JP3846839B2 - Method of attaching skin material in laminated molded product - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for attaching a skin material in a laminated molded product , and in particular, it can be molded well even at a site with a high unfolding rate, and in addition, the skin material can be applied to a laminated molded product that can eliminate a peeling failure of the skin material. It relates to how to wear .
[0002]
[Prior art]
For example, as shown in FIG. 7 , an automobile door trim mounted on an automobile door panel includes a core material 2 formed into a desired curved surface shape, and a skin material 3 integrally attached to the surface side of the core material 2. As a function of the core member 2, it is desirable that the core member 2 has an attachment rigidity to the door panel and an appropriate shape retaining property, and that the skin member 3 has a cushioning property, a good surface appearance, and a surface feel.
[0003]
And as shown in FIG. 8 , the manufacturing method of the said door trim 1 for motor vehicles sets the core material 2 which shape | molded the wood fiber board to the required shape by the hot press molding beforehand on the metal mold | die 4 for vacuum forming, A non-breathable skin material 3 on the upper side, for example, a non-breathable laminated sheet material lined with polyethylene foam on the back surface of a vinyl chloride sheet is heat-softened and held by a clamp device 5, and a vacuum mold 4 7 is formed by vacuuming the air between the core material 2 and the skin material 3 by the vacuum suction mechanism provided in the vacuum molding die 4 . is doing. The core material 2 and the skin material 3 may be bonded by applying an adhesive to the joint surface of the core material 2 or by laminating a hot melt film on the back surface side of the skin material 3.
[0004]
[Problems to be solved by the invention]
Thus, conventionally, when the skin material 3 is pasted on the surface of the core material 2 by using vacuum forming, it is shown enlarged in FIG. Thus, the skin material 3 is sucked only on the side facing the core material 2, and the thickness of the skin material 3 becomes thick at this portion, and in particular, the corner line or the like cannot be clearly formed, and the appearance performance is deteriorated. There was a problem of inviting.
[0005]
Further, in the region A having a high development rate, the tension during vacuum suction remains applied, and a restoring force acts on the skin material 3, so that the skin material 3 in the region A having a high development rate is applied. There is a problem that a large amount of adhesive is required to prevent the skin material 3 from being peeled off. For example, a large amount of adhesive is required to be set at this portion.
[0006]
The present invention has been made in view of such circumstances, and the application of the skin material in a laminated molded article in which the skin material is adhered to the surface of the core material molded into a required shape using a vacuum suction force. Provides a method of attaching the skin material in a laminated molded product that can adhere the skin material without securing the thickness of the skin material even at a site with a high unfolding rate and ensuring strong adhesive strength. The purpose is to do.
[0007]
[Means for Solving the Problems]
In order to achieve the above-mentioned object, the present invention provides a skin material in a laminated molded article in which a non-breathable skin material subjected to heat softening is attached to the surface of a core material molded into a required shape by vacuum molding. In the sticking method, the skin material subjected to heat softening is positioned above the core material set on the lower die provided with the vacuum suction mechanism, and the box-like upper die having the lower surface opened is positioned on the upper side, and then The upper and lower molds are clamped to polymerize the core material and the skin material, and a compressed air chamber is formed on the surface side of the skin material, and air is supplied to the compressed air chamber from the compressed air mechanism attached to the upper mold. While vacuuming from the lower mold while applying air pressure over the entire surface, the skin material is adhered to the surface of the core material , and the pressure mechanism provided on the upper mold is operated before the upper and lower molds are clamped, The air pressure in the compressed air chamber is detected by a sensor and After receiving the input signal at the control device, in accordance with a command from the controller performs the opening and closing operation of the relief valve, and wherein applying the air pressure over the entire surface of the skin material while adjusting the air pressure in the pressure chamber To do.
[0008]
Here, the timing of applying the pneumatic force from the pneumatic mechanism provided in the upper mold is good to perform before clamping the upper and lower molds in consideration of the shape of the laminated molded product and the material to be used, As for the pneumatic force from the pneumatic mechanism, air is released to the outside by the relief valve so that an appropriate air pressure can be maintained while detecting the air pressure in the pressurized air chamber so that excessive pneumatic force does not act. Adjust the appropriate air pressure in the compressed air chamber.
[0009]
Next, the skin material sticking device used in the method of the present invention can move up and down, has a vacuum suction mechanism, has a lower mold for setting a core material, and a pressure air mechanism. It consists of a box-shaped upper mold that seals the periphery of the material to form a sealed pressurized air chamber.
[0010]
Here, the vacuum suction force from the vacuum suction mechanism provided in the lower mold is −760 mHg, and the air pressure from the pressure pneumatic mechanism provided in the upper mold is 0.2 to 0.5 kgf / cm ^2. It is adjusted by the relief valve so that
[0011]
As is apparent from the above configuration, as a method of attaching the skin material to the surface of the core material, vacuum forming performed by eliminating the air between the core material and the skin material by a vacuum suction force, and the surface side of the skin material Since the appropriate air pressure is applied to press the skin material against the core material to ensure an appropriate adhesive strength, the thickness of the skin material is thick even in areas with a high development rate, such as uneven shapes. A clear shape can be obtained without becoming flesh, and a tension that causes peeling does not remain in the skin material, and the peeling failure of the skin material can be effectively eliminated.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the embodiment applied to the manufacturing method of the door trim for motor vehicles about the sticking method of the skin material in the laminated molded product which concerns on this invention is described.
[0013]
1 and 2 are a front view and a cross-sectional view of an automobile door trim manufactured by applying the method of the present invention, FIG. 3 is a schematic diagram showing the overall configuration of a sticking device used in the method of the present invention, and FIG. FIG. 5 and FIG. 6 are process charts showing a method for attaching a skin material.
[0014]
1 and 2, an automotive door trim 10 is configured as a laminated molded article in which a skin material 12 excellent in cushioning property, decorativeness, and touch feeling is attached to the surface of a core material 11 molded into a desired curved surface shape. An armrest 10a is provided at the center of the surface, a door pocket opening 10b, a speaker grill 10c, and a corner line 10d along the outer shape of the product.
[0015]
More specifically, the core material 11 is made of a wood-based fiberboard, is lightweight and inexpensive, has air permeability, and can be attached to the skin material 12 by vacuum forming.
[0016]
The skin material 12 uses a laminated sheet material in which a cushion layer such as polyethylene foam is lined on the back surface of a TPO (thermoplastic olefin) sheet, and the skin material 12 is non-breathable.
[0017]
The automobile door trim 10 can ensure good moldability even in a high deployment ratio such as the armrest 10a and the corner line 10d, and can clearly form a highlight line and the like, and can have an appearance design of the product. This is characterized in that the adhesion strength of the skin material 12 is sufficiently ensured in these regions where the development rate is high and the peeling failure of the skin material 12 is solved.
[0018]
Next, the configuration of the sticking device 20 for attaching the skin material 12 to the surface of the core material 11 in the automobile door trim 10 will be described with reference to FIG. 3. The sticking device 20 is a lower mold 30 for setting the core material 11. In addition, the pressure chamber is hermetically sealed in cooperation with the lower mold 30 and is composed of an upper mold 40 provided with a pressure mechanism for applying a predetermined air pressure in the pressure chamber.
[0019]
More specifically, the lower mold 30 is provided with a set mold 32 on an elevating lower table 31. The set mold 32 is provided with vacuum suction holes 33 at appropriate pitch intervals. Is in communication with the internal air chamber 34. The air chamber 34 is connected to a vacuum pump 36 through a vacuum suction pipe 35, and the vacuum suction force from the vacuum pump 36 is actuated by opening / closing an opening / closing valve 37. When the opening / closing valve 37 is opened, a negative pressure of -760 mHg is applied.
[0020]
On the other hand, in the upper mold 40, an outer peripheral wall 42 made of a metal panel or the like is fixed to the lower surface of the upper plate 41 by welding or the like, and the upper plate 41 and the outer peripheral wall 42 form a box having an opened lower surface, A sealing material 43 such as silicone rubber is attached along the lower edge of the outer peripheral wall 42, and when the lower table 31 of the lower mold 30 is raised, the upper surface of the set mold 32 and the lower edge of the outer peripheral wall 42 are the sealing material. The compressed air chamber 44 can be formed in contact with the air through the air pressure chamber 43, and a compressed air mechanism 50 is provided in the upper mold 40 to apply a desired air pressure in the compressed air chamber 44. .
[0021]
In other words, a compressed air pump 52 is connected to the compressed air pipe 51 so as to communicate with the compressed air chamber 44, and the air pressure from the compressed air pump 52 acts in the compressed air chamber 44 by the opening / closing operation of the open / close valve 53. Further, a branch pipe 54 is connected to the compressed air pipe 51 so that the air pressure in the compressed air chamber 44 can be appropriately adjusted, and a relief valve 55 is provided in the branch pipe 54. The relief valve 55 detects the air pressure in the compressed air chamber 44 by the sensor 56, and when a predetermined value is reached, a signal from the sensor 56 is input to the control device 60, and the relief valve 55 is supplied from the control device 60. Is issued, and the relief valve 55 is opened.
[0022]
It should be noted that the opening / closing valve 36 on the side of the vacuum pump 35 and the opening / closing valve 53 for driving the compressed air pump 52 are also configured such that a command is issued from the control device 60 and the timing of the air pump 52 is controlled. 53, the relief valve 55 is a conventional solenoid valve.
[0023]
Next, the method of sticking the skin material 12 on the surface of the core material 11 using the said sticking apparatus 20 is demonstrated based on FIG. 4 thru | or FIG.
[0024]
FIG. 4 is a time chart showing the operation timings of the upper and lower molds, the vacuum mechanism and the pressure air mechanism in the first embodiment of the sticking method, and FIGS. 5 and 6 are explanatory views showing the respective steps.
[0025]
First, as shown in FIG. 5, when the upper and lower molds 30 and 40 are in the mold open state, that is, when the lower table 31 of the lower mold 30 is in the lower position, it is molded in a required shape on the set mold 32 of the lower mold 30 beforehand. The core material 11 is set. The surface of the core material 11 is coated with an adhesive in advance.
[0026]
Then, the skin material 12 heated and softened in advance to a predetermined temperature is positioned above the set core material 11 with the periphery held by the clamp frame 61. At this time, no command is issued from the control device 60 to the on-off valves 37, 53, and 55.
[0027]
Thus, if the core material 11 is set in the lower mold 30, the skin material 12 that has been heat-softened in the upper and lower molds 30 and 40, and the setting process of each material is completed, The elevating lower table 31 is raised by a predetermined stroke, and the lower end edge of the outer peripheral wall 42 of the upper mold 40 and the upper surface of the set mold 32 in the lower mold 30 are joined via the sealing material 43, as shown in FIG. Thus, the upper and lower molds 30 and 40 are clamped.
[0028]
At this time, as shown in the time chart of FIG. 4, before the upper and lower molds 30 and 40 are clamped, the open / close valve 53 is opened by a command from the control device 60, and the compressed air pump 52 receives the compressed air chamber. Since air of a predetermined pressure is sent into 44, when the upper and lower molds 30 and 40 are clamped, the compressed air chamber 44 defined by the upper plate 41 and the outer peripheral wall 42 is maintained at a predetermined air pressure. Simultaneously with or after the tightening, the opening / closing valve 37 of the vacuum pump 36 is opened by receiving a command from the control device 60, the vacuum pump 36 is driven, and the air between the core material 11 and the skin material 12 is molded. A predetermined air pressure is applied to the entire surface of the skin material 12 by the air pressure that is discharged to the outside and is sent into the compressed air chamber 44 from the compressed air pump 52 over the entire surface of the skin material 12 during vacuum forming of the skin material 12. .
[0029]
In the compressed air / vacuum forming process shown in FIG. 6, the air pressure in the compressed air chamber 44 is always managed by the sensor 56 so that excessive compressed air force does not act on the skin material 12, and the air pressure in the compressed air chamber 44 is predetermined. When the value is higher than the value, the signal from the sensor 56 is input to the control device 60, the command is sent from the control device 60 to the relief valve 54, the relief valve 54 is opened, and the air pressure in the compressed air chamber 44 is maintained at a predetermined value. The
[0030]
Accordingly, even in a portion where the deployment rate is high such as the armrest 10a and the corner line 10d in the door trim 10, an appropriate air pressure is applied from the surface side of the skin material 12, and therefore, even in a portion where the deployment rate is high in the skin material 12. It is possible to obtain a clear shape such as a corner line 10d, a highlight line, etc. without being fleshed out, and to greatly improve the appearance design, and to improve the adhesive strength of the skin material 12, No peeling failure occurs.
[0034]
【The invention's effect】
As described above, according to the method for attaching the skin material in the laminated molded product according to the present invention, when the skin material is bonded to the surface of the core material by the vacuum suction mechanism provided in the lower die, the compressed air chamber is provided in the upper die. Since the air pressure is supplied from the air pressure mechanism to the air pressure chamber and the air pressure is applied to the entire surface of the skin material, the vacuum suction force and the air pressure force are used in combination even at a site where the product deployment rate is high. As a result, the skin material is not thickened, a clear shape can be obtained, and the appearance design of the product can be improved.
[0035]
Furthermore, by using a vacuum suction force and a pneumatic force in combination at a high deployment rate, the adhesive strength can be increased, the peeling failure of the skin material can be drastically solved, and the core material and the skin can be solved. The adhesive used for bonding to the material also has the effect that the basis weight can be set small, and the adhesive can be saved and the adhesive application operation can be simplified.
[Brief description of the drawings]
FIG. 1 is a front view showing an automobile door trim manufactured by using the method of the present invention.
FIG. 2 is a sectional view taken along line II-II in FIG.
FIG. 3 is a schematic diagram showing a configuration of an embodiment of an apparatus for attaching a skin material used in the method of the present invention.
FIG. 4 is a time chart showing the operation of the upper and lower molds in the method of the present invention.
FIG. 5 is an explanatory view showing a material setting step in the method of the present invention.
FIG. 6 is an explanatory view showing a pressure-assisted vacuum forming process in the method of the present invention.
FIG. 7 is a cross-sectional view showing a configuration of a conventional automobile door trim.
FIG. 8 is an explanatory view showing a vacuum forming process of a skin material in a conventional automobile door trim.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Automobile door trim 10a Armrest 10d Corner line 11 Core material 12 Skin material 20 Adhering device 30 Lower mold 31 Lower table 32 Set mold 33 Vacuum suction hole 34 Air chamber 35 Vacuum suction pipe 36 Vacuum pump 37 On-off valve 40 Upper mold 41 Upper plate 42 Outer peripheral wall 43 Sealing material 44 Pneumatic chamber 50 Pneumatic mechanism 51 Pneumatic tube 52 Pneumatic pump 53 Opening and closing valve 54 Branch pipe 55 Relief valve 56 Sensor 60 Controller 61 Clamp frame

Claims (1)

In the method for attaching a skin material in a laminated molded product obtained by attaching a non-breathable skin material (12) subjected to heat softening to the surface of a core material (11) molded into a required shape by vacuum molding,
A box-shaped upper mold (40) in which a heat-softened skin material (12) is positioned above a core material (11) set on a lower mold (30) provided with a vacuum suction mechanism, and a lower surface is opened on the upper side (40). ), And then the upper and lower molds (30, 40) are clamped to polymerize the core material (11) and the skin material (12), and the pressure chamber (44) is formed on the surface side of the skin material (12). ), And air is supplied into the compressed air chamber (44) from the compressed air mechanism (50) attached to the upper die (40), and the lower die (30 is applied while applying air pressure over the entire surface of the skin material (12). ) Is vacuum-sucked to attach the skin material (12) to the surface of the core material (11) , and the compressed air mechanism (50) provided in the upper mold (40) is a mold of the upper and lower molds (30, 40). While operating before tightening, the air pressure in the compressed air chamber (44) is detected by the sensor (56). After receiving the input signal by the control device (60), an opening / closing operation of the relief valve (55) is performed in accordance with a command from the control device (60), and the skin material is adjusted while adjusting the air pressure in the compressed air chamber (44). (12) A method for attaching a skin material in a laminated molded product, wherein an air pressure is applied over the entire surface .

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