JPH0957775A5 - - Google Patents

Description

[0002]
2. Description of the Related Art
One type of interior material comprises a base material made of synthetic resin formed into a predetermined shape, a skin material that is adhered to the base material and covers the entire surface of the base material, and a sheet-like decorative material that is adhered to the skin material and covers predetermined areas of the skin material, with the peripheral edges of the decorative material being set into grooves provided in the base material.

[0003]
This interior material is manufactured by placing the skin material in a tensioned state between upper and lower molds having molding surfaces of a predetermined shape, releasably adhering the decorative material to a predetermined portion of the molding surface of one of the molds, supplying molten synthetic resin to the molding surface of the other mold, and compressing this synthetic resin between the two molds to form a base material, thereby fixing the skin material to the surface of the base material and adhering the decorative material to the surface of the skin material .

[0004]
In the interior material manufactured as described above , the peripheral edge of the decorative material is interposed between the concave and convex portions of the molding surfaces of both molds during molding of the base material and is embedded in the groove formed in the base material. However, in the embedded portion, as shown in Figure 4(b), the end face of the embedded peripheral edge of the decorative material 13 adhered to the skin material 12 is easily visible through the groove. Therefore, if such an interior material is used with the embedded portion exposed on the surface, the embedded portion will detract from the appearance. Furthermore, because the groove formed in the base material 11 has a substantially constant width, the appearance of the embedded portion will vary depending on the thickness of the decorative material 13.

[0005]
The object of the present invention is to improve the appearance of this type of interior material by treating the end face of the peripheral end of the decorative material in the inlaid wood portion so that it is not visible from the groove of the inlaid wood portion.

[0006]
In order to achieve the above-mentioned object, the present invention provides a method and apparatus for manufacturing interior materials by the steps of: interposing a skin material supported in a tensioned state between upper and lower molds having molding surfaces of predetermined shapes that are arranged opposite each other; releasably adhering a sheet-like decorative material that locally covers a predetermined portion of the skin material at a predetermined position on the molding surface of one of the upper or lower molds; supplying molten synthetic resin to the molding surface of the other mold; and compressing the supplied synthetic resin between the two molds to form a base material, thereby fixing the skin material to the surface of the skin material and adhering the decorative material to the surface of the skin material; wherein the upper mold is a molding die having protrusions or recesses formed on its molding surface that correspond to the periphery of the decorative material, and the lower mold is a molding die having recesses or protrusions formed on its molding surface that correspond to the protrusions or recesses, and the peripheral edge of the decorative material is pressed into a groove formed in the base material during molding, with the grain of the peripheral edge being embedded in the groove, and the peripheral edge is forced through the skin material to fit into the side wall of the groove.

[0009]
According to the present invention, when the base material constituting the interior material is molded, a skin material is adhered to the surface of the base material, and a decorative material is simultaneously adhered to a predetermined portion of the surface of the skin material to manufacture the interior material. During molding of this base material, the peripheral edge of the decorative material is wedged into the side wall of the groove in the base material via the skin material, so that it is not exposed to the outside and is not noticeable, thereby improving the appearance of the interior material.

[0010]
1 to 4 show a vehicle door trim, which is an interior material according to one embodiment of the present invention. The door trim 10 comprises a lower base 10a, an upper base 10b, and an armrest member 10c. The upper base 10b is integrally fixed to the upper edge of the lower base 10a to form the door trim 10, and the armrest member 10c is fixed to a horizontal step in the center of the lower base 10a to form an armrest on the inner surface of the door trim 10.

[0011]
2, 3, and 4(a), the lower base 10a includes a substrate 11 made of synthetic resin and molded into a predetermined shape, a skin material 12 that is bonded to the substrate 11 to cover its entire surface, and ornaments 13 that are decorative materials that are bonded to the skin material 12 to cover predetermined portions of the substrate, with upper and lower ends of the ornament 13 being fitted into grooves 11a formed at the top and bottom of the substrate 11, and front and rear ends being fitted into front and rear grooves 11b formed in the substrate 11. As shown in FIG. 4(a), the front and rear ends of the ornament 13 are fitted into the substrate 11 via the skin material 12, so that the end faces of the ends are not visible from outside the grooves 11b. As a result, the grooves 11b of the lower base 10a that are exposed on the passenger compartment side of the door trim 10 do not detract from the appearance of the surface of the door trim 10.

[0012]
Fig. 5 shows an example of a manufacturing method for the lower base 10a that constitutes the door trim 10 , and Figs. 6 and 7 show an upper mold 21 that constitutes a manufacturing apparatus 20 for the lower base 10a. This mold is composed of an upper mold 21 and a lower mold 22, and these upper mold 21 and lower mold 22 have opposing molding surfaces 21a, 22a, and are provided with protrusions 21b on the molding surface 21a of the upper mold 21 at positions that face each end of the ornament 13, and are provided with recesses 22b on the molding surface 22a of the lower mold 22 at positions that correspond to the protrusions 21b of the upper mold 21, into which the protrusions 21b can be inserted. These protrusions 21b and recesses 22b function to form the grooves 11a, 11b of the substrate 11.

[0014]
To manufacture the lower base 10a of the door trim 10, first, as shown in Figure 5(a), an ornament 13 coated with adhesive is fixed to the underside of a predetermined portion of the mold surface 21a of the upper mold 21 using double-sided adhesive tape, and the skin material 12 is placed in a tensioned state between the upper mold 21 and the lower mold 22 using clamps 23. Next, molten synthetic resin 14 is supplied onto the mold surface 22a of the lower mold 22. Thereafter, as shown in Figure 5(b), the upper mold 21 is lowered onto the lower mold 22 to overlap the two molds 21, 22. Finally, hydraulic pressure is supplied into the bulging member 21c.

[0015]
As a result, the synthetic resin 14 is compressed and expanded, molding the base material 11 into a predetermined shape, and the skin material 12 is adhered to all parts of the surface side of the molded base material 11, while the ornaments 13 are locally adhered to predetermined parts of the surface side of the skin material 12. During this molding process, the expanding member 21c is supplied with hydraulic pressure and slides the movable member 21d forward from the state shown in Figure 8(a), and as shown in Figure 8(b), the movable member 21d presses the end of the ornament 13 against the side wall of the groove 11b of the base material 11, which is in a plastic state, via the skin material 12. As a result, the end of the ornament 13 is wedged into the side wall of the groove 11b of the base material 11 through the skin material 12, and the end face of the end is not exposed to the groove 11b.

[0016]
In this way, by carrying out the manufacturing method of the present invention using the above-described manufacturing apparatus 20, the lower base 10a is manufactured by simultaneously bonding the skin material 12 to the surface of the base material 11 and locally bonding the ornament 13 to a predetermined portion of the surface of the skin material 12 during molding of the base material 11. When molding the base material 11, the end of the ornament 13 is wedged into the groove 11b of the base material 11 via the skin material 12. Therefore, the end face of the end of the ornament 13 is not exposed to the outside from the groove 11b of the base material 11 and is not visible to the naked eye, thereby significantly improving the appearance of the interior of the door trim 10.

[Explanation of symbols]
10...door trim, 10a...lower base, 10b...upper base, 10c...armrest member, 11...base material, 11b...groove portion, 12...skin material, 13...ornament, 14...synthetic resin, 20...manufacturing apparatus, 21...upper mold, 21a...mold surface, 21b...protrusion portion, 21c...bulge member, 21d...movable member, 22...lower mold, 22a...mold surface, 22b...recess, 23... clamp

Claims (4)

A method for manufacturing an interior material, comprising the steps of: interposing a skin material supported in a tensioned state between upper and lower dies having molding surfaces of predetermined shapes arranged opposite each other; releasably adhering a sheet-like decorative material that locally covers a predetermined portion of the skin material at a predetermined position on the molding surface of one of the upper or lower dies; supplying molten synthetic resin to the molding surface of the other die; and compressing the supplied synthetic resin between the two dies to fix the skin material to the surface of a base material formed by the process; and adhering the decorative material to the surface of the skin material, causing peripheral edges of the decorative material to bite into the base material via the skin material. a molding die having a projection or recess on its molding surface that corresponds to the periphery of the decorative material; and a molding die having a recess or projection on its molding surface that corresponds to the projection or recess. The peripheral edge of the decorative material is pressed into a groove formed in the base material during molding, and the peripheral edge is forced through the molding die to fit into the side wall of the groove. 3. An interior material manufacturing device comprising the upper and lower dies for carrying out the manufacturing method described in claim 2, and also comprising a pressing means for pressing the peripheral edge of the decorative material embedded in the groove of the base material against the side wall of the groove. An interior material such as a door trim for a vehicle, in which a skin material is adhered to the surface of a base material made of synthetic resin formed into a predetermined shape, and a sheet-like decorative material is locally adhered to the surface of the skin material in a predetermined portion, the peripheral edge of the decorative material is pressed into a side wall of the groove formed in the surface of the base material in a state where the peripheral edge is embedded in the grain of the skin material via the groove.