JP2003112327A - Urethane skin and molding method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a urethane skin constituted by preliminarily bonding a urethane film and a decorative sheet material, and a molding method suitable for the urethane skin. SOLUTION: The urethane skin 10 is constituted of the urethane film 12 formed by spraying a urethane material on the molding surface of a mold and the decorative sheet material 14 formed into a required contour shape and connected to the urethane film 12 by mutually bonding the end parts of the urethane film 12 and the decorative sheet material 14. For example, the decorative sheet material 14 is a fabric having a soft urethane or the like laminated thereto or the like.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a urethane skin and a method for molding the same, and more specifically, to a urethane film formed by spraying a urethane material onto a molding surface of a molding die at a required position and a required contour shape. The present invention relates to a urethane skin configured by mounting the formed decorative sheet material, and a molding method capable of suitably molding the urethane skin.

[0002]

2. Description of the Related Art In a passenger compartment of a vehicle such as a passenger car, various vehicle interior members such as an instrument panel, a floor console and a door panel are provided. Since the color, design and texture of these vehicle interior members greatly affect the atmosphere and texture of the passenger compartment, the interior members are required to have improved texture and a sense of luxury. Therefore, in the vehicle interior member, by applying a preformed skin on the outer surface of the synthetic resin base material formed into a required shape by injection molding technology or the like based on vacuum molding technology or powder slush molding technology, A method for improving the texture is adopted. Further, in order to produce a high-class feeling, various specific members such as a decorative panel part having a grain of wood or a fabric are often additionally mounted at required positions on the outer surface of the skin.

[0003]

By the way, in the vehicle interior member described above, the work of applying the preformed skin to the base material based on the above-described molding technique and the installation portion provided at a required position of the skin. On the other hand, it is necessary to perform the work of mounting the specific member in separate steps. This is because with the vacuum forming technique or the powder slush forming technique, it was extremely difficult to form the skin and mount the specific member to the formed skin at the same time.

For example, in the powder slush molding, as is well known, the powder slush molding die has two skin molding surfaces.
By heating the mold heated to a high temperature of around 00 ° C. and charged with resin powder such as PVC, TPU, TPO, the resin powder in contact with the heated skin forming surface is appropriately melted and the skin forming surface is This is a technique for forming a skin with a conforming shape.
Therefore, when the specific member is set on the skin forming surface which is heated to the temperature described above, the specific member is softened and deformed / melted or deteriorated by this heat, and therefore the specific member is also inserted. It can be said that skin forming with and is almost impossible. Although it is possible to prevent thermal deformation of the specific member by setting the heating temperature of the skin forming surface to a low value, there is a new problem that the melting of the powder resin becomes insufficient and molding defects and quality defects occur. Will occur.

On the other hand, the vacuum forming technique is well known as follows.
This is a technique for forming a skin having a shape along the skin forming surface by suction-adhering a softened resin sheet material heated to a predetermined temperature to the skin forming surface of a vacuum forming mold that is evacuated. . However, when the vacuum forming of the skin is performed while the specific member is preset on the skin forming surface, the portion corresponding to the specific member of the sheet material does not adhere to the skin forming surface, and thus the appropriate forming cannot be performed. There were problems and so on.

That is, when using a skin formed by each of the above-mentioned molding techniques, the work of forming the skin and the work of mounting the specific member on the skin are performed in separate steps. There was an inherent problem that the number of steps increased and the molding cost increased. Further, since the specific member is retrofitted from the outside of the outer skin after the outer skin is applied to the base material, a gap is formed at the boundary between the outer skin and the specific member, which rather deteriorates the texture. It was pointed out that there are some drawbacks such as being lost.

[0007]

DISCLOSURE OF THE INVENTION The present invention has been proposed in order to suitably solve the above-mentioned problems. Based on urethane spray molding technology capable of molding at low temperature, a decorative sheet material is set on the molding surface of a molding die. By spraying a urethane material on the molding surface to mold a urethane film, the molding of the urethane film and the connection of the decorative sheet material to the urethane film can be performed at the same time to reduce the molding cost and improve the texture. It is an object of the present invention to provide a urethane skin as described above and a molding method for suitably molding this urethane skin.

[0008]

Means for Solving the Problems In order to solve the above problems and achieve the intended purpose, a urethane skin according to the present invention comprises a urethane film formed by spraying a urethane material onto the molding surface of a mold. It is characterized in that it is formed in a required contour shape, and is composed of the urethane film and a decorative sheet material which is connected to each other by joining the ends thereof.

Similarly, in order to solve the above problems and achieve the intended purpose, a method for molding a urethane skin according to another invention is as follows:
The decorative sheet material formed in the required contour shape is set on the molding surface of the mold after being attached to the shape retaining member, and the urethane material is blown to the molding surface and the end portion of the decorative sheet material set on the molding surface. To form a urethane film having a required thickness, and after curing the urethane film, remove the shape-retaining member from the decorative sheet material, form the urethane film, and simultaneously connect the decorative sheet material to the urethane film. It is characterized by having done.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Next, a urethane skin according to each invention of the present application and a method for molding the same will be described below with reference to the accompanying drawings with reference to preferred embodiments.

FIG. 1 is a schematic perspective view of a urethane skin according to a preferred embodiment of the present invention, and this urethane skin is exemplified as one molded for an instrument panel as a vehicle interior member, for example. This urethane skin 10
As will be described later and as shown in FIG. 3, it is molded based on the urethane spray molding technique using the molding die 20, and is formed by spraying the urethane material 16 on the molding surface 22 of the molding die 20. The urethane film 12 and a decorative sheet material 14 formed by cutting the urethane film 12 into a required contour shape and connected to each other by joining the urethane film 12 to each other by joining the ends to each other and attached to a required position of the urethane film 12. It is configured (Fig. 2 (a)). That is, in the urethane skin 10 of the embodiment, when the urethane coating 12 is molded, the decorative sheet material 14 is simultaneously connected to the molded urethane coating 12 and mounted. It can be handled as a pre-mounted epidermis.

The urethane coating 12 is formed of, for example, a soft type urethane material 16 and has a thickness h of about 1 mm, and is rich in flexibility and has appropriate elasticity. Further, the surface pattern such as "texture pattern" formed on the molding surface 22 of the molding die 20 is directly reproduced and reproduced on the surface, and a texture similar to genuine leather is applied to improve the texture. ing.

The decorative sheet material 14 is formed by pulling it out from an original fabric and cutting it into a desired outer shape, and is a one-layer laminate type in which either PU film or soft urethane is laminated, or both PU film and soft urethane are laminated. A two-layer laminated type fabric is exemplified. Such a laminate type fabric 14 has appropriate flexibility without impairing the original soft texture of the fabric, and is excellent in water repellency and waterproofness. Further, the laminated PU film and / or the soft urethane also imparts appropriate elasticity. The decorative sheet material is not limited to this fabric, and various sheet materials such as tricot (knit), genuine leather, synthetic leather, vinyl sheet material and resin sheet material are targeted.

FIG. 3 shows a molding die 20 for molding the urethane skin 10 based on the urethane spray molding technique.
FIG. 3 is an explanatory cross-sectional view showing a state where the urethane coating 12 is being molded. The molding die 20 is the same as the urethane skin 10.
The molding surface 22 is formed in the shape of the above and has a textured surface, and the urethane material 16 sprayed to a required thickness by the spray gun 36 is cured to have a thickness h.
Is designed to mold the urethane film 12 having a thickness of about 1 mm.
The pattern of can be faithfully reproduced. On the back side of the molding surface 22, a heating pipe 24 through which a heat medium such as water or oil flows is laid in a meandering manner, and the surface temperature of the molding surface 22 is set to an optimum temperature (for example, 65) for curing the urethane material 16. (° C)
It can be heated to.

A setting portion 26 for setting the fabric 14 as the decorative sheet material is formed at a required position on the molding surface 22 prior to the molding of the urethane film 12. As shown in FIG. 5, the set portion 26 has a concave shape capable of holding the fabric 14, and convex portions 28, 28 are provided on the outer edge portion so as to project. When the urethane film 12 is molded, as described above, the molding surface 22 is not heated to about 65 ° C. or higher, which is the optimum temperature for curing the urethane material 16, so that the fabric 14 set in the setting section 26 is molded on the molding surface 22. There is no risk of deterioration or discoloration by the heat of.

Since the above-mentioned fabric 14 cannot retain its shape by itself, when it is set in the set portion 26 prior to the molding of the urethane film 12, as shown in FIGS. 26 is set in a state of being attached to a shape holding member 30 having a shape matching with 26. The shape retaining member 30 has a sheet material mounting surface 32 formed in an outer surface shape that matches the setting portion 26, and has locking pins (locking members) protruding outward on the left and right side surfaces in the figure. 34, 34 are provided. As a result, the fabric 14 has the slits or the locking holes 18 and 18 provided at appropriate portions with the locking pins 34 and 34.
It is attached in a stretched state along the sheet material mounting surface 32 of the shape-retaining member 30 (FIG. 4B). In addition, the locking pin 34 may be pierced into the fabric 14 in the form of a so-called "needle" having a fine tip, and in this case, the locking hole 18 need not be formed in the fabric 14 in advance.

Then, the shape holding member 30 is set on the setting portion 26 in a posture in which the portion to which the fabric 14 is attached is directed to the contact surface of the setting portion 26 (see FIG. 5).
(a)), the fabric 14 is the shape retaining member 30.
The weight is set by the sheet holding surface 32 of the shape holding member 30 and the contact surface of the setting portion 26 in a pinched state (FIG. 5B). The fabric 14 set in the setting unit 26 using the shape retaining member 30 is shown in FIG.
As shown in FIG.
It is desirable that the portion sandwiched by the 28 be appropriately crushed. By setting in this way, a so-called sealed state is formed and the urethane material 16 is prevented from protruding to the contact surface side of the setting portion 26. You can In addition, the end portion 14 a of the fabric 14 attached to the shape retaining member 30
Is exposed to the outside from the set portion 26, and a part of the urethane material 16 for molding the urethane coating 12 can be sprayed onto the end portions 14a, 14a.

Next, a method of molding the urethane skin 10 using the molding die 20 having the above-described structure will be described.

First, as shown in FIGS. 4 (a) and 4 (b), the fabric 14 formed in the required contour shape is locked to the sheet material mounting surface 32 of the shape retaining member 30 by locking pins 34, 34.
The molding surface 2 of the molding die 20 after being attached using
It is set in the setting unit 26 provided in FIG. 2 (FIG. 5 (a)). At this time, the main part of the fabric 14 is sandwiched between the sheet material mounting surface 32 of the shape retaining member 30 and the contact surface of the setting portion 26, and is fixed by the weight of the shape retaining member 30,
Further, the end portion 14a of the fabric 14 is exposed along the convex portion 28 (FIG. 5 (b)). In addition, the convex portion 2
8 and 28 press the fabric 14 appropriately to form a sealed state with respect to the urethane material 16 (FIG. 6).

After the setting of the fabric 14 on the setting part 26 is completed and the heating medium is supplied to the heating pipe 24 to heat the molding surface 22 to a required temperature, the molding surface 22 on which the fabric 14 is set is By spraying the urethane material 16 with the spray gun 36, the urethane film 12 having a thickness h of about 1 mm is formed (FIGS. 3 and 7). Here, the urethane material 16 is sprayed not only on the molding surface 22 but also on the end portions 14a, 14a of the fabric 14 so that the end portions 14a, 14a are bonded to the urethane film 12 to be molded. . It should be noted that the urethane material 16 should not be sprayed onto the back surface (upper surface) of the shape-retaining member 30 (to hinder the removal of the shape-retaining member 30).

As the urethane material 16, there are a non-foaming type and a foaming type, etc., which are colored in a required color. As long as it is used as a skin of a vehicle interior member, the non-foaming soft material has excellent durability. Type is preferably used. When the uncolored urethane material 16 is used, it is necessary to spray urethane paint of a desired color onto the molding surface 22 before spraying the urethane material 16.

Since the urethane material 16 sprayed on the surface of the molding surface 22 is heated to the above-mentioned temperature, the curing is accelerated immediately after spraying and the curing is completed in a short time. To do. When the urethane film 12 is cured and molding is completed, the urethane film 12 and the fabric 14 attached to the urethane film 12,
Shape-retaining member 30 to which the fabric 14 is attached
Is integrally removed from the molding die 20 (FIG. 8). Then
By removing the shape retaining member 30 from the fabric 14, the molding of the urethane skin 10 is completed (FIG. 9).

As described above, the urethane skin 10 molded by using the molding die 20 based on the above-mentioned urethane spray molding technique is used as a decorative sheet material when the urethane film 12 constituting the urethane skin 10 is molded. Since the fabric 14 of the above is simultaneously attached to the urethane film 12, the fabric 14 can be handled as a pre-attached single member as described above. And fabric 14
Since the end portions 14a, 14a are bonded to the urethane film 12, the ends do not come off or fall off from the urethane film 12.

As shown in FIG. 10, the molded urethane skin 10 has an injection molding technique similar to a conventional general molding skin (a skin formed based on a vacuum molding technique or a powder slush molding technique). The base material 40 is formed on the outer surface of the base material 40 to form the decorative surface of the instrument panel 44, which is an interior member of the vehicle, and the fabric 14 is formed at a required portion (for example, in front of the passenger seat). Will be located. In FIG. 10, the urethane skin 10 of the embodiment, the base material 40, and the urethane foam 42 foamed / interposed between the members 10 and 40 are shown.
An instrument panel having a three-layer structure is exemplified. Here, when the end portions 14a, 14a of the fabric 14 joined to the urethane film 12 project too much to the back side, the urethane film 12 and the fabric 14 may be cut and removed at an appropriate position so as not to be separated.

As described above, in the urethane skin 10 of the embodiment, since the fabric 14 is previously attached to the urethane film 12, the urethane film 1 is formed on the outer surface of the base material 40.
2 and the fabric 14 can be integrally applied at the same time, and the work of separately mounting the fabric 14 in a later step is not required. Therefore, the man-hours for manufacturing the vehicle interior member such as the instrument panel 44 are reduced. The cost can be reduced. Also, the ends 14a, 14 of the fabric 14
Since the urethane material 16 is cured while adhering to a, it is possible to prevent a gap from being defined at the boundary between the fabric 14 and the urethane film 12, and to improve the texture.

On the other hand, in the urethane skin 10 molded as described above, as another embodiment, as shown in FIG. 12, the molding die (for convenience, referred to as a "first molding die") 20 and a molding paired therewith. By using a mold (for convenience, referred to as a “second molding mold”) 50, the urethane material 16 is formed on the back surface of the urethane film 12.
It is also possible to simultaneously apply the urethane film 12 and the fabric 14 to the urethane base material 48 formed by foaming. That is, the cavity 52 is defined when the first molding die 20 is completely closed in the second molding die 50, and the urethane material 46 injected into the back surface of the urethane coating 12 is filled in the cavity 52. The urethane film 1 in which the fabric 14 is attached to the outer surface of the urethane base material 48 that is formed by foaming and curing inside
A vehicle interior member in which 2 is simultaneously applied is molded.

Specifically, similar to the above-described process, first, the fabric 14 is set using the shape retaining member 30 on the setting portion 26 of the molding surface 22 of the first molding die 20, and then the molding is performed. Spray urethane material 16 onto surface 22
(FIG. 5, FIG. 6, FIG. 7). Then, the urethane material 1 sprayed
When 6 is cured and the urethane film 12 is completely molded, the molded urethane film 12 and the fabric 14 are not released from the mold, and only the shape retaining member 30 is removed from the fabric 14. Then, a two-liquid reaction type semi-hard type urethane material 46 is supplied by a urethane injection nozzle (not shown).
Is injected onto the upper surface of the urethane film 12. Then, when the injection work of the urethane material 46 is completed, the second molding die 50 is closed from above with respect to the first molding die 20, and the urethane material 46 is foamed in the cavity 52 defined thereby. By curing, the urethane base material 48 is molded on the back surfaces of the urethane film 12 and the fabric 14 (FIG. 12). Then, when the urethane material 16 is foamed and cured in the cavity 52 and the molding of the urethane base material 48 is completed, the second molding die 50 is released from the first molding die 20, and the integrated urethane base material 48 and urethane film are formed. 12 and fabric 14 are demolded from the first mold 20.

The urethane material 46 is classified into the above-mentioned semi-hard type that has appropriate elasticity after curing and the hard type that does not have elasticity after curing, and is selected based on the strength required for the vehicle interior member. Is used for. However, assuming that the urethane base material 48 is implemented as the instrument panel 44 on which various in-vehicle devices and in-vehicle parts are mounted, since the urethane base material 48 is required to have considerable strength and rigidity, glass fiber or the like is mixed. It is desirable to use the semi-rigid urethane material 46 described above.

As described above, in the urethane skin 10 of the embodiment, if the molding dies 20 and 50 are used based on the urethane spray molding technique described above, the urethane film on which the fabric 14 is mounted on the molding surface 22 of the molding die 20 is used. After molding 12, it may be possible to mold a urethane substrate 48 on the backside of these fabrics 14 and urethane coatings 12.

Although not specifically shown, when molding the urethane base material 48 on the back surface of the urethane coating 12 using the molding dies 20, 50 shown in FIG. 12, a material such as PP separately injection-molded is used. If a hard base material is set on the molding surface of the second molding die 50, the urethane base material 48 is molded with the urethane coating 12 of the base material. This makes it possible to form a so-called three-layer type vehicle interior member including the base material, the urethane base material 48, and the urethane skin 10.

The urethane skin 10 shown in the above embodiment
In the above, an example is shown in which the urethane film 12 is mainly used and a fabric 14 as a decorative sheet material, which is considerably smaller than the urethane film 12, is attached to a required position of the urethane film 12. However, the urethane skin 10 targeted by the present application may have a form in which the decorative sheet material 14 is mainly used and a considerably small urethane film 12 is attached to a required position of the decorative sheet material 14 thereby. Further, the urethane film 12 and the decorative sheet material 14 may have the same size.

The urethane skin 10 molded by the molding method of this embodiment is not limited to the one used for the instrument panel 44, but may be used as a skin for a floor console, a door panel, and various other vehicle interior members. It is possible.

[0033]

As described above, in the urethane skin according to the present invention, the urethane film and the decorative sheet material are preliminarily connected to each other, so that the decorative sheet material is attached when the skin is attached to the base material or the like. Are also installed at the same time, and the number of man-hours for manufacturing the vehicle interior member is reduced, and there is a beneficial effect that the cost can be reduced. In addition, since no gap is defined at the boundary between the decorative sheet material and the urethane film, there is an advantage that the texture can be improved. The decorative sheet material is
By joining the ends of the sheet material to the urethane film,
It is suitably connected and attached to the urethane film. The decorative sheet material is specifically a fabric or the like.

In a method for molding a urethane skin according to another invention, based on urethane spray molding technology, a decorative sheet material is set on the molding surface of a molding die using a shape-retaining member, and then the molding surface is formed on the molding surface. Since a urethane film is formed by spraying a urethane material, it is possible to connect the decorative sheet material to the urethane film formed on the molding surface, and it can be handled as a single member that interconnects the decorative sheet material and the urethane film. A urethane skin can be suitably manufactured. Moreover, since the urethane material can be cured while being in close contact with the decorative sheet material, a gap is not defined at the boundary between the decorative sheet material and the urethane film, and the texture can be improved. There are also advantages.

[Brief description of drawings]

FIG. 1 is a schematic perspective view of a urethane skin according to a preferred embodiment of the present invention.

2A is a sectional view taken along the line IIa-IIa in FIG. 1, and FIG.
It is a principal part expanded sectional view of (a).

FIG. 3 is an explanatory cross-sectional view showing a molding die for molding the urethane skin shown in FIG. 1 based on a urethane spray molding technique in a state where a urethane film is being molded.

FIG. 4A is a cross-sectional view showing a fabric and a shape-retaining member to which the fabric is attached, and FIG. 4B is a cross-sectional view showing a state in which the fabric is locked and attached to the shape-retaining member.

5A is a cross-sectional view showing a state in which a fabric attached to a shape-retaining member is set on a setting portion provided on the molding surface of the molding die shown in FIG. 3, and FIG. It is sectional drawing which shows the state fixed to.

FIG. 6 is a cross-sectional view showing that the fabric is appropriately crushed and a sealed state is formed by the convex portion and the shape retaining member provided in the setting portion.

[Figure 7] With the fabric set in the set section,
FIG. 3 is a cross-sectional view showing a state in which a urethane film is molded by spraying a urethane material on the molding surface and the end of the fabric.

FIG. 8 is a cross-sectional view showing a state in which a urethane coating formed of a urethane material and a fabric connected to and attached to the urethane coating are integrally released from the molding die together with the shape retaining member.

FIG. 9 is a cross-sectional view showing a state where molding of the urethane skin is completed by removing the shape retaining member from the fabric.

10 is a cross-sectional view of an instrument panel as a vehicle interior member manufactured by applying the urethane skin shown in FIG. 2 to a separately molded base material.

11A is a cross-sectional view of an instrument panel formed by simultaneously mounting a urethane film and a fabric on the outer surface of the urethane base material molded by the mold shown in FIG. 12, and FIG. () Is an enlarged cross-sectional view of a main part of (a).

FIG. 12 is an explanatory cross-sectional view showing a state in which a urethane film is formed based on a urethane spray molding technique, and subsequently, a urethane material is foamed on the back surface of the urethane film to form a urethane base material. .

[Explanation of symbols]

12 Urethane film 14 Fabric (decorative sheet material) 16 Urethane material 20 Mold (1st mold) 22 Molding surface 30 Shape retaining member 34 Locking pin (locking member) 40 base material 46 Urethane material 48 Urethane base material 50 Mold (second mold) 52 cavity

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) B29K 105: 04 B29K 105: 04 B29L 31:58 B29L 31:58 F term (reference) 3D023 BA01 BB08 BC01 BD03 BE04 BE11 BE31 4F204 AA42 AD05 AD16 AF07 AG03 AG20 AH25 AH26 EA01 EA04 EB01 EB11 EB13 EB22 EF05 EK17 EK24 EK27 4F205 AA31 AD08 AD17 AG03 AG21 AH26 GA05 GA15 GB01 GB12 GB16 GB22 GC01 GE27 GF04 GN07GN04 GF06 GN25GN04

Claims (7)

[Claims] 1. A urethane material for the molding surface (22) of the molding die (20).
A urethane film (12) formed by spraying (16) and a decorative sheet material (1) formed in a required contour shape and connected to each other by joining the urethane film (12) and ends thereof.
4) Urethane skin characterized by being composed of and. 2. A urethane base material (48) formed by foaming a urethane material (46) on the back surface of the urethane film (12), the urethane film (12) having the decorative sheet material (14) attached thereto. The urethane skin according to claim 1, which can be applied simultaneously. 3. A substrate (40) separately preformed into a desired shape.
The urethane skin according to claim 1, wherein the urethane film (12) having the decorative sheet material (14) attached thereto can be applied to the outer surface of the urethane skin. 4. The urethane skin according to claim 1, wherein the decorative sheet material (14) is a fabric. 5. A decorative sheet material (1 having a required contour shape
4) is set on the molding surface (22) of the molding die (20) while being attached to the shape retaining member (30), and the molding surface (22) and the decorative sheet material set on the molding surface (22) ( At the end of 14), a urethane material (16) is sprayed to form a urethane film (12) of a required thickness, and after the urethane film (12) is cured, the shape-retaining member (3
(0) is removed from the decorative sheet material (14), the urethane film (12) is molded and the urethane film (12) is formed.
A method for molding a urethane skin, characterized in that the decorative sheet material (14) is connected at the same time. 6. After molding the urethane film (12), another urethane material (46) is injected on the back surface of the urethane film (12),
The urethane material is provided in a cavity (52) defined by closing the mold (20) and a mold (50) paired with the mold (20).
By foaming (46), the urethane film (12) and the decorative sheet material (14) are simultaneously formed on the outer surface of the urethane base material (48) formed by foaming and curing the urethane material (46). The method for molding a urethane skin according to claim 5, which is adapted to be adhered. 7. The decorative sheet material (14) is attached to the shape retaining member (30) in a state of being retained by an engaging member (34) provided on the shape retaining member (30). 6. The method for molding the urethane skin according to 6.