the frame side. It has a semicircular shape, the semicircular side is the front side of the frame, the flat side is the front side of the frame, and a slit opening 55 is formed on the front side of the frame along the longitudinal direction to communicate with the hollow inside the frame side. Further, the base portion is integrally connected to the frame body at strategic points along the length of the outer edge of the frame body 5, and outwardly projecting band pieces 56 having a length longer than the width dimension of the frame side are provided. Each band piece 56 can be freely folded back toward the front side of the frame around the thin wall portion 57 of the base.

Also, on the frame side at the position of each band piece 56, there is a large diameter seat 58 at the base.
1 is inserted into the hollow 54 of the frame side, and the side part 582 is made to protrude from the slit opening 55 toward the front side of the frame, and the pin member 58 is disposed.

Reference numeral 591 indicates a small hole provided on one side of the band where the tip of the needle portion 582 of the pin member 58 faces when the band piece 56 is folded back toward the front side of the frame, and 592 indicates a small hole provided closer to the tip of the band piece than the position of the small hole 59□. This is the second small hole.

Then, the sheet material 1b' for the patterned skin material layer, which has been cut to approximately match the outer peripheral shape of the frame 5, is applied to the back side of the frame 5, and its peripheral edge is inserted into the needle portion 58 of each pin member 58. □, then each band piece 56 is folded back to the front side of the frame, the small hole 591 is fitted into the side part 582, and the sheet material lb'
By securing the edge of the frame from the pin member 58, the sheet material is stretched and held on the back side of the frame. Then, this frame 5 is applied to a predetermined position on the molding surface of the mold 6 with the front side of the frame facing the molding surface as shown in FIG. The small holes 592 are aligned with the pins Q161 provided protruding at positions corresponding to the second small holes 592 to form a piercing state, thereby positioning and holding.

Reference numeral 66 denotes a groove portion into which the front side of the frame previously formed on the surface of the mold is inserted.

Next, a molded body A with a base skin material layer la is molded using a mold 6 in which the frame 5 is set, and the outer periphery of the pattern skin material layer 1b is formed into the frame 5, that is, a molding material (beam edge). A product with a decorative border is obtained.

As described above, according to the method of the present invention, since the sheet material 1b' which becomes the patterned skin material layer 1b is stretched and held on the frame 5, and the frame 5 is positioned and set on the 5th surface of the mold, the patterned skin material layer 1b is It is possible to always produce a molded article with no misalignment or wrinkles in the material layer 1b.

Also, since the sheet material 1b' of the layer is held in the frame 5, the outer peripheral contour of the patterned skin material layer 1b does not become an irregular straight line or an irregular curve, and the patterned skin material layer always has a predetermined outline that is aesthetically pleasing. form is obtained. Due to the materials of the sheet material lb' and the ground skin material layer a, when the outer peripheral contour of the patterned skin material layer ib is disturbed due to the welding phenomenon of both materials during molding, the surrounding frame 64 is used as shown in the example in FIG. If the frame 5 holding the sheet I/material lb' is positioned on the mold 6 side using this method, when the molded body A is viewed from the front, the pattern skin material layer lbl! l - Ground skin material layer 1 without contact
It is possible to mold a.

Since the holder for the sheet material 1b', which is the patterned skin layer 1b, is a frame rather than the plate 4 as shown in FIGS. The parts are also soft, except for the part where the frame is located.

By making the molding surface portion on which the frame 5 with the sheet material 1b' stretched and held is nested in the mold body as shown in Figure 5, the setting of the frame 5 to the mold 5 can be done externally. This makes the work easier, and is advantageous when molding multiple pieces at the same time, and the molding production cycle time can be shortened. Furthermore, if the nesting die is also used as a manufacturing jig for the pattern skin material layer 1b, it is possible to divide the frame 5 with a good material yield without increasing the number of setup steps. 65 indicates a spacer member.

The frame body 5 is appropriately bent to correspond to the parts where the molded body surface is convexly curved or concavely curved or stepped.
The sheet material 1b' is stretched and held there, or if the frame 5 is a thermoplastic resin plate, by slightly preheating, the ground skin material layer 1a is vacuum formed, or even if the frame 5 is a thin metal plate, the forming mold 6 On the other hand, if a press mold corresponding to the irregularities of the patterned skin material layer 1b is prepared and press molding is performed, the patterned skin material layer ib can be formed beautifully and neatly by following the surface shape of the molded body surface part as described above with a slight force. can be deposited and formed.

[Brief explanation of drawings]

FIG. 1(a) is a front view of an example of a molded product in which the material of the skin layer is partially different, and FIG. 1(b) is a
2(a) and 2(b) are partially enlarged sectional views of a molded body on which a patterned skin material layer was formed by a conventional method, and FIG. FIGS. 4 and 5 are perspective views of the state in which the frame is stretched and held, and the frame is positioned on the surface of the vacuum mold, and the laminated material plate for the molded body is vacuum formed. FIG. 6(a) is a partial sectional view, and FIG. 6(b) is a perspective view of a portion of a modified example of the frame.
6(a) is an enlarged cross-sectional view taken along the line b-b, and FIG. 7 is a cross-sectional view of a part of the laminated material plate for the molded body, which has been vacuum-formed by setting the frame on the surface of the vacuum-forming mold. figure. A is a composite molded body consisting of a base layer 3, an intermediate layer 2, and a skin material layer l, la is a ground skin material layer, 1b is a patterned skin material layer, lb
'' is a sheet material for a pattern skin layer, 5 is a frame, and 6 is a mold. Patent applicant Meiwa Sangyo Co., Ltd.

Claims (1)

[Claims] (1) When obtaining a molded body with a skin layer, in which the material, hue, pattern, etc. of the skin layer are partially different on the outer surface of the molded body, the base skin material layer (la ) to the pattern skin material layer (1b
) is stretched and held on a frame (5) whose external shape substantially matches that of the predetermined patterned skin control layer, and the frame (5) is placed on the skin material layer side of the molded body. A mold to form the surface of (
The patterned skin material layer sheet material is positioned at a predetermined surface position within the effective molding surface of 6), and a molded body with a base skin material layer (1a) is molded and manufactured using the mold, and set on the surface of the mold. (1b') is integrally applied to the outer surface of the ground skin material layer (1a) of the molded product together with the frame (5).