JPS61220822A - Manufacture of formed body bonded partially with skin member - Google Patents

Abstract

PURPOSE:To mass-produce the formed body of high grade and high quality efficiently by bonding the skin member on the part of necessary surface partially. CONSTITUTION:The surface of a forming mold, forming the base body 1 of the formed body, is divided into two parts of first forming mold surface 11, which is the area of surface of forming mold corresponding to the area of the surface skin member bonded to the objective formed body A locally, and second forming mold surface 12, which is the remaining area of the forming mold surface. A core mold is set at the side of the second forming mold surface to define the first forming mold surface from the second forming mold surface. The skin member 2 is formed in the first forming mold surface and is held in the same forming mold surface. Next, the nesting mold is removed and the base body 1 of the formed body is formed by the forming mold in a condition that the formed skin member is being held. The skin member is formed by vacuum forming by equipping the forming mold with vacuum forming function. On the other hand, the base body of the formed body is formed by the press forming of the material of the based body for the formed body.

Description

DETAILED DESCRIPTION OF THE INVENTION 41 OBJECTS OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for manufacturing a molded article partially covered with a skin material.

(Prior Art) FIGS. 11(a) to 11(C) illustrate a vehicle door trim board A as an example of a molded body partially covered with a skin material.

(a) In the figure, when the door trim board A is assembled to the vehicle body, the road half of the board's outer surface is the externally exposed surface (visible surface), but the approximately lower half of the board is attached to other parts. In such cases, the decorative skin material 2 is applied only to the road half surface area, which is the externally exposed surface of the outer surface of the door trim board molded base 1, for the purpose of retaining materials, etc., and approximately the lower half surface is covered. The region has a form in which the bare surface of the molded substrate 1 is left as it is.

(b) Due to the design, the one shown in the figure is a different type of skin material 2 with different materials, colors, patterns, textures, etc. on the road half surface area and the approximately lower half surface area of the outer surface of the door trim board molded base 1. 3
This is a form in which the image is pasted and processed.

(c) In the figure, a different type of skin material 2 having a different material from the ground skin material 3 is applied to the road half area of the outer surface of the door trim board molded base 1 having the ground skin material 3. .

Specifically, the skin materials 2 and 3 are woven fabrics, knitted fabrics, non-woven fabrics, synthetic resin sheets, natural or synthetic leathers, etc., with other intermediate materials such as a cushioning material layer laminated on the back side thereof. .

[Problem that the invention seeks to solve]

Conventionally, the above-mentioned partially stretched molded body A is manufactured by first manufacturing a molded body base 1 (the one in FIG. The skin material 2 or 2 and 3 (in the case of the one in figure (b)) was applied manually to the area, which was inefficient. When the outer surface of the molded body base l is a large curved surface or an uneven surface, the skin materials 2 and 3 are applied along the curved surface or uneven surface.
It is difficult to attach the molded body to the outer surface of the base body neatly and neatly without any raised parts or wrinkles. The boundary line 4 tends to be an irregular line, and it is necessary to take measures such as high-frequency welding of the decorative molding member 5 along the boundary line 4 to improve the appearance.

The present invention has been proposed in view of the above, and an object of the present invention is to efficiently mass-produce a partially stretched skin material without the above-mentioned problems.

Summary: Structure of the Invention [Means for Solving the Problems] The present invention provides a first method for forming a mold surface for forming a molded body substrate by first forming a mold surface region corresponding to a partially stretched skin material region of a target molded body. When the remaining mold surface area is used as the second mold surface part, a nesting mold is set on the second mold surface part side of the mold, and the first mold surface part is set as the mold surface part. Second
Separate from the mold surface part, mold the skin material on the first mold surface part and hold it on the mold surface part, remove the nesting mold, and leave the mold with the molded skin material held. A molded body base is modeled using the following steps. This is a method for manufacturing a partially stretched skin material molded article.

[For production]

In the above, the skin material may be formed by any suitable method such as vacuum forming, pressure forming, vacuum pressure forming, press forming, etc. It is convenient to perform vacuum forming by equipping the mold with a vacuum forming function.

The molded body substrate can be shaped by any suitable method such as press molding, air pressure molding, injection molding, etc. Press molding is easy.

According to the above-mentioned method, the molding of the skin material and the modeling of the base material are performed using the same mold, and also the molding of the base material and the molding of the base material.

The bonding of the molded skin material to the required surface portion of the modeling base is done in the same process, which reduces the number of man-hours and is efficient.0 The skin material is molded following the surface of the mold used to model the base, so it is similar to the base surface. All parts are in close contact with each other without any raised or wrinkled parts. The skin material molding surface area on the molding surface of the mold is defined by the nested mold. You can get a beautiful product that is borderline beautiful.

〔Example〕

Example 1 (Figs. 1 to 5) In this example, as shown in Fig. 11(a), the skin material 2 is applied only to the road half area of the outer surface of the molded body base 1, and approximately the lower half area is covered with the molded body base 1. or, as shown in the same figure (C), on the outer surface of the molded body base l, which originally has the ground skin material 3, in the road half area, the material is different from the ground skin material 3. This is an example of manufacturing a material in which a different type of skin material 2 is pasted.

In FIG. 1, 10 and 20 are female and male fitting press molds for forming the base 1 of the target molded body A, and 30 is a removable core mold that is fitted into the female mold 10.

In the i-type 10, 11-12 is a mold surface area (first mold surface part) corresponding to the area of the partially stretched skin material 2 on the outer surface of the target molded object A, and a remaining mold surface area (second mold surface part). The first T-shaped surface portion 11, which is a surface portion), has small vacuum holes 13 opened in each part, and when a valve 14 leading to a vacuum pump VP is opened, a vacuum suction state is created. Reference numeral 15 denotes a thin partition wall fixedly disposed along the boundary between the first and second mold surface portions 11-12 of the mold surface, protruding from the mold surface by, for example, about a few to a dozen or so inches. It is a plate, for example, a band-shaped metal plate coated with a release material such as fluororesin.

16 is a cooling water pipe buried within the thickness of the mold.

The core mold 30 is attached to the second mold surface portion 12 of the male mold 10.
It is a mold that fits in like a dotted chain line, and is caused by mutual engagement with the corresponding fitting uneven parts 31 and 17 provided on the mold 30 side and the female mold 10 side, and the thin partition plate 15 described above. 2nd female mold 10
It is positioned relative to the mold face portion 12.

In the male mold 20, 21 is a cooling water pipe buried within the wall thickness of the mold, and 22 is a cooling water pipe between the male mold 10 and the female mold 10, as will be described later (Fig. 4). This heater is placed on the mold surface portion corresponding to the effective molding material portion. (1) The core mold 30 is fitted and set on the second mold surface portion 12 of the female mold 10. Then, the desired skin material having thermoformability is heat-treated with the first mold surface portion 11. 2 is subjected to vacuum forming treatment according to a conventional method. FIG. 2 is a diagram showing the state in which the skin material 2 has been vacuum formed. 40 is a seal clamp that presses the peripheral edge of the skin material 2. First mold surface portion 1 of female mold IO
By carving an uneven grain pattern etc. on 1, the surface material 2
The engraved pattern can be transferred and applied to the outer surface of the skin material 2 at the same time as the skin material 2 is vacuum formed.If the skin material 2 is breathable and vacuum forming is difficult or impossible by itself, the skin material 2
If a non-breathable, ripeable sheet material is previously laminated on the back side of the skin material 2, a non-breathable/stretchable sheet such as a rubber film is applied to the back side of the skin material 2, and vacuum forming is performed. good.

(2) Remove the core mold 30 from the female mold lO, and
is held as it is by vacuum suction force on the first mold surface ll of the female mold IO, and the unnecessary end portion of the skin material on that side is trimmed (bleeded) to an appropriate width along the thin partition plate 15. -c.

(3) Next, the first mold surface portion 11 and the second mold surface portion 12 holding the molded skin material 2 are placed in the female mold 10.
As shown in the third figure, a lump of thermoplastic resin or thermosetting resin compound in a softened state as a base material (
Block) Add an appropriate amount of La. If the block material 1a is filled with a recycled material (black) in the molded skin material 2 portion and a virgin material with a predetermined color in the second mold surface portion 12, the material cost will be reduced.

(4) The female die 10 and the male die 20 are fitted and clamped. Then, the compound mass 1a as the base material is pressed between the molds 10 and 20 as shown in FIG. 4, and a molded body base 1 is formed. At the same time as this molded body base l is formed, the skin material 2 molded and held on the first mold surface portion 11 of the female mold lO is integrally bonded to a predetermined surface portion of the molded base lO. The ineffective molding material portion 2a is pressed between the facing surfaces of the female die 10 and the male die 20, and the heater 2
It is soaked and processed into a thin layer using heat from step 2.

(5) Cooling water is introduced into the cooling water pipes 16 and 21 of the female mold 10 and the male mold 20 to cool the molds 10-20 and the molded product between them, and when the molds are cooled to a predetermined temperature, the mold is opened and the molded product is Take out.

(6) Trim the ineffective molding material portion 2a that has been pressed and dipped into the thin wall of the skin material 2 to an appropriate width, roll the material portion 2a onto the back side of the base l, and apply adhesives, fasteners, etc. Finish the edges by stopping with. As a result, the purpose of the configuration shown in FIG. A partially stretched skin material molded article A is obtained.

(7) Use a maturing sheet or plate material 1b (Fig. 5) as the base material of the molded body, or a material with the ground skin material 3 pasted on its outer surface in advance, and partially stretch it with the skin material 2. A female mold 10 formed and held by the above steps (1) and (2),
It is also possible to perform press molding between the male molds 2G.

In the case of a material to which the ground skin material 3 is bonded, a molded body A having the form shown in FIG. 10(C) is obtained. Also, as a material for the molded body base l.

A two-component mixture curing type liquid material may be filled.

Example 2 (Figures 6 and 7) The trimming process C-C of the end portion of the molded skin material in item (2) of Example 1 above can be omitted depending on the molded shape. An example of this is shown below.

That is, as shown in FIG.
By designing the core mold 30 and the clamp 40 to have a relative structure that is approximately the same as the height position of the molded skin material 5, it is possible to avoid trimming the end portion of the molded skin material 2 along the thin partition wall plate 15. Seal clamp 40 is φ type 30
It may also be fixed using a magnetic method.

Then, as shown in FIG. 7, when molding the molded base 1, the base 1 can be molded so that the ends thereof do not come out onto the surface.

By making the tip of the thin partition plate 15 serrated, it is possible to prevent the skin material from shifting during molding of the base body 1.

Embodiment 3 (Figures 8 and 9) In this example, as shown in Figure 1O (b), different materials are used for the road half surface region and the approximately lower half surface region of the outer surface of the molded body base 1, respectively. This is an example of manufacturing a product in which skin materials 2 (first skin material) and 3 (second skin material) are separately pasted.

(1) The first skin material 2 is molded and trimmed on the first mold surface portion 11 of the female mold IO according to the steps (1) and (2) of Example 1, or Molding according to the procedure,
It is held in the first mold surface portion 11 as it is without being trimmed.

(2) The second core mold 50 is fitted into the first mold surface portion 11 that molds and holds the first skin material 2 of the female mold IO, and heated by the second mold surface portion 12. The treated second skin material 3 having thermoformability is subjected to vacuum forming treatment. FIG. 8 is a diagram showing this state.

(3) In the case of the first skin material 2, the second core mold 50 is removed from the female mold IO, and the molded second skin material 3 is held by the second mold surface portion 12 by vacuum suction force. Similarly, along the thin partition wall plate 15, the unnecessary end portion of the skin material on that side is trimmed to an appropriate width c-c. Alternatively, molding treatment is performed in the same manner as in Example 2.

Figure 1θ (b
), that is, a molded body having a shape in which different types of skin materials 2 and 3 are separately pasted is obtained.

C1. Effects of the Invention As described above, according to the method of the present invention, it is possible to efficiently mass-produce high-grade and high-quality molded articles in which the skin material is partially applied to the required surface area.

The intended purpose is well achieved.

[Brief explanation of drawings]

! Figure 1 is a cross-sectional view of the female/male mating press mold and core mold, Figure 2 is a cross-sectional view of the skin material vacuum-formed using the female mold,
Fig. 3 is a cross-sectional view of a state in which a lump of dung pound is set as a base material, Fig. 4 is a cross-sectional view of a state in which the base material is press-molded as a base, and Fig. 5 is a sheet or plate-shaped body as a base material. Figure 6 is a cross-sectional view of an example of trimming sail m at the end of the molded skin material.
The figure is a cross-sectional view of the base layer formed, FIG. 8 is a cross-sectional view of the first skin material vacuum-formed using a female die, and then the second skin material is vacuum-formed, and FIG. 9 is a cross-sectional view of the second skin material after the molding process. FIGS. 10(a) to 10(c) are sectional views of various embodiments of the partially stretched skin material obtained; , FIG. 11(a) to FIG. 11(C) are sectional views of various embodiments of the conventional molded body. A is a partially stretched skin material molded product, 1 is a molded product base, 2-3 is a skin material, 10 and 20 are female and male mating press summers, 30φ50
is the core type, and la and lb are the base materials.

Claims (3)

[Claims] (1) Regarding the mold surface for modeling the molded body base, the mold surface area corresponding to the partially stretched skin material area of the target molded body is the first mold surface area, and the remaining mold surface area is the second mold surface area. When it is a mold surface part, a nesting die is set on the second mold surface part side of the mold to separate the first mold surface part from the second mold surface part, and the first mold surface is separated from the second mold surface part. A skin characterized in that a skin material is molded in a portion and held on the surface portion of the mold, the nested mold is removed, and a molded body base is formed using a mold that holds the molded skin material. A method for manufacturing a material stretch molded body. (2) The method for producing a partially stretched skin material molded article according to claim 1, wherein the molding process of the skin material is performed by vacuum forming by equipping a mold with a vacuum forming function. (3) The method for producing a partially stretched skin material molded article according to claim 1, wherein the molded body substrate is shaped by press molding of the molded body base material.