JPS61118230A - Manufacture of molded member with cloth - Google Patents

Abstract

PURPOSE:To prevent generation of defective article, an increase in weight and complication of a process, by a method wherein simultaneously with molding of a resin plate cloth is made to be stuck to a desired position on the outside of the resin plate. CONSTITUTION:The surface of cloth 21 is laid along a vacuum mold surface 12 of a predetermined sphere 17 to be obtained by partitioning the cloth 21 with a thin wall 16 and the vacuum mold surface 12 adheres closely to the cloth 21 by sucking air. A space between a resin plate 22 and the vacuum mold surface 12 is sealed by coming the resin plate 22 into contact with a corner part 24 of a mold and the resin plate 22 is adsorbed to the vacuum mold surface 12 through the cloth 21 by making the heated resin plate 22 descend by a clamp 23 so as to surround the mold 11 and then vacuum molding is completed by cooling the same. A door trim for a vehicle is completed by separating this molded member from the mold 11. With this construction, as the resin plate 22 is molded into a Z-shaped cross section and a terminal of the cloth 21 is held into a recessed groove, the terminal is concealed and not visible from the outside.

Description

[Detailed Description of the Invention] San U Chu Gong! The present invention relates to a method for manufacturing a fabric-attached molded article, and particularly relates to a fabric-attached molding method for manufacturing a fabric-attached molded article, in which a fabric is applied to a desired position on the outer surface of a molded article of a thermoplastic resin plate or a laminated resin plate.

Synthetic resin products can be seen where fabric is attached to the exterior parts of vehicle interior parts, decorative architectural components, and household electrical appliances, and the materials and color patterns are partially varied to give a luxurious appearance. . Some attempts have been made to treat the ends of the fabric, but all of these methods involve complicated processes or are of poor quality.

For example, in a vehicle door trim, a decorative fabric called an ornament 1- is attached above or below an armrest and is made of a different material or color pattern from the skin layer of other parts. In the examples shown in Fig. 1 and Fig. 2 (a), hardboard coated with vinyl chloride resin paint is used as the base layer 1 material, weldable urethane foam is used as the cushion layer 2, and a soft vinyl chloride sheet is used as the cushion layer 2. at a desired position on the laminated resin plate 4 with the skin layer 3 as the material.

The end of a fabric 5 made of a decorative carpet is hidden with a molding 6 made of vinyl chloride resin, and the base material layer l and the molding 6 are welded together using a high-frequency welder. At this time, it is difficult to fix the end of the fabric 5 on the surface layer 3 of the laminated resin board 4 with cushioning properties within the width of the welding surface of the molding 6, and the end of the fabric 5 is placed outside the molding 6. Defective products were often produced in which the skin layer 3 protruded or a gap was formed between the molding 6 and the skin layer 3. The example in FIG. 2(b) also shows a method for concealing the ends of the fabric 5. In this method, the fabric 5 is overlapped with the outer skin layer 3 at their front end portions, and the portions are sewn together. After that, it is placed at a desired position on the cushion layer 2, the stitched portion is fixed to the base material layer 1 with a stopper 19, and then the first skin layer 3 is folded back. In this method, operations such as positioning, sewing, and fixing of the fabric 5 are complicated, and when the boundary between the skin layer 3 and the fabric 5 is a curve, wrinkles occur in the folded portion of the skin layer 3, degrading the appearance. . The example shown in FIG. 3 is also used for the same purpose as the example shown in FIG. is fixed to the back surface of the core material 7, and a decorative component 10 including the fabric 5 is fixed at a desired position on the preformed laminated resin plate 4 by a clip 9 attached to the core material 7. . In this case, the core material 7 is essential for stretching the fabric 5, which increases the weight of the product and increases the number of parts, and winding up the fabric 5 is also a time-consuming task.

The present invention is a method for molding a resin plate and at the same time applying a fabric to a desired position on the outer surface of the plate, which eliminates the problem of the ends of the fabric peeking out as in the conventional method. Preventing the occurrence of non-defective products,
This eliminates the increase in weight and complexity of the process due to the use of core materials and clips.

. The method for producing a fabric-attached molded article according to the present invention is to provide a thin wall at the outer edge of a predetermined area of a thermoforming mold, the upper part of which extends outside the area, and to attach the front side of the fabric to the surface of the thermoforming mold in that area. At the same time, the end of the fabric is placed on the extrusion part of the thin wall, and then a thermoplastic resin plate or laminated resin plate is thermoformed from above the fabric over the entire heat mold surface, and the resin plate is A fabric is applied to a desired position on the outer surface of the molded body, and the ends of the fabric are hidden inside the resin plate. Furthermore, a protrusion for removably adhering the end of the fabric to the protruding part of the thin wall is formed, and/or a protrusion for removably attaching a predetermined area divided by the thin wall of the thermoforming mold is provided. This method also uses a mold as a child mold.

Therefore, according to the above-mentioned means of the present invention, at the end of the fabric, the resin plate is thermoformed to have an rZJ-shaped cross section or a "self" shape, and the end of the fabric is housed in the groove. , a molded article is obtained in which the fabric is adhered to the desired position of the resin plate. As a result, the ends of the fabric are hidden from the outside, giving a good appearance, and since the main process is only thermoforming, the work is easy and the processing time is short.

Example The present invention will be explained in detail below with reference to the drawings.

FIG. 4 is an example of a vacuum molding mold used in the present invention to mold a door trim, which is installed on the passenger compartment side of a vehicle door and whose outer surface is covered with fabric, and shows a cut end view of the mold. In the figure, a vacuum forming mold 11 is formed with a vacuum forming mold surface 12 corresponding to the outer surface shape of the door trim to be molded on the passenger compartment side, and a large number of exhaust holes 1 are formed on the vacuum molding mold surface 12.
3 is excavated and the exhaust cavity 14. exhaust pipe 1
5 and is connected to a vacuum pump (not shown).

Further, on the vacuum forming mold surface 12, an a-wall 16 whose upper portion protrudes outside the area is arranged around the outer edge of a predetermined area corresponding to the outer edge shape of a desired portion of the door 1-rim onto which the fabric is to be applied.

A thin wall [6] is a band-shaped material such as a metal band whose wall surface is bent in the horizontal direction as shown in FIG. ing. The thickness of the thin wall 16 is 0.5 m, and its cross-sectional shape rises 3 m from the vacuum forming mold surface 12, bends at that position, extends 3 m outside the predetermined area to form the mounting table 35, and further rises 2IIW1 above. A rising portion 36 is formed.

A carpet with a pile length of 5 m is laid as the fabric 21 on the front side along the surface of the vacuum mold in a predetermined area 17 divided by the thin wall 16 shown in FIG. Cut the fabric 21 and place the terminal on the mounting table 35,
Adhesive is applied to the back side of the fabric 21 to an extent that does not impede the breathability of the fabric 21.

The resin plate 22 is, for example, a soft vinyl chloride resin skin layer 25 with a thickness of 0.3 + nm, as shown in FIG. Foaming ratio 15 with thickness 3mm
A laminated resin board 22 consisting of a double-thickness highly foamed polyethylene seat cushion layer 26 and a 3 m thick polypropylene base material layer 27 is prepared, and is held with a clamp 23 so that the skin layer 25 faces the fabric 21. Heating is performed by a heating device not shown.

Next, a vacuum pump (not shown) is operated to pass through the exhaust pipe 15, exhaust cavity 14, and exhaust hole 13.
The air on the vacuum mold surface 12 is sucked. This operation brings the fabric 21 into close contact with the vacuum mold surface 12 in the predetermined region 17 .

As shown by the chain line in FIG. 5, the heated resin plate 22 is lowered around the mold 11 by the clamp 23, so that the resin plate 22 comes into contact with the corner 24 of the mold.

The space between the resin plate 22 and the vacuum mold surface 12 is sealed, the resin plate 22 is adsorbed to the vacuum mold surface 12 directly or through the fabric 21, and then the vacuum molding is completed by cooling.

This molded body is separated from the mold 11 and unnecessary portions on the outer periphery are trimmed and removed to complete a vehicle door trim.

The end of the door trim fabric 21 formed in this way is
The state is as shown in the sectional view shown in FIG. That is, the resin plate 22 is formed into an rZJ-shaped or "self"-shaped cross section, and the end of the fabric 21 is housed in the groove, so that the end is hidden and cannot be seen from the outside. Of course, the resin plate 22 presses against the back surface of the fabric 2I due to the action of atmospheric pressure.

Adhere both firmly.

As an example of the resin plate 22 used in the present invention, a single layer P
A thermoplastic resin board such as VC, PE, PP, ABS, or EVA, or a thermoplastic resin board thereof as the base layer 27, a high foam material such as PVClPE, PP, or polyurethane as the cushion layer 26, and a skin layer 25. PVC, EV
A. There is a laminated resin board with three layers made of a thermoplastic elastomer film or a fabric that stretches when heated, or two layers selected from these three.

The fabric 21 may be a woven fabric, a woven fabric, a knitted fabric, a carpet, etc., and is particularly preferably a material that can be shaped by pressurization during normal conditions, heating or humidification, or a material that has been treated so that it can be shaped. The fabric 21 may be made of a material other than the above-mentioned textile products, as long as it is a breathable material or a material that can be made breathable.

When laying the fabric 21 in a predetermined area of the vacuum forming mold 11, a vacuum pump (not shown) passes the exhaust hole 13 into the area 1.
It is preferable to stretch the fabric 21 from the center of the area 17 toward the thin wall 16 while exhausting the air 7 so as not to cause wrinkles. For this purpose, as shown in FIG.
8 to communicate with the exhaust pipe 15 other than the above region 17.
It is effective to make it possible to evacuate the area 17 separately from the area 17, since it becomes possible to evacuate only the area 17 when necessary. In addition, if the fabric 21 does not conform to the surface of the vacuum molding mold in the area 17 where it is to be laid, the fabric 21 is heated under normal conditions between male and female press dies that correspond to the vacuum molding mold surface in the area 17 that was prepared separately. It is also effective to preform the fabric 21 under or under humid conditions and then lay the preformed fabric 21 in the area 17 of the mold 11. Furthermore, it is convenient to cut the periphery of the fabric 21 into approximately the external shape of the area I7 at the same time as this preforming.

Before or after laying the fabric 21 on the surface of the vacuum molding mold in the region 17, the back side of the fabric 21 is completely or partially vacuum-formed to the extent that the air permeability during vacuum forming of the resin plate 22 in the next step is not inhibited. For example, polyester on the side opposite to the side in contact with the mold surface.

Apply adhesive such as polyurethane, or
Attach a slit or non-woven adhesive sheet made of VA type or polyamide type. Note that when the fabric 21 and the resin plate 22 or the skin layer 25 of the resin plate are compatible, or when the fabric 21 is a carpet and its base fabric has a coarse weave, the fabric 21 and the resin plate 22 are welded together by heat. There are cases where adhesives or adhesive sheets are not needed because the adhesives or adhesive sheets can become entangled or tangled.

In the above embodiment, the thin wall 16 was crank-shaped as shown in FIG. 8(a).

In addition, as shown in FIG. 3(b), for example, a needle-shaped protrusion 37 is provided on the mounting table 35 to hold the end of the fabric 21, so that the fabric 21 moves inside the thin wall 16 during thermoforming of the resin plate 22. This prevents wrinkles from forming in the portion 31 (FIG. 6). When the projection 37 is provided on the platform 35, it may be as shown in FIG. 8(c) in which the rising portion 36 is removed, or the upper side of the rising portion 36 of the thin wall 16 may be serrated.

As a modification of the thin wall 16, the present invention can also be implemented by using a thin wall 16a that is inclined toward the outside of the predetermined region 17 of the vacuum forming mold 11, as shown in FIGS. 8(d) and (e). In this case, providing the protrusion 37 on the upper part of the thin wall 16a is particularly effective for the reasons mentioned above.

A general metal is used as the material for the thin wall 16, but it is preferable to use a copper alloy with good workability. The thickness of the material of the thin wall 16 is preferably 0.3 to 3 layers, as long as it does not deform under pressure during vacuum forming.

The dimensions of the exposed portion of the thin wall 16 on the molding surface 12 of the vacuum mold 11 are determined by the fabric 21 and resin plate 22 used. The fabric 21 is determined based on the compressed thickness when a load of about 1 kg/ci is applied, the presence or absence of a backing layer of the fabric 21, and the resin plate 22 is determined based on the presence or absence of the cushion NJ26. - As an example, in the case where the fabric 21 is attached to the outer surface of the laminated resin plate 22 consisting of the skin layer 25, the cushion layer 26 and the base material 527, FIGS. To explain with reference to FIG. 8(a), the height A from the molding surface 12 of the mold 11 to the first bending point forming the platform 35, and the height A from the first bending point to forming the rising portion 36. The length B from the second bending point to the second bending point is 1 to 2 times the sum of the thicknesses of the skin layer 25 and the cushion M26 before vacuum forming, and the length B from the second bending point to the top of the rising portion 36 The height C may be approximately equal to the compressed thickness of the fabric 21.

If the resin plate 22 does not include the cushion layer 26, the thin wall 16 forms an undercut with respect to the molded resin plate 22 as shown in FIG. The thin wall 16 is made in consideration of the thickness of the skin layer 25 and the base layer 27, the hardness immediately after molding, thermoformability (elongation when heated), etc., so that the body can be removed from the mold 11.
Determine the dimensions.

As shown in FIGS. 8(d) and 8(e), when the thin wall I6 is inclined to the outside of the predetermined area of the vacuum forming mold 11, the inclination angle is different from that of the vacuum forming mold 11 outside the predetermined area. 30 to 60 degrees from the molding surface 12, preferably 40 to 50 degrees,
The width of the leakage outside the predetermined area is such that the resin plate 22
When a laminate containing 6.

1 to 2 of the sum of the thicknesses of the skin layer 25 and the cushion layer 26
Just double it.

In order to make the manufacturing method of the present invention more efficient, the area portion 17 of the vacuum forming mold 11 divided by the thin wall 16 is made into a removable nesting mold 41 as shown in FIG. By separately preparing the nesting die 41 and the corresponding press die 42, the aforementioned preforming of the fabric 21, holding the thin wall 16 at the end of the fabric 21 on the platform 35, and cutting the periphery of the fabric 21 can be carried out. Since the vacuum forming mold 11 can perform vacuum forming of another resin plate 22 at the same time, the occupation time of the vacuum forming mold 11 can be shortened.

Then, the preformed fabric 21 is inserted between the nesting die 41 and the press die 42 and moved to a predetermined position in the vacuum forming die 11, and the exhaust pipe 18 for the nesting die 41 is evacuated. 21 is adsorbed to the vacuum mold surface of the nesting mold 41, the press mold 42 is removed, and then the next step of vacuum forming of the resin plate 22 is carried out. This is particularly effective when the fabric 21 has a strong elasticity since it does not return to its original shape until it is worn.

In the example shown in FIG. 10, the exhaust system for the nesting mold 41 is separated from the exhaust system for the vacuum forming mold 11, but the construction may be such that the exhaust system for the mold 11 exhausts the nesting mold 41.

In this example, the resin plate 22 was formed using a vacuum forming method, but the fabric-attached molded article manufacturing method of the present invention can also be carried out by a thermoforming method in a wide sense, including a pressure forming method, and the same effect can be obtained. is obtained.

Further, in the above embodiment, the vacuum mold surface 12 was made to be the same plane inside and outside the thin wall 16, but it was taken into consideration that the nap of the fabric 21 would return to its natural state after thermoforming.

If the fabric side is made higher than the resin plate side by the difference in thickness between the fabric 21 in its natural state and the compressed state, the vicinity of the boundary between the fabric 21 and the resin plate 22 portion of the molded product becomes flat.

Furthermore, it is also possible to manufacture a fabric-attached molded article of the present invention by using the resin plate 22 as a laminated resin plate of the skin layer 25 and the cushion layer 26, and then adhere it to a separately molded base material M27.

As described above, according to the fabric-attached molded article manufacturing method of the present invention, at the end of the fabric, the resin plate is thermoformed into a ``z''-shaped or ``self''-shaped cross section.

The end of the fabric is stored in the groove.

Since the fabric is applied to the desired position of the resin plate,
The following effects are achieved compared to the conventional example.

(1) The end of the fabric is deep inside the recess at the boundary between the fabric and the resin plate, so it is not visible from the outside and looks good.

(2) The main process is only thermoforming, and molding of the resin plate and adhesion of the fabric can be carried out at the same time, making one task easy.
The process is simplified and processing time is short.

(3) There is no concealment failure due to the use of the molding, and no increase in weight due to the use of the core material.

Although the embodiments have been described using the production of vehicle door trims as an example, the present invention can be applied to the production of fabric-attached molded articles in a wide range of other fields.

[Brief explanation of drawings]

FIG. 1 is a perspective view of a vehicle door trim manufactured by a conventional method, and FIGS. 2(a) and 2(b) are partial cross-sectional views showing a conventional door trim fabric end treatment method. Fig. 3 is a partial cross-sectional view of a door trim manufactured by another conventional method, Fig. 4 is a cut end view of a vacuum forming mold according to the present invention, and Fig. 5 is a method of manufacturing a molded article using the same vacuum forming mold. FIG. 6 is a partial cross-sectional view of the molded product after thermoforming, FIG. 7 is an end view of the cut portion showing another example of the vacuum forming mold, and FIG. 8 (a), ( b)
, (c) + (d) ,
(e) A partial cross-sectional view of the thin wall as shown in FIG. 9 is a partial cross-sectional view showing the state of the thin wall and the resin plate portion at the end of the fabric after vacuum forming. FIG. 11 is an end view of the cut portion of the nested mold and the press mold into which the fabric is inserted. 11...Thermoforming mold 12...Thermoforming mold surface 16...
・Thin wall 17... Area 21... Fabric
22...Resin plate 37...Protrusion 41...
- Nested type Fig. 2 (a) Fig. 3 Fig. 4 Fig. 5 Fig. 71!1 Fig. 9 Fig. 8 (0) Cb) (c) (d') Ce) Fig. 1O! Figure 11

Claims (3)

[Claims] (1) At the outer edge of a predetermined area of the thermoforming mold, a thin wall with the upper part extending outside the area is provided, and the front side of the fabric is laid on the surface of the thermoforming mold in that area, and the fabric is placed on the extrusion part of the thin wall. After placing the end portion, a thermoplastic resin plate or a laminated resin plate is thermoformed from above the fabric over the entire heat mold surface, and the fabric is adhered to a desired position on the outer surface of the molded resin plate. A method for manufacturing a fabric-attached molded article, in which the ends of the fabric are hidden inside a resin plate part. (2) The method for producing a fabric-attached molded article according to claim 1, wherein a protrusion for detachably attaching an end portion of the fabric is formed on the extrusion portion of the thin wall. (3) Claims 1 or 2 in which the predetermined area sectioned by the thin wall of the thermoforming mold is a removable nesting mold.
A method for manufacturing a fabric-attached molded article as described in 2.