JPS6327171B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a fabric-attached molded article, and in particular, to a method for manufacturing a fabric-attached molded article, in which a fabric is applied to the outer surface of a molded article of a thermoplastic resin plate or a thermoplastic laminated resin plate. Regarding the method.

Fabric is pasted on the exterior parts of vehicle interior parts, decorative building materials, and household electrical appliances to partially change the material.
You can find products with different colors and patterns to make them look more luxurious. 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 the door trim of a vehicle, a decorative fabric called an ornament is attached above or below the armrest and is made of a different material or color pattern from the skin material of other parts. In the examples shown in FIGS. 1 and 2, the substrate 1 is a hardboard coated with vinyl chloride resin paint, and the cushion material 2 is a urethane foam that can be welded.
Then, the end of the fabric 5 made of a decorative carpet is hidden with a molding 6 made of vinyl chloride resin at a desired position of the laminate 4 with a soft vinyl chloride sheet as the skin material 3, and a high frequency wave is applied between the substrate 1 and the molding 6. It is integrated by welding. At this time, the fabric 5
The edge of the cover material 3 of the laminate plate 4 with cushioning properties is
It is difficult to fix the fabric 5 within the width of the welding surface of the molding 6 on the surface, and the end of the fabric 5 may protrude outside the molding 6 or a gap may be created between the fabric 5 and the molding 6 and the skin material 3 may peek out. Good products were often produced. The example shown in FIG. 3 is also used for the same purpose as the example shown in FIG. The fabric 5 is glued to the back side of the core material 7, and the clip 9 attached to the core material 7 is used to attach the fabric 5 to the desired position on the pre-formed laminate 4.
A decorative component 10 including the following is fixed.
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 method for producing a fabric-attached molded article of the present invention eliminates the above-mentioned drawbacks, in which a thin wall is provided at a desired position of a vacuum forming mold, and a predetermined area divided by the thin wall is formed in a vacuum forming mold. After laying the front side of the fabric on the surface and raising the edge of the fabric along the inner surface of the thin wall and fixing it to the thin wall, a thermoplastic resin plate or The method is characterized in that thermoplastic laminated resin plates are vacuum-formed and a fabric is attached to the outer surface of the molded resin plate. Details will be explained below with reference to the drawings.

FIG. 4 is an example of a vacuum molding mold used when molding a door trim with a fabric covered on the outer surface, which is installed on the passenger compartment side of a vehicle door, according to the present invention.
An end view of the cut portion is shown. 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.
A large number of exhaust holes 13 are cut in the vacuum mold surface 12, and an exhaust cavity 14 and an exhaust pipe 1 are formed.
It is connected to a vacuum pump (not shown) through 5. Further, a thin wall 16 is provided on the vacuum mold surface 12 at a position corresponding to the outer edge shape of a desired portion to which the door trim fabric is to be applied.

The thin wall 16 is used to attach a suitable band-shaped material such as a metal band or a saw blade to a desired position on the vacuum forming mold surface 12.
For example, the vacuum forming mold 11 is made to protrude by 3 to 20 mm.
It is embedded and fixed in. The thickness of the thin wall 16 is usually
It is preferably about 0.2 mm to 3.0 mm, and points to be considered when determining this thickness will be described later.

In order to manufacture a molded article with fabric using the vacuum forming mold 11 described above, first, as shown in FIG.
The surface of the fabric 21 is laid along the surface of the vacuum mold in a predetermined area 17 divided by 6, and the fabric is formed into a thin wall 16.
Cut on the outside. Of course, the fabric 21 may be cut in advance to match the external shape of the area 17. Especially when the vacuum mold surface of the area 17 is flat, it is relatively easy to pre-cut the fabric 21 into a predetermined shape. You can keep it.

In the illustrated embodiment, the thin wall 16 is extended into an endless shape, and the fabric is laid in the inner area 17, but if necessary, the fabric can be laid in a predetermined area outside of the thin wall 16. It is also possible to divide the vacuum forming mold surface by thin walls at the ends, and to lay the fabric in the predetermined areas thus divided.

When laying the front side of the fabric 21 as described above, the end of the fabric is raised along the inner surface of the thin wall 16 and fixed to the thin wall 16.

The fabric 21 is a woven fabric, a non-woven fabric, a knitted fabric, a carpet, etc., and is particularly preferably a material that can be shaped under pressure during normal conditions, heating, or humidification. Also fabric 2
First, the present invention can be implemented using materials other than the textile products described above, as long as they are breathable materials or materials that can be made breathable.

Before or after laying the fabric 21 on the surface of the vacuum molding mold in the area 17, the resin plate 22 (FIG. 5) is used in the next step.
Apply a polyester-based, polyurethane-based adhesive, etc. to the back surface of the fabric 21, that is, the surface opposite to the surface in contact with the vacuum forming surface, to the extent that it does not impede air permeability during vacuum forming.
Attach a slit or non-woven adhesive sheet made of EVA or nylon.

Next, the resin plate 2 is held by the clamp 22a and placed above the vacuum mold 11.
2 and the mold 11 are relatively approached in the vertical direction,
As shown by the chain line in FIG. 5, the resin plate 22 is placed on the mold 11 on which the cloth 21 is partially laid. As the resin plate 22, single layer PVC, PE, PP, ABS,
Using thermoplastic resin plates such as EVA and those thermoplastic resin plates as the base material, PVC,
A thermoplastic laminate of 3 layers consisting of a highly foamed material such as PE, PP, or polyurethane, and a film or fabric that stretches when heated as a skin material such as PVC, EVA, or thermoplastic elastomer, or 2 layers selected from these 3 materials. A resin plate is used.

After placing the resin plate 22 on the vacuum mold 11,
As is known per se, the exhaust pipe 15 and the exhaust cavity 1 are closed by the suction action of a vacuum pump.
4, and the exhaust hole 13, and the resin plate 22
is molded using a vacuum mold surface, and the cloth 21 and the resin plate 22 are bonded together. Further, as is well known, the resin plate 22 is heated before its molding, but at this time, it is preferable to heat the resin plate from the top and bottom using, for example, a double-sided heater. Useful for heat activation of adhesive sheets.

After cooling, the vacuum-formed resin plate 22 is taken out from the vacuum mold 11, and as shown in FIG. 6, a resin plate molded body with cloth 21 covered on the outer surface is obtained. The outer periphery of this molded body is trimmed at necessary locations to complete the product, in this example a door trim for a vehicle.

By the way, the thin wall 16 shown in FIGS. 4 and 5 forms a recess 33 at the boundary between the fabric portion 31 and the resin plate portion 32, as shown in FIG. 6, in the appearance of the molded product. Therefore, the distance between the recesses 33 is determined by the thickness of the thin wall 16. Therefore, the thickness is preferably as thin as possible as long as the thin wall 16 is not deformed during vacuum forming, and is usually 0.2 to 3.0 mm as described above. In addition, since the protruding height of the thin wall 16 from the surface of the vacuum molding die is the depth of the recess 33 at the boundary, the thickness of the thin wall 16 is adjusted so that the recess can hide the end of the fabric 21 after molding. It is determined by taking into account the length of the pile, the vacuum formability of the resin plate 22, etc.

Further, in the above embodiment, the fabric 21 and the resin plate 22 are bonded together using an adhesive or an adhesive sheet, but when the fabric 21 and the skin material of the thermoplastic resin plate or the thermoplastic laminated resin plate are compatible, or Fabric 21
When the fabric 21 is a carpet and the base fabric has a coarse weave, the fabric 21 and the thermoplastic resin plate or thermoplastic laminated resin plate are welded or entangled by heat, so an adhesive or an adhesive sheet may not be necessary.

Furthermore, when laying the fabric 21 in a predetermined area 17 of the vacuum forming mold 11 prior to molding the resin plate 22, the fabric 21 is spread from the center of the area 17 to the thin wall 1 while evacuating the area 17 through the exhaust hole 13 with a vacuum pump.
It is best to stretch it toward 6 so that wrinkles do not occur. For this purpose, as shown in FIG.
It is effective to make it possible to exhaust air separately from the exhaust pipes 15 other than the exhaust pipes 7, since it becomes possible to exhaust 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. The fabric 21 after the preforming is preformed in the area 1 of the mold 11.
7 is also effective. Furthermore, it is convenient to cut the periphery of the fabric 21 to approximately the external shape of the region 17 at the same time as this preforming.

Furthermore, when the fabric was laid, its ends were fixed to the thin wall 16, but this is because when the resin plate 22 is vacuum-formed and attached to the fabric 21 in the next step, the fabric 21 will be attached to the inside of the thin wall 16. This is to prevent the fabric 21 from shifting and causing wrinkles in the fabric portion 31, or from protruding the fabric 21 to the outside of the thin wall 16 and exposing its ends on the surface of the molded product.

Therefore, if the fabric 21 is difficult to slip and is weak, there may be no need to pay special consideration to the top of the thin wall 16; Blade-shaped protrusion 35 and (8th
(a), the inner surface of the area 17 of the thin wall 16 is provided with a locking part such as a hook part 36 of a hook-and-pile hook-and-loop fastener (FIG. 8(b)), or the thin wall 16 is The end of the fabric 21 that straddles the top part is attached to the entire circumference or part of the thin wall 16 using a fitting-type locking tool 37 having a U-shaped cross section.
It is advantageous to fix the ends of.

Furthermore, as shown in FIG. 9, the thin wall 1 of the vacuum forming mold 11 is
By making the area portion 17 divided by 6 into a removable nesting mold 41 and preparing a plurality of press molds 42 corresponding to the nesting molds 41 as shown in FIG. Molding, fabric 21
The fixing of the end of the thin wall 16 to the top of the thin wall 16 and the cutting of the periphery of the fabric 21 are simultaneously carried out using separate equipment while the vacuum forming mold 11 is performing the next process of vacuum forming the resin plate 22. Therefore, 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 forming mold surface of the nesting mold 41, the press mold 42 is removed,
If the next process of vacuum forming the resin plate 22 is then carried out, the fabric 21 will not be deformed during the period from preforming to adhesion to the resin plate 22, which is particularly effective when the fabric 21 is stiff. It is.

As described above, according to the method of the present invention, when the fabric is applied to the outer surface of the resin plate molded body, the end of the fabric is hidden inside the recess at the boundary between the resin plate part and the fabric part. There is no need to use moldings or core materials as in the conventional method, which simplifies the process, reduces processing time, and makes it possible to produce molded articles with fabrics that look better and have a more luxurious appearance than conventional products. can.

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 the drawing]

Figure 1 is a perspective view of a vehicle door trim manufactured by a conventional method, Figure 2 is a partial cross-sectional view of Figure 1, Figure 3 is a partial cross-sectional view of a door trim manufactured by another conventional method, and Figure 4. 5 is an end view of a cut section of the vacuum forming mold according to the present invention, FIG. Figure 7 is a cut end view showing another example of the vacuum forming mold, Figure 8 a, b, c
9 is a cross-sectional view showing the locked state of the locking part or locking tool that fixes the end of the fabric, FIG. 9 is an end view of the cut part showing still another example of the vacuum forming mold, and FIG. 10 is the insertion of the fabric. FIG. 11... Vacuum forming mold, 12... Vacuum forming mold surface,
16...thin wall, 17...area, 21...fabric, 2
2... Resin plate, 37... Locking tool, 41... Nested type.

Claims (1)

[Claims] 1. A thin wall is provided at a desired position of a vacuum forming mold, and the front side of the fabric is laid on the surface of the vacuum forming mold in a predetermined area divided by the thin wall, and the fabric is placed along the inner surface of the thin wall. After raising the end of the fabric and fixing it to a thin wall, vacuum forming a thermoplastic resin plate or a thermoplastic laminated resin plate over the entire vacuum mold surface from above the fabric,
A method for producing a fabric-attached molded body, which comprises applying a fabric to the outer surface of the resin plate molded body. 2. The method for manufacturing a fabric-attached molded article according to claim 1, wherein a locking part is provided or a locking tool is used to fix the end of the fabric to the top of the thin wall. 3 Claim No. 1 in which a predetermined area divided by a thin wall of a vacuum molding mold is a removable nesting mold.
A method for producing a fabric-attached molded article according to item 1 or 2.