JPH0423902B2 - - Google Patents

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention relates to a method for manufacturing a skin material having patterned parts made of different materials, and mainly relates to a method for manufacturing a skin material having patterned parts made of different materials, and mainly for use in automobiles, railway vehicles,
Transportation vehicles such as aircraft and ships, other furniture,
The present invention relates to a method suitable for manufacturing various interior and exterior products and skin materials for clothing that have excellent decorative appearance and are used for bags, clothing, and the like.

(Prior art) Recently, there has been a demand for interior-oriented designs that are luxurious and have a good texture for the appearance of interior materials such as safety pads (hereinafter abbreviated as instrument pads) of automobile instrument panels and other interior materials such as door trims. As a result, there is a demand for the decorative surface not only to be made of a single material, but also to use a composite skin material, for example, a combination of vinyl chloride skin material and fabric.

Conventionally used methods for creating these composite skin materials include sewing thermoplastic synthetic resin sheets such as vinyl chloride sheets and fabrics, flocking short fibers onto the surface of the vinyl chloride skin material, or fabricating polyvinyl chloride sheets. The joining methods used include joining the joint ends of the sheet and fabric by skin folding, or adhering the fabric lined with a vinyl chloride sheet to the surface of the vinyl chloride skin material with an adhesive, or welding. Ta.

However, the methods for manufacturing composite skin materials according to the above-mentioned conventional techniques each have the following problems, and solutions to these problems have been sought. In other words, a skin material in which a thermoplastic synthetic resin sheet and another skin material are joined by sewing requires a lot of man-hours, and the perforations are exposed, which is undesirable in terms of appearance. There was a drawback that the foaming liquid leaked out due to the foaming pressure. The problem with the method of flocking short fibers onto the surface of the skin material is that it lacks freedom in design. In addition, skin materials joined by the skin folding method are prone to leakage of injected liquid from the joint during urethane foaming, and it is difficult to apply the skin folding method to join three-dimensional parts, due to design considerations. was subject to restrictions. Conventionally, the method of attaching fabric to the surface of a skin material using an adhesive is a labor-intensive process because it is a manual application process, and the adhesive tends to seep into the edges of the fabric, causing stains. However, there were drawbacks such as the fabric portion rising on the surface of the finished product, spoiling its decorative appearance. On the other hand, a method in which a fabric with a vinyl chloride sheet lined on the back side with an adhesive is placed on top of the vinyl chloride skin material and the peripheral edges of the fabric are welded using a welder does not require the use of solvents and the joining is completed in a short time, increasing productivity. It has many advantages such as high efficiency and low cost. However, in this method, it is necessary to strictly match the overlap between the upper weld bar and the planned welding portion of the fabric periphery, but the overlap often deviates, which impairs the appearance.

For the purpose of solving these problems, for example,
175650 describes a method for manufacturing automotive interior materials such as door trims that have surface layers made of different materials, but this method requires a lower mold that is divided into two parts, and the pattern is adjusted according to the divided mold. However, it is not possible to obtain more complex decorative patterns, and there are serious drawbacks such as low productivity and high cost.

In addition, JP-A-59-101324 describes a method for manufacturing skin materials with partially different materials using the slush molding method, but this method requires molds and holding jigs depending on the pattern, and is still complicated. It is difficult to obtain decorative patterns, and productivity is also low.

Furthermore, JP-A No. 60-2320 describes a method of manufacturing a skin material having a multicolored surface by an in-die extension method using a masking material, but it is also difficult to obtain a complex decorative pattern with this method. Productivity is low.

In addition, Publication of Utility Model Publication No. 61-34104 describes a weld mold suitable for setting the cut skin material in the lower weld mold and then layering different skin materials for high frequency welding. In this case, a trimming die is required to cut the skin material from the front, which increases the number of man-hours and reduces productivity.

Furthermore, in the molding of door trims for automobile interiors,
A method is used in which the skin sheet, ornament, and core material are laminated in this order, and the cutting blade is fixed to a weld bar, and high-frequency welding and fusing are performed simultaneously, but in this case, the cutting conditions of the skin sheet It is not possible to set different weld conditions. Therefore, if the ornament is made of polyvinyl chloride, the boundary line on the ornament side may melt due to the high frequency current from the cutting blade tip, resulting in poor appearance. Conversely, if the welding conditions are weakened or the height of the cutting blade is lowered in order to reduce damage to the ornament base material, the cut of the skin sheet may become insufficient and the welt strength between the skin sheet and the ornament may become weak. Sometimes it happens.

(Problems to be Solved by the Invention) The object of the present invention is to provide a composite skin that does not shift the welding overlap between different skin materials, has patterned parts made of different materials, and has an excellent decorative appearance. The object of the present invention is to provide a method for manufacturing materials.

Another object of the present invention is to provide a method for manufacturing a composite skin material having excellent bonding strength with fewer man-hours.

(Means for Solving the Problems) The present invention involves lowering the upper electrode plate of the first skin material on the lower electrode plate of the welder, cutting it under pressure with a cutting blade attached to the lower weld bar, and then cutting the first skin material on the lower electrode plate of the welder. The cutting edge height of the cutting blade is set to be the same as or lower than the height of the lower weld bar, and the first skin material and the second skin material laminated on the skin are welded under pressure using the upper weld bar. The present invention relates to a method for manufacturing a skin material having patterned portions made of different materials.

Hereinafter, the present invention will be explained with reference to the drawings. The apparatus used in the present invention is, for example, a joining apparatus for joining different skin materials having an upper electrode plate attached with an upper weld bar and a lower electrode plate attached with a lower weld bar, as shown in FIG.
The lower weld bar is characterized by a cutting blade that can adjust the height of the cutting edge.

Here, FIGS. 1A, B, and C are schematic diagrams illustrating a welding process using high-frequency welding as an embodiment of the present invention. Lower electrode plate 1 as shown in Figure 1A
The first skin material 7 is set on top, and then the upper electrode plate 2 is lowered to cut a predetermined portion. In this case, the cutting blade is the lower weld bar 3.
It is set at a higher position than the surface. FIG. 1B shows a state in which the upper electrode plate 2 is raised and the second skin material 8 is set. FIG. 1C shows a state in which the upper electrode plate 2 has been lowered and predetermined portions have been welded. In this case, the cutting blade should be set at the same height as the surface of the lower weld bar, or at a lower position.

In this way, by lowering the cutting blade during welding, the second
can prevent the effects on the skin material. For example, if the second skin material is a soft polyvinyl chloride sheet, the portion in contact with the cutting blade will melt and form grooves or discolor, which can be prevented.

In addition, by setting the cutting blade height sufficiently high and cutting the first skin material reliably, it is easy to remove the first skin material that covers the surface of the second skin material after welding. Become. This is advantageous when the thickness of the first skin material is large compared to conventional skins.

As the cutting blade height adjustment mechanism in the present invention, a wedge mechanism, a cam mechanism, a jack mechanism, and others can be used as appropriate. A schematic diagram of these mechanisms is shown in FIG.

FIG. 2A shows a mechanism for moving the movable lower electrode plate 1' up and down to change the height of the cutting blade. FIG. 2B shows a mechanism for changing the height of the cutting blade by moving the taper pin in and out.

FIG. 2C shows a mechanism in which a cam is arranged below the cutting blade and the height of the cutting blade is adjusted by rotating the cam.

Figure 2D shows a mechanism for changing the height of the cutting blade by inserting a jack into the lower part of the cutting blade.

In the present invention, the welding method is performed by combining the first skin material and the second skin material, for example, by heat pressing,
Methods such as high frequency welding and ultrasonic welding can be selected as appropriate.

In the case of a high-frequency welder, the first and second skin materials are polyvinyl chloride, polyvinylidene chloride, polyethylene, polypropylene, polyamide, polyurethane, polyacetal, polycarbonate,
A thermoplastic sheet having a large dielectric loss, such as polytetrafluoroethylene, polystyrene, polyester, or polycellulose acetate, is preferred. Furthermore, if a short wave welder is used, it can be applied to all thermoplastic plastics. In this case, a tool horn is used as the upper die and a pedestal is used as the lower die. In addition, either the first or second skin material may be phenol-formalin resin, resolmin resin, urea resin, melamine resin, epoxy resin,
Even if it is not a thermoplastic plastic such as furan resin or silicone resin, it can be melted in the form of a net.
Both skin materials can be joined if the structure allows PVC to easily penetrate. Furthermore, even if either the first or second skin material is a fabric made of natural fibers or recycled fibers such as rayon, or a fabric made of a blend of these and other chemical fibers, the material has relatively high breathability, Both skin materials can be joined if the surface is laminated with a thermoplastic plastic sheet.

(Effects of the Invention) The method of the present invention eliminates process defects caused by misalignment of overlapping margins, which have conventionally been a problem when welding different skin materials, and also solves problems such as crushing of the boundary between different skin materials. Furthermore, cutting and welding can be performed using the same mold, reducing the number of man-hours and making it possible to stably manufacture products with decorative beauty. The method of the present invention is also advantageous for welding sheets with large variations in thickness.

(Example) A detailed explanation will be given below using examples.

Example 1 A polyvinyl chloride sheet with a thickness of 0.8 mm was used as the first skin material, and as shown in Figure 3A, this was placed on the lower electrode plate of the welder, the upper electrode plate was lowered, and the lower It was cut using the cutting blade attached to the weld bar. The dimensions of the lower weld mold used at this time are h = 1.0 in Figure 5.
mm, α=30°, W=2 mm, and w=1.0 mm, and cutting was carried out by applying current at a frequency of 27.12 MHz and an output of 1.5 kW for 1 second at a pressing force of 5 kg/cm ² using an upper weld bar.

Next, the second skin foamed polyvinyl chloride sheet is loaded, and after lowering the upper weld bar, the third
As shown in Figure B, the cutting blade was set low and high frequency welding was performed under the conditions of a pressurizing force of 10 kg/cm ² , an output of 3 kW, and a welding time of 3 seconds to join both skins.

Example 2 As the first skin material, a skin made by laminating a non-foamed polyvinyl chloride sheet with a thickness of 0.3 mm and a 10 times foamed polyvinyl chloride sheet with a thickness of 1.0 mm was used, and the skin was set in a lower weld shape, The epidermis was fused as shown in Figure 4A. The dimensions of the lower weld mold used at this time were the same as in Example 1, but the height h of the cutting blade was adjusted to 1.5 mm. The welding conditions are a pressure of 6 kg/cm ² from the upper weld bar and a frequency of 6 kg/cm 2.
Cutting was performed at 27.12MHz, output 2kW, and energized for 1 second. A polyester moquette skin is laminated at a predetermined location, and then the cutting blade is lowered in the state shown in FIG. 4A and welded in the state shown in FIG. 4B. The conditions at this time were a pressurizing force of 10 kg/cm ² , an output of 3 kW, and a current application time of 4.5 seconds.

[Brief explanation of drawings]

Fig. 1 is a schematic diagram illustrating a weld welding process as an embodiment of the present invention, Fig. 2 is a schematic diagram showing a height adjustment mechanism of the cutting blade of the present invention, and Fig. 3 is a schematic diagram illustrating the height adjustment mechanism of the cutting blade according to the invention. The state of cutting the material and the first
FIG. 4 is a schematic diagram showing a state in which the first skin material is cut by a cutting blade and the first and second skin materials, the core material and the cushion material are welded together. FIG. 5 is an explanatory diagram showing an example of a lower weld bar provided with a cutting blade.

Claims (1)

[Claims] 1. After lowering the upper electrode plate and cutting the first skin material on the lower electrode plate of the welder with a cutting blade attached to the lower weld bar under pressure, the height of the cutting edge of the cutting blade is is set at the same height as or lower than the height of the lower weld bar, and the first skin material and the second skin material laminated on the skin material are
A method for producing a skin material having patterned portions made of different materials, characterized in that the skin materials are pressure-welded using an upper weld bar. 2. The manufacturing method according to claim 1, wherein the skin material is cut using a high frequency current during the cutting.