JP4224779B2 - Manufacturing method of electroforming mold - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing an electroforming mold, and more specifically, an electroforming material for forming a skin material having a skin molding surface having a convex portion having a required contour shape and having a concave portion formed by reversing the shape of the convex portion. The present invention relates to a method for manufacturing a mold.
[0002]
[Prior art]
For example, vehicle interior members (instrument panels, center consoles, door panels, etc.) installed in passenger compartments such as passenger cars are molded into required shapes (injection molding and A method in which a synthetic resin skin material is attached to the outer surface of a molded synthetic resin molded substrate is employed. The synthetic resin skin material is: (1) one formed from a resin sheet material based on vacuum forming technology, (2) one formed from resin powder into a required shape based on powder slush molding technology, (3) Based on spray molding technology, those molded into a required shape from polyurethane or the like have been put into practical use. The skin molds corresponding to each of the above-mentioned molding technologies are based on the skin model produced by pasting a real skin sheet such as woven fabric, knitted fabric (fabric, tricot, etc.) or genuine leather. It is said to be a so-called `` electric mold '' produced, and the surface pattern (texture pattern) of the skin sheet is faithfully reproduced on the skin material molded with the skin molding surface transferred and reproduced on the skin mold. It has become so.
[0003]
Here, as shown in FIG. 23, for example, the instrument panel 10 is made of a synthetic resin-made panel base 12 injected into a required shape, and the skin material 14 disposed outside the panel base 12. And a three-layer structure comprising a foam 20 interposed by foam molding between the panel base material 12 and the skin material 14. For example, since an air outlet (accessory part) 24 having a substantially rectangular shape is mounted, an installation portion 22 for accommodating and holding the air outlet 24 is opened at a required position of the skin material 14. It is necessary to form a skin recess 16 for this purpose. Therefore, the skin molding die 30 for molding the skin material 14 having the skin recess 16 described above has a surface molding surface having a surface shape that can faithfully reproduce the uneven shape of the skin material 14 as illustrated in FIG. 32 and a convex portion 34 having a required contour shape for forming the skin concave portion 16 needs to be provided at a required position on the skin molding surface 32. The skin mold 30 shown in FIG. 21 has a structure corresponding to the spray molding technique (3).
[0004]
The skin forming die 30 illustrated in FIG. 21 is a so-called “electroforming mold” manufactured based on, for example, a known electroforming technique, and is manufactured through work processes according to the process diagram shown in FIG. That is, the manufacturing method of the skin mold 30 that is an electric mold includes a step of manufacturing the wooden model 40 (FIG. 16), and a skin sheet S such as genuine leather on the sheet mounting surface 42 of the molded wooden model 40. A step of manufacturing the skin model 50 by pasting (FIG. 17), a step of manufacturing the reverse model 60 having the transfer surface 62 onto which the surface pattern of the skin sheet S is transferred (FIG. 18), and the reverse model 60 And a step (FIG. 19) of producing a tank model 70 having a reference surface 72 on which the surface pattern of the transfer surface 62 of the inverted model is transferred, and using the tank model 70, the reference model 72 is used. And a step of manufacturing the skin molding die 30 having the skin molding surface 32 onto which the surface pattern of the surface 72 is transferred (FIG. 20).
[0005]
The wooden model 40 is formed of wood, artificial wood, or the like. For example, the skin forming surface 32 of the skin forming die 30 illustrated in FIG. 21 is inverted based on machining by an appropriate cutting tool 80 such as an end mill. The surface unevenness-shaped sheet mounting surface 42 thus formed is formed. Further, a concave portion 44 having the same contour shape as the skin concave portion 16 of the skin material 14 is provided in the seat mounting surface 42 when the machining is performed. However, the sheet mounting surface 42 is formed in a shape offset by the thickness of the skin sheet S to be pasted (for example, about 1 mm).
[0006]
Then, the skin sheet S is pasted on the sheet mounting surface 42 of the manufactured wooden model 40 using an adhesive or the like, and the skin model 50 as a reference model is manufactured (FIG. 17). Here, when the skin sheet S is pasted, the skin sheet S is stuck on the entire surface of the recess 44 provided on the sheet mounting surface 42. Thereby, the skin sheet S is attached to the entire surface of the sheet mounting surface 42 including the concave portion 44.
[0007]
The inversion model 60 is manufactured using the skin model 50 and is also referred to as a “silicon type”. As illustrated in FIG. 18, the skin model 50 and a base model closed to the skin model 50 are used. (Not shown) is formed by curing the silicon injected into the cavity defined between the two. The reversal model 60 obtained in this way is formed with a transfer surface 62 in which the surface pattern and the uneven shape of the skin sheet S are faithfully transferred and the convex portions 64 are formed by reversing the shape of the concave portions 44. Has been.
[0008]
The tank model 70 is manufactured using the reversal model 60, and a thermosetting resin (a thermoplastic resin can also be used) is poured into a recess facing the transfer surface 62 of the reversal model 60. The resin is hardened while being in close contact with the transfer surface 62 made of silicon. In the tank model 70 thus obtained, the surface pattern and the uneven shape of the transfer surface 62 of the reversal model 60 are faithfully transferred, and a reference is provided with a concave portion 74 formed by reversing the shape of the convex portion 64. A surface 72 is formed. That is, the reference surface 72 of the tank model 70 is transferred with the same surface pattern and uneven shape as the surface pattern of the skin sheet S of the skin model 50 and the uneven shape of the sheet mounting surface 42. Examples of the thermosetting resin used as the resin include an epoxy resin, a phenol resin, a polyester resin, a urea resin, and a melamine resin.
[0009]
The tank model 70 manufactured as described above and having the reference surface 72 provided with the recess 74 was subjected to a conductive process (a process of applying a conductive film by a silver mirror reaction process) as a pretreatment for the tank, for example. Thereafter, the skin molding die (electroforming mold) 30 having a thickness of about 4 to 5 mm is formed on the reference surface 72 by an electroforming technique (electroplating is applied to the tank model 70) performed in the electroforming tank 82. (FIG. 20). The skin molding die 30 thus obtained has a skin molding surface 32 in which the surface pattern and the concavo-convex shape of the reference surface 72 are faithfully transferred, and the convex portion 34 is provided by reversing the shape of the concave portion 74. Is formed.
[0010]
Then, as shown in FIG. 21, the skin forming die 30 manufactured through the above-described steps is subjected to piping processing of the temperature control pipe 36 and the like, and then sprayed onto the skin forming surface 32 kept at a predetermined temperature. After the urethane material U is sprayed and applied by the gun 38, the skin material 14 is formed by curing the urethane material U. In the skin material 14 thus molded, the surface shape of the skin sheet S is transferred, and the skin concave portion 16 is formed by reversing the shape of the convex portion 34. The above-described electroforming technique is disclosed in, for example, Patent Document 1.
[0011]
[Patent Document 1]
JP-A-10-128775
[0012]
[Problems to be solved by the invention]
Incidentally, the conventional method for manufacturing an electroforming mold (skin forming mold) based on the above-described electroforming technique has the following problems. That is, in the wooden model 40, when the recess 44 is provided at a required position of the seat mounting surface 42 by machining (end milling or the like), the opening twill edge 46 of the recess 44 is formed as shown in FIG. As shown in (1), it is possible to form an angular convex shape with an edge. However, when the skin sheet S is pasted over the surface of the sheet mounting surface 42 and the recess 44, as shown in FIG. 17B, the opening twill edge formed on the outer peripheral edge of the recess 44 46 becomes a convex curved surface about the thickness of the said skin sheet S, and it becomes a rounded convex curved surface shape instead of the convex angular shape which the edge worked and was squared. That is, it is impossible to paste the skin sheet S into an angular shape with an edge that is effective and square with any skill, and the opening twill edge 46 has a radius of at least 0.5 to 1 mm. The above-mentioned rounded convex curved surface shape is obtained.
[0013]
For this reason, for example, when the opening twill edge 46 of the recess 44 has a rounded convex curved surface shape with a radius of 1 mm, the inversion model 60 manufactured using the skin model 50, the inversion model This is transferred to the bathing model 70 manufactured using No. 60, and the opening twill edge 76 of the recess 74 in the bathing model 70 is also rounded with a radius of 1 mm as illustrated in FIG. It becomes a convex convex curved surface shape. Therefore, the convex curved surface shape of the opening twill edge portion 76 is transferred as it is on the skin molding surface 32 of the skin molding die 30 manufactured using the tank model 70, and the base contour edge of the convex portion 34 is transferred as it is. The edge 35 has a rounded concave curved surface shape with a radius of 1 mm (FIG. 20B). Therefore, the skin material 14 formed by the skin molding surface 32 has a skin concave portion as shown in FIG. 21B. The outer twill edge 18 formed on the outer peripheral edge 16 has a rounded convex curved shape with a radius of 1 mm.
[0014]
Therefore, in the instrument panel 10 equipped with the skin material 14 formed as described above, the storage and holding position of the air outlet 24 with respect to the installation portion 22 formed by the skin recess 16 of the skin material 14 is illustrated. 23 and FIG. 24A, the front surface of the air outlet 24 is set so as to recede from the outer surface of the skin material 14 by an appropriate offset amount (about 1 to 1.5 mm). This is because the skin twill edge 18 of the skin recess 16 has a convex curved surface shape as described above, so that the front surface of the air outlet 24 and the surface of the skin material 14 are formed as illustrated in FIG. When the air outlet 24 is accommodated and held in the installation portion 22 so as to coincide with each other, a groove having a width of about 1 mm is defined in the boundary contour portion between the air outlet 24 and the skin material 14, and the instrument panel 10. This is because a problem that causes deterioration in the texture of the material occurs.
[0015]
However, as illustrated in FIGS. 23 and 24 (a), when the accommodation holding position of the air outlet 24 is set to be offset rearward as described above, the air outlet 24 and the skin material 14 are set. In this way, it is impossible to avoid deterioration of the texture of the instrument panel 10.
[0016]
OBJECT OF THE INVENTION
The present invention has been proposed to suitably solve the above-described problems, and the skin twill edge formed in the skin concave portion or the like of the skin material can be formed into an angular convex shape with an effective edge. It is an object of the present invention to provide a method for manufacturing an electroforming mold.
[0017]
[Means for Solving the Problems]
In order to solve the above-mentioned problems and achieve the intended purpose, the present invention forms a skin material having a skin molding surface having a convex portion having a required contour shape and having a skin concave portion by reversing the shape of the convex portion. A method for producing an electroforming mold, comprising:
The skin model is manufactured by sticking the skin sheet to the sheet mounting surface of the wooden model so as to adhere to the entire surface,
Using the epidermis model, producing a reversal model having a transfer surface on which the surface pattern of the epidermis sheet is transferred,
Using the reversal model, to produce a tank model having a reference surface to which the surface pattern of the transfer surface is transferred,
On the reference surface of the tank model that has been manufactured, a recess having the same contour shape as the skin recess is provided,
Using the basin model in which the concave portion is provided, the electroforming mold having the skin molding surface on which the surface pattern of the reference surface is transferred and the convex portion is provided by reversing the shape of the concave portion is manufactured. It is characterized by doing.
[0018]
Similarly, in order to solve the above-mentioned problems and achieve the intended purpose, another aspect of the present invention is to provide a skin forming surface having a convex portion having a required contour shape and a skin concave portion formed by reversing the shape of the convex portion. A method of manufacturing an electroforming mold for molding a material,
On the seat mounting surface of the wooden model, a concave portion having the same contour shape as the above-mentioned skin concave portion is provided, and after attaching the skin sheet so as not to adhere to the surface of the concave portion on the seat mounting surface of the wooden model, Remove the unnecessary sheet part that faced this recess, and make a skin model,
Using the epidermis model, the surface pattern of the epidermis sheet is transferred, and a reversal model having a transfer surface in which convex portions are formed by reversing the shape of the concave portions,
Using the reversal model, the surface pattern of the transfer surface is transferred, and a basin model having a reference surface with a concave portion formed by reversing the shape of the convex portion is manufactured,
Using the basin model in which the concave portion is provided, the electroforming mold having the skin molding surface on which the surface pattern of the reference surface is transferred and the convex portion is provided by reversing the shape of the concave portion is manufactured. It is characterized by doing.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Next, a method for manufacturing an electroforming mold according to the present invention will be described below with reference to the accompanying drawings by way of preferred examples. In each example to be described later, a skin mold for molding the skin material 14 to be attached to the instrument panel 10 illustrated in FIGS. 22 and 23 is illustrated as an electroforming mold. The target shape is the same as that illustrated in FIG. Accordingly, in the description of the prior art with reference to FIGS. 15 to 24, the same members / parts as those already described are designated by the same reference numerals.
[0020]
[First embodiment]
FIG. 1 is a process diagram schematically showing a method for manufacturing an electroforming mold (skin forming mold) according to a first embodiment of the present invention.
The manufacturing method according to the first embodiment is as follows:
A process of manufacturing the skin model 50 by sticking the skin sheet S to the sheet mounting surface 42 of the wooden model 40 so as to be in full contact (FIGS. 2 and 3);
Using the skin model 50 to produce a reversal model 60 having a transfer surface 62 onto which the surface pattern of the skin sheet S is transferred (FIG. 4);
Using the reversal model 60 to produce a tank model 70 having a reference surface 72 onto which the surface pattern of the transfer surface 62 has been transferred (FIG. 5);
A step of forming a concave portion 74 having the same contour shape as the skin concave portion 16 on the reference surface 72 of the manufactured tank model 70 (FIG. 6);
The skin molding surface 32 having the surface pattern of the reference surface 72 transferred and the convex portion 34 formed by reversing the shape of the concave portion 74 is formed by using the tank model 70 in which the concave portion 74 is provided. A process of manufacturing the skin mold 30 (FIG. 7),
It is made up of.
[0021]
In the manufacturing method according to the first embodiment, as illustrated in FIG. 2, when the wooden model 40 is manufactured, the sheet mounting surface 42 of the wooden model 40 has the same contour shape as the skin recess 16. The recess 44 is not provided. In other words, the sheet mounting surface 42 of the wooden model 40 is formed in a shape capable of forming a skin material having a shape that does not have the skin recess 16.
[0022]
And it sticks so that the skin sheet S may adhere | attach the whole surface using the adhesive etc. with respect to the sheet | seat mounting surface 42 of the wooden model 40 which does not provide the said recessed part 44, and it is set as a reference | standard model. An epidermis model 50 is produced (FIG. 3). Therefore, even in the skin model 50, no recess corresponding to the skin recess 16 is formed.
[0023]
An inversion model 60 manufactured using the skin model 50 illustrated in FIG. 3 includes, as illustrated in FIG. 4, the skin model 50 and a base mold (not shown) closed to the skin model 50. It is formed by curing the silicon injected into the cavity defined therebetween. In the inversion model 60 obtained in this manner, the surface pattern and the uneven shape of the skin sheet S are faithfully transferred, and a transfer surface 62 that does not have the convex portion 64 is formed.
[0024]
As shown in FIG. 5, the tank model 70 manufactured using the reversal model 60 illustrated in FIG. 4 has a thermosetting resin (thermoplastic resin) in the recess facing the transfer surface 62 of the reversal model 60. And the resin is cured while being in close contact with the transfer surface 62 made of silicon. In the tank model 70 obtained in this way, the surface pattern and the concavo-convex shape of the transfer surface 62 of the inversion model 60 are faithfully transferred, and a reference surface 72 that does not have the recess 74 is formed. .
[0025]
And in the manufacturing method which concerns on 1st Example, as illustrated in FIG. 6, with respect to the reference plane 72 of the tank model 70 manufactured in the shape illustrated in FIG. A recess 74 to be presented is provided. As a method for forming the recess 74, as shown in FIG. 6A, a method of cutting and forming based on a machining technique using an appropriate cutting tool 84 such as an end mill is suitably employed. When the concave portion 74 is provided by using such a cutting tool 84, since machining is controlled by NC, the machining accuracy is high and the cutting process is appropriately set, so that FIG. As shown in FIG. 2, the opening twill edge 76 of the concave portion 74 can be formed in a convex corner shape having an angular shape. In FIG. 6, only a single cutting tool 84 is illustrated, but actually, the concave portion 74 is formed using a plurality of cutting tools.
[0026]
As described above, the basin model 70 having the reference surface 72 formed in the convex corner shape in which the concave portion 74 is formed by machining technique and the opening twill edge 76 in the concave portion 74 is angular is disclosed in the prior art. Similarly, after performing a conductive process (a process of applying a conductive film by a silver mirror reaction process) as a pretreatment for entering the tank, the electrocasting technique is performed by placing the tank in the electroformed tank 82 (into the tank model 70). By applying electroplating), the surface molding die (electroforming mold) 30 having a thickness of about 4 to 5 mm is formed on the reference surface 72 (FIG. 7). The skin molding die 30 thus obtained has a skin molding surface 32 in which the surface pattern and the concavo-convex shape of the reference surface 72 are faithfully transferred, and the convex portion 34 is provided by reversing the shape of the concave portion 74. Is formed.
[0027]
In the skin mold 30 manufactured as described above, the opening twill edge 76 in the reference surface 72 of the tank model 70 is formed in an angular convex shape, and therefore, as shown in FIG. As described above, the base contour edge 35 of the convex portion 34 to which the shape of the opening twill edge portion 76 is transferred is formed into an angular concave corner shape.
[0028]
And in the skin material 14 molded by the skin molding surface 32 of the skin molding die 30 manufactured by the manufacturing method according to the first embodiment, as illustrated in FIG. 8A and FIG. The surface shape of the skin sheet S is transferred, and the skin concave portion 16 is formed by reversing the shape of the convex portion 34. In addition, since the base contour edge 35 of the convex portion 34 of the skin mold 30 is formed in an angular recess shape, the skin twill edge 18 facing the skin recess 16 has the shape of the base contour edge 35. It is transferred to form an angular convex shape.
[0029]
Therefore, an instrument equipped with the skin material 14 molded on the skin molding surface 32 of the skin molding die 30 using the skin molding die (electroforming mold) 30 manufactured based on the manufacturing method according to the first embodiment. When the air outlet 24 is accommodated and held in the installation portion 22 formed by the skin concave portion 16 of the skin material 14, as shown in FIGS. 14 (a) and 14 (b), It becomes possible to make the front surface of the outlet 24 and the surface of the skin material 14 coincide with each other. That is, no groove is defined at the boundary contour portion between the air outlet 24 and the skin material 14, and no step is formed between the air outlet 24 and the skin material 14, thereby improving the texture of the instrument panel 10. It can contribute greatly.
[0030]
Thus, according to the manufacturing method of the electroforming mold according to the first embodiment, the skin molding die 30 having a shape in which the base contour edge 35 of the convex portion 34 projecting on the skin molding surface 32 is squared is manufactured. Therefore, the skin material 14 molded by the skin molding surface 32 may be formed in a shape in which the skin twill edge 18 of the skin recess 16 formed by reversing the shape of the projection 34 is angular. It becomes possible. Therefore, in the instrument panel 10 equipped with the skin material 14 molded by the skin molding die 30, the front surface of the air outlet 24 and the surface of the skin material 14 which are accommodated and held in the installation portion 22 formed by the skin recess 16 are formed. Since it becomes possible to match the same, it becomes possible to improve the texture.
[0031]
[Second embodiment]
FIG. 9 is a process diagram schematically showing a method for manufacturing an electroforming mold (skin molding die) according to a second embodiment of the present invention.
The manufacturing method according to the second embodiment is as follows:
A step of forming a concave portion 44 having the same contour shape as the skin concave portion 16 of the skin material 14 on the seat mounting surface 42 of the wooden model 40 (FIG. 10);
After the skin sheet S is pasted on the sheet mounting surface 42 of the wooden model 40 so as not to be in close contact with the surface of the recess 44 provided on the sheet mounting surface 42, the contour of the recess 44 with respect to the skin sheet S Making a cut along the line, removing the unnecessary sheet portion S1 facing the recess 44, and manufacturing the skin model 50 (FIG. 11);
Using the skin model 50, a process of manufacturing a reversal model 60 having a transfer surface 62 on which a surface pattern of the skin sheet S is transferred and a convex portion 64 is formed by reversing the shape of the concave portion 44 (FIG. 12). )When,
Using the reversal model 60, a process of manufacturing a basin model 70 having a reference surface 72 in which a surface pattern of the transfer surface 62 is transferred and a concave portion 74 is formed by reversing the shape of the convex portion 64 (see FIG. 13) and
The skin molding surface 32 having the surface pattern of the reference surface 72 transferred and the convex portion 34 formed by reversing the shape of the concave portion 74 is formed by using the tank model 70 in which the concave portion 74 is provided. A process of manufacturing the skin mold 30 (FIG. 7),
It is made up of.
[0032]
In the manufacturing method according to the second embodiment, as illustrated in FIG. 10A, the recess 44 having the same contour shape as the skin recess 16 is formed on the seat mounting surface 42 when the wooden model 40 is manufactured. Concave. That is, the wooden model 40 basically forms the seat mounting surface 42 by cutting the recess 44 based on machining with an appropriate cutting tool 80 such as an end mill, as in the conventional example illustrated in FIG. To do. However, the sheet mounting surface 42 excluding the recess 44 is formed in a shape offset by the thickness of the skin sheet S to be pasted (for example, about 1 mm).
[0033]
Then, with respect to the sheet mounting surface 42 of the wooden model 40 in which the concave portion 44 is provided, as shown in FIG. 11A, the skin sheet S is attached to the surface of the concave portion 44 using an adhesive or the like. Affix it so that it does not adhere. Furthermore, by using an appropriate cutting tool 86 such as a cutter with good cutting performance (sharpness), an unnecessary sheet portion that cuts into the skin sheet S along the contour line of the recess 44 and faces the recess 44 The skin model 50 is manufactured by cutting S1. That is, when cutting the skin sheet S with the cutting tool 86, if the tip is moved while being applied to the edge of the opening contour of the recess 44, the sheet contour that faces the recess 44 is obtained. As illustrated in FIG. 11B, the end edge S <b> 2 can be formed into a beautiful cut face and can be formed into a convex angular shape that is relatively easily squared. Accordingly, the opening twill edge 46 of the recess 44 formed by the sheet contour edge S2 has an angular convex shape.
[0034]
An inversion model 60 manufactured using the skin model 50 illustrated in FIG. 11 is in a cavity defined between the skin model 50 and a base mold (not shown) closed to the skin model 50. It is formed by curing the silicon injected into. In the inversion model 60 obtained in this way, as illustrated in FIG. 12, the surface pattern and the uneven shape of the skin sheet S are faithfully transferred, and the convex portion 64 due to the shape inversion of the concave portion 44 is convex. And a transfer surface 62 is formed. Accordingly, the base contour edge 66 of the convex portion 64 that is projected on the transfer surface 62 is formed into an angular concave corner shape by transferring the angular convex shape of the sheet contour edge S2.
[0035]
The tank model 70 manufactured using the reversal model 60 illustrated in FIG. 12 pours a thermosetting resin (a thermoplastic resin can also be used) into the recess facing the transfer surface 62, and this resin It is formed by being cured while being in close contact with the transfer surface 62 made of silicon. As illustrated in FIG. 13, the surface pattern and the concavo-convex shape of the transfer surface 62 of the inversion model 60 are faithfully transferred to the entrance model 70 thus obtained, and the shape inversion of the convex portion 64 is reversed. A reference surface 72 having a concave portion 74 is formed. Therefore, the opening twill edge 76 along the outer peripheral edge of the recess 74 provided in the reference surface 72 is formed into an angular convex shape by transferring the angular concave corner shape of the base contour edge 66. ing.
[0036]
As described above, the tank model 70 having the concave surface 74 and the reference surface 72 formed in an angular convex shape with the opening twill edge 76 in the concave portion 74 is the same as in the first embodiment. In addition, after conducting a conductive treatment (a treatment for applying a conductive film by a silver mirror reaction treatment) as a pretreatment for entering the tank, the electroforming technique is performed by placing the tank in the electroformed tank 82 (electricity is supplied to the tank model 70). By applying the plating), the surface molding die (electroforming mold) 30 having a thickness of about 4 to 5 mm is formed on the reference surface 72 (FIG. 7). The skin molding die 30 thus obtained has a skin molding surface 32 in which the surface pattern and the concavo-convex shape of the reference surface 72 are faithfully transferred, and the convex portion 34 is provided by reversing the shape of the concave portion 74. Is formed.
[0037]
In the skin mold 30 manufactured as described above, the opening twill edge 76 in the reference surface 72 of the tank model 70 is formed in an angular convex shape, and therefore, as shown in FIG. As described above, the base contour edge 35 of the convex portion 34 to which the shape of the opening twill edge portion 76 is transferred is formed into an angular concave corner shape.
[0038]
Therefore, in the skin material 14 molded by the skin molding surface 32 of the skin molding die 30 manufactured by the manufacturing method according to the second embodiment, as illustrated in FIGS. 8A and 8B, The surface shape of the skin sheet S is transferred, and the skin concave portion 16 is formed by reversing the shape of the convex portion 34. Moreover, since the base contour edge 35 of the convex portion 34 of the skin mold 30 is formed in an angular shape, the skin twill edge 18 facing the skin recess 16 is shaped like the base contour edge 35. Is transferred to form an angular shape. Therefore, like the first embodiment, it can contribute to the improvement of the texture of the instrument panel 10 on which the skin material 14 is mounted.
[0039]
In each of the above embodiments, the case where the skin mold 30 corresponding to the urethane spray molding technology is molded based on the electroforming technology is exemplified. However, the method for manufacturing the electroforming mold according to the present application is a skin corresponding to the vacuum molding technology. The present invention can also be applied to manufacturing a mold and a skin mold corresponding to the powder slush molding technology.
[0040]
Moreover, in each said Example, although the skin shaping | molding die 30 for shape | molding the skin material 14 with which the instrument panel 10 was mounted | worn was illustrated, the electromold which this application makes object is not limited to this, It can also be applied to a skin molding die for molding a skin material to be mounted on various vehicle interior members (floor console, door panel, pillar garnish, etc.). That is, the present invention can be applied to electroforming molds having various shapes of the skin molding surface 32.
[0041]
【The invention's effect】
As described above, according to the method for manufacturing an electroforming mold according to the present invention, an electroforming mold having a shape in which the base contour edge of the protruding portion provided on the skin molding surface is squared can be manufactured. The skin material molded by the skin molding surface of the mold has a beneficial effect that allows the convex portion to be formed in a shape in which the opening twill edge of the skin concave portion formed by reversing the shape is squared. . Therefore, there is an advantage that it is possible to improve the texture of the member using the skin material formed by the electroforming mold.
[Brief description of the drawings]
FIG. 1 is a schematic process diagram illustrating a method for manufacturing an electroforming mold according to a first embodiment of the present invention.
FIG. 2 is an explanatory sectional view partially showing a tree model in the manufacturing method of the first embodiment.
FIG. 3 is an explanatory cross-sectional view showing a state in which a skin model is manufactured by sticking a skin sheet to a wooden model.
4 is an explanatory cross-sectional view showing an inverted model manufactured using the skin model illustrated in FIG. 3. FIG.
FIG. 5 is an explanatory cross-sectional view showing a basin model manufactured using the inverted model illustrated in FIG. 4;
6A is an explanatory cross-sectional view showing a state in which a recess is formed using a cutting tool on the reference surface of the tub model illustrated in FIG. 5, and FIG. 6B is a recess. It is explanatory sectional drawing which showed that the opening twill edge part which faced the recessed part was formed in the convex-angle shape which was squared.
7A is an explanatory cross-sectional view showing a state in which a skin forming die is manufactured by an electroforming technique using the basin model illustrated in FIG. 6, and FIG. It is explanatory sectional drawing which showed that the base part contour edge in the convex part of the outer skin shaping | molding die was formed in the square-shaped concave corner shape.
8A is an explanatory cross-sectional view showing a state in which a skin material is molded on the skin molding surface of the skin molding die manufactured in FIG. 7, and FIG. 8B is a molded skin material. It is explanatory sectional drawing which showed that the skin twill edge part of the skin recessed part in was formed in the square-shaped convex-angle shape.
FIG. 9 is a schematic process diagram showing a method for manufacturing an electroforming mold according to a second embodiment of the present invention.
FIG. 10 is an explanatory sectional view showing a state in which a wooden model is manufactured in the manufacturing method of the second embodiment.
FIG. 11 (a) is an explanatory cross-sectional view showing a state in which the skin model is manufactured by pasting the skin sheet on the wooden model and then cutting off the unnecessary sheet portion facing the recess; These are explanatory sectional drawings which showed that the opening twill edge part formed of the sheet | seat outline edge which faced the recessed part was formed in the convex-angle shape which was angular.
12 is an explanatory sectional view showing an inversion model manufactured using the skin model illustrated in FIG. 11. FIG.
FIG. 13 is an explanatory cross-sectional view showing a basin model manufactured using the inversion model illustrated in FIG. 12;
FIG. 14 (a) shows an instrument panel equipped with a skin material molded with a skin molding die manufactured by the manufacturing method of each of the above embodiments, broken at a portion where an air outlet is accommodated and held. It is a fragmentary sectional view, (b) is the principal part enlarged view of (a).
FIG. 15 is a schematic process diagram showing a conventional method for producing an electroforming mold.
FIG. 16A is an explanatory cross-sectional view showing a state in which a wooden model is manufactured by a conventional manufacturing method, and FIG. 16B is an enlarged view of a portion A in FIG.
FIG. 17A is an explanatory cross-sectional view showing a state in which the skin model is manufactured by sticking the entire surface of the skin sheet to the seat mounting surface of the wooden model, and FIG. It is explanatory sectional drawing which showed that an opening twill edge part was formed in the convex curved surface shape which was roundish.
18 is an explanatory cross-sectional view showing an inversion model manufactured using the skin model illustrated in FIG. 17;
FIG. 19 is an explanatory cross-sectional view showing a basin model manufactured using the inversion model illustrated in FIG. 18;
20A is an explanatory cross-sectional view showing a state in which a skin forming die is manufactured by an electroforming technique using the tank model illustrated in FIG. 19, and FIG. It is explanatory sectional drawing which showed that the base part outline edge in the convex part of the outer skin shaping | molding die was formed in the rounded concave curved surface shape.
21A is an explanatory cross-sectional view showing a state in which a skin material is molded on the skin molding surface of the skin molding die manufactured in FIG. 20, and FIG. 21B is a molded skin material. It is explanatory sectional drawing which showed that the opening twill edge part of the skin recessed part in is formed in the rounded convex curved surface shape.
FIG. 22 is a partial perspective view of an instrument panel equipped with a skin material molded using a skin mold that is an electroforming mold.
23 is a cross-sectional view taken along line XX in FIG.
FIG. 24: When the skin twill edge portion in the skin recess is formed in a rounded convex curved surface shape, there is an inconvenience in the arrangement of the air outlet accommodated and held in the installation portion formed by the skin recess. (A) illustrates the inconvenience that a step is formed between the air outlet and the skin, and (b) illustrates a gap in the boundary contour between the air outlet and the skin. It illustrates the inconvenience that is defined.
[Explanation of symbols]
14 skin material, 16 skin recess, 18 skin twill edge,
30 skin mold (electroforming mold), 32 skin molding surface, 34 convex part,
35 Base contour edge, 40 Wood model, 42 Seat mounting surface,
44 recesses, 50 skin model, 60 reversal model, 62 transfer surface,
64 convex portions, 70 entry model, 72 reference plane, 74 concave portions,
76 open twill edge, 84 cutting tool, 86 cutting tool,
S skin sheet, S1 unnecessary sheet part, S2 sheet contour edge

Claims (6)

An electroforming mold for forming a skin material (14) having a skin molding surface (32) having convex portions (34) having a required contour shape and having a skin concave portion (16) by reversing the shape of the convex portions (34) (30) A manufacturing method comprising:
The skin model (50) is manufactured by sticking the skin sheet (S) to the seat mounting surface (42) of the wooden model (40) so that it adheres completely.
Using the epidermis model (50), a reversal model (60) having a transfer surface (62) onto which the surface pattern of the epidermis sheet (S) is transferred,
Using the reversal model (60) to produce a tank model (70) having a reference surface (72) to which the surface pattern of the transfer surface (62) is transferred,
On the reference surface (72) of the tank entry model (70) manufactured, a recess (74) having the same contour shape as the skin recess (16) is provided,
Using the tank model (70) in which the concave portion (74) is provided, the surface pattern of the reference surface (72) is transferred, and the convex portion (34) is formed by reversing the shape of the concave portion (74). A method for producing an electroforming mold, comprising producing the electroforming mold (30) having the skin molding surface (32) having a protrusion formed thereon. The method of manufacturing an electroforming mold according to claim 1, wherein the recess (74) is formed by cutting the reference surface (72) based on a machining technique using an appropriate cutting tool (84). By forming the recess (74) with the cutting tool (84), the outer peripheral edge of the recess (74) is formed as an open twill edge (76),
Thereby, in the electroforming mold (30), the base contour end edge (35) of the convex portion (34) has an angular concave shape, and in the skin material (14) formed by the electroforming mold (30), the skin material (14) The method for producing an electroforming mold according to claim 2, wherein the outer peripheral edge of the skin recess (16) is formed as an angular skin twill edge (18). An electroforming mold for forming a skin material (14) having a skin molding surface (32) having convex portions (34) having a required contour shape and having a skin concave portion (16) by reversing the shape of the convex portions (34) (30) A manufacturing method comprising:
On the seat mounting surface (42) of the wooden model (40), a concave portion (44) having the same contour shape as the skin concave portion (16) is provided,
After pasting the skin sheet (S) on the sheet mounting surface (42) of the wooden model (40) so as not to adhere to the surface of the recess (44), an unnecessary sheet facing the recess (44) Remove the part (S1) and make the skin model (50),
Using the skin model (50), the surface pattern of the skin sheet (S) is transferred, and has a transfer surface (62) in which convex portions (64) are formed by reversing the shape of the concave portions (44). Produced an inversion model (60)
Using the reversal model (60), the surface pattern of the transfer surface (62) is transferred, and the reference surface (72) has a concave portion (74) formed by reversing the shape of the convex portion (64). Make the tank model (70)
Using the tank model (70) in which the concave portion (74) is provided, the surface pattern of the reference surface (72) is transferred, and the convex portion (34) is formed by reversing the shape of the concave portion (74). A method for producing an electroforming mold, comprising producing the electroforming mold (30) having the skin molding surface (32) having a protrusion formed thereon. The method for producing an electroforming mold according to claim 4, wherein the skin sheet (S) is cut along the contour line of the recess (44) by using an appropriate cutting tool (86). By cutting into the skin sheet (S) with the cutting tool (86), the sheet contour edge (S2) of the skin sheet (S) facing the recess (44) is formed into an angular shape. ,
Thereby, in the electroforming mold (30), the base contour end edge (35) of the convex portion (34) has an angular concave shape, and in the skin material (14) formed by the electroforming mold (30), the skin material (14) 6. The method for producing an electroforming mold according to claim 5, wherein the outer peripheral edge of the skin recess (16) is formed as an angled skin twill edge (18).

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