JPH0822553B2 - Forming method of skin material - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of molding a skin material used for automobile interior parts such as automobile door trims.

[0002]

2. Description of the Related Art FIG. 5 shows an automobile door trim which is a typical example of automobile interior parts. The automobile door trim 1 has a core member 2 formed by press molding into a required shape and a surface of the core member 2. It is composed of a pad material 3 which is laminated and integrated with the pad material 3 to give a cushioning property, and a skin material 4 which covers the outer surface of the pad material 3. The peripheral edge of the skin material 4 is wrapped around the back surface side of the core material 2 as a folded portion 5. It is made by bonding.

Recently, there is a tendency that good surface appearance and surface feel are required for automobile interior parts.
Therefore, as the skin material 4, a slush-molded skin material (usually, the slush foam layer 4 is formed on the back surface of the slush skin layer 4a).
a two-layer laminated body in which b is laminated) is often used.

Further, as described above, as the end treatment of the skin material 4, the peripheral edge portion of the skin material 4, that is, the folded portion 5
When the winding operation is performed, since the thickness of the slush molded skin material 4 including the slash skin layer 4a and the slush foam layer 4b is large, the winding operation is troublesome, and the thickness of the end portion of the product is large, so that The problem of interference arises.

As a countermeasure against this, for example, as shown in FIG. 6, a powder box 7 filled with a foamable resin powder is joined to a slush molding die 6 for molding a skin material 4, and a rotation operation is performed. At the stage where the foamable powder is attached to the upper surface of the slush skin layer 4a attached to the mold 6, a plurality of pipes 8 for blowing out air are installed in the powder box 7 and a large number of pipes 8 provided on the pipe 8 are installed. In the step of blowing excess air onto the mold 6 surface through the air outlet 8a to remove the excess foaming powder, the air pressure is adjusted so that the thickness of the folded-back portion 5 of the skin material 4 is reduced, A method is used in which removal of the expandable powder in the folded-back portion 5 is focused.

Further, as shown in FIG. 7, after forming a slash skin layer 4a and a slush foam layer 4b on a slush molding die 6, a portion corresponding to the folded-back portion 5 of the skin material 4 is pressed. It is also known that the method of pressing by pressing to form a thin wall.

[0007]

However, the former method, that is, the piping 8 installed in the powder box 7 is used.
Therefore, in the method of intensively removing the foamable powder in the folded-back portion 5, the foamed layer 4b in the folded-back portion 5 is used.
Although there is a limit to the thickness of the general part, it is not an effective measure to achieve the thinning of the folded part 5, and there is a problem in smooth winding operation, and it adheres to the folded part 5. The foamable powder 4b is wasted and there is a drawback that there is a lot of material loss.

Further, in the method of removing the foamable powder through the air outlet 8a of the pipe 8, it is difficult to apply a uniform air pressure, the slush foam layer 4b is unevenly thickened, and appears as irregularities on the product surface. It has been pointed out that there is a problem in that it is unfavorable in terms of appearance and feel.

In the latter method using the pressing tool 9, the slush molding die 6 must be pressed when the temperature of the die 6 is 100 ° C. or lower and 60 ° C. or higher during cooling. The equipment cost for timing the press working is high, which leads to high cost, and silicon rubber is usually used as the press tool 9, but the silicon rubber is not durable and must be replaced frequently. However, this also causes a high cost.

Further, in the method of thinning the folded-back portion 5 of the skin material 4 by the press tool 9, although the folded-back portion 5 is thin, the rigidity is increased and the repulsive force is increased, so that the folded-back portion 5 is rolled up. At the time of operation, there is a fatal drawback that smooth retraction operation cannot be expected due to this repulsive force.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a slush molded skin comprising a laminate of a slush skin layer and a slush foam layer as a skin material for interior parts. In the method of molding materials , for the automobile where the peripheral edge of the skin material can be easily rolled up and the peripheral edge of the product is made thinner to prevent interference with other parts . Used for interior parts
It is intended to provide a method for forming a skin material for use .

[0012]

In order to achieve the above object, the present invention provides a slush skin layer and a slush foam layer.
And a core material, which is affixed to the surface side of the core material.
A table where only the slash skin layer is folded back on the back surface of the periphery.
In the method of molding the skin material, a slush molding die is joined with a powder box filled with resin powder, and a rotation operation is performed to form a slush skin layer for adhering and melting the resin powder on the die surface, and foamability. Join the powder box filled with resin powder to the mold and perform the rotation operation to attach the foamable resin powder to the upper surface of the slush skin layer,
At the folded portion of the slash skin layer, an air passage is formed between the sealing material and the mold, and air is blown into the air passage to remove the foamable resin powder adhering to the upper portion of the folded portion of the slash skin layer. And a step of heating and cooling the die for heating and cooling the die having the expandable powder adhered on the slush skin layer.

[0013]

[Function] As is clear from the above structure, the folding of the skin material
The return part is formed only by the slash skin layer,
Since the foam layer is not attached,
Material loss is small.

In addition, since the folded-back portion of the skin material is only the slash skin layer and the thickness of the peripheral edge portion of the product is small, it is possible to prevent interference with the mating parts and to form a gap between the mating parts. There is nothing to do.

Further, when the foamable powder is adhered in the slush molding, an air passage is formed between the sealing material and the mold at the folded portion of the slush skin layer, and air is blown into the air passage. Therefore, the foamable powder does not have uneven thickness, the thickness of the folded-back portion can be made uniform, and a simple structure for forming the air passage is sufficient.

[0016]

The method for forming a skin material according to the present invention will be described in detail below with reference to the accompanying drawings.

FIG. 1 shows a skin formed using the method of the present invention.
2 is a cross-sectional view showing an embodiment in which the material is applied to an automobile door trim, FIG. 2 is a cross-sectional view showing a structure of a folded portion of a skin material of the automobile door trim, and FIGS. 3 and 4 are skins in a method of the present invention . It is each sectional drawing which shows the slush molding process of a material.

First, a door trim will be described as an example to which the method of the present invention is applied . In FIG. 1, a vehicle door trim 10 includes a core material 11 press-molded into a required shape, and a core material 11 of the core material 11. Layered and integrated on the front side,
The pad material 12 is generally made of a polyurethane foam or the like for providing cushioning properties, and a slush molded skin material 13 laminated on the outer surface thereof for the purpose of improving the surface appearance and the surface feel.

More specifically, the slush molded skin material 1
3 is composed of a two-layer laminate of a slush skin layer 14 and a slush foam layer 15 from the surface side, and
The peripheral edge portion of the skin material 13, that is, the folded-back portion 16 wound around and bonded to the back surface side of the core material 11 is composed of only the slash skin layer 14, and the slush foam layer 15 is removed.

That is, as shown in FIG. 2, since the folded-back portion 16 at the peripheral end portion of the slush-molded skin material 13 is composed of only the slash skin layer 14 and has a thin rigidity and a small thickness, the repulsive force is extremely small, There is an advantage that the back surface side of the core material 11 can be smoothly rolled up and adhered, and the terminal processing work can be performed smoothly.

Further, since the thickness of the peripheral portion of the door trim 10 can be set small by making the folded-back portion 16 thin, it is possible to prevent interference with the mating component in advance, and when the folded-back portion is unevenly thickened, the mating component can be prevented. It is possible to effectively solve the conventional inconvenience that a gap is generated between the two and and the appearance is deteriorated.

In addition, since the folded-back portion 16 has only the slash skin layer 14, the foaming powder can be saved and the cost can be reduced and the weight can be reduced as compared with the case where the slush foam layer is conventionally attached to this portion. .

Next, a preferred embodiment of the forming process of the slush molded skin material 13 will be described with reference to FIGS.

FIG. 3 shows a step of forming the slush skin layer 14 in the slush molding skin material 13. A slush molding die 20 is provided with a powder box 30 filled with a resin powder P1 such as a vinyl chloride resin powder. After joining through the sealing material 31, the mold 20 and the powder box 30 are provided around the rotary shaft 21 provided in the mold 20.
The resin powder P1 is attached to the mold surface of the mold 20 by rotating the mold, and is melted to form the slush skin layer 14.

Then, as shown in FIG. 4, in succession to the step of forming the slush skin layer 14, a powder box 40 filled with a foaming powder P2 in which a foaming agent such as azodicarbonamide is mixed in a vinyl chloride resin powder, The expandable powder P2 is adhered to the upper surface of the slash skin layer 14 by bonding it to the mold 20 on which the slash skin layer 14 is formed via a sealing material 41 and performing a rotation operation.

At this time, the shape of the sealing material 41 is shown in FIG.
As shown in FIG. 3, the seal portion 42 that contacts the mold 20 is provided, and the folded portion 16 of the slash skin layer 14 is provided.
The extending portion 43 extending to the set position is provided, and a clearance of 3 to 5 mm is formed between the extending portion 43 and the die 20. Then, this clearance is used as the air passage 44 so that air is blown from the peripheral portion toward the center.

Accordingly, the air from the air supply pipe 45 is blown into the air passage 44, and the air is blown from the peripheral portion of the mold toward the central portion, so that this portion, that is, the folded portion 16 of the skin material 13, is blown. At a corresponding position, all of the foamable powder P2 attached to the upper surface of the slush skin layer 14 is removed and collected in the powder box 40. Reference numeral 46 in the drawing denotes an air outlet for discharging the internal air to the outside.

After that, the skin material 13 shown in FIG. 1 is formed by heating and cooling the mold 20 on which the expandable powder P2 adhered to the upper surface of the slush skin layer 14 is formed. So that the folded portion 16
For No. 3, the foamable powder P2 is not adhered, and the slash skin layer 14 alone is used.

As described above, according to the steps shown in FIGS. 3 and 4, the skin material 13 in which the folded-back portion 16 is formed only by the slash skin layer 14 is simply and surely formed only by changing the shape of the sealing material 41. Therefore, there is an advantage that the folded-back portion 16 can be surely thinned without requiring large-scale equipment.

[0030]

As described above, according to the present invention, the following operational effects are achieved.

(1) By the method for molding a skin material according to the present invention
Then, from the periphery to the center between the mold and the sealing material.
A molding device with a simple structure that forms an air passage toward
Since it can be carried out with no need for a large-scale device,
It has the effect that it can be implemented in a strike.

(2) By the method for forming a skin material according to the present invention
If this is the case, apply foaming powder to the folded part of the peripheral edge of the skin material.
Because it is a construction method that does not adhere, you can save foaming powder.
Being able to contribute to cost reduction and weight reduction
Has the effect.

(3) By the method for molding a skin material according to the present invention
The fold-back portion of the peripheral edge of the skin material.
Since it is composed of only a single layer, it has a thick wall
Part or mating part-folded part
It is possible to prevent interference with the product, and
There is no gap between them, which is preferable for appearance.
Have an effect.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing the structure of an automobile door trim manufactured by applying the method of the present invention.

FIG. 2 is a cross-sectional view showing a terminal processing step of the automobile door trim shown in FIG.

FIG. 3 is a sectional view showing a slush skin layer forming step in the method of the present invention .

FIG. 4 is a cross-sectional view showing a step of forming a slush foam layer in the method of the present invention .

FIG. 5 is a sectional view showing a configuration of a conventional automobile door trim.

FIG. 6 is a cross-sectional view showing a conventional method for thinning the folded portion of the skin material.

FIG. 7 is a cross-sectional view showing a conventional method for thinning the folded portion of the skin material.

[Explanation of symbols]

 10 Automotive Door Trim 11 Core Material 13 Slush Molding Skin Material 14 Slush Skin Layer 15 Slash Foaming Layer 16 Folding Part 20 Slash Molding Mold 21 Rotating Shaft 30 Powder Box 31 Sealing Material 40 Powder Box 41 Sealing Material 44 Air Passage P1 Resin Powder P2 expandable resin powder

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Claims (1)

[Claims] 1. A slush skin layer (14) and a slush.
A foamed layer (15) and a core material (11)
Surface side, and slush on the back surface of the peripheral edge of the core material (11)
Molding of skin material in which only the skin layer (14) is folded back
In the method, resin powder (P1) is added to the slush molding die (20).
A slush skin layer (1) in which a powder box (30) filled with is bonded and a rotation operation is performed to adhere and melt the resin powder (P1) to the surface of the mold (20).
4) Forming step, the powder box (40) filled with the expandable resin powder (P2) is joined to the mold (20), and a rotation operation is performed to form the expandable resin powder on the upper surface of the slash skin layer (14). (P2) is attached, and at the folded-back portion (16) of the slash skin layer (14), an air passage (44) is formed between the sealing material (41) and the mold (20), and this air passage (44) is formed. 44) by blowing air into the slush skin layer (14)
Forming a slush foam layer (15) for removing the foamable resin powder (P2) adhering to the upper surface of the folded portion (16) of the slash skin layer (14), and forming the slush foam layer (P) on the slush skin layer (14).
2. A method for forming a skin material, which comprises the steps of heating and cooling the die (20) for heating and cooling the die (20) to which 2) is attached.