JP5967009B2 - Molding method of skin material - Google Patents

Description

  The present invention relates to a method for forming a skin material.

  Conventionally, the composite member provided with a skin material is known (the following patent document 1). In the thing of patent document 1, after mounting a skin material in a shaping | molding die (lower mold | type), a skin material is shape | molded into a product shape by attracting | sucking a skin material using a vacuum pump.

JP-A-57-152927

  As shown in Patent Document 1, the mold for molding the skin material has a concave portion that is shaped like the product shape, and the skin material is made into the product shape by sucking the skin material into the inner surface of the concave portion. Can be molded. Here, when the skin material is molded into a shape (convex shape) that bulges to the design surface side, the skin material is placed on the mold so that the design surface of the skin material and the inner surface of the recess face each other. Thereby, the back surface of the skin material is exposed. For this reason, the work of the next process (for example, the work of injecting a foaming agent into the back surface of the skin material or the work of pasting the base material on the back surface of the skin material) can be easily performed on the back surface of the skin material after molding. It can be carried out.

  However, when the design surface of the skin material and the inner surface of the concave portion are arranged to face each other, the operator cannot visually observe the design surface of the skin material and cannot confirm the state of the design surface. For this reason, it is difficult to confirm whether or not the skin material is correctly placed in the recess. Further, in the process of placing the skin material on the mold, for example, even if wrinkles occur on the design surface of the skin material, it is difficult to confirm the occurrence of wrinkles because the design surface cannot be visually observed.

  The present invention has been completed based on the above circumstances, and when placing the skin material on a mold, the design surface of the skin material can be visually observed, and after the molding, the back surface of the skin material. An object of the present invention is to provide a method for forming a skin material capable of exposing the surface.

  In order to solve the above problems, the present invention provides a skin material for molding a skin material using a first molding die having a convex portion and a second molding die having a concave portion into which the convex portion can be fitted. The skin material placing step of placing the skin material on the surface of the convex portion with the back surface of the skin material facing the surface of the convex portion, and mounting the skin material Forming the skin material into a shape following the surface shape of the convex portion by sucking the skin material through the convex side suction holes formed on the surface of the convex portion. The first molding step is performed after the first molding step, and the convex portion of the first molding die is second molded in a state where the skin material is held on the surface of the convex portion by the holding means. A fitting step for fitting in the concave portion of the mold, and a concave portion formed on the surface of the concave portion after the fitting step; A second forming step of forming the skin material into a shape following the surface shape of the concave portion by sucking the skin material through the suction hole, and in the fitting step, A part of the skin material is sandwiched between the protruding end surface and the back surface of the recess, and a gap is formed between the design surface of the skin material and the side surface of the recess, and the size of the gap The height of the concave portion increases from the back surface side of the concave portion toward the opening end portion of the concave portion.

In the present invention, in the skin material placing step, the skin material is placed on the surface of the convex portion with the back surface of the skin material facing the surface of the convex portion. Thereby, the operator can place the skin material on the convex portion while observing the state of the design surface (the surface opposite to the back surface) of the skin material.
And after shape | molding a skin material in the shape which followed the convex part, the convex part of a 1st shaping | molding die is fitted to the recessed part of a 2nd shaping | molding die. Thereafter, the skin material is sucked into the concave portion, thereby forming the skin material into a shape that follows the surface shape of the concave portion.

  Thereby, after shape | molding a skin material in a predetermined | prescribed shape, the back surface of a skin material will be in the state exposed by removing a 1st shaping | molding die from a 2nd shaping | molding die. Thereby, the operation | work of the following process (For example, the injection | pouring operation | work of a foaming agent, the sticking operation | work of a base material etc.) can be easily performed with respect to the back surface of the skin material after shaping | molding. In the fitting process, a gap is provided between the design surface of the skin material and the side surface of the recess. Thereby, when fitting a convex part to a recessed part, the situation where the design surface of a skin material slides with respect to the side surface of a recessed part can be suppressed, and the design surface of a skin material can be protected.

  In the above configuration, the skin material includes at least two skin pieces overlapped with each other at the end portions, and each of the overlapped end portions protrudes from the back surface of the skin material, and the skin material In the placing step, each of the overlapped end portions can be inserted into the convex portion side suction hole.

  In this manner, by inserting each of the end portions of the skin piece into the convex side suction holes, the end portions can be positioned more reliably.

  Further, the holding means is a pair of holding members capable of holding the skin material, and in the fitting step, the pair of holding members attracted by a first magnet provided in the first mold. The second magnet may be disposed at a location facing the second magnet provided in the second mold, and the second magnet may have a stronger magnetic force than the first magnet.

  The skin material can be clamped by the pair of clamping members. And in a fitting process, a pair of clamping members are arranged in the portion facing the 2nd magnet provided in the 2nd forming die. Since the second magnet has a stronger magnetic force than the first magnet, when the first mold is moved away from the second mold after the second molding step, the pair of clamping members are strongly attracted by the second magnet. , Remains in the second mold. Thus, the skin material can be clamped by the pair of clamping members even after the first mold is moved away from the second mold.

  According to the present invention, there is provided a method for forming a skin material capable of exposing the back surface of the skin material after molding while allowing the design surface of the skin material to be visually observed when the skin material is placed on a mold. Can be provided.

The perspective view which shows the 1st shaping | molding die concerning Embodiment 1 of this invention. Sectional drawing showing the skin material placement process Sectional drawing which shows a 1st shaping | molding process (corresponding to the figure cut | disconnected by the AA line of FIG. 1) Sectional drawing which shows the state which has arrange | positioned the 1st shaping | molding die facing the 2nd shaping | molding die Sectional view showing the mating process Sectional drawing showing the second molding process Sectional drawing which shows the state which spaced apart the 1st shaping | molding die from the 2nd shaping | molding die Sectional drawing which shows the 1st shaping | molding die concerning Embodiment 2 of this invention. Sectional drawing which shows the state which has arrange | positioned the 1st shaping | molding die of FIG. 8 facing the 2nd shaping | molding die. Sectional drawing which shows the fitting process which concerns on Embodiment 2. FIG. Sectional drawing which shows the state which separated the 1st shaping | molding die from the 2nd shaping | molding die in Embodiment 2. FIG.

<Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS. In the present embodiment, the skin material 10 is molded using the first mold 30 and the second mold 60. Specifically, after the skin material 10 is molded (preliminary molding) with the first molding die 30, it is molded into the product shape (main molding) with the second molding die 60.

  The skin material 10 covers the surface of the base material (for example, trim board) of the vehicle interior material (for example, door trim), for example. The skin material 10 of this embodiment is shape | molded in the shape which has the protrusion part 20 (bulging part) protruded to the design surface 10A side, as shown in FIG.1 and FIG.2. The protruding portion 20 has a substantially trapezoidal shape, for example. In addition, as a material of the skin material 10, although a genuine leather, a synthetic leather, etc. can be illustrated, it is not limited to this, It can change suitably.

  As shown in FIG. 2, the skin material 10 is composed of a plurality of skin pieces. In the following description, the skin piece constituting the protruding end surface of the protruding portion 20 is denoted by reference numeral 11, and the skin piece constituting the side surface of the protruding portion 20 is denoted by reference numeral 12. Moreover, the code | symbol 13 shall be attached | subjected to the skin piece which comprises the outer periphery edge part (around the protrusion part 20) of the skin material 10. FIG.

  Among the skin pieces 11, 12, and 13 constituting the skin material 10, two adjacent skin pieces (see, for example, the skin pieces 12 and 13) have their design surfaces facing each other as shown in FIG. After being overlapped in the form, for example, sewing is performed by sewing together with a sewing thread (not shown). And the two skin pieces 12 and 13 stitched together are spread in the direction in which the design surfaces are away from each other.

  In the two adjacent skin pieces, each of the overlapped end portions protrudes from the back surface 10B (surface opposite to the design surface) of the skin material 10. In the following description, reference numeral 15 is attached to each of the overlapped end portions (constituting a sewing portion) of each skin piece.

  Next, the structure of the 1st shaping | molding die 30 which preforms the skin material 10 is demonstrated. The first mold 30 has a convex portion 31 that follows the product shape of the skin material 10. As shown in FIG. 1, the convex portion 31 has, for example, a substantially columnar shape whose width dimension decreases toward the tip.

  The surface facing the back surface 10B of the skin material 10 in the first mold 30 is a molding surface 32 that molds the skin material 10 into a predetermined shape. A plurality of suction holes 33 (convex portion side suction holes) are formed on the molding surface 32, and each suction hole 33 is connected to an air pressure supply device P1 such as a pump (see FIG. 3).

  By operating the air pressure supply device P1 in a state where the skin material 10 is set in the first mold 30, it is possible to apply a negative pressure (vacuum evacuation) to the skin material 10 through the suction holes 33. It has a configuration. Thus, by sucking the skin material 10, the skin material 10 can be brought into close contact with the molding surface 32 of the first mold 30, and the skin material 10 can be molded into a shape that follows the shape of the molding surface 32. it can.

  In addition, as shown in FIG. 3, the end portions 15 and 15 of the superposed skin pieces can be inserted into the suction hole 33. In FIG. 1, the suction hole 33 is omitted. Moreover, the 1st shaping | molding die 30 becomes a structure which can be moved in the horizontal direction and an up-down direction, and can be reversed up and down with the die moving apparatus which is not shown in figure.

  On the molding surface 32, a pair of sandwiching members 41 and 42 are provided at a portion where the peripheral end portion (corresponding to the skin piece 13) of the skin material 10 is placed. The pair of clamping members 41, 42 are members for holding the first molding die 30 by clamping the peripheral end portion of the skin material 10.

  The clamping member 42 disposed on the side close to the first mold 30 has, for example, a rectangular parallelepiped shape, and is fitted into a fitting portion 36 that is recessed in the surface of the first mold 30.

  A magnet 43 is embedded in the clamping member 42. In the first mold 30, a magnet 35 (first magnet) is embedded in a portion facing the clamping member 42. The sandwiching member 42 is fixed to the first mold 30 by attracting the magnet 43 and the magnet 35 to each other.

  The clamping member 41 is a metal plate member having magnetism. Thereby, the clamping member 41 can be clamped between the clamping member 42 by being attracted to the magnet 43. The sandwiching member 41 may be any member as long as it has a property of being attracted by a magnet, and iron, magnetic stainless steel, or the like can be used.

  In addition, as shown in FIG. 1, a pair of clamping members 41 and 42 are provided in multiple places (4 places in this embodiment) along the peripheral edge part of the skin material 10. As shown in FIG. Specifically, the pair of sandwiching members 41 and 42 are provided on, for example, four sides of the peripheral end portion of the skin material 10.

  Next, the structure of the 2nd shaping | molding die 60 which carries out the main shaping | molding of the skin material 10 is demonstrated. The second mold 60 has a recess 61 that follows the product shape of the skin material 10. The concave portion 61 has a shape that allows the convex portion 31 of the first mold 30 to be fitted.

  In the present embodiment, as shown in FIG. 5, after fitting the convex portion 31 of the first molding die 30 in a state where the pre-formed skin material 10 is arranged into the concave portion 61 of the second molding die 60, The main molding of the skin material 10 is performed by the second mold 60.

  As shown in FIG. 4, the recess 61 has a shape in which the opening width increases toward the opening side (upper side in FIG. 4). On the other hand, the width of the convex portion 31 of the first mold 30 fitted in the concave portion 61 increases toward the base end.

  Specifically, the inclination angle of the side surface 61A of the concave portion 61 with respect to the vertical direction (the vertical direction in FIG. 5, the fitting direction of the convex portion 31 with respect to the concave portion 61) is as shown in FIG. It is set to a value larger than the inclination angle with respect to the vertical direction (mold closing direction).

  As a result, when the convex portion 31 is fitted in the concave portion 61 in a state where the skin material 10 is arranged on the convex portion 31 side, the gap S is formed between the design surface 10A of the skin material 10 and each side surface 61A of the concave portion 61. Are each formed. The size of the gap S increases from the back surface side of the recess 61 toward the opening end of the recess 61.

  In addition, as shown in FIG. 1, in the 1st shaping | molding die 30, the boundary line X1 of the convex part 31 and its peripheral edge part 37 (around the convex part 31) is comprised by the four curves L1. Each curve L <b> 1 (see also FIG. 4) has a shape in which the central portion in the longitudinal direction curves to the inside of the first mold 30.

  On the other hand, the boundary line X2 (see also FIG. 4) between the side surface 61A of the recess 61 and the open end 61B of the recess 61 in the second mold 60 is constituted by four line segments L2. The line segment L2 is indicated by a two-dot chain line in FIG. The length of the curve L1 and the length of the line segment L2 are set to the same value. That is, the length of the boundary line X1 between the convex portion 31 and the peripheral end portion 37 is equal to the length of the boundary line X2 between the side surface 61A and the opening end portion 61B.

  The surface facing the design surface 10A of the skin material 10 in the second mold 60 is a molding surface 62 for molding the skin material 10 into a product shape. A plurality of suction holes 63 (recess side suction holes) are formed in the molding surface 62, and an air pressure supply device P2 (see FIG. 6) such as a pump is connected to each suction hole 63.

  It is possible to apply a negative pressure (vacuum evacuation) to the skin material 10 through each suction hole 63 by operating the air pressure supply device P2 in a state where the skin material 10 is set in the second mold 60. It has a configuration. Thus, by sucking the skin material 10, the skin material 10 can be brought into close contact with the molding surface 62 of the second molding die 60, and the skin material 10 has a shape (product shape) following the shape of the molding surface 62. Can be molded.

  A magnet 64 is embedded in the opening end of the recess 61 in the second mold 60. The magnet 64 is provided at a location facing the clamping member 41 of the first mold 30. Further, the magnetic force of the magnet 64 acting on the pair of sandwiching members 41 and 42 is, for example, larger than the magnetic force of the magnet 35. In addition, as a magnet 35,43,64 mentioned above, a neodymium magnet can be illustrated, for example.

  Next, a method for forming the skin material 10 of the present embodiment will be described. The molding method of the skin material 10 in the present embodiment includes a skin material placing process, a first molding process (preliminary molding process), a fitting process, a second molding process (main molding process), a detaching process, It has.

<Skin material placement process>
In the skin material placing step, the skin material 10 is placed on the molding surface 32 (including the surface of the convex portion 31) of the first mold 30. At this time, the back surface 10B of the skin material 10 and the molding surface 32 are arranged to face each other. Moreover, each edge part 15 and 15 of each skin piece 11, 12, and 13 is each inserted in each suction hole 33 corresponding.

  And after mounting the skin material 10, each clamping member 41 is each arrange | positioned so that the peripheral edge part of the skin material 10 may be pinched | interposed between each clamping member 42 (refer FIG. 3). Each clamping member 41 is attracted (attracted) to the magnet 43 of each clamping member 42. Thereby, the peripheral edge part of the skin material 10 is clamped by each of a pair of clamping member 41,42.

<First molding step>
Next, in the first molding step, the air pressure supply device P1 of the first mold 30 is operated. As a result, as shown in FIG. 3, the skin material 10 is sucked to the molding surface 32 by applying a negative pressure to the skin material 10 through the suction holes 33, and the skin material 10 has a shape of the molding surface 32. It is molded into a shape following the above.

<Mating process>
Next, in a state where the skin material 10 is sucked by the air pressure supply device P1 and the suction hole 33 of the first molding die 30, the first molding die 30 is turned upside down, and as shown in FIG. The concave portion 61 and the convex portion 31 of the first mold 30 are arranged to face each other. The skin material 10 is held on the molding surface 32 of the first molding die 30 by the suction through the suction holes 33 and the pair of clamping members 41 and 42, and the design surface 10 A of the skin material 10 is the second molding die 60. The molding surface 62 is opposed to the molding surface 62.

  The pair of clamping members 41 and 42 is an example of a holding unit that holds the skin material 10 and is fixed to the first molding die 30 by a magnetic force in a state where the skin material 10 is sandwiched.

  Next, the first molding die 30 is moved closer to the second molding die 60 (the first molding die 30 and the second molding die 60 are closed), whereby the first molding die 30 is recessed into the first molding die 60. The convex part 31 of the shaping | molding die 30 is fitted. Thereby, as shown in FIG. 5, the skin piece 11 (a part of the skin material 10) is sandwiched between the protruding end surface 31 </ b> B of the convex portion 31 and the back surface 61 </ b> D of the concave portion 61.

  And in the state which made the convex part 31 fit to the recessed part 61, the clearance gap S is formed between the design surface 10A of the skin material 10 (specifically, the design surface of the skin piece 12) and the side surface 61A of the recessed part 61. It becomes the state. In other words, in the process of fitting the convex portion 31 to the concave portion 61, the design surface 10 </ b> A of the skin material 10 does not slide on the side surface 61 </ b> A of the concave portion 61.

  Further, in a state where the convex portion 31 is fitted to the concave portion 61, the clamping member 41 is in contact with the opening end portion 61 </ b> B of the concave portion 61 of the second mold 60. That is, the pair of clamping members 41 and 42 is disposed at a location facing the magnet 64 (second magnet).

<Second molding step>
Next, in the second molding step, the air pressure supply device P1 of the first mold 30 is stopped and the air pressure supply device P2 of the second mold 60 is operated. Thereby, as shown in FIG. 6, the skin material 10 is sucked to the molding surface 62 through the suction holes 63. Thereby, the skin material 10 is molded into a shape that follows the shape of the molding surface 62.

  Instead of stopping the air pressure supply device P1 of the first mold 30, positive pressure is applied to the skin material 10 from the air pressure supply device P 1 of the first mold 30 through the suction hole 63, thereby forming the molding surface 32. It is good also as a structure which extrudes the skin material 10 to the molding surface 62 side.

<Separation process>
Next, in the separation step, the first mold 30 is separated from the second mold 60, and the convex portion 31 is separated from the concave portion 61 of the second mold 60. Thereby, as shown in FIG. 7, the back surface 10B of the skin material 10 is exposed.

  Further, as described above, the magnet 64 of the second mold 60 has a stronger magnetic force than the magnet 35 of the first mold 30. For this reason, when the first mold 30 is separated from the second mold 60, the pair of clamping members 41 and 42 does not follow the first mold 30 side and remains in the second mold 60. That is, the pair of clamping members 41 and 42 can be passed from the first mold 30 to the second mold 60.

  In addition, after the detachment process, the skin material 10 is sent to the next base material attaching process in a state of being arranged in the second mold 60. In the base material attaching step, the base material is attached to the back surface 10B of the skin material 10 via a foamed resin layer or an adhesive. Thereby, it will be in the state by which the skin material 10 was affixed with respect to the base material, and manufacture of the interior material for vehicles is completed.

  Next, the effect of this embodiment will be described. According to the present embodiment, in the skin material placing step, the skin material 10 is placed on the molding surface 32 with the back surface 10B of the skin material 10 facing the molding surface 32 (including the surface of the convex portion 31). To do. Thereby, the operator can place the skin material 10 on the convex portion 31 while observing the state of the design surface 10 </ b> A (surface opposite to the back surface) of the skin material 10. Thereby, for example, when a wrinkle occurs on the design surface 10A, it is possible to quickly find and correct the wrinkle.

  In the present embodiment, after the skin material 10 is molded into a shape that follows the convex portion 31, the convex portion 31 of the first molding die 30 is fitted into the concave portion 61 of the second molding die 60. Thereafter, the skin material 10 is sucked to the concave portion 61 side, thereby forming the skin material 10 into a shape following the surface shape of the concave portion 61.

  Thereby, after shape | molding the skin material 10 in a predetermined shape (product shape), the back surface 10B of the skin material 10 will be in the state exposed by removing the 1st shaping | molding die 30 from the 2nd shaping | molding die 60. FIG. Thereby, the operation | work of the next process (for example, injection | pouring operation | work of a foaming agent, the sticking operation | work of a base material, etc.) can be easily performed with respect to the back surface 10B of the skin material 10 after shaping | molding.

  Thus, in the present embodiment, after the skin material 10 is placed on the first mold 30 so that the design surface 10A can be visually observed, preliminary molding is performed. Thereafter, the skin material 10 is transferred to the second mold 60 and finally molded. Thereby, when placing the skin material 10, the back surface 10 </ b> B of the skin material 10 can be exposed when the molding is completed while allowing the design surface 10 </ b> A to be visible.

  Moreover, the skin material 10 can be made into the shape close | similar to a product shape by preforming the skin material 10 with the 1st shaping | molding die 30. FIG. Thereby, in the process which moves the skin material 10 to the 2nd shaping | molding die 60 and performs this shaping | molding, the shape of the skin material 10 does not change a lot, and the situation which a wrinkle etc. arises can be suppressed.

  In the fitting process, a gap S is formed between the design surface 10 </ b> A of the skin material 10 and the side surface 61 </ b> A of the recess 61. Thereby, when fitting the convex part 31 to the recessed part 61, the situation where the design surface 10A of the skin material 10 slides with respect to the side surface 61A of the recessed part 61 can be suppressed, and the design surface 10A of the skin material 10 is protected. be able to.

  Further, in the present embodiment, the skin material 10 includes at least two skin pieces 12 and 13 that are overlapped with each other at the end portions 15 and 15, and each of the overlapped end portions 15 and 15 includes the skin material 10. In the skin material placement step, each of the overlapped end portions 15 and 15 is inserted into the suction hole 33.

  Thus, by inserting each of the end portions 15 and 15 of the skin pieces 12 and 13 into the suction hole 33, the end portions 15 and 15 (sewing portions) can be positioned more reliably.

  Further, as a holding means for holding the skin material 10, a pair of clamping members 41 and 42 capable of clamping the skin material 10 is provided, and is attracted by the magnet 35 provided in the first mold 30 in the fitting process. The pair of sandwiching members 41 and 42 is disposed at a location facing the magnet 64 provided in the second mold 60, and the magnet 64 has a stronger magnetic force than the magnet 35.

  The skin material 10 can be clamped by the pair of clamping members 41, 42. And in a fitting process, a pair of clamping members 41 and 42 are arranged at a part facing magnet 64 provided in the 2nd forming die 60. Since the magnet 64 has a stronger magnetic force than the magnet 35, the pair of clamping members 41 and 42 are strongly attracted by the magnet 64 when the first molding die 30 is moved away from the second molding die 60 after the second molding step. As a result, it remains in the second mold 60. Thereby, even after the 1st shaping | molding die 30 is moved away from the 2nd shaping | molding die 60, the skin material 10 can be clamped with a pair of clamping members 41 and 42. FIG.

  Further, in the present embodiment, the boundary line X1 (configured by four curves L1) between the convex portion 31 and the peripheral end portion 37 in the first molding die 30, and the side surface 61A and the concave portion of the concave portion 61 in the second molding die 60. The boundary line X2 (configured by four line segments L2) with the 61 open end 61B is set to have the same length.

  The shape of each curve L1 is reflected in the shape of the base end 14 of the protrusion 20 in the skin material 10 after preforming (in the present embodiment, the boundary line between the skin piece 12 and the skin piece 13, see FIG. 1). That is, the length of the boundary line X1 is equal to the length of the entire circumference at the base end 14 of the protrusion 20 after the preforming (referred to as the circumference LA in the following description). Moreover, the shape of each line segment L2 is reflected in the shape of the base end 14 of the protrusion part 20 in the skin material 10 after this shaping | molding. That is, the length of the boundary line X2 is equal to the length of the entire circumference at the base end 14 of the projecting portion 20 after the main molding (referred to as the circumferential length LB in the following description).

  For this reason, if the length of the boundary line X1 between the convex portion 31 and the peripheral end portion 37 and the length of the boundary line X2 between the side surface 61A and the opening end portion 61B are set to the same value, the base of the projecting portion 20 after the preforming is set. The circumferential length LA at the end 14 can be matched with the circumferential length LA at the base end 14 of the projecting portion 20 after the main molding.

  If the circumferential length LA is set to be smaller than the circumferential length LB, due to the difference between the circumferential length LA and the circumferential length LB, a surplus occurs in the vicinity of the base end 14 of the skin material 10 at the time of preforming. As a result, wrinkles may occur in the skin material 10.

  In the present embodiment, the circumferential length LA at the base end 14 of the projecting portion 20 after the preforming can be matched with the circumferential length LB at the base end 14 of the projecting portion 20 after the main molding. There is no remainder in the vicinity of the base end 14 of the skin material 10. As a result, a situation in which wrinkles occur in the skin material 10 can be suppressed, and the quality of the skin material 10 can be further increased.

  In the state where the convex portion 31 is fitted in the concave portion 61, as shown in FIG. 1, the boundary line X2 is arranged so as to surround the boundary line X1 from the outside. For this reason, if the boundary line X1 is configured by a straight line (not a curve), the length of the boundary line X1 is smaller than the length of the boundary line X2. Therefore, in the present embodiment, the boundary line X1 is configured by the curve L1 (having the same length as the line segment L2), thereby making the length of the boundary line X1 coincide with the length of the boundary line X2.

  In addition, the method for molding the skin material of the present embodiment is more suitable when applied to a leather skin material. This is because the skin material of genuine leather generally has a large dimensional tolerance and it is difficult to control the thickness. Temporarily, in the case of a configuration in which the size of the gap between the convex portion 31 and the concave portion 61 is set to the same value as the thickness of the skin material 10, when the thickness of the skin material 10 becomes larger than a predetermined dimension due to dimensional tolerance, The thickness of the skin material 10 becomes larger than the gap between the convex portion 31 and the concave portion 61. Thereby, when fitting the convex part 31 in the recessed part 61, the skin material 10 will be rubbed strongly by the side surface 61A of the recessed part 61, and it will become a cause of wrinkles.

  In the present embodiment, even if the thickness of the skin material 10 is larger than a predetermined dimension by opening the gap S between the design surface 10A of the skin material 10 and the side surface 61A of the recess 61, the fitting is performed. In the joint process, the situation in which the side surface 61A of the recess 61 slides with respect to the design surface 10A of the skin material 10 can be suppressed.

<Embodiment 2>
Next, a second embodiment of the present invention will be described with reference to FIGS. In the present embodiment, the configurations of the skin material, the first mold, and the second mold are different from those of the above embodiment. In the present embodiment, the same reference numerals are used for portions having the same names as those in the above-described embodiment, and redundant description of the structure, operation, and effect is omitted.

  As shown in FIG. 8, the skin material 110 of the present embodiment is configured by sewing at least two skin pieces 111 and 112. Further, the first mold 130 of the present embodiment has a convex portion 131. Suction holes 133 are provided in a plurality of locations on the surface of the convex portion 131. An air pressure supply device (not shown) is connected to each suction hole 133.

  As shown in FIG. 8, a groove portion 134 into which the end portions 115 and 115 of the skin pieces 111 and 112 can be fitted is recessed in the surface of the convex portion 131 (which constitutes a molding surface) (also in FIG. 11). reference). A magnet 135 is provided at a location corresponding to the groove 134 inside the first mold 130.

  The magnet 135 is a neodymium magnet, for example, and is attached to the tip of the rod 138A of the cylinder device 138 provided in the first mold 130. Accordingly, by driving the cylinder device 138 with hydraulic pressure (or air pressure) or the like, the magnet 135 can be displaced in a direction in which the magnet 135 approaches or separates from the groove portion 134 (vertical direction in FIG. 8).

  In addition, the clamping member 141 is arranged at the location where the groove 134 is formed in the first mold 130. The clamping member 141 is a member for clamping the sewing parts of the skin pieces 111 and 112 between the molding surface 132 of the first mold 130 (the protruding end surface of the convex portion 131).

  The clamping member 141 has a protrusion 142 corresponding to the surface shape of the sewn part of the skin pieces 111 and 112. The clamping member 141 has a shape extending along the extending direction of the sewing parts (and consequently the sewing line) of the skin pieces 111 and 112, and is made of, for example, a metal having magnetism. Thus, the clamping member 141 is configured to be attracted to the magnet 135 when the magnet 135 is brought close to the groove 134.

  In FIG. 8, the clamping member 141 in a state before being set in the first mold 130 is indicated by a two-dot chain line, and is denoted by reference numeral 141A. Further, the protrusion 142 of the holding member 141 in a state before being set in the first mold 130 is denoted by reference numeral 142A. The protrusion 142 has a shape that can be fitted into a gap (groove) formed between the skin pieces 111 and 112.

  As shown in FIGS. 9 and 10, the second mold 160 of the present embodiment has a concave portion 161 into which the convex portion 131 of the first mold 130 can be fitted. Note that a gap is formed between the design surface 110 </ b> A of the skin material 110 held by the first mold 130 and the side surface 161 </ b> A of the recess 161, and the process of fitting the protrusion 131 to the recess 161. Then, the design surface 110A of the skin material 110 is configured not to slide on the side surface 161A.

  Suction holes 163 are provided at a plurality of locations on the back surface 161D of the recess 161. An air pressure supply device (not shown) is connected to each suction hole 163. In addition, in the inner surface 161D of the recess 161, a fitting recess 162 into which the clamping member 141 can be fitted is formed at a portion facing the clamping member 141.

  Further, as shown in FIG. 10, insertion holes 139 into which the guide pins 164 formed in the second mold 160 can be inserted are formed at a plurality of locations on the peripheral end portion of the first mold 130. Each guide pin 164 is inserted through each insertion hole 139, whereby the first molding die 130 and the second molding die 160 are aligned.

  Next, a method for forming the skin material 110 of this embodiment will be described. First, as shown in FIG. 8, the skin material 110 is placed on the molding surface 132 of the first molding die 130 (skin material placing step). At this time, the back surface 110 </ b> B of the skin material 110 and the molding surface 132 are disposed to face each other, and the end portions 115 and 115 (sewn portions) of the skin pieces 111 and 112 are inserted into the groove portion 134.

  Next, the clamping member 141 is placed on the portion corresponding to the end portions 115 of the design surface 110 </ b> A of the skin material 110. At this time, the magnet 135 is close to the groove 134. Therefore, the clamping member 141 is attracted to the groove 134 side by the magnet 135. As a result, the sewn portions of the skin pieces 111 and 112 can be clamped by the clamping member 141 and the molding surface 132.

  Next, a negative pressure is applied to the skin material 110 through each suction hole 133 to mold the skin material 110 into a shape that follows the shape of the molding surface 32 (first molding step). Subsequently, as shown in FIG. 9, the first mold 130 is turned upside down and disposed above the second mold 160.

  Next, as shown in FIG. 10, the first mold 130 is brought close to the second mold 160 and the convex 131 of the first mold 130 is fitted into the concave 161 of the second mold 160 ( Mating process). At the same time, the holding member 141 is fitted into the fitting recess 162 of the second mold 160.

  Then, after stopping the suction of the skin material 110 by each suction hole 133, a negative pressure is applied to the skin material 110 through each suction hole 163 of the second mold 160, and the skin material 110 is shaped into the shape of the recess 161. Is formed into a shape following the above (second forming step). After the skin material 110 is formed, the cylinder device 138 is driven to move the magnet 135 away from the groove 134.

  Next, the first mold 130 is separated from the second mold 160, and the convex 131 is separated from the concave 161 of the second mold 160 (detachment process). Thereby, the back surface 110B of the skin material 110 is exposed.

  In addition, since the magnet 135 is moved away from the groove 134 in the previous step, the magnetic force acting on the clamping member 141 from the magnet 135 is weak (or hardly acts). For this reason, in the process of separating the first molding die 130 from the second molding die 160, the clamping member 141 is not attracted to the magnet 135 (on the first molding die 130 side) and is fitted into the fitting recess 162. It is maintained in the state.

  Thus, in this embodiment, by providing the clamping member 141 and the magnet 135, the sewing parts of the skin pieces 111 and 112 can be clamped, and the displacement of the sewing parts and by extension, the sewing line can be suppressed. .

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.

  (1) In the above embodiment, a method of holding the skin material 10 on the molding surface 32 of the first mold 30 by using a pair of clamping members 41 and 42 and suction by the suction hole 33 is exemplified. It is not limited to. The skin material 10 may be held in the first mold 30 by using only one of the pair of holding members 41 and 42 or suction by the suction hole 33. That is, only the suction by the suction hole 33 may be used as the holding means.

  (2) Although the neodymium magnet was illustrated as a magnet in the said embodiment, the kind of magnet is not limited to this. For example, as the magnets 35 and 64, an electromagnet can be exemplified instead of a permanent magnet. If the magnet 35 is an electromagnet, for example, when the first molding die 30 is moved away from the second molding die 60, the generation of the magnetic force of the magnet 35 can be stopped by stopping energization of the magnet 35. The pair of clamping members 41 and 42 can be left in the second mold 60.

  (3) In the said embodiment, although the skin material comprised from several skin pieces was illustrated, it is not limited to this. For example, the skin material may be composed of only one skin piece.

  (4) The product shape of the skin material (the shape of the skin material after the main molding) is not limited to those exemplified in the above embodiment, and can be appropriately changed. The skin material should just be shape | molded in the shape which makes the shape which at least one part protruded to the design surface side. The shape of the protruding portion 20 of the skin material is not limited to a substantially trapezoidal shape. In addition, the shapes of the first mold and the second mold can be appropriately changed according to the product shape of the skin material.

  (5) The clamping member 141 and the magnet 135 of the second embodiment may be provided in the first mold 30 of the first embodiment.

DESCRIPTION OF SYMBOLS 10 ... Skin material, 10A ... Design surface of skin material, 10B ... Back surface of skin material, 11 ... Skin piece (part of skin material), 12, 13 ... Skin piece, 15 ... Overlapped end, 30 ... No. DESCRIPTION OF SYMBOLS 1 Mold, 31 ... Convex part, 31B ... Projection end surface of a convex part, 32 ... Molding surface (the surface of a convex part is comprised), 33 ... Suction hole (convex part side suction hole), 35 ... Magnet (1st magnet) 41, 42 ... clamping member (holding means), 60 ... second mold, 61 ... recess, 61A ... side surface of recess, 61D ... back surface of recess, 63 ... suction hole (recess side suction hole), 64 ... magnet (Second magnet), S ... Gap

Claims (3)

A skin material molding method for molding a skin material using a first molding die having a convex portion and a second molding die having a concave portion into which the convex portion can be fitted,
A skin material placing step of placing the skin material on the surface of the convex portion, with the back surface of the skin material facing the surface of the convex portion,
After the skin material placement step, the skin material is sucked through the convex-side suction holes formed on the surface of the convex portion, so that the skin material follows the surface shape of the convex portion. A first molding step of molding into a different shape;
After the first molding step, the convex portion of the first molding die is fitted into the concave portion of the second molding die in a state where the skin material is held on the surface of the convex portion by the holding means. A mating process to
The skin material is sucked through the recess-side suction hole formed on the surface of the recess, which is performed after the fitting step, so that the skin material is shaped into a shape following the surface shape of the recess. A second molding step,
In the fitting step,
While sandwiching a part of the skin material between the projecting end surface of the convex portion and the back surface of the concave portion, and to form a gap between the design surface of the skin material and the side surface of the concave portion,
A method for forming a skin material, wherein the size of the gap increases from the back surface side of the recess toward the opening end of the recess. The skin material comprises at least two skin pieces overlapped with each other at the ends,
Each of the overlapped end portions protrudes from the back surface of the skin material,
In the skin material placement process,
The method for forming a skin material according to claim 1, wherein each of the overlapped end portions is inserted into the convex portion side suction hole. The holding means is a pair of clamping members capable of clamping the skin material,
In the fitting step, the pair of clamping members that are attracted by the first magnet provided in the first molding die are arranged at locations facing the second magnet provided in the second molding die,
The method for molding a skin material according to claim 1, wherein the second magnet has a stronger magnetic force than the first magnet.

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