JPS6365492B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to a method for manufacturing a fabric-attached molded article, and in particular, to a method of manufacturing a molded article made of a thermoplastic resin plate or a laminated resin plate at a desired position on the outer surface of the molded article. The present invention relates to a method for manufacturing a fabric-attached molded article.

Conventional technology Fabric is attached to the exterior parts of vehicle interior parts, decorative building materials, and household electrical appliances to partially change the material.
You can find synthetic resin products with different colors and patterns to give them 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 is attached above or below the armrest and is made of a different material or color pattern from the skin layer of other parts. In the examples shown in Figures 1 and 2a, hardboard coated with vinyl chloride resin paint is used as the base layer 1, weldable urethane foam is used as the cushion layer 2, and a soft vinyl chloride sheet is used as the outer layer. At a desired position of the laminated resin plate 4 as the layer 3 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 1 and the molding 6 are welded together with a high-frequency welder. At this time, the end of the fabric 5 is placed on the surface layer 3 of the cushioned laminated resin board 4 at the molding 6.
It is difficult to fix within the width of the welding surface.
Defective products often occur in which the end of the fabric 5 protrudes outside the molding 6 or a gap is created between the fabric 5 and the molding 6 so that the skin layer 3 is exposed. The example shown in FIG. 2b 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 then sewn together. It is placed on the cushion layer 2 at a desired position, and the sewn portion is fixed to the base layer 1 with a fastener 19, and then the 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. The core material 7
A decorative component 1 including a fabric 5 is fixed to the back surface of the fabric 5 and placed in a desired position on a pre-formed laminated resin plate 4 by means of a clip 9 attached to a core material 7.
It is fixed at 0. 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.

Problems to be Solved by the Invention The present invention is a method for molding a resin plate and at the same time attaching fabric to a desired position on the outer surface of the plate. The purpose is to prevent the occurrence of this problem, and eliminate the increase in weight and complexity of the process due to the use of core materials and clips.

Means for Solving the Problem The method for manufacturing a fabric-attached molded article of the present invention is to provide a thin wall with an upper part extending outside the area at the outer edge of a predetermined area of a thermoforming mold, and to apply fabric to the surface of the thermoforming mold in that area. After laying the front side of the fabric and placing the edge of the fabric on the seepage part of the thin wall, from above the fabric, wrap the entire edge of the fabric across the seepage part of the thin wall. A thermoplastic resin plate or a laminated resin plate is thermoformed over the surface of the thermoforming mold, a fabric is applied to a desired position on the outer surface of the molded resin plate, and the end of the fabric is placed inside the resin plate part. It is something to hide. 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 means of the present invention, the resin plate is thermoformed to have a "Z"-shaped or "self"-shaped cross section at the end of the fabric, and the end of the fabric is housed in the groove. In this manner, 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 details of the present invention 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, which is equipped on the passenger compartment side of a vehicle door and whose outer surface is covered with fabric, 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, on the vacuum forming mold surface 12, a thin wall 1 whose upper portion extends outside the area is formed on the outer edge of a predetermined area corresponding to the outer edge shape of a desired portion on which the door trim fabric is to be applied.
6 is circulating.

The thin wall 16 is made of a band-shaped material such as a metal band whose wall surface is bent in the transverse direction as shown in FIG. The thickness of the thin wall 16 is 0.5
mm, and its cross-sectional shape is from vacuum mold surface 12 to 3
mm rises, bends at that position and extends 3 mm out of the predetermined area to form a platform 35, and further rises 2 mm upward to form a rising portion 36.

A predetermined area 17 divided by a thin wall 16 shown in FIG. 5 is a carpet having a pile length of 5 mm as the fabric 21.
The front side of the fabric 21 is laid along the surface of the vacuum forming mold, the fabric 21 is cut inside the top 36 of the thin wall 16, the end thereof is placed on the mounting table 35, and the back side of the fabric 21 is placed for ventilation. Apply adhesive to an extent that does not interfere with performance.

The resin plate 22 is, for example, a soft vinyl chloride resin skin layer 25 with a thickness of 0.3 mm, and a highly foamed polyethylene sheet with a foaming ratio of 15 times with a thickness of 3 mm, as shown in FIG. A laminated resin plate 22 consisting of a cushion layer 26 and a polypropylene base layer 27 with a thickness of 3 mm is prepared, and held with a clamp 23 so that the skin layer 25 faces the fabric 21, and a heating device (not shown) is used. Heat.

Next, a vacuum pump (not shown) is operated to suck air from the vacuum mold surface 12 through the exhaust pipe 15, exhaust cavity 14, and exhaust hole 13. By this operation, the fabric 21 is brought into close contact with the vacuum mold surface 12 in the predetermined area 17.

As the clamp 23 surrounds the mold 11 and lowers the heated resin plate 22, as shown by the chain line in FIG. The space is sealed, and the resin plate 22 is adsorbed to the vacuum mold surface 12 directly or through the fabric 21 so as to sandwich the thin wall 16 and wrap the end of the fabric 21 as shown in FIG. Vacuum forming is then 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 has a state as shown in the sectional view shown in FIG. 6. That is, the resin plate 22 is formed to have a "Z"-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 the back side of the fabric 21 by the action of atmospheric pressure,
Adhere both firmly.

Examples of the resin plate 22 used in the present invention include:
A single-layer thermoplastic resin plate such as PVC, PE, PP, ABS, or EVA or such thermoplastic resin plate is used as the base material layer 27, and the cushion layer 26 is made of PVC, PE,
A laminated resin board consisting of a highly foamed material such as PP, polyurethane, and a film or fabric that stretches when heated as the skin layer 25, such as PVC, EVA, or thermoplastic elastomer, or two layers selected from these three. be.

Further, as the fabric 21, woven fabric, woven fabric, knitted fabric,
A material such as a carpet that can be shaped by pressurization under normal conditions, heating or humidification, or a material that has been treated to be shaped is particularly preferred. Further, even if the fabric 21 is made of a material other than the textile products described above, the present invention can be practiced 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, the exhaust hole 13 is opened by a vacuum pump (not shown).
It is preferable to stretch the fabric 21 from the center of the region 17 toward the thin wall 16 while evacuating the region 17 through the cloth 21 so as not to cause wrinkles. For this purpose the seventh
As shown in the figure, the exhaust hole on the vacuum mold surface of the area 17 divided by the thin wall 16 is communicated with an exhaust pipe 18 of a separate system, so that exhaust can be performed separately from the exhaust pipe 15 other than the area 17 mentioned above. This is effective because it allows only the region 17 to be evacuated when necessary. In addition, if the fabric 21 does not fit easily into 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 molds that correspond to the surface of the vacuum molding mold 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 to approximately the external shape of the region 17 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. Apply an adhesive such as polyester or polyurethane to the surface opposite to the surface that contacts the mold surface, or
Alternatively, attach a slit or non-woven adhesive sheet made of EVA or polyamide. 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 the 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.

As the thin wall 16, a crank-shaped one shown in FIG. 8a was used in the above embodiment, but in addition, as shown in FIG. and resin plate 2
This prevents the fabric 21 from shifting inside the thin wall 16 during thermoforming in step 2 and causing wrinkles in the fabric portion 31 (FIG. 6). When the protrusion 37 is provided on the platform 35, it may be as shown in FIG.

As a modification of the thin wall 16, the present invention can also be implemented by using a thin wall 16a that is inclined outward from the predetermined region 17 of the vacuum forming mold 11, as shown in FIGS. 8d and 8e. 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 thin wall 16 material is 0.3 to 3 mm, and the thinner the material is, the better, 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. Regarding fabric 21, the compressed thickness when applying a load of approximately 1 kg/cm ² and fabric 2
The resin plate 22 is determined with reference to the presence or absence of the backing layer 1 and the presence or absence of the cushion layer 26 for the resin plate 22. 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, cushion layer 26, and base material layer 27, FIG. 9 and FIG. Figure 8a
To explain this with reference to FIG. The length B to the bending point is 1 to 2 times the sum of the thicknesses of the skin layer 25 and the cushion layer 26 before vacuum forming, and the height C from the second bending point to the top of the rising portion 36 is The compressed thickness of the fabric 21 may be approximately equal to the compressed thickness.

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. Body mold 11
The dimensions of the thin wall 16 are determined in consideration of the thickness of the skin layer 25 and the base material layer 27, the hardness immediately after molding, thermoformability (elongation upon heating), etc., so that they can be removed from the mold.

As shown in FIGS. 8 d and 8 e, when the thin wall 16 is inclined outward from the predetermined area of the vacuum forming mold 11, the inclination angle is different from that of the forming surface 12 of the vacuum forming mold 11 outside the predetermined area. The extrusion width outside the predetermined area is 30 to 60 degrees, preferably 40 to 50 degrees, from the resin plate 22.
is a laminate including a cushion layer 26, 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, as shown in FIG. 10, the region 17 of the vacuum forming mold 11 divided by the thin wall 16 is made into a removable nesting mold 41, and as shown in FIG. By separately preparing a nesting die 41 and a corresponding press die 42, the above-described preforming of the fabric 21 and the thin wall 16 at the end of the fabric 21 can be performed.
Holding on the mounting table 35 and cutting around the fabric 21 can be performed simultaneously while the vacuum forming mold 11 is vacuum forming another resin plate 22, reducing the time the vacuum forming mold 11 is occupied. can do. 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 nested mold 41 is separated from the exhaust system for the vacuum forming mold 11, but it is also possible to configure the nested mold 41 to be evacuated by the exhaust system for the mold 11. good.

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 the same plane on the inside and outside of the thin wall 16, but considering that the nap of the fabric 21 returns to its natural state after thermoforming, the fabric side is set to the natural state of the fabric 21. By making the molded product higher than the resin plate side by the difference in thickness between the thickness and the thickness when compressed, the vicinity of the boundary between the fabric 21 and the resin plate 22 portion of the molded product becomes flat.

Furthermore, after manufacturing the 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, the base material layer 27 is formed separately.
It is also possible to bond with.

Effects of the Invention 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,
Since the end of the fabric is housed in the groove and the fabric is attached to a desired position on the resin plate, the following effects are achieved compared to the conventional example.

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

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

(3) There is no concealment failure due to the use of moldings or an increase in weight due to the use of core materials.

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]

Figure 1 is a perspective view of a vehicle door trim manufactured by a conventional method, Figures 2 a and b are partial cross-sectional views showing a conventional door trim fabric end treatment method, and Figure 3 is a door trim manufactured by another conventional method. 4 is a cross-sectional partial view of the door trim, FIG. 4 is an end view of a cut portion of the vacuum forming mold according to the present invention, FIG. FIG. 7 is a cross-sectional partial view of the molded product after thermoforming, and FIG.
b, c, d, and e are partial cross-sectional views of the thin wall; FIG. 9 is a partial cross-sectional view showing the state of the thin wall and the resin plate at the end of the fabric after vacuum forming; and FIG. 10 is a partial cross-sectional view of the thin wall. FIG. 11 is an end view of a cut part showing an example of the cut part of a nested mold and a press mold into which cloth is inserted. 11...Thermoforming mold, 12...Thermoforming mold surface, 16
...thin wall, 17...area, 21...fabric, 22...
... Resin plate, 37... Protrusion, 41... Nested type.

Claims (1)

[Claims] 1. A thin wall whose upper part extends outside the area is provided at the outer edge of a predetermined area of a thermoforming mold, and the front side of the fabric is laid on the surface of the thermoforming mold in that area, and the thin wall extends out of the area. After placing the end of the fabric on the top of the fabric, a thermoplastic resin plate or Characterized by thermoforming laminated resin plates,
A method for producing a fabric-attached molded article, in which the fabric is attached to a desired position on the outer surface of the resin plate molded article, and the ends of the fabric are hidden inside the resin plate part. 2. The method for manufacturing a fabric-attached molded article according to claim 1, wherein a protrusion for detachably attaching an end portion of the fabric is formed in the extrusion portion of the thin wall. 3. The method for producing a fabric-attached molded article according to claim 1 or 2, in which the predetermined area divided by the thin wall of the thermoforming mold is a removable nesting mold.