【発明の詳細な説明】（産業上の利用分野）この発明は自動車の内装材の製造方法に関し、特には織
布等からなるオーナメントを内装材表面に固着する内装
材の製造方法に関する。DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method of manufacturing an interior material for an automobile, and more particularly to a method of manufacturing an interior material in which an ornament made of woven fabric or the like is fixed to the surface of the interior material.
近年、ドアトリムに代表される自動車用内装材はアーム
レスト等の内装品をその一部に一体に形成した、所謂一
体成形内装材が多用きれる傾向にある。In recent years, so-called integrally molded interior materials, in which interior parts such as armrests are integrally formed as a part of the interior materials for automobiles, typified by door trims, have been increasingly used.
（従来の技術）ところで、この様なアームレスト等を一体に形成するに
は、内装材の一部を膨出する等して形成する必要がある
ため、通常その表面層は成形可能な−の素材で構成され
る。そして、その素材として多用されているのは軟質塩
化ビニルからなる擬革である。(Prior art) By the way, in order to integrally form such an armrest, etc., it is necessary to bulge out a part of the interior material, so the surface layer is usually made of a moldable - material. Consists of. The most commonly used material is fake leather made of soft vinyl chloride.
しかし、この擬革単体のみでは装飾性に乏しく又その感
触も冷たい等のきらいが有り、アームレスト近辺等手が
触れる機会の多い部位には織布等手触りの良いものの装
着が望まれている。However, this faux leather alone lacks decorative properties and feels cold to the touch, so it is desired to wear something that feels good to the touch, such as woven fabric, in areas that are frequently touched, such as near the armrests.
なお、一部には織布等の表面材を有するオーナメントが
貼着或いは固着されているが、この貼着等は一体成形ド
ア） ＩＪムの成形後、後工程で行う必要が有る等工数
上杆ましいものとは云えな′かった。In addition, some ornaments with surface materials such as woven fabric are pasted or fixed, but this pasting requires a lot of man-hours, such as having to be done in a post-process after molding the IJ (integrated door). I couldn't say it was serious.
そこで、本願出願人は先に特願昭５９−４２０５０号に
おいて織布等のオーナメント部材をドア）ＩＪムの成形
時に固着する内装材の製造方法を提案した。Therefore, the applicant of the present application previously proposed in Japanese Patent Application No. 59-42050 a method for producing an interior material in which an ornament member such as a woven fabric is fixed during molding of a door (IJ).
その概要は、織布等の表面材を有するオーナメント部材
を真空成形型の所定位置に載置しておき、内装材の表面
層となる合成樹脂ソートを前記オーナメント部材の上か
ら真空成形等によって成形することにより、オーナメン
ト部材の周縁を合成樹脂シートで巻込むように被覆固着
する方法である。The outline is that an ornament member having a surface material such as woven cloth is placed in a predetermined position in a vacuum forming mold, and a synthetic resin sort, which will become the surface layer of the interior material, is formed over the ornament member by vacuum forming, etc. By doing so, the peripheral edge of the ornament member is wrapped and fixed with a synthetic resin sheet.
（発明が解決しようとする問題点）しかしながら、この方法において次の様な不具合が生じ
易いことが判明した。(Problems to be Solved by the Invention) However, it has been found that the following problems tend to occur in this method.
例えば、ドアトリムの感触を向」ニさせるためにオーナ
メントの表面材として起毛等を施した毛足の長い織布、
絹物等を使用した場合、その成形時に起毛等による毛足
が毛倒れを起こし、その復元度が小さいことである。For example, a long-pile woven fabric that has been brushed as a surface material for an ornament to give a different feel to the door trim.
When silk or the like is used, the bristles due to brushing etc. will fall during molding, and the degree of recovery is low.
その原因は、合成樹脂シートの真空成形等による吸引押
圧力によってオーナメント部材が型面に密着するように
圧接されること、および合成樹脂シートが成形可能な温
度に加熱されていること、並びに成形の繰り返しによっ
て型表面が相当の高温に加温されていること、すなわち
、オーナメント部材表面の織布等が型と合成樹脂シート
の間に強く挟着されると共に該織布が加熱される所謂ヒ
ートセット現象によるものと推定される。The cause of this is that the ornament member is brought into close contact with the mold surface by suction pressure during vacuum forming of the synthetic resin sheet, that the synthetic resin sheet is heated to a temperature that allows molding, and that the molding process The surface of the mold is repeatedly heated to a considerably high temperature, that is, the woven fabric on the surface of the ornament member is tightly sandwiched between the mold and the synthetic resin sheet, and the woven fabric is heated, which is called heat setting. It is presumed that this is due to a phenomenon.
よって本発明は、かかる織布等の毛倒れが生じ難い新規
な内装材の製造方法を提供しようとするものである。Therefore, it is an object of the present invention to provide a novel method for producing interior materials such as woven fabrics that are less likely to fall.
（問題点を解決するだめの手段）本発明の要旨とするところは、オーナメント部材を真空
成形型上に載置し、然後熱可塑性合成樹脂シートを真空
成形することにより本体表面層を成形すると同時にオー
ナメント部材を該表面層」二に固着する内装材の製造方
法において、オーナメント部材載置面の減圧度を他部よ
り小としながら真空成形し、オーナメント部材が型面に
圧接されるのを軽減すると共に前記減圧度を小とするだ
めの気流によってオーナメント部材表面を冷廂すること
を特徴とするところにある。(Another Means to Solve the Problems) The gist of the present invention is to place an ornament member on a vacuum mold, and then vacuum form a thermoplastic synthetic resin sheet to mold the main body surface layer at the same time. In a method for manufacturing an interior material in which an ornament member is fixed to the surface layer, vacuum forming is performed while the degree of vacuum on the ornament member mounting surface is smaller than that on other parts to reduce pressure contact of the ornament member to the mold surface. At the same time, the surface of the ornament member is cooled by a flow of air that reduces the degree of pressure reduction.
本発明を図に基いて説明するに、第１図は型」二にオー
ナメント部材を載置した状態の拡大断面図であり、第２
図は内装材を成形する前の真空成形型、オーナメント部
材および合成樹脂シート夫々の位置関係を示す合体側面
図である。To explain the present invention based on the drawings, FIG. 1 is an enlarged cross-sectional view of the ornament member placed on the mold 2.
The figure is a combined side view showing the positional relationship of the vacuum mold, the ornament member, and the synthetic resin sheet before molding the interior material.
なお本実施例においては、ドアトリムの例を示す。また
本明細書において真空成形なる語は、真空成形および真
空と圧縮空気を併用する真空圧空成形を包含する語を意
味する。In this embodiment, an example of a door trim is shown. Further, in this specification, the term "vacuum forming" includes vacuum forming and vacuum-pressure forming using a combination of vacuum and compressed air.
真空成形型１０は、その上面にドアトリム表面の形状を
規定するキャビティＪ１が設けられている。The vacuum forming mold 10 is provided with a cavity J1 on its upper surface that defines the shape of the door trim surface.
そのキャビテイ面の所定位置には後述するオーナメント
部材２０の支承用突起又は壁１２が立設されていると共
に裏面に通ずる細孔１３．１３ａが多数設けられている
。その中、真空成形用の吸引孔として作用する細孔１３
は夫々又は一体化され、弁１４を介して真空ポンプ（図
示せず）に連結されており、前記支承用突起又は壁１２
に囲まれるオーナメント載置部分の細孔１３ａは別の弁
１４ａを介して外気に開放又は圧縮ポンプ（図示せず）
に連結されている。なお前記の支承用突起又は壁１２に
よって囲まれる部分にはオーナメント部材全体を支承す
るための針状突起（図示せず）を所望数立設しておいて
もよい。A protrusion or wall 12 for supporting an ornament member 20 (to be described later) is erected at a predetermined position on the cavity surface, and a large number of pores 13.13a communicating with the back surface are provided. Therein, pores 13 act as suction holes for vacuum forming.
are each or integrally connected to a vacuum pump (not shown) via a valve 14, and the bearing protrusion or wall 12
The pore 13a of the ornament mounting portion surrounded by
is connected to. Note that a desired number of needle-like projections (not shown) for supporting the entire ornament member may be erected in the portion surrounded by the supporting projection or wall 12.
オーナメント部材２０は、少なくとも表面材２１と裏打
材２２とからなる。表面材２１は織布、絹布又は植毛層
等の感触に優れる装飾材からなり、起毛等を施したもの
が好適である。裏打材２２は前記織布等の表面材２１を
所定の形状に保持するだめのものであり、プラスチック
シート、ハードボード又は金属板等の適度の剛性を有す
るものからなる。なおこの両者の間に軟質ポリウレタン
フォーム等のクッション材２３を介装してもよい。これ
ら表面材２１、裏打材２２及び要すればクッション材２
３は積層され、その周縁において厚みを減するように圧
着されている。The ornament member 20 includes at least a surface material 21 and a backing material 22. The surface material 21 is made of a decorative material with excellent feel, such as woven fabric, silk cloth, or a flocked layer, and is preferably brushed. The backing material 22 serves to hold the surface material 21 such as the woven fabric in a predetermined shape, and is made of a material having appropriate rigidity such as a plastic sheet, hardboard, or metal plate. Note that a cushioning material 23 such as flexible polyurethane foam may be interposed between the two. These surface material 21, backing material 22 and cushioning material 2 if necessary
3 are laminated and crimped to reduce the thickness at the periphery.
合成樹脂シート３０は、第３図に示す内装材４０の表面
層４１を形成するためのものであり、軟質塩化ビニルを
主体とする真空成形可能なシート状物からなっている。The synthetic resin sheet 30 is for forming the surface layer 41 of the interior material 40 shown in FIG. 3, and is made of a vacuum-formable sheet material mainly made of soft vinyl chloride.
なおこのシート３０は、真空成形を阻害しない他材質の
層、例えば発泡ポリエチレンシート等と積層されていて
もよいものである。Note that this sheet 30 may be laminated with a layer of other material that does not inhibit vacuum forming, such as a foamed polyethylene sheet.
次に、本発明の詳細な説明する。Next, the present invention will be explained in detail.
先ず、真空成形型１０のキャビティ内の所定位置にオー
ナメント部材２０をその表面材２１がキャビテイ面に対
向するように載置する。このときオーナメント部材２０
の周縁が支承用突起又は壁１２から所定量はみ出ずよう
に載置するものである。First, the ornament member 20 is placed at a predetermined position in the cavity of the vacuum mold 10 so that its surface material 21 faces the cavity surface. At this time, the ornament member 20
It is placed so that its peripheral edge does not protrude from the supporting protrusion or wall 12 by a predetermined amount.
次いで、加熱した合成樹脂ンート３０を前記オーナメン
ト部材２０の上に被覆するようにして、真空成形する。Next, the ornament member 20 is coated with a heated synthetic resin cartridge 30 and vacuum formed.
このとき圧縮ポンプ又は大気に連結された細孔１３ａか
ら僅かにキャビティ内に空気が流入するようにして成形
する。他方、真空ポンプに連結された細孔１３からは勿
論キャビティ」−面の空気を吸引するものである。なお
、この真空成形時、初期の段階において圧縮ポンプに連
結する細孔１３ａから殆ど空気が流入しないように弁１
４ａを閉鎖又は絞っておき、次いで空気が流入するよう
に調節するのが好ましい。さすれば、初期の成形時にお
いてオーナメント部材２０下面のキャビティも減圧とな
り、加熱された合成樹脂シート３０が第１図の破線で示
すようにオーナメント部材２０周縁を巻き込むようにし
て被覆すると共に所定の内装材表面形状に賦形される。At this time, the molding is performed so that a slight amount of air flows into the cavity from the pores 13a connected to the compression pump or the atmosphere. On the other hand, air from the surface of the cavity is of course sucked through the pore 13 connected to the vacuum pump. In addition, during this vacuum forming, the valve 1 is set so that almost no air flows in from the pore 13a connected to the compression pump in the initial stage.
Preferably, 4a is closed or constricted and then adjusted to allow air to flow in. Then, during the initial molding, the pressure in the cavity on the lower surface of the ornament member 20 is also reduced, and the heated synthetic resin sheet 30 wraps around the periphery of the ornament member 20 as shown by the broken line in FIG. It is shaped into the surface shape of the interior material.
それに続いてオーナメント部材２０下面の細孔１３ａか
ら流入する空気によって織布等の表面材２１とその載置
面との間が他の一般成形面より気圧が高くなり、すなわ
ち減圧度が小となり、オーナメント表面材２１の型面へ
の圧接が解放されるようにして阻害される。又それにと
もなって表面材２１表面の熱気が真空ポンプ側の方へ吸
引され、外気が該表面へ供給されるので表面材が常に冷
却されるようにして内装材表面層が成形される。このと
きオーナメント部材載置面に針状突起が立設してあれば
表面材２１がそれによって支承され、すなわち表面材２
１と型面との間に空間を形成しより気流の流れが改善さ
れる。Subsequently, due to the air flowing in from the pores 13a on the lower surface of the ornament member 20, the air pressure between the surface material 21 such as woven fabric and its mounting surface becomes higher than that of other general molding surfaces, that is, the degree of decompression becomes small, Pressure contact of the ornament surface material 21 to the mold surface is released and inhibited. Along with this, hot air on the surface of the surface material 21 is sucked toward the vacuum pump side, and outside air is supplied to the surface, so that the surface layer of the interior material is molded so that the surface material is constantly cooled. At this time, if a needle-like protrusion is provided on the ornament member mounting surface, the surface material 21 is supported by it, that is, the surface material 2
A space is formed between 1 and the mold surface to further improve air flow.
このようにしてオーナメント部材２０と一体に成形され
た内装材表面層４１は、然後その裏面へガラスマット等
の補強材を載置し、硬質ポリウレタンフォーム等の液状
原料を注入し、発泡成形される。The interior material surface layer 41 integrally molded with the ornament member 20 in this way is then foam-molded by placing a reinforcing material such as a glass mat on the back surface and injecting a liquid raw material such as rigid polyurethane foam. .
なおこの場合、真空成形型１０を発泡成形型の一方の分
割型として使用してもよい。又前記の成形されたオーナ
メント部材付の表面層１１は別個に加工又は成形された
芯材等に被覆固着してドア） ＩＪム等の内装材とする
こともできるものである。In this case, the vacuum mold 10 may be used as one of the divided molds of the foam mold. Further, the above-mentioned surface layer 11 with the molded ornament member can be coated and fixed to a separately processed or molded core material, etc., to be used as an interior material for a door, IJ, or the like.
（効果）本発明は以上の如く、オーナメント部材を内装材表面層
の真空成形時に一体とする内装材の製造方法において、
オーナメント部材下面の減圧度を他部より小としながら
成形するものであるから、その表面材が型に圧接される
度合は小さく、又圧接されても直ぐに解放されるもので
ある。また、該表面材の下面の熱気が他部の一般成形而
下の細孔に吸引され、そこに外気が流入するものである
から表面材表面は常に冷却作用を受ける。従って、前記
表面材が毛足の長い織布、植毛等からなるもものであっ
ても従来の如きヒートセット現象を殆ど防止しろる効果
を有し、織布等の風合を継持しうるものである。(Effects) As described above, the present invention provides a method for manufacturing an interior material in which an ornament member is integrated during vacuum forming of the surface layer of the interior material.
Since the lower surface of the ornament member is molded with a lower degree of vacuum than the other parts, the surface material is not pressed against the mold to a small degree, and even if it is pressed, it is quickly released. In addition, the hot air on the lower surface of the surface material is drawn into the pores under the general molding in other parts, and the outside air flows therein, so that the surface of the surface material is constantly subjected to a cooling effect. Therefore, even if the surface material is made of long-pile woven fabric, flocked hair, etc., it has the effect of almost preventing the conventional heat-set phenomenon and retains the texture of woven fabric, etc. It is something.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1039785AJPS61169223A (en) | 1985-01-22 | 1985-01-22 | Manufacture of interior material |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1039785AJPS61169223A (en) | 1985-01-22 | 1985-01-22 | Manufacture of interior material |
| Publication Number | Publication Date |
|---|---|
| JPS61169223Atrue JPS61169223A (en) | 1986-07-30 |
| JPH0475810B2 JPH0475810B2 (en) | 1992-12-01 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1039785AGrantedJPS61169223A (en) | 1985-01-22 | 1985-01-22 | Manufacture of interior material |
| Country | Link |
|---|---|
| JP (1) | JPS61169223A (en) |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS63233818A (en)* | 1987-03-23 | 1988-09-29 | Arakawa Shatai Kogyo Kk | Method for mounting decorative trim |
| JPS63233827A (en)* | 1987-03-24 | 1988-09-29 | 東洋ゴム工業株式会社 | Polyurethane foam molded form and manufacture thereof |
| FR2957019A1 (en)* | 2010-03-04 | 2011-09-09 | Faurecia Interior Systems Inc | VACUUM THERMOFORMING OF THERMOPLASTIC SHEETS WITH DECORATIVE INSERTS |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS63233818A (en)* | 1987-03-23 | 1988-09-29 | Arakawa Shatai Kogyo Kk | Method for mounting decorative trim |
| JPS63233827A (en)* | 1987-03-24 | 1988-09-29 | 東洋ゴム工業株式会社 | Polyurethane foam molded form and manufacture thereof |
| FR2957019A1 (en)* | 2010-03-04 | 2011-09-09 | Faurecia Interior Systems Inc | VACUUM THERMOFORMING OF THERMOPLASTIC SHEETS WITH DECORATIVE INSERTS |
| Publication number | Publication date |
|---|---|
| JPH0475810B2 (en) | 1992-12-01 |
| Publication | Publication Date | Title |
|---|---|---|
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