JP2010240987A - Method and apparatus for manufacturing interior component for vehicles - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To materialize a method and an apparatus for manufacturing an interior component for vehicles which can stick a skin while a uniform beautiful decorative pattern such as a crimped pattern is kept. <P>SOLUTION: The method for manufacturing the interior component for vehicles in which the skin is stuck on a resin core material molded in a shape having a convex surface includes a core material attachment process for attaching the resin core material to a vacuum forming mold, a core material contact process for making the resin core material attached to the vacuum forming mold be contacted with the skin, and a skin sticking process for sticking the skin to the resin core material. In the core material attachment process, the vacuum forming mold is inclined, and the shoulder of the convex surface of the resin core material is tip-contacted with the skin. In the skin sticking process, the sticking surface of the skin is spread while the inclination angle of the vacuum forming mold is decreased. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a vehicle interior part manufacturing method and a manufacturing apparatus for attaching a sheet-like skin material to the surface of a resin-molded core material.

  Many of the interior parts that are used by being mounted in the interior of an automobile are configured by attaching a decorative skin to a synthetic resin core. On the other hand, in order to increase the market value as an industrial product, it is important to create a comfortable cabin as a living space and provide satisfaction to those who use automobiles. For this reason, there is a demand for a manufacturing technique that can evenly adhere the skin evenly and improve the aesthetics of the vehicle interior parts.

  FIG. 1A is a schematic view showing a door trim 1 mounted on a door panel of a vehicle as a typical vehicle interior part. The tortrim 1 has a complicated curved surface shape because it incorporates a plurality of functions such as an armrest, a pocket for a container, and absorption of impact at the time of collision. For this reason, it is usually configured by a plurality of parts, and the manufacturing process is simplified. For example, as shown in FIGS. 1B to 1D, the door upper trim 2, the door center trim 3, and the door lower trim 4 are manufactured separately. As for the door upper trim 2 and the door lower trim 4, the sticking surface of the skin is convex, while the door center trim 3 is concave, and a manufacturing method suitable for each shape is used.

  Any of the above three parts must be manufactured by attaching a skin to the surface of the resin core material formed into a desired curved shape by a molding method such as injection molding, cold press molding, mold press molding or the like. Will not change. For the resin core material, a general-purpose thermoplastic resin such as polypropylene resin, polyethylene resin, ABS resin or the like is used, and rigidity for attachment to the body panel and shape retention is secured.

  As in the case of the door upper trim 2 and the door lower trim 4 shown in FIGS. 1B and 1D, the vacuum forming method is used when the surface of the skin is a convex surface. As shown in FIG. 2, the vacuum molding is performed by mounting the resin core 2a on a molding die (not shown) and raising the support housing 9 on which the molding die is placed toward the skin, or the skin gripping frame 8 The sheet-like skin material 7 held in the lower part is lowered and pasted so as to cover the resin core material 2a. At this time, the inside of the mold is depressurized by a vacuum pump disposed inside the support housing 9, and the skin material 7 is adsorbed through the suction holes of the mold and a large number of small holes provided on the entire surface of the resin core 2a. By doing so, the epidermis is brought into close contact with the surface of the resin core material 2 without causing air accumulation, thereby completing the adhesion.

  On the other hand, in the vacuum forming method described above, in the process of placing the skin material 7 along the mold surface, elongation of the skin inevitably occurs corresponding to the shape of the resin core material. Since the elongation rate is partially different due to the difference in the shape of the undulations, when the decorative pattern is formed on the skin material 7, the pattern is deformed and is different for each part. Appearance will be produced. In particular, in the case of a so-called wrinkle pattern expressed by fine irregularities provided on the surface of the skin, the effect appears remarkably, the pattern becomes partially shallow and uneven, or the pattern disappears depending on the conditions There was a case where the trouble of doing.

  Patent Document 1 describes a sticking method in which when a skin material is covered, the resin core material is tilted so that the convex surface comes into contact with the skin first, and then the adhesive surface of the skin is spread to another region. The purpose of this method is to prevent the occurrence of wrinkles by giving the resin core a slope so as to control the tension at the time of sticking to eliminate the slackness of the epidermis.

JP 2008-126428 A

  By inclining the resin core material as in the method of attaching the skin described in Patent Document 1, and further starting the attachment from a portion where the elongation rate of the skin is increased, as described later, the deformation of the decorative pattern is changed. It becomes possible to prevent. However, in the above prior art, the holding of the resin core material may become unstable, and the resin core material may move in the process of attaching the skin to cause defects such as wrinkles on the surface of the skin. .

  Accordingly, the present invention has been made in view of the above-described problems, and provides a method and apparatus for manufacturing an interior part for a vehicle capable of attaching an epidermis in a state where a uniform and beautiful texture pattern is held. It is intended to do.

  In order to solve the above-described problems, a method for manufacturing an interior part for a vehicle according to the present invention is a manufacturing method in which a skin is attached to a resin core formed into a shape having a convex surface, and the resin core is vacuum-formed. A core material attaching process for attaching to the mold, a core material abutting process for contacting the resin core material attached to the vacuum forming mold to the skin, and reducing the inside of the vacuum forming die to make the skin into the resin core material. And a core material contact step in which the vacuum mold is inclined to cause the convex shoulder portion of the resin core material to contact the skin, and further, the skin adhesion step Is characterized in that the adhesion surface of the skin is widened while reducing the inclination angle of the vacuum forming die.

  According to the method for manufacturing an interior part for a vehicle according to the present invention, by inclining the vacuum forming die, the undulation of the mounted resin core material or the attachment of the skin material from the shoulder of the convex surface having a large step is started. Can do. The part where the elongation rate of the epidermis is the largest is the shoulder of the convex surface with large undulations or steps, and by sticking the epidermis from that part, it is possible to prevent the generation of large tension and suppress the elongation rate of the epidermis It becomes. Furthermore, the tension applied to the skin during that time can be reduced by gradually returning the inclination of the mold when the surface of the skin is spread. Thereby, it becomes possible to adhere to the resin core material while maintaining a uniform and beautiful state without deforming decoration such as a texture pattern provided on the surface of the skin.

  The vehicle interior part manufacturing apparatus according to the present invention is a manufacturing apparatus for attaching a skin to a resin core formed in a shape having a convex surface, wherein a vacuum forming die having a resin core mounted thereon is provided. A mold transfer mechanism for moving the abutment against the skin, and a mold tilting mechanism for inclining the vacuum mold so that the shoulder of the convex surface of the resin core attached to the vacuum mold comes into contact with the skin. It is characterized by providing.

  Thereby, the manufacturing apparatus of the vehicle interior component which sticks to a resin core material, without deform | transforming decorations, such as the embossed pattern provided in the surface of the skin, is implement | achieved.

  Furthermore, the vehicle interior component manufacturing apparatus according to the present invention includes a support housing that supports the vacuum forming mold in a tiltable manner, a bellows-shaped connection portion that connects the vacuum forming mold and the support housing in a depressurizable manner, It is characterized by providing.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method and apparatus of a vehicle interior component which can stick an outer skin in the state which hold | maintained the uniform and beautiful wrinkle pattern etc. are realizable.

It is a mimetic diagram showing an example of interior parts for vehicles. It is explanatory drawing which shows the structure of the sticking method of the skin by vacuum forming. It is explanatory drawing which shows the manufacturing process of the vehicle interior component which concerns on this invention. It is explanatory drawing which shows the manufacturing process of the vehicle interior component which concerns on this invention. It is explanatory drawing which shows the manufacturing process of the vehicle interior component which concerns on this invention. It is explanatory drawing which shows the manufacturing process of the vehicle interior component which concerns on this invention. It is explanatory drawing which shows the manufacturing process of the vehicle interior component which concerns on this invention. It is explanatory drawing which shows the preliminary process which concerns on the embodiment of this invention. It is explanatory drawing which shows the preliminary process which concerns on the embodiment of this invention. It is explanatory drawing which shows the 2nd embodiment of this invention. It is explanatory drawing which shows the 3rd embodiment of this invention. It is explanatory drawing which shows the manufacturing process of the vehicle interior component which concerns on a prior art.

  DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments according to the present invention will be described in detail with reference to the drawings. In the following description, a manufacturing process of the door upper trim 2 shown in FIG. The door upper trim 2 is designed in a shape having a large step at the boundary between the waist surface 5 and the side surface 6 having an armrest function. For this reason, the door upper trim 2 is a vehicle interior part having a large elongation rate when the skin is stuck to the resin core material formed on the convex surface. It is also a part that is easily noticeable and requires aesthetics. Therefore, the door upper trim 2 is a vehicle interior part that is highly required to be implemented as an object of the present invention, and that the effect is remarkable.

  3-7 is explanatory drawing which shows the manufacturing process of the interior component for vehicles which concerns on this invention. Each drawing schematically shows the AA cross section (see FIG. 2) of the vacuum forming apparatus 10 on which the forming die is placed and the cross section of the skin material 7, and shows a state corresponding to each step.

≪Core mounting process≫
FIG. 3 is an explanatory view showing a state where the resin core material 2 a is mounted on the vacuum mold 12. A vacuum molding apparatus 10 which is a vehicle interior part manufacturing apparatus according to the present invention includes a molding die 12 on which a resin core material 2a is mounted and a support housing 9 that supports the molding die 12. The molding die 12 is rotatably attached to the support housing 9 via a hinge portion 13. Inside the support housing 9, a mold drive cylinder 14 and a vacuum pump 17, which are a mold tilt mechanism that pushes the mold 12 up and tilts it, are arranged.

  An internal space 18 surrounded by the upper surface of the support housing 9 and the inner surface of the mold 12 is hermetically sealed by a bellows-like connection portion 19 that connects the support housing 9 and the mold 12, and the vacuum tube 16. It is possible to evacuate by a vacuum pump 17 via Further, the vacuum forming apparatus 10 includes a housing driving cylinder 21 that is a forming die transfer mechanism that raises the supporting housing 9 toward the skin material 7 disposed above the forming die 12.

  As will be described later, an adhesive for fixing the skin is applied to the surface of the resin core material 2a mounted on the mold 12 in the previous step. As shown in FIG. 3, the resin core material 2 a may be mounted when the mold 12 is in a horizontal state, or the mold 12 in a state inclined by the mold driving cylinder 14 (see FIG. 4). It may be attached to.

≪Core contact process≫
FIG. 4 shows a state in which the molding die 12 to which the resin core material 2 a is attached is pushed up by the cylinder arm 15 of the molding die drive cylinder 14 and tilted. In this state, when the supporting housing 9 is pushed up by the housing driving cylinder 21 in the direction of the arrow in the figure, the shoulder S of the convex surface of the resin core material 2a comes into contact with the skin material 7 disposed at the top. Then, contact is started, and sticking is started. At this time, the maximum inclination angle of the mold 12 is adjusted to a suitable amount corresponding to the position of the shoulder portion S of the resin core material 2a and the size of the step.

≪Skin application process≫
As will be described later, the skin material 7 disposed above the vacuum forming apparatus 10 is warmed and softened by a heater for skin heating. For this reason, as shown in FIG. 5, when the shoulder portion S of the resin core material 2a comes first, and the support housing 9 is pushed up by the housing drive cylinder 21, the skin material 7 has the shape of the resin core material 2a. It adheres along. At this time, the adhesive applied to the surface of the resin core material 2a recovers the adhesive force by the heat of the skin material 7, and fixes the skin to the surface of the resin core material 2a. The supporting housing 9 is raised by the housing driving cylinder 21 until the skin is adhered to the entire portion of the door upper trim 2 that becomes the waist surface 5.

  On the other hand, when the support housing 9 starts to rise by the housing drive cylinder 21, the vacuum pump 17 starts evacuation of the space 18 inside the mold, and the internal space 18 is in a decompressed state. The molding die 12 is provided with a plurality of suction holes, the internal space 18 is depressurized, and the resin core material 2a is vacuum-adsorbed. Furthermore, the resin core material 2a is formed with a large number of small holes, and adsorbs the skin material 7 and sucks air from an air reservoir between the adhered skin and the resin core material 2a. Adhere closely.

  As described above, when a general-purpose thermoplastic resin such as polypropylene resin, polyethylene resin, ABS resin or the like is used as the material of the resin core material 2a, fine holes for evacuation are formed in the molding process. It is necessary to form. On the other hand, in the case where the resin core material 2a is manufactured with a material having air permeability, for example, a material such as a wooden base material, it is not necessary to form micropores, and the manufacturing method becomes simple.

  Next, as shown in FIG. 6, the support housing 9 is raised while the inclination of the mold 12 is gradually returned to the horizontal direction to spread the surface of the skin. That is, the amount of contraction of the cylinder arm 15 of the mold drive cylinder 14 is controlled in conjunction with the rising amount of the housing drive cylinder 21, and the inclination angle of the mold 12 is decreased in the direction indicated by the arrow D in the figure. By these movements of the support housing 9 and the mold 12, the sticking surface of the skin material 7 spreads from the shoulder portion S to the flat surface portion F of the resin core material 2 a. At this time, the correlation between the amount of increase of the casing drive cylinder per unit time and the amount of contraction of the mold drive cylinder 14 is controlled so that the tension of the skin material 7 is maintained at the minimum necessary value.

  Furthermore, as shown in FIG. 7, in the state where the mold 12 is returned to the horizontal state, the support housing 9 is pushed up, and the skin is stuck to the peripheral end of the resin core material 2a. Next, after the exhaust of the vacuum pump 17 is stopped and the internal space 18 is returned to atmospheric pressure, the support housing 9 is lowered. At this time, the resin core material 2a is released from the mold 12 in a state of being fixed to the skin material 7, and the skin sticking step is completed. In the subsequent process, the skin material 7 is removed from the skin gripping frame 8, and the excess skin around the resin core material 2a is trimmed. Finally, a process of bending the end of the skin to the back surface of the resin core material 2a is performed, and the door upper trim 2 is completed.

  FIGS. 12A and 12B are illustrations showing a conventional vacuum forming apparatus 40 in which a forming die 42 is fixed to a support housing 41. As shown in FIG. 11 (a), when the support housing 41 of the vacuum forming apparatus 40 is raised by the housing drive cylinder 21, the skin material in the region from the shoulder S to the flat portion F of the resin core 2a. 7 is started. At this time, since the internal space 43 of the mold 42 is evacuated by the vacuum pump 17 and is in a reduced pressure state, the region where the skin material 7 is adhered is in close contact with the resin core material 2a. Further, as shown in FIG. 11 (b), when the support housing 41 is raised, the skin material 7 around the region extending from the shoulder S to which the skin is stuck and fixed to the flat portion F has a resin core. It is pasted along the shape of the material 2a. At this time, as shown by the arrow W in the figure, the skin is stretched under tension before coming into contact with the surface of the resin core 2a, and a large elongation ratio is generated in the large step portion around the shoulder S. It will end up.

  As described above, in the method for manufacturing an interior member for a vehicle according to the present invention, the supporting housing of the vacuum forming apparatus 10 is compared with the method using the conventional vacuum forming apparatus 40 to which the forming mold 42 is fixed. 9 and the mold 12 move in conjunction with each other, so that the skin material 7 is not given any more than necessary tension. For this reason, the elongation rate of the skin can be kept small, and the skin can be adhered to the resin core material 2a while maintaining the form of a decorative pattern such as a texture pattern. Further, since the resin core material 2a is attached to the molding die 42 and is vacuum-sucked, there is no fear of movement during the attachment of the skin material 7, and defects such as wrinkles do not occur.

  Next, the preliminary process for implementing the manufacturing method of the interior component for vehicles which concerns on this invention is demonstrated.

  FIGS. 8A and 8B are explanatory views showing a process of applying an adhesive to the skin attachment surface of the resin core material 2a. It is necessary to apply an adhesive on the surface of the skin, and an adhesive such as chloroprene rubber, nitrile rubber, or urethane is used as the adhesive. As shown in FIG. 8A, an adhesive layer is formed by spraying uniformly on the entire surface of the skin using an adhesive spraying head. Then, as shown in FIG.8 (b), it heats using the heater 24 for adhesive agent drying, volatilizes the solvent contained in an adhesive agent, and is dried.

  FIG. 9 is an explanatory diagram illustrating a process of heating and softening the skin material 7. The skin material 7 held on the skin gripping frame is inserted between the skin heating heaters 25 and heated to be softened. As the material of the skin material 7, a non-breathable thermoplastic resin sheet or a laminated sheet material in which a cushion material is lined with a thermoplastic resin sheet can be used.

  Since the above-described heat-softened skin material 7 causes so-called drawing that hangs down due to its own weight, the skin gripping frame 8 is spread and stretched, and is set above the vacuum forming apparatus 10 (see FIG. 2). Further, the adhesive applied to the resin core material 2a recovers the adhesive force by the heat of the adhered skin material 7, and adheres the skin to the resin core material 2a.

  FIG. 10 is a schematic view showing a second embodiment of the vacuum forming apparatus according to the present invention. In the vacuum forming apparatus 30 according to this embodiment, two support housings 32 and 33 are disposed on a base 31 supported by the housing drive cylinder 21. A mold 12 is rotatably attached to each support housing by a hinge portion 13. In addition, a vacuum pump 17 and a mold drive cylinder 14 are provided inside each support housing. By using the vacuum forming apparatus 30, the skin can be adhered to the two resin cores 2 a.

  FIG. 11 is a schematic view showing a third embodiment of the vacuum forming apparatus according to the present invention. In the vacuum forming apparatus 40 according to the present embodiment, a forming die 47 attached to the support housing 45 via the hinge portion 13 has an independent internal space 46. The vacuum pump 17 disposed inside the support housing 45 evacuates and decompresses the internal space 46 via the vacuum pipe 16b. The vacuum pipe 16b uses flexible piping and can follow the movement of the molding die 47 inclined by the molding die drive cylinder 14. In the configuration of this embodiment, even if the mold 47 is tilted by the mold drive cylinder 14, the volume of the internal space 46 to be evacuated is constant, and the volume can be reduced according to the size of the mold. It is. That is, since the exhaust capacity of the vacuum pump 17 can be reduced, there is an advantage that the apparatus can be reduced in weight and size.

  The preferred embodiments of the present invention have been described in detail above. However, the method and apparatus for manufacturing vehicle interior parts according to the present invention are not limited to the above-described embodiments, but the present invention described in the claims. Various modifications and changes can be made within the scope of the present invention.

DESCRIPTION OF SYMBOLS 1 Door trim 2 Door upper trim 2a Resin core material 5 Waist surface 6 Upper trim side surface 7 Skin material 9, 32, 33, 41 Support housing | casing 12, 42 Mold 14 Mold drive cylinder 18, 43, 46 Mold inner space 19 Bellows connection 21 Housing drive cylinder S Convex shoulder

Claims (3)

A method for manufacturing an interior component for a vehicle, in which a skin is adhered to a resin core formed into a shape having a convex surface,
A core mounting step of mounting the resin core on a vacuum mold; and
A core material contact step in which the resin core material mounted on the vacuum mold is in contact with the skin; and
A skin sticking step of sticking the skin to the resin core by depressurizing the inside of the vacuum mold, and
In the core material contact step, the vacuum molding die is inclined so that the convex shoulder portion of the resin core material comes into contact with the skin,
The method for manufacturing an interior part for a vehicle, wherein, in the skin attaching step, the surface to which the skin is attached is widened while reducing the inclination angle of the vacuum forming die. A vehicular interior part manufacturing apparatus for attaching a skin to a resin core formed into a shape having a convex surface,
A mold transfer mechanism for moving the vacuum mold mounted with the resin core material so as to come into contact with the skin;
A mold tilt mechanism for tilting the vacuum mold so that the shoulder of the convex surface of the resin core mounted on the vacuum mold comes in contact with the skin;
A vehicle interior part manufacturing apparatus comprising: A support housing that supports the vacuum forming mold in a tiltable manner;
A bellows-like connecting portion that connects the vacuum mold and the support housing in a depressurizable manner;
The vehicle interior part manufacturing apparatus according to claim 2, comprising:

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