JPH0464859B2 - - Google Patents

Description

[Detailed Description of the Invention] Purpose of the Invention (Field of Industrial Application) The present invention relates to various molded products such as automobile interior parts and indoor equipment products, and specifically relates to a method for producing molded products having irregularities on their surfaces. It is.

(Prior art) Various molded products such as automobile interior parts and indoor equipment products are coated with a separate material on the surface to give them an excellent appearance and to hide defects such as scratches and unevenness on the product surface. It is useful to add decorations.

For this reason, conventionally, a method has been used in which a sheet made of a synthetic resin such as vinyl chloride PVC, which has been provided with irregularities such as a grain pattern, is shaped into a desired shape and bonded to the surface of a molded product.

(Problems to be Solved by the Invention) However, in the above manufacturing method, since vacuum forming is used to shape the sheet into a desired shape, the grain pattern formed on the sheet surface due to the heat during molding. In some cases, the material stretched and sagged, damaging the appearance of the molded product. Therefore, the present invention aims to solve the above problems.

Structure of the Invention (Means for Solving the Problems) Therefore, in order to solve the above-mentioned problems, there is a step of providing the surface of the skin with a cut that does not penetrate to the back side, and simultaneously shaping the skin into a desired shape. , a configuration is adopted that includes a step of opening the cut and transforming it into a concave portion, and a step of joining the shaped skin and the base material.

(Function) When shaping the epidermis in which an incision has been formed into a desired shape, the incision is opened by actively utilizing the heat and tensile force required for shaping, and the cut is shaped according to its depth. Transform into recesses with different widths and depths. Therefore, an uneven pattern is imparted to the skin at the same time as it is shaped. Subsequently, the skin is bonded to a base material via an adhesive or the like to produce a molded article having an uneven surface.

(First Example) Next, a first example in which the present invention is embodied in a center pillar interior material, which is one of automobile interior parts, will be described.
This will be explained according to Figures 5 to 5.

As shown in FIG. 1, an adhesive layer 3 is formed by applying an adhesive on the surface of a base material 1 formed by injection molding ABS resin, and the surface of the adhesive layer 3 is A skin 5 made of a thermoplastic sheet is adhered to. The skin 5 includes a semi-rigid sheet 5a of vinyl chloride (PVC) on the side of the adhesive layer 3 and polypropylene (PP) on the surface thereof.
It is composed of a soft foam sheet 5b. Further, a plurality of recesses 7 arranged in stripes are formed on the entire surface of the foamed sheet 5b, so that the entire surface of the skin 5 appears to have an uneven shape.

Next, a method of manufacturing the center pillar interior material of this embodiment using a vacuum forming apparatus will be explained with reference to FIGS. 2 to 5.

First, the back surface of the soft foam sheet 5b is heated with a burner to partially melt it, and the semi-rigid sheet 5a is thermally welded to the back surface while being sandwiched between rollers.

Next, as shown in FIG. 2, a plurality of incisions 8 are made in stripes on the entire surface of the skin 5 (the side of the soft foam sheet 5b). This notch 8 is a portion that opens to become a recess 7 during subsequent shaping, and the depth and width of the recess 7 can be determined by the depth of the notch 8 and the narrowing down during shaping. In this embodiment, the notch 8 has a depth of 1 to 2 mm, and the recess 7 has a width of 1 to 3 mm.

Next, this skin 5 is shaped to match the shape of the base material 1 by vacuum forming, and at the same time, the cut 8 is opened to transform it into a recess 7.

The vacuum forming equipment used for this vacuum forming is the third one.
As shown in the figure, a clamp frame 11 is provided approximately at the center of the main body 10 for holding the skin 5 to be molded. A slidingly movable heater section 13 to which an infrared heater 12 is attached is provided on the side of the clamp frame 11, and is adapted to slide and be positioned above the clamp frame 11 during heating. . A mold mounting table 15 is provided below the clamp frame 11 and is movable up and down by hydraulic pressure or the like. A hole 16 is provided in the approximate center of the table 15, and the main body 11
It is connected by vacuum piping 18 to a vacuum tank 17 placed on the side of the vacuum tank 17 . Furthermore, a mold 19 used in this embodiment is arranged on the upper surface of the mold mounting table 15 including the hole 16.

Now, when forming using this device, after cutting the skin 5 to the size of the clamp frame 11,
The semi-rigid sheet 5a of the skin 5 is set on the same clamp frame 11 so that the surface of the mold 19 faces. Thereafter, the heater section 13 is slid onto the clamp frame 11 to heat and soften the skin 5 and bring it into a drawdown state. In this state, as shown in FIG. 4, by returning the heater section 13 to its original position and raising the mounting table 15 on which the mold 19 is placed, the skin 5 is pushed up and the skin 5 is stretched appropriately. At the same time, the outer skin 5 is sealed at the end of the mold 19. Then, the vacuum tank 1
The valve 20 of No. 7 is opened to make the inside of the mold 19 evacuated, and the plurality of holes 2 transparently provided in the mold 19 are opened.
1 to press the skin 5 onto the surface of the mold 19.

At this time, the skin 5 is softened by heating during molding, and is further suctioned by a vacuum, so that the skin 5 as a whole is stretched. Due to this elongation, the cut 8 is opened and transformed into a recess 7, as shown in FIG. Since a plurality of the recesses 7 are formed, the skin 5 as a whole appears to have an uneven pattern.

Subsequently, an adhesive is applied to the surface of the base material 1 formed by injection molding, and the skin 5 is adhered to the surface.

As described above, in this manufacturing method, an uneven pattern is formed on the surface of the skin 5 by actively utilizing the heat and tensile force generated during shaping, so the heat and It is possible to form an excellent uneven pattern that does not sag due to tension.

Furthermore, since the uneven pattern can be formed simultaneously with shaping the skin 5, the manufacturing process can also be shortened.

In addition, by arbitrarily changing the depth and width of the cut 8 in the cutting process before shaping, it is possible to form any uneven pattern, making it easy to manufacture molded products with partially different uneven patterns. I can do it.

In addition, since the skin 5 has a two-layer structure of a soft foam sheet 5b and a semi-rigid sheet 5a, and the cuts 8 are formed only in the surface soft foam sheet 5b, the skin 5 may be partially pulled during shaping. The semi-rigid sheet 5a can prevent the skin 5 from tearing at that part when it is stretched.

Furthermore, since the surface side of the skin 5 is made of the soft foam sheet 5b, an uneven pattern that is soft to the touch can be formed.

Moreover, since the uneven pattern can be formed by using a conventionally used vacuum forming apparatus, the process can be carried out without changing the process.

(Second Embodiment) Next, a second embodiment of the present invention will be described with reference to FIG.

This embodiment differs from the first embodiment only in that a flocking process is added to the first embodiment.

That is, a primer layer 22 for flocking is coated on the surface of the skin 5 of the molded product manufactured according to the first embodiment, and an adhesive layer 23 for flocking is further coated on that surface, and then a flocking adhesive layer 23 is further coated on the surface. This is what we do.

Therefore, according to this embodiment, the same effects as in the first embodiment are achieved, and the flocked pile 24 and the uneven pattern on the surface of the molded product combine to provide a soft texture with a more three-dimensional effect. It is possible to produce molded products.

In this embodiment, the hair is transplanted after the uneven pattern is formed, but the hair may be transplanted to the epidermis 5 before the incisions 8 are made, and then the incisions 8 are made and shaped. In this way, when the notch 8 is opened to form the recess 7, a complicated part appears where the hair is implanted and a part where it is not, and furthermore,
The 5 parts of the epidermis become interesting.

Note that the present invention is not limited to the above-mentioned embodiments, and can be embodied as follows, for example.

(1) Regarding the structure of the skin 5, as shown in FIG. 7, a two-color laminate sheet 25 may be used as the skin 5. In this way, the back sheet 25b portion is exposed in the recess 7 formed at the same time as the shaping, and provides an excellent appearance in combination with the color of the front sheet 25a.

Furthermore, as shown in FIGS. 8 and 9, arbitrary characters 2 can be created by making partial cuts in the skin 5.
7, patterns, etc. can be easily added.

Note that, of course, a soft or hard sheet having a single layer structure may be used as the skin 5. However, it is preferable to use a material with a certain degree of tensile strength or a thick sheet.

Further, the surface of each of the sheets may be flocked as shown in the second embodiment, and by doing so, the surface of the skin 5 becomes interesting due to the uneven pattern.

(2) In addition to the vacuum forming of this example, any method may be used for the shaping as long as it uses a method of softening the epidermis with heat or the like and stretching it.
For example, hot press molding or the like may be used.

Effects of the Invention As detailed above, the present invention forms an uneven pattern on the epidermis by making incisions in the epidermis and actively utilizing the heat and tensile force generated during shaping. This not only makes it possible to produce a molded product with an excellent appearance without the concavo-convex pattern sagging, but also reduces the number of steps. Furthermore, by changing the incisions made in the epidermis, it is possible to easily create any uneven pattern, which is an excellent effect.

[Brief explanation of the drawing]

Fig. 1 is a cross-sectional view showing an automobile center pillar interior material molded by the manufacturing method of the present invention, and Fig. 2 shows the process of manufacturing the skin of the center pillar interior material of Fig. 1, forming an uneven pattern. 3 is a partial sectional view showing the vacuum forming device for shaping the skin shown in FIG. 2, and FIG. 4 is the vacuum forming device shown in FIG. 3 in operation. FIG. 5 is a partially enlarged sectional view showing the state of the skin during vacuum forming, FIG. 6 is a sectional view showing the second embodiment, and FIG. The figure is a partial sectional view showing another example, Nos. 8 and 9.
The figure shows another example, and FIG. 8 is a front view showing the seat.
FIG. 9 is a perspective view showing a part of the center pillar to which the seat of FIG. 8 is attached. Base material...1, Outer skin...5, Recess...7, Notch...8.

Claims (1)

[Scope of Claims] 1. A step of providing a notch 8 that does not penetrate to the back side on the surface of the outer skin 5, 25, and simultaneously shaping the same skin 5, 25 into a desired shape, opening the notch 8 to form the recess 7. A method for manufacturing a molded product having an uneven surface, comprising a step of deforming the formed product and a step of joining the shaped skin 5, 25 and the base material 1. 2 The cut 8 is 0.1 from the surface of the epidermis 5, 25.
2. The method for manufacturing a molded article having an uneven surface according to claim 1, wherein the depth is 10 mm. 3. The method for manufacturing a molded product having an uneven surface according to claim 1, wherein the shaping of the skins 5 and 25 is performed by vacuum forming. 4 The skin 5 has a soft foam sheet 5b on the surface,
A method for manufacturing a molded product having an uneven surface according to claim 1, characterized in that the semi-rigid sheet 5a is formed on the back surface of the molded product. 5. The method for manufacturing a molded product having an uneven surface according to claim 1, wherein the surface of the epidermis 5 is flocked. 6. The method of manufacturing a molded product having an uneven surface according to claim 1, wherein the skin 25 is a laminate sheet made of laminated sheets of different colors.