JPH0458779B2 - - Google Patents

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention provides an attractive material in which the surface of a base material is covered with an ornamental material such as moquette material or carpet material, and a synthetic resin skin material. The present invention relates to a manufacturing method and manufacturing apparatus for automobile interior materials that can easily mass-produce automobile interior materials.

(Prior art) A synthetic resin skin material is entirely coated on the surface of a base material to which a raised ornament member is partially attached, and this is welded to the periphery of the ornament member, and the synthetic resin skin material is A manufacturing method for automobile interior materials in which the portion of the material that covers the ornament member is removed along the welding line is disclosed in Japanese Patent Publication No. 59-
It is widely known from Publication No. 24008, etc.

(Problem to be solved by the invention) However, many of the synthetic resin skin materials used in this type of method have a foam layer, so the thickness is 2 mm or more. If the fusing blade is set high, the welding pressure will be insufficient and a clear weld pattern will not be obtained.
In addition, sparks are generated when welding pressure is increased to obtain a clear weld pattern, so we have no choice but to weld without increasing the welding pressure and manually peel off the thinned part with a low welding blade. It was time consuming. In addition, ornament parts,
In particular, when coating a synthetic resin skin material on the surface of a base material partially attached with a raised ornament material and welding a part of it to the periphery of the ornament material, the molten synthetic resin skin material The problem is that the excess material builds up along the weld line, melts the nap of the ornament member, or causes the hair to fall down, causing a so-called whitening phenomenon that looks whitish along the weld line, making it impossible to obtain a good-looking product. It was hot.

(Means for Solving the Problems) The present invention solves the above-mentioned problems and allows synthetic resin skin materials to be applied to ornament members without causing any adverse effects such as whitening on the parts along the welding lines of the ornament members. This product was developed for the purpose of producing a manufacturing method and manufacturing device for automobile interior materials that can be accurately and easily welded to the peripheral edge of a substrate to obtain a product with a good finish. An automobile interior material in which a synthetic resin skin material is coated and welded to the periphery of the ornament member, and a portion of the synthetic resin skin material that covers the ornament member is removed along the welding line. In the manufacturing method, when the synthetic resin skin material is welded to the peripheral edge of the ornament member, a bag in which a portion of the synthetic resin skin material that covers the ornament member is interposed between the ornament member and the synthetic resin skin material. The first invention is a method for producing an automobile interior material, which is characterized by welding a shaped member while lifting it up by expansion and removing it from a welding line. In the skin material welding device, the synthetic resin skin material to be coated on the surface of the base material is welded to the periphery of the ornament member with an upper surface plate that can be freely matched opposed to a lower surface plate that supports the base material. An apparatus for manufacturing an automobile interior material, characterized in that it is equipped with a fluid supply pipe connected to a bag-like member interposed between the surface ornament member and the synthetic resin skin material to inflate the bag-like member. This is the second invention.

The base material used in the present invention may be of any material such as synthetic resin board or hard fiber board, and its structure may be a flat plate or a molded base material with unevenness. The ornamental member to be coated on the surface of the material may be any fiber fabric such as a woven or knitted fabric woven or knitted with chemical fibers, natural fibers, or any other fiber, but in particular,
This effect is noticeable when using brushed fabrics with a nap length of about 0.5 to 10 mm, such as moquette fabric or carpet fabric, or fiber fabrics with relatively long naps, such as flocked fabrics.On the other hand, synthetic resin-based The surface material may be of any material as long as it can be welded by high frequency welding or other means, but generally solid type sheets made of thermoplastic synthetic resin or laminated type sheets with a foam layer are used. In some cases, a synthetic resin adhesive layer for welding, such as a hot melt adhesive, may be formed in advance on the back surface of the part to be welded. Furthermore, the welding means for welding the synthetic resin skin material to the periphery of the ornament member may be performed using any welder such as an ultrasonic welder in addition to the high frequency welder. Compressed air is normally used as the fluid supplied to the bag-like member that causes the covering portion to rise slightly above the surface of the ornament member, but other inert gases or liquids such as water may also be used.

(Example) Next, an example of the present invention will be described in detail with reference to the skin material vacuum forming apparatus shown in FIGS. 4 and 5, and the apparatus of the present invention shown in FIGS. 1 to 3. First, in Fig. 4, reference numeral 1 is a receiving mold with a vacuum box 2 at the bottom, the mold surface is formed into an uneven surface with vacuum suction holes 3 arranged, and a part of this mold surface is an air blowing pipe 4 connected to an air supply source.
are being communicated. Reference numeral 5 denotes an assist mold which is arranged to be freely matched with the receiving mold 1, and most of the mold surface of the assist mold 5 corresponds to the mold surface of the receiving mold 1, but some That is, only the portion of the receiving mold 1 that faces the portion where the ornament member is set has a concave surface sufficient to form a required cavity 6 between the mold surface of the receiving mold 1 during mold matching. In addition, 7 in the figure is set so that the base material protrudes slightly from the mold surface of the receiving mold 1 in order to maintain the balance of the base material and enhance the sealing effect when setting the base material on the mold surface of the receiving mold 1. A soft sealing material is partially embedded in the mold surface of the assist mold 5, and a pressing protrusion 8 is provided on the assist mold 5 so as to correspond to the outer shape of the ornament member.

Reference numeral 11 denotes a base material that is set on the mold surface of the receiving mold 1, and the base material 11 is made of a synthetic resin board or hard fiberboard and is preformed into a textured material, and small holes are provided therein. The base material 11 is made of a breathable material, and its surface is entirely coated with an adhesive, and a part of the surface of the base material 11 has a nap length of about 0.5 to 10 mm and a softening point of 70 to 120°C. A moquette fabric or carpet fabric, which is a type of woven fabric or knitted fabric made of polyester or polyamide fibers, is cut into a desired shape after being installed, or the ornament member 21 that has been attached after being cut into a desired shape is pasted. Furthermore, a fluid supply pipe 44 (described later) is inserted into the bag-like member 51 by inserting a supply pipe portion 52 of a bag-like member 51 (described later) through the portion to which the ornament member 21 is attached.
An opening 13 is provided to allow more fluid to be supplied.

Reference numeral 31 denotes a synthetic resin skin material on which a foam layer is laminated on the back side if necessary, and the synthetic resin skin material 31 is made of thermoplastic synthetic material such as vinyl chloride resin, polyethylene resin, or thermoplastic polyester resin. The mold 1 and the assist mold 5 are made of vacuum molded resin and weldable leather or film material, and are heated to an optimum temperature of, for example, 100 to 200°C, which is not melted but sufficiently softened. It is now set between .

On the other hand, FIGS. 1 to 3 show a process for carrying out the method of the present invention on an intermediate product in which a synthetic resin skin material 31 is coated on the surface of a base material 11 with an ornamental member 21 using the skin material vacuum forming apparatus. This is an explanatory diagram of the apparatus, and numeral 41 in the figure is a lower surface plate for welding and fusing using high frequency waves, and the contour line on the back surface of the upper end corresponds to the outer shape of the ornament member 21. A bag-shaped member 51 whose tip is connected to a fluid supply source such as a compressor, and has a fluid inlet connected to the fluid supply source such as a compressor.
It is provided so that it can be connected to the lower surface plate 41.
Above there is a weld tooth type 4 with a fusing blade 47 at the lower end.
As shown in FIG. 8, upper surface plates 45 in the form of a frame box are arranged facing each other so that the shapes can be freely matched.

51 is a bag-shaped member interposed between the ornament member 21 of the base material 11 and the synthetic resin skin material 31, and has a supply pipe portion 52 connected to the fluid blowing pipe 44. The shaped member 51 is supplied with fluid from the fluid blowing pipe 44 through the supply pipe portion 52 and expands, thereby lifting the portion of the synthetic resin skin material 31 that covers the ornament member 21. In the figure, reference numeral 53 indicates a retaining flange formed on the upper portion of the supply pipe section 52, and 54 indicates a backing plate supported on the upper surface of the flange 53 as necessary when the opening 13 has a large diameter. It is.

Next, to show a specific example of manufacturing a door trim as an automobile interior material using the above-mentioned equipment and materials, first, a piece of wood 11 is formed by three-dimensionally molding a wood-based hard fiberboard into the shape of a door trim using a well-known molding device. A piece of fabric made of polyester fiber with a 2 mm long nap on the surface and a softening point of 90°C is attached partially around the convex portion formed on the surface of the base material, and this is shaped into the desired shape. By trimming, the ornament member 21 is partially attached to the surface of the base material 11. Then, the assist mold 5 of the apparatus shown in FIG. is set in a softened state by heating to 150°C, and the assist mold 5 and the receiving mold 1 are clamped. At this time, at the same time or just before the assist mold 5 comes into contact with the base material 11, air is blown at atmospheric pressure or higher, preferably from 2 to 6 kg/cm ² , through the air blowing pipe 4 which is connected to the mold surface of the receiving mold 1. The part of the synthetic resin skin material 31 above the ornament member 21 is lifted toward the cavity 6 formed between the assist mold 5 and the receiving mold 1, while the vacuum box connected to the vacuum source is lifted up. 2 and the synthetic resin skin material 31 that has been softened by heating through the vacuum suction hole 3 provided in the receiving mold 1 is vacuum-formed on the surface of the base material 11. In a state where the contact with the parts is cut off, the synthetic resin skin material 31 is completely covered with the surface of the base material to which the brushed ornament member 21 is partially attached, and the base material excluding the ornament member 21 is completely covered. Although it is pasted on the surface, the ornament member 21
This results in an intermediate product with voids remaining between the two. Then, the assist mold 5 is opened and the intermediate product is taken out.

Once the intermediate product has been obtained in this way, then
Now we move on to the welding and fusing steps of the present invention. This welding,
The fusing process is shown in FIG. 1, and in the first embodiment, the bag-like member 51 is cut through the opening 13 of the base material 11 onto the front side of the ornament member 21 so that only the supply pipe portion 52 thereof is left on the back side of the base material 11. and place the base material 11 on the lower surface plate 41 such that the receiving surface of the lower surface plate 41 is positioned below the periphery of the ornament member 21 on the front side thereof, and the supply pipe part 52 on the back side of the base material 11. is fitted into the fluid supply pipe 44 to connect the bag-shaped member 51 and the fluid supply pipe 44, and the flange 5 is connected to the fluid supply pipe 44.
3 is prevented from coming into contact with the lower surface of the base material 11 and coming off. Then, at the same time or just before the upper surface plate 45 is lowered and the weld tooth pattern 48 comes into contact with the synthetic resin skin material 31, the fluid blowing pipe 4
A fluid such as compressed air is blown into the bag-like member 51 from 4 through the supply pipe 52 to expand the bag-like member 51, and the portion of the synthetic resin skin material 31 above the ornament member 21 is expanded into the expanded bag. If a part of the synthetic resin skin material 31 is welded to the periphery of the ornament member 21 using the weld tooth pattern 48 by applying a high frequency current and applying pressure in this state, a weld line is formed. At the same time, the synthetic resin skin material 31 thinned by the fusing blade 47 is mechanically cut at the thinned portion by the expansion force of the bag-like member 51. The portion covering the member 21 is separated, and the separated synthetic resin skin material is removed from the spot after the upper surface plate 45 is raised. In addition, in order to improve the efficiency of fusing, the bag-like member 51 may be further expanded during fusing. In this way, the synthetic resin skin material 3
1 to the peripheral edge of the ornament member 21, when the weld tooth pattern 48 comes into contact with the synthetic resin skin material 31, at least the portion of the synthetic resin skin material 31 adjacent to the welding line forming portion is welded. Since it does not come into contact with the raised part of the lever part that rises above the surface of the ornament member 21, the effects of high-frequency heat generation, heat conduction, or heat pressure from the weld tooth pattern 48 are weakened, which tends to occur along the weld line. It is possible to prevent the whitening phenomenon and provide excellent products. In addition,
Base material 1 partially attached with ornament member 21
1, the synthetic resin skin material 31 does not come into contact with the portion covering the ornament member 21 even during vacuum forming of the synthetic resin skin material 31. In addition to the method of the above embodiment, which eliminates hair fall, vacuum forming may be performed by a well-known method and only welding may be performed by the method of the present invention, or the welding process may be performed simultaneously with the vacuum forming in the above embodiment. Furthermore, even when performing the welding process after obtaining the intermediate product, welding can be performed on the base material, which is set so that the weld tooth pattern is provided on the irregular plate and the synthetic resin skin material is on the bottom side. You may also do this. Moreover, the bag-like member 51 is attached to the ornament member 21.
In addition to the one shown in FIG. 1 which covers almost the entire surface of the welding line, it may be shaped like a floating ring and positioned only inside the welding line as shown in FIG. In the embodiment shown in the figure, the bag-like material 51 is inserted through the opening 13 of the base material 11, but as shown in FIG. 32, or, as shown in FIG. The cover 61 to which the bag-shaped member 51 is attached is set, and this cover 61
It is also possible to provide an intermediate product with a bag-like member 51 in which the synthetic resin skin material 31 is vacuum-formed with a built-in bag member 51 . In addition, in order to prevent the supply pipe portion 52 of the bag-shaped member 51 from being disconnected from the fluid supply pipe 44, in addition to using the collar portion 53 and the cover plate 54 as in the above embodiment, the method shown in FIG. As shown, the inflated bag-like member 51 may be pushed down by pressing with a presser mold 71 above the fluid supply pipe 44.

(Effects of the Invention) As is clear from the above description, the present invention is a bag-like member that expands the portion of the synthetic resin skin material that covers the ornament member when the synthetic resin skin material is welded to the peripheral edge of the ornament member. Since the welding and fusing are removed while raising the weld slightly, it is possible to prevent the whitening phenomenon caused by the excess material that occurs along the weld line of the ornament member, resulting in a product with a good appearance, and the welding and fusing of the bag-like member. Since the expansion process eliminates the need for stripping, and the equipment is simple, it can be mass-produced at low cost. There are some extremely important contributions to the development of the world.

[Brief explanation of the drawing]

Fig. 1 is a partially cutaway front view showing a first embodiment of the device of the present invention, Fig. 2 is a partially cutaway front view showing a second embodiment of the device of the present invention, and Fig. 3 is a bag-like member. FIG. 4 is a partially cutaway front view showing an example of a skin material vacuum forming device, and FIG. 5 is a partial cutaway front view showing an example of a skin material vacuum forming device, and FIG. It is a partially cutaway front view showing the board. 11: Base material, 21: Ornament member, 31:
Synthetic resin skin material, 41: lower surface plate, 44: fluid blowing pipe, 45: upper surface plate, 51: bag-shaped member.

Claims (1)

[Scope of Claims] 1. A synthetic resin skin material is coated on the surface of a base material partially attached with an ornament member, and this is welded to the periphery of the ornament member. In a manufacturing method for automobile interior materials in which the part covering the ornament member is removed along the welding line, when the synthetic resin skin material is welded to the periphery of the ornament member, the part of the synthetic resin skin material that covers the ornament member is removed. A method for manufacturing an automobile interior material, characterized in that the parts are welded while being slightly raised by expanding a bag-like member interposed between the ornament member and a synthetic resin skin material, and removed from a welding line. . 2. The synthetic resin skin material coated on the surface of the base material is placed on the periphery of the ornament member by placing the upper surface plate 45, which can be freely matched, in opposition to the lower surface plate 41 that supports the base material partially attached with the ornament member. In the skin material welding device, the fluid supply is connected to a bag-like member 51 interposed between the ornament member on the surface of the base material and the synthetic resin skin material to inflate the bag-like member 51. An apparatus for manufacturing automobile interior materials, characterized by comprising a pipe 44.