JP2006326904A - Skin material mold and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a skin material molding die that is easy to manufacture and low in cost, and a manufacturing method thereof.
A base mold BM is formed, and a second grain layer 3 is formed on the base mold BM by placing and hardening an epoxy resin containing fine aluminum grains. The first grain layer 2 is formed by placing and hardening an epoxy resin containing coarse aluminum grains. The first grain layer 2 and the second grain layer 3 are removed from the base type BM and inverted in the vertical direction, and then the resin sheet 4 is bonded onto the second grain layer 3. The surface of the resin sheet 4 bonded to the second particle layer 3 is perforated to form a vent hole 41 to complete the skin material molding die 1.
[Selection] Figure 1

Description

  The present invention relates to a skin material molding die for molding a skin material.

There has been a conventional technique relating to a method of manufacturing a mold for transferring a texture pattern on a skin material covering the surface of an interior material (see, for example, Patent Document 1). This relates to a method of manufacturing a molding die in which a skin material is sucked from an air hole opened in a mold surface during molding and pre-shaped on the skin material. First, a first model made of resin A mold is manufactured, a sheet with a texture pattern is pasted on its surface, silicon is filled into it, the texture pattern is inverted, and a preservation model mold is fabricated. Next, the second model mold is manufactured using the preservation model mold, and the surface of the second model mold is subjected to silver mirror processing, and then submerged in an electroforming tank, and a metal such as nickel is laminated and adhered to the corresponding surface. To make an electroforming mold. By disposing the electroforming mold in the mold together with the cooling pipe, a target forming die is completed.
JP-A-6-25884 (FIGS. 1 and 2)

  According to the manufacturing method described above, there are problems that a plurality of types of model molds must be manufactured, the mold manufacturing time is long, and the manufacturing cost is increased. The present invention has been completed based on the above circumstances, and an object thereof is to provide a skin material mold that is easy to manufacture and low in cost, and a method for manufacturing the same.

  As a means for achieving the above object, the invention of claim 1 is characterized in that a vent hole is opened on a mold surface, and a skin material is placed on the mold surface, and then the skin material is placed through the vent hole. In a skin material molding die that sucks toward the mold surface and molds the skin material, a resin sheet is bonded onto a base formed by solidifying a granular material, and the air holes are formed in the resin sheet. It was set as the skin material shaping | molding die characterized by having.

  According to a second aspect of the present invention, the base includes a first grain layer in which metal particles are solidified by a binder resin, and a metal grain finer than the first grain layer is solidified by a binder resin, and the second grain joined to the first grain layer The skin according to claim 1, wherein the resin sheet is bonded to a surface of the second particle layer opposite to the bonding side with the first particle layer. A material molding die was used.

  The invention according to claim 3 is the skin material mold according to claim 1 or 2, wherein the resin sheet contains ceramic whiskers.

  According to a fourth aspect of the present invention, in the skin material mold according to the second aspect, the first grain layer includes a grid-like rib.

  According to a fifth aspect of the present invention, a vent hole is opened in the mold surface, and after the skin material is placed on the mold surface, the skin material is sucked toward the mold surface through the vent hole, In a manufacturing method of a skin material molding die for molding a material, a base mold forming step for forming a base die, a substrate forming step for forming a base by placing and solidifying a granular material on the base die, and the base A step of removing the base from the mold and bonding a resin sheet on the surface of the base that has been in contact with the base mold, and a step of forming a vent hole for perforating the surface of the resin sheet bonded to the base The manufacturing method of the skin material mold is characterized by comprising:

<Invention of Claim 1>
In the skin material molding die, a resin sheet is joined to a base formed by solidifying a granular material, and a single base die is manufactured by forming a vent hole in the resin sheet. After forming the film, it is completed by bonding a resin sheet on the substrate, so that it can be manufactured in a short time, and can be manufactured easily and at a low cost.

<Invention of Claim 2>
The base is formed by a first grain layer in which metal particles are solidified by a binder resin, and a second grain layer in which finer metal grains are solidified by a binder resin and bonded to the first grain layer. By forming the resin sheet on the surface of the grain layer opposite to the side joined to the first grain layer, the skin material can be sufficiently sucked by the grainy first grain layer. With the fine second grain layer, the smoothness of the design surface can be obtained, and from the point that there are many interstices between grains, any surface of the resin sheet joined to the second grain layer during mold production can be obtained. Vent holes can be easily drilled in position.

<Invention of Claim 3>
Since the resin sheet contains ceramic whiskers, it is possible to easily form a fine texture pattern and increase the strength.

<Invention of Claim 4>
The 1st grain layer can improve the rigidity by including a lattice-like rib.

<Invention of Claim 5>
A base mold forming step for forming a base mold, a base body forming process for forming a base by placing and solidifying a granular material on the base mold, and a base surface that is in contact with the base mold after the base is removed from the base mold In addition, since the resin sheet joining step for joining the resin sheets and the air hole forming step for perforating the surface of the resin sheet joined to the substrate, the molding die can be manufactured by producing only one type of model die. Thus, the manufacturing method can be easily manufactured in a short time.

  An embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 1, the skin material molding die 1 according to the present embodiment hardens particles of coarse aluminum particles (hereinafter referred to as an aluminum grid) in a mold 5 formed of synthetic resin or the like. The first grain layer 2 formed by hardening using an epoxy resin as a binder is accommodated, and the first grain layer 2 is placed on the first grain layer 2 (below the first grain layer 2 in FIG. 1). A second grain layer 3 is provided in which an aluminum grid finer than the grain size is solidified with an epoxy resin in the same manner as the first grain layer 2 (the first grain layer 2 and the second grain layer 3 are also called porous materials). , Corresponding to the substrate of the present invention and bonded to each other), and the surface of the second particle layer 3 (the surface opposite to the bonding side with the first particle layer of the present invention, second in FIG. A resin sheet 4 having a texture pattern formed on the surface thereof is bonded to the lower surface of the grain layer 3. There. The resin sheet 4 forms the mold surface of the mold 1 and is formed of an epoxy resin containing ceramic whiskers. The resin sheet 4 is extensible and has a plurality of vent holes 41 perforated. The resin sheet 4 in the present invention is the same as that described in Japanese Patent Publication No. 2-14173 which is a patent publication.

  In FIG. 1, the upper end portion of the mold 1 is closed by a lid 6, and lattice-like ribs 7 are included in the first grain layer 2. The grid-like ribs 7 are integrally formed of a metal or a resin material, and are in contact with the mold 5 and the lid body 6 at their ends in order to improve the rigidity of the first particle layer 2. Further, a plurality of water-cooled tubes 8 are incorporated in the first grain layer 2 to suppress heat storage of the mold 1 during molding of the skin material SK and reduce the number of molding processes. A vacuum pump PU is connected to an inlet (not shown) of the lid 6 via a valve VE, so that a negative pressure can be introduced into the first grain layer 2.

  When performing pre-shaping to form the skin material SK, the skin material SK that has been heated and softened is placed between the mold 1 and the mating die MD and is placed in the mold 1 by the vacuum pump PU. Close both molds while introducing negative pressure. Thereby, the negative pressure by the vacuum pump PU passes between the aluminum grids of each of the first grain layer 2 and the second grain layer 3, and the skin material SK is transferred to the resin sheet 4 via the vent holes 41 of the resin sheet 4. Aspirate to the side. Due to the suction by the vacuum pump PU and the support to the resin sheet 4 by the mating mold MD, the skin material SK is uniformly attracted to the resin sheet 4, and a texture pattern is formed on the surface thereof. To be molded.

  Next, based on FIG. 2 thru | or FIG. 7, the manufacturing method of the shaping | molding die 1 by this embodiment is demonstrated. As shown in FIG. 2, first, a base mold BM is formed by machining, for example, by machining (base mold forming process). The base mold BM is made of a synthetic resin and has a shape obtained by inverting the mold surface shape of the mold 1. Next, after placing the mold 5 on the base mold BM, the second grain layer 3 is formed on the surface of the base mold BM. The second grain layer 3 is formed by laminating a soft epoxy resin containing an aluminum grid having a predetermined roughness on the base BM, and then pressing and solidifying it from above for a predetermined time ( 3). Next, after the water-cooled tube 8 is disposed at a predetermined position on the solidified second particle layer 3, a soft epoxy resin containing an aluminum grid is applied on the second particle layer 3 in the same manner as the second particle layer 3. Are laminated together with the grid-like ribs 7 and pressed from above for a predetermined time to be solidified to form the first grain layer 2 (substrate forming step). From above the first grain layer 2, the lid 6 is placed to close the top (shown in FIG. 4).

  Next, as shown in FIG. 5, the laminate of the first grain layer 2 and the second grain layer 3 is removed from the base type BM, inverted in the vertical direction, and then a resin sheet on the second grain layer 3. 4 is stuck (resin sheet joining step). If the process of sticking the resin sheet 4 on the 2nd grain layer 3 is explained in full detail based on FIG. 6, first, the resin sheet 4 to which the master sheet 4a was stuck on the upper surface as a reinforcing material for handling will be described. After applying a thermosetting epoxy resin, which is the same kind of material, to the lower surface (shown in FIG. 6 (A)), it is placed on the second particle layer 3 and heated at a predetermined temperature for a predetermined time. Temporary baking is performed (shown in FIG. 6B). Thereafter, the master sheet 4a is peeled off from the resin sheet 4 (shown in FIG. 6C), and further heated at a predetermined temperature and time for main firing (shown in FIG. 6D). Since the epoxy resin interposed between the second grain layer 3 and the resin sheet 4 is the same material as the second grain layer 3 and the resin sheet 4, they are solidified by firing after being mixed with these, and both of them are anchored by the anchor effect. Are firmly joined. In addition, the master sheet 4a is stuck in order to improve the rigidity of the resin sheet 4 and prevent the resin sheet 4 from wrinkling when sticking.

  When the resin sheet 4 is bonded onto the second particle layer 3, as shown in FIG. 7, a plurality of vent holes 41 are drilled on the surface of the resin sheet 4 with a drill DR or the like (a vent hole forming step). The vent hole 41 is, for example, a through hole having a diameter of about 0.1 mm and reaches the second particle layer 3, and a negative pressure is guided to the surface of the resin sheet 4 through the vent hole 41.

  According to this embodiment, the skin material molding die 1 joins the resin sheet 4 on the first grain layer 2 and the second grain layer 3 formed by solidifying the aluminum grid, and the vent holes 41 are formed in the resin sheet 4. Since it is completed by drilling, only one type of base mold needs to be manufactured, and the mold 1 can be manufactured in a short time, and can be manufactured easily and at low cost. The mold 1 includes a first grain layer 2 in which an aluminum grid having a predetermined roughness is hardened with an epoxy resin, and a second grain in which a finer aluminum grid is hardened with an epoxy resin and joined to the first grain layer. By providing the layer 3 and joining the resin sheet 4 on the second grain layer 3, it is possible to improve the passage of air evacuated by the coarse grained first grain layer 2, and to apply the skin material SK. The second granular layer 3 with fine grains can be sufficiently sucked, and the smoothness of the design surface can be obtained. Further, there are many interstices between the grains. The pore 41 can be set at an arbitrary position and can be easily drilled, so that workability is improved. Further, since the resin sheet 4 contains ceramic whiskers, it is possible to easily form a fine texture pattern and increase the strength.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention, and further, within the scope not departing from the gist of the invention other than the following. Various modifications can be made.
(1) When perforating the resin sheet, it may be punched out by a punch or the like. Moreover, you may stick the resin sheet pierced previously on the 2nd grain layer.
(2) The first particle layer and the second particle layer may be a resin material including a metal particle other than aluminum or a granular material made of a material other than metal.
(3) The mold may be cooled by other methods such as sending cold air without providing a water-cooled tube in the mold.

It is sectional drawing of the shaping | molding die by this embodiment, and a counterpart die. It is the schematic which shows the place which has manufactured the base type | mold by shaving. It is sectional drawing which showed the state when laminating | stacking a 1st grain layer on a 2nd grain layer. It is sectional drawing which showed the state which laminated | stacked the 1st grain layer on the 2nd grain layer. It is sectional drawing which showed the state at the time of sticking a resin sheet on a 2nd grain layer. Sectional view (A) showing a state in which a resin sheet is disposed on the second grain layer, sectional view (B) showing a state in which the resin sheet is pre-fired, and a state in which the master sheet is peeled from the resin sheet. It is sectional drawing (D) which showed the state which carried out the main baking of the cross-sectional view (C) and the resin sheet. It is sectional drawing which showed the place drilled on the resin sheet.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Skin material shaping | molding die 2 ... 1st particle layer 3 ... 2nd particle layer 4 ... Resin sheet 7 ... Lattice-like rib 41 ... Air vent BM ... Base type MD ... Opposite type SK ... Skin material

Claims (5)

A skin material for forming the skin material by opening a vent hole in the mold surface and placing the skin material on the mold surface and then sucking the skin material toward the mold surface through the vent hole In the mold
A skin material molding die characterized in that a resin sheet is bonded onto a substrate formed by solidifying a granular material, and the air holes are formed in the resin sheet. The base is formed by a first grain layer in which metal particles are solidified by a binder resin, and a second grain layer in which finer metal grains are solidified by a binder resin and bonded to the first grain layer, The skin material molding die according to claim 1, wherein the resin sheet is bonded to a surface of the second particle layer opposite to the bonding side with the first particle layer. The skin material molding die according to claim 1 or 2, wherein the resin sheet contains ceramic whiskers. The skin material molding die according to claim 2, wherein the first grain layer includes a grid-like rib. A skin material for forming the skin material by opening a vent hole in the mold surface and placing the skin material on the mold surface and then sucking the skin material toward the mold surface through the vent hole In the manufacturing method of the mold,
A base mold forming step for forming a base mold, a base material forming step for forming a base by placing and solidifying a granular material on the base mold, and removing the base from the base mold and contacting the base mold A skin material molding die comprising: a resin sheet joining step for joining a resin sheet on the substrate surface; and a vent hole forming step for perforating the surface of the resin sheet joined to the substrate. Method.

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