JPS6131239A - Manufacture of interior for auto car - Google Patents

Abstract

PURPOSE:To reduce the cost of molds and materials by a method in which projected are formed on the required portions of a surface material and bonded to the surface of unmolded flat base plate. CONSTITUTION:A surface material 20 is formed to have a predetermined shape and projected portions 21-23 or dappled patterns 26 are formed on the requireel rotations of the surface material 20. The surface material 20 is then bonded to the surface of a base material 2 in such a way as to form enclosed hollow portions 21a and 22a between the projected portions 21 and 22 of the surface material 20 and the base material 2, where the peripheral side of the material skin 20 is rolled up on the back side of the material 2 and bonded, or the peripheral side of the material 20 is fixed with tackers and fitted with retainers 15 through holes 5 from the back side. The door trim 1 is fixed to the door body by retainer, tapping screws, etc. By forming the projected hollow portions by the unmolded flat base plae and the surface material, the necessityh of forming an uneven surface in the base material can be eliminated and the costs of molding die and material can be reduced.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing interior materials such as door trims and quarter trims of automobiles.

Conventional technology and its problems Conventionally, interior materials such as door trims were generally manufactured using
As described in Japanese Patent Application No. 04717, it is known that a base material and a skin material are integrated with a pad interposed therebetween. This type of interior material includes armrests, pulhasiders,
``Since it is necessary to provide an uneven surface such as the seat surface of the regulator handle, the manufacturing method is to press-form the base material into the desired uneven shape, then attach a pad to the surface, and then apply a skin material to the surface. Usually, the material is attached while being vacuum-formed, or a previously press-molded skin material is applied onto the base material and pad.

However, the above method requires two types of molds: a mold for the base material and a mold for the skin material, which increases the cost of the molds and also requires the formation of irregularities on the base material and the trimming of the outer periphery. For this reason, there is a problem in that the cost of the base material increases. In particular, since the base material is thicker than the skin material, there is a lot of wasted material.

Purpose of the Invention The present invention has been made in view of such conventional problems.
The purpose is to provide a method for manufacturing automobile interior materials that can reduce the cost of molds and materials.

Structure of the Invention In order to achieve the above object, the manufacturing method according to the present invention includes a step of forming a curved part in a required part of a relatively rigid skin material, and a step of forming a curved part on a non-formed flat base of the skin material. The method is comprised of a step of forming a hollow sealed part between the curved part and the base material by adhering it to the surface of the material. That is, since a non-molded flat plate is used as the base material, material removal is improved and material waste is reduced, and a large mold for molding the base material is not required.

DESCRIPTION OF EMBODIMENTS FIGS. 1 to 3 show a door trim 1 which is an example of an automobile interior material according to the present invention.
and a skin material 20.

The base material 2 is made of a non-molded flat hardboard or the like, and has an inside handle hole 3. Regulator handle hole 4. A retainer lower hole 5 and the like are formed.

The skin material 20 is made of a relatively rigid and non-breathable material such as foamed vinyl chloride, foamed polyethylene, or a fabric sheet with a resin coating on the back side, and is formed into a predetermined shape by vacuuming, press molding, etc. ing. The skin material 20 includes curved parts 21, 22, 23, an inside handle hole 24, and a seat surface 2 of the regulator handle hole.
5. The grain pattern 26 necessary for design, the rolled-up portion 27 on the outer periphery, etc. are molded at the same time.

The skin material 20 is adhered to the surface of the base material 2, and by adhering and sealing the periphery of the curved part 21.22 to the base material 2, a hollow seal is formed inside the curved part 21.22 (7). Portions 21a and 22a are formed. This sealed part 21a
, 22a, the curved part 21.22 is formed by the skin material 2.
Coupled with the rigidity of 0 itself, it is possible to maintain a constant shape and provide a predetermined cushioning property. This cushioning property provides the door trim 1 with a soft feel and has the effect of omitting a conventional cushion pad.

Here, a method for manufacturing the door trim 1 having the above structure will be explained. First, the skin material 20 is molded into a predetermined shape by vacuuming or press molding, and the curved molded portion 21 is placed on the required part.
．． 22, 23, grain pattern 26, etc. are formed. Next, when the skin material 20 is adhered to the surface of the base material 2, since the curved molded parts 21 and 22 are formed in the skin material 20, there is a gap between the curved molded parts 21 and 22 and the base material 2. Hollow sealed part 2
1a and 22a are formed. Then, the rolled-up portion 27 formed on the outer circumference of the skin material 20 is rolled into the back side of the base material 2 and bonded, or rolled and fastened with a tack, and then the retainer 15 is inserted into the retainer lower hole 5 from the back side of the base material 2. Installation and manufacturing completed.

Note that when bonding the skin material 20 to the base material 2, the portion of the skin material 20 corresponding to the retainer pilot hole 5 is masked in advance to prevent adhesive from getting on it.
is attached after the skin material 20 is applied to the base material 2. Generally, in the case of molded door trims, retainer fixing parts such as sheet metal are insert-molded during molding of the door trim in order to fix the retainer, but the above method eliminates the need for retainer fixing parts, making it cheaper to manufacture. can.

The door trim 1 manufactured as described above is fixed to the door body 30 with a retainer 15 as shown in FIG. 4, or with tapping screws or the like.

In the above embodiment, the skin material 20 has three curved parts 21.2.
2.23 was molded, but among these, the curved molded parts 21 and 22 are provided solely as necessary for the design, such as to form a convex surface continuous with the instrument panel, while the convex molded part 23 is provided for the armrest. provided to form a However, since a large load acts on the armrest m6 molded part 23, if it is made into a hollow structure like the other curved molded parts 21 and 22, there is a risk that the armrest m6 molded part 23 will lack strength. In order to improve this, for example, a filler 10 serving as a core material (see Fig. 3) is fixed to the surface of the base material 2 by means of adhesive, rivets, screws, etc., and the above-mentioned The curved portion 23 of the skin material 20 may be applied.

Effects of the Invention As is clear from the above explanation, according to the present invention, a hollow convex portion is formed by an unmolded flat base material and a skin material having a curved portion. There is no need to mold the base material into an uneven shape, and mold costs and material costs can be significantly reduced. Furthermore, since the base material is not bent in an uneven shape, the mechanical strength is improved, and a material with poor moldability can also be used as the base material. Furthermore, since the convex molded portion is hollow, it is possible to obtain a soft-touch interior material that has desired cushioning properties and does not use a band or the like.

[Brief explanation of drawings]

Fig. 1 is a perspective view of a door trim which is an example of an interior material according to the present invention, Fig. 2 is a sectional view taken along line nn of Fig. 1, Fig. 3 is an exploded perspective view of the door trim, and Fig. 4 is a It is an enlarged view of part A in the figure. DESCRIPTION OF SYMBOLS 1... Door trim, 2... Base material, 20... Skin material, 21.22... Convex molded part, 21a. 22a... sealed part. Applicant Daihatsu Motor Co., Ltd. Taiyo Kogyo Co., Ltd.

Claims (1)

[Claims] (1) A step of forming a convex molded part in a necessary part of a relatively rigid skin material, and applying the skin material to the surface of a non-formed flat base material, the convex molded part and the base A method for producing an interior material for an automobile, comprising the step of forming a hollow sealed part between the material and the material.