JPH0751312B2 - Interior material manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing an interior material having a composite structure including at least a base material and a skin material.

2. Description of the Related Art For example, as an interior material for a roof mounted inside the roof of an automobile, there is a structure shown in FIGS. 4 and 5, for example. This is a cushioning material on a cardboard base material 32.
33 and a skin material 34 are laminated in this order and molded into a predetermined three-dimensional shape.In the state of the interior material 31 alone, the interior material 31 is mounted on the roof rail 36 on the roof 35 side without any special terminal treatment. The terminal portion of is fixed by garnish 37. 38 is a wind glass, 39 is a tapping screw.

In such an interior material 31, since a separate garnish 37 is indispensable as the terminal treatment, it is not desirable in appearance, and it tries to make the interior space of the vehicle as wide and neat as possible by eliminating extra accessories. This is against recent trends.

Therefore, instead of the terminal treatment by the garnish 37 in FIG. 5, as shown in FIG. 6, the cushion material 43 and the skin material 44 are used.
The end of the above is folded back on the back side of the base material 42 made of corrugated board, the end treatment is performed to make the base material 42 invisible, and then the interior material is fixed to the roof rail 36 with the tapping screw 39.
41 is adopted (a similar structure is disclosed in, for example, Japanese Patent Laid-Open No. 55-1599).
No. 36).

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention However, when the manufacturing process of the interior material 41 shown in FIG. 6 is examined, after the molding and trimming of the base material 42, the attachment and trimming of the cushion material 43 and the skin material 44 Adhesive and trim, as well as cushioning material 43 and skin material 44 at the end
It is necessary to fold it back to the back side of 42, which will increase the cost due to the increase in the number of processing steps, and the interior material due to the elimination of the garnish 37 shown in FIG.
There is a problem that the rigidity of the terminal portion of 41 is deteriorated.

The present invention has been made in view of the above problems,
The purpose is to maintain the basic beauty that the terminal part of the base material is invisible from the outside, eliminate the garnish and reduce the processing man-hours, and the terminal part alone provides a sufficient sense of rigidity. An object of the present invention is to provide a manufacturing method capable of obtaining the interior material.

Means for Solving the Problems The present invention is a method of manufacturing an interior material in which a surface material is attached to a surface of a base material, and a resin-based base material in which the surface material is attached to one surface is added to a predetermined three-dimensional shape. When pressing and heat-molding, the end of the base material that becomes the non-product part is bent to the opposite skin material side, and at the same time, the vicinity of the bent base part near the non-product part is locally crushed to form a thin part. Forming a terminal flange portion at the end of the product portion by cutting and removing the non-product portion of the base material laminated from the skin material from the thin portion.

Here, in the above-mentioned interior material, a cushion material may be interposed between the base material and the skin material, if necessary.

Action According to the method described above, at least the base material to which the skin material is attached is pressed and heat-molded by a predetermined molding die, and then the non-product portion of the peripheral portion of the base material is cut and removed from the thin portion together with the skin material. As a result, the end of the product portion is formed with the end flange portion that is bent to the side opposite to the skin material.

When the interior material thus obtained is mounted on, for example, the roof of an automobile as shown in FIG. 3, the terminal flange portion serves to conceal the base material from the outside,
No other terminal processing means are required. Moreover, since the equipment itself is made of resin, the terminal portion of the interior material itself can have a sufficient sense of rigidity.

Example FIG. 3 shows an assembled state of an interior material for a roof of an automobile obtained by the method of the present invention, and parts common to FIGS. 5 and 6 are designated by the same reference numerals.

As shown in the figure, the interior material 1 comprises a resin-based base material 2 and a cushion material 3 and a skin material 4 which have a good affinity for each other, which are bonded to each other in that order. The terminal flange portion 5 is formed with a relatively large curvature. And the interior material 1 is tapping screw 39
It is fixed to the roof rail 36 by the terminal flange 5
The end surface of the base 2 faces the roof rail 36, and the base material 2 is exposed from the outside.
Plays a role in preventing people from seeing.

Next, one embodiment of a method for manufacturing the interior material 1 will be described with reference to FIGS. 1 and 2.

First, as shown in FIG. 2 (A), the cushion material 3 and the skin material 4 are preliminarily bonded to the sheet-shaped base material 2, and the base material 2 to which the cushion material 3 and the skin material 4 are bonded is the same. As shown in the figure, it is set in a molding die 6 composed of an upper die 7 and a lower die 8. The upper mold 7 and the lower mold 8 have built-in heating means (not shown), and at the same time, the respective molds 7 and 8 have molding surfaces 9 and 10 corresponding to the three-dimensional shape of the interior material 1, as well as FIG. As shown, the bend forming portions 11 and 12 and the thin wall forming portions 13 and 14 are formed.

Then, when the upper mold 7 is lowered from the state of FIG. 2 (A) and pressure / heat molding is performed, the base material 2 is softened by heat, and together with the cushion material 3 and the skin material 4, FIG. 1 and FIG. It is molded into a predetermined three-dimensional shape as shown in B). At this time, a portion of the terminal portion of the base material 2 which finally becomes the non-product portion 15 is bent and formed on the side opposite to the skin material by the bend forming portions 11 and 12, while the non-product portion 15 is bent. A portion near the base portion 16 is locally crushed by the thin-walled molding portions 13 and 14 to form a thin-walled portion 17.

Subsequently, under the condition of FIG. 2 (B), after a predetermined holding pressure cooling time, the upper die 7 is raised to take out the base material 2 from the molding die 6, while the base material 2 is shown in FIG. As shown in (C), it is transferred to the trim processing die 18 for the purpose of trim processing.
This trim processing die 18 consists of an upper die 19 and a lower die 20,
The upper die 19 has a built-in mechanical cam driven cutter 21 that operates at the bottom dead center position of the upper die 19.

Then, the upper mold 19 is lowered from the state of FIG. 2 (C),
By the cooperation of the cutter 21 and the lower mold 20, the non-product portion 15 of the base material 2 is cut and removed from the thin portion 17 with the cutting line l.
As a result, as shown in FIGS. 1 and 3, an interior material 1 having a terminal flange portion 5 whose plate thickness gradually decreases at the end of the product portion 22 is obtained.

At the time of this cutting, since the thin portion 17 having a plate thickness that has been crushed and hardened in advance is cut, so-called sharpness is obtained, and a clean cut surface free from shape slumps and cracks can be obtained.

EFFECTS OF THE INVENTION As described above, according to the present invention, when the resin-based base material to which the skin material is pasted in advance is pressed and heat-molded into a predetermined shape, the end portion of the base material that becomes the non-product portion is not At the same time as bending to the skin material side, the vicinity of the bent base near the non-product part is locally crushed to form a thin part, and then the non-product part of the base material is cut and removed from the thin part to end the product part. By adopting the method of forming the terminal flange portion at the end, it becomes possible to obtain an interior material having sufficient rigidity with a small number of processing steps even with the terminal portion alone, and the processing cost can be reduced.

In addition, since the terminal flange portion also has a cosmetic function that prevents the base material from being seen from the outside when the interior material is assembled to the counterpart member, other terminal treatment means such as garnish. Is not necessary at all, and this also contributes greatly to the above cost reduction.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagram showing an embodiment of the present invention, and b in FIG. 2 (B).
Part enlarged views, FIGS. 2A, 2B and 2C are process explanatory views of the manufacturing process showing one embodiment of the present invention, and FIG. 3 is an interior for automobile roof obtained by the method of the present invention. FIG. 4 is an enlarged view of an essential part showing the assembled state of the material, FIG. 4 is a perspective view of the automobile, and FIG.
FIG. 6 and FIG. 6 are views showing a conventional end treatment structure for interior materials, and are views corresponding to a cross section taken along line VV of FIG. 1 ... Interior material, 2 ... Base material, 3 ... Cushion material, 4 ... Skin material, 5 ... Terminal flange part, 6 ... Mold, 15 ... Non-product part,
16 ... bent base, 17 ... thin part, 21 ... cutter, l ... cutting line.

Claims (1)

[Claims] 1. A method of manufacturing an interior material in which a surface material is attached to a surface of a base material, wherein a resin-based base material having a surface material attached to one surface thereof is pressed and heat-molded into a predetermined three-dimensional shape. In addition, the step of bending the terminal part of the base material to be the non-product part toward the anti-skin material side and at the same time locally crushing the vicinity of the bent base part near the non-product part to form a thin part, and the skin material being attached. A step of forming a terminal flange portion at the end of the product portion by cutting and removing the non-product portion of the combined base material from the thin portion, and a method for manufacturing an interior material.