JP2015112741A - Manufacturing method of ceiling material for vehicle, and mold for hot press molding in the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of ceiling material for vehicles, capable of molding two types of ceiling material, ceiling material having a convex or concave shape on the design surface and ceiling material having no convex or concave shape on the design surface, by using one mold without exposure of a parting line on the design surface, the ceiling material being excellent in usability and workability.SOLUTION: A manufacturing method of ceiling material for vehicles includes hot pressing a laminate material 6 composed of a surface material 9 laminated on a substrate 7, with a male mold 1 and a female mold 2. A mold for hot pressing has a thin plate 3 composed of a plate surface 31 in parallel with a molding surface 11 of the male mold 1 and an outside area surface 36 extending outward from the plate surface and a tangible expression object 4 formed of a plate piece 46 fastened to a plate surface 32 on the opposite side of the plate surface 31, or formed by boring in the plate surface 32. Between the opened male mold 1 and female mold 2, the tangible expression object 4 is opposed to the surface material 9. The laminate material 6 and the thin plate 3 having the tangible expression object 4 which is placed more adjacent to the male mold 1 are set, and then the molds are closed. Subsequently hot pressing is performed, and in parallel with molding of a ceiling material body 51, a concave or convex decoration pattern 55 of the tangible expression object 4 is transfer molded on a design surface 5a on the surface material 9 side.

Description

  The present invention relates to a method for manufacturing a vehicular ceiling material arranged on the inner side of a roof panel of a vehicle, and a hot press mold used therefor.

  In a vehicle such as an automobile, a vehicle ceiling material is attached to the inside of the roof panel. What gave this ceiling material the uneven | corrugated shape is also known (for example, patent document 1).

JP 2010-195261 A

  However, as described in paragraph 0005, Patent Document 1 is an invention that provides “a vehicle ceiling material with improved rigidity and improved appearance without making the bead shape conspicuous on the design surface of the ceiling material”. . In order to prevent highlight lines from appearing on the ceiling surface, as described in the claims, "... the back surface of the ceiling material is provided with a plurality of beads having a cross-sectionally recessed groove shape". The invention content is limited to providing a groove on the back side.

  Conventional ceiling materials are generally formed with a gentle and uniform design surface facing the passenger compartment, and a person, animal, or geometrical object is formed on the design surface with recesses or projections. There are no drawings of decorative figures. However, if you get into the car, you can see the design surface of the ceiling material from inside the passenger compartment, and if a decorative figure consisting of the figure of a person or thing or a geometric shape is drawn on it, the occupant Can see and enjoy it, increasing the added value of the vehicle.

Incidentally, when trying to add the shape of the convex part 55u (or concave part) which consists of a decoration figure to the design surface 5a side of the ceiling material 5, according to a prior art, the nesting R which has concave part R9 like FIG. Or engrave directly on the mold K.
However, in the case of the nesting specification, there is a problem that the parting line PL of the nesting R can be seen on the design surface 5a. In addition, the nesting R is heavy and it is difficult to replace. On the other hand, when the shape of the concave portion R9 (or the convex portion) is directly engraved in the mold K, when the portion is damaged, the repair takes cost and time. Further, when the mold becomes dirty, it is difficult to remove the dirt, and maintenance maintenance becomes troublesome. Furthermore, if it is necessary to create a ceiling material 5 having a convex 55u (or concave) shape and a ceiling material having no convex 55u (or concave) shape, two molds are prepared. There is also a problem that puts a burden on you.

  The present invention solves the above-mentioned problem, and there is no parting line on the design surface, which is excellent in usability and workability, and in addition, a case with a convex or concave shape on the design surface side and a case without it It is an object of the present invention to provide a method for manufacturing a vehicle ceiling material capable of forming two types of ceiling materials with a single mold and a hot press mold used for the method.

In order to achieve the above object, the gist of the invention described in claim 1 is a lamination in which a male mold (1) and a female mold (2) are provided, and a surface material (9) is laminated on a base material (7). A hot press molding die for a vehicle ceiling material formed by hot press molding a material (6), the plate surface (31) along the molding die surface (11) of the male mold (1) and an outer surface from the plate surface A thin plate (3) having an outer surface (36) extending in the direction and a plate piece (46) fixed on the plate surface (32) opposite to the plate surface (31). Or a tangible expression body (4) cut and formed on the plate surface (32), the tangible expression body (4) facing the surface material (9), and the laminated material (6) and a thin plate (3) with a tangible expression body (4) arranged on the male mold (1) side than this, sandwiching the male mold (1) and the female mold (2), and heating press Simultaneously with the molding of the ceiling material body (51), the concave or convex decorative figure (55) by the tangible representation (4) is transferred to the design surface (5a) on the surface material (9) side. It is in the heating press molding die of the ceiling material for vehicles characterized by being shape | molded. According to a second aspect of the present invention, there is provided a heating press molding die for a vehicle ceiling material according to the first aspect, wherein the locked portion (36k) formed at the portion of the thin plate (3) having the outer surface (36) is provided. Further, using the locked portion (36k), the thin plate (3) with the tangible expression (4) is detachably attached and fixed to the male mold (1), and is subjected to hot press molding. It is characterized by.
The gist of the invention described in claim 3 is that a laminated material (6) comprising a male mold (1) and a female mold (2) and having a surface material (9) laminated on a base material (7) is heated and pressed. A method of manufacturing a vehicle ceiling material to be molded, comprising: a plate surface (31) along the mold surface (11) of the male mold (1); and an outer surface (36) extending outward from the plate surface. A thin plate (3) and a plate piece (46) fixed on the plate surface (32) opposite to the plate surface (31), or a cut-out formation on the plate surface (32) The tangible representation (4), and using a hot press mold comprising the tangible representation (4) between the male mold (1) and the female mold (2) in the mold open state After setting the laminate (6) and the thin plate (3) with the tangible expression (4) placed on the male mold (1) side than the laminated material (6) The mold is closed and then heated and press-molded, and at the same time as the ceiling material body (51) is molded, the design surface (5a) on the surface material (9) side is attached to the tangible expression (4) In the manufacturing method of a vehicle ceiling material, which comprises transferring molding a concave or convex decorative figure (55).

As in the inventions of claims 1 and 3, the laminated material (6) and the thin plate (3) with a tangible expression (4) arranged on the male mold (1) side from the laminated material (6) And a female mold (2), a hot press molding is performed to produce a ceiling material in which a decorative figure (55) is transferred and molded with a tangible expression. If the thin plate (3) with the tangible representation (4) is omitted or replaced with a thin plate (3) without the tangible representation (4), a ceiling material without decorative figures is obtained. You can easily create ceiling materials with and without decorative figures. Since the thin plate with a tangible representation can be reduced in weight by an independent component, the specification change with or without decorative figures goes smoothly, leading to a reduction in man-hours. If there is a specification requirement to make the tangible representation (4) into various shapes such as animals, vehicles, geometric shapes, etc., multiple pairs of male and female molds with the corresponding decorative figures transferred and molded A variety of ceiling materials can be provided, which can greatly reduce mold production costs. The thin plate (3) with a tangible representation (4) is separate from the male and female types, making it lighter and easier to handle than nested specifications. Maintainability in the case of dirt and damage is improved, and the repair cost at the time of damage can be repaired and replaced only by the thin plate (3) with the tangible expression (4).
When the thin plate (3) with the tangible expression (4) is detachably attached and fixed to the male mold (1) using the locked portion (36k) as in the invention of claim 2, a decorative figure is attached. It becomes easier to form the ceiling material. Since the thin plate with a tangible representation is attached and fixed to the male mold, the laminate is sandwiched between the thin plate with the tangible representation and the female mold, and the ceiling material with a decorative figure is made by hot press molding. Can do.

  The method for manufacturing a vehicle ceiling material according to the present invention and the hot press mold used for the same include two types of ceiling materials, a case having a convex or concave shape on the design surface side and a case having no shape. Two male molds and female molds can be molded, and the manufacturing equipment cost can be greatly reduced. In addition, it has excellent usability and workability, and also exhibits numerous excellent effects without any defects in the parting line that appears when nesting is used in the design surface.

FIG. 2 is an exploded explanatory cross-sectional view of a male plate, a female die, and a thin plate with a tangible expression body in a hot press mold according to the first embodiment. FIG. 2 is an explanatory sectional view in which the thin plate with a tangible expression body of FIG. 1 is attached and fixed to a male mold. It is explanatory sectional drawing which sets the laminated material and the thin board with a tangible expression body set | placed on the male mold side rather than this under a mold open state. FIG. 4 is an explanatory cross-sectional view after the mold shown in FIG. FIG. 5 is an explanatory cross-sectional view showing a state of demolding after FIG. 4. (B) is a plan view of a male type with a thin plate with a tangible representation attached to a male mold, and (b) is a plan view of the thin plate with a tangible representation of (a). is there. In Embodiment 2, (a) is a plan view of a thin plate with a tangible expression body, and (b) is a longitudinal sectional view of the thin plate with a tangible expression body (a). It is explanatory sectional drawing which sets the laminated material and the thin board with a tangible expression body set | placed on the male mold side rather than this under a mold open state. FIG. 9 is an explanatory cross-sectional view after the mold is closed and the mold is heated and press-formed. It is explanatory drawing which shows a mode of mold removal after FIG. It is explanatory sectional drawing of a prior art.

Hereinafter, the manufacturing method of the ceiling material for vehicles which concerns on this invention, and the hot press molding die used for this are explained in full detail.
(1) Embodiment 1
1 to 6 show a method for manufacturing a vehicle ceiling material according to the present invention and a form of a heat press mold used for the method. FIG. 1 is an exploded explanatory sectional view of a male plate, a female die, and a thin plate with a tangible expression. 2 is an explanatory cross-sectional view in which the thin plate with a tangible representation of FIG. 1 is attached and fixed to the male mold, and FIG. 3 is a laminate with the tangible representation and placed on the male mold side in the mold open state. FIG. 4 is an explanatory cross-sectional view showing the state of mold release after FIG. 4 and FIG. 5 is an explanatory cross-sectional view showing the state of demolding after FIG. Shows a plan view of a thin plate with a tangible expression of another embodiment. In each figure, the drawings are simplified for easy understanding, and the thickness of the thin plate 3 and the thickness of the plate piece 46 of the tangible expression 4 are emphasized and drawn. In addition, hatching for displaying a cross section is omitted as appropriate.

(1a) Heat press mold The heat press mold T of the vehicle ceiling material 5 includes a pair of male mold 1, female mold 2, thin plate 3, and tangible expression 4 (FIG. 1). 3 is a hot press molding die for a vehicle ceiling material 5 obtained by hot press molding a laminated material 6 as shown in FIG. 3 in which a surface material 9 is laminated by applying an adhesive binder to a base material 7 made of hard foam or the like. T. The present embodiment uses a tangible representation 4 shaped like a bear as shown in FIG. 2, and a ceiling material on which a concave decorative figure 55 is formed on the ceiling design surface 5a by directly transferring and molding the bear shape. 5 is a production hot press mold T.

  The male mold 1 is an upper mold having a mold surface 11 having a convex bulge as shown in FIG. 1, and forms the design surface 5a side of the ceiling material 5 in which the mold surface 11 is curved. The male mold 1 is provided with a section outer mold surface 16 that is a mold mating surface extending outward from the section Z of the molding mold surface 11 facing the female mold 2. The outer area die surface 16 is recessed with respect to the female mold 2 relative to the molding die surface 11, and the outer area die surface 16 is provided with a plurality of female screw holes 16n as engaging portions for attaching the thin plate 3. The A heating means (not shown) for heating the mold surface 11 is provided in the male mold 1. Reference numeral M denotes a permanent magnet embedded in the male mold 1 with the cavity side surface flush with the mold surface 11. Here, the permanent magnet M is shown only in FIG. 3, and the others are omitted.

  The female die 2 is a lower die having a molding die surface 21 that is recessed in a curved shape as shown in FIG. 1, and the molding die surface 21 forms the back surface 5b side of the ceiling material 5 facing the inside of the vehicle roof panel. A heating means (not shown) for heating the mold surface 21 is provided in the female mold 2. The laminated material 6 set in the cavity between both the mold surfaces 11 and 21 of the female mold 2 and the male mold 1 is heated by heating means and compressed by press molding of the male mold 1 and the female mold 2. If it is cured, a general-purpose ceiling material that forms a smooth and uniform surface on the design surface 5a side can be made. Reference numeral 26n denotes a recess provided in the outer die surface 26 on the female die 2 side facing the screw hole 16n of the male die 1 and is illustrated only in FIGS. When the mold is closed, the head of the mounting bolt B (described later) of the thin plate 3 is accommodated in the recess 26n.

  The thin plate 3 corresponds to the plate surface 31 along the mold surface 11 of the male mold 1 and the outer region surface 16 outside the region Z of the mold surface 11, and outwards from the plate surface 31. It is a dish-shaped thin plate which has the area | region outer surface 36 extended. In FIG. 1, reference numeral Z <b> 3 indicates an area of the plate surface 31 that is opposite to the area Z of the mold surface 11. The thin plate 3 is a metal member obtained by pressing a thin plate made of a ferromagnetic material that is strongly attracted to a magnet, such as iron, nickel, cobalt, and alloys thereof. The thickness t of the main constituent member of the present invention is about 1 mm.

The thin plate 3 according to the present embodiment includes a curved plate surface 31 in contact with the mold surface 11 of the male mold 1 at the center, and an out-of-section mold of the male mold 1 extending outward from the plate surface 31. A substantially flat outer surface 36 that can be brought into contact with the surface 16. Then, a through-hole serving as the locked portion 36k is formed in a portion of the thin plate 3 where the outer surface 36 is present, and the thin plate 3 that can be detachably attached to the male mold 1 using the through-hole. To do.
When the plate surface 31 of the thin plate 3 is aligned with the mold surface 11 of the male mold 1 and the outer region surface 36 is aligned with the outer region surface 16, the female screw hole 16n is disposed at a position corresponding to the through hole 36k. . The thin plate 3 is screwed and fixed to the male mold 1 by passing the bolt B through the through hole 36k and screwing it into the female screw hole 16n (FIG. 2). When the thin plate 3 is attached and fixed to the male mold 1, the plate surface 31 of the thin plate 3 in contact with the male mold 1 covers the entire area of the mold surface 11 and closely contacts the mold surface 11. When the magnet M is disposed, the thin plate 3 is more securely adhered and held over the entire area of the mold surface 11, which is more preferable.
When the thin plate 3 is attached to the mold surface 11 of the male mold 1, the plate surface 32 of the thin plate 3 facing the mold surface 21 of the female mold 2 is connected to the mold surface 21 of the female mold 2. Then, a cavity for the ceiling material 5 is formed. Reference numeral 32a denotes a ceiling surface forming portion formed by the plate surface 32, and reference numeral 32b denotes a deep drawing forming portion. The tangible expression body 4 is provided on the plate surface 32 of the thin plate 3.

  The tangible representation 4 is formed by a plate piece 46 fixed on a plate surface 32 opposite to the plate surface 31 or is formed by hollowing out the plate surface 32, or the shape of a person or object, or It is a formation of a tangible two-dimensional expression consisting of geometric shapes. The two-dimensional shape by the plate piece surface 46m having a flat upper surface of the plate piece 46 shown in FIG. 1 or the two-dimensional shape by the hole or hole formed in the cutout shown in the second embodiment is a figure of a person or a figure or geometry of an object. It becomes a scientific form. Here, “human figure” includes characters such as anthropomorphic characters and animation. The “appearance of an object” is the shape of a tangible appearance of an animal, plant, vehicle, or building. When the ceiling material 5 is viewed from the passenger compartment, the entire object is in a two-dimensional expression. Or a partial shape such as a face.

  The tangible expression body 4 of this embodiment includes a plate piece 46. A recess 55c is formed in the design surface 5a of the ceiling material 5 by the plate piece 46, and the two-dimensional shape formed by the opening surface of the recess 55c creates a person, an object, or a geometric two-dimensional expression. The plate piece 46 is fixed to the thin plate 3 to form the thin plate 3 with the tangible expression 4. The thin plate 3 with the tangible expression 4 shown on the left side of FIG. 2 is a plan view of the thin plate 3 as viewed from the female die 2 side after being attached to the male die 1. The shape of the plate piece surface 46m, which is the plan view shape of the plate piece 46, is made into the shape of an animal bear as shown in FIG. 2, and the area of the plate piece 46 corresponds to the plate thickness h at the time of hot press molding of the ceiling material 5. The concave decorative figure 55 of FIG. 5 in the shape of a bear is drawn so as to be recessed from the surrounding ceiling material design surface 5a.

  The plate thickness h of the plate piece 46 is preferably in the range of 0.8 mm to 1.6 mm. This is because if the thickness is 0.8 mm or more, the concave decorative pattern 55 can be sufficiently visually recognized from the passenger compartment even if there is a spring back after hot press molding. On the other hand, if the thickness is 1.6 mm or less, the manufacturing of the ceiling material 5 proceeds smoothly, and the base material 7 such as a foam constituting the ceiling material 5 is generally 4 mm or more in thickness, which hinders the formation of the recess 55c. Because I will never come. The ceiling material 5 seen from the passenger compartment is shaded so that it is easy to see, and the depth of the concave portion 55c that becomes the bear decorative figure 55 is 0.6 mm. As shown in the enlarged view in a circle of FIG. 1, the side wall 461 of the plate piece 46 stands vertically with respect to the surrounding plate surface 32, and in particular, a corner portion is formed by the proximal end portion of the side wall 461 and the surrounding plate surface 32. It is preferable. This is because a sharp contour can be obtained on the concave decorative figure 55. In FIG. 2, the left direction of the drawing indicates the vehicle traveling direction, and eight (a plurality) of plate pieces 46 having a plate-like surface 46m in the shape of a bear are provided on the thin plate 3. However, only one piece may be used.

Using such a heat press mold T, the tangible representation 4 is made to face the surface material 9 of the laminated material 6, and the laminated plate 6 and the thin plate with the tangible representation 4 arranged on the male mold 1 side. 3 is sandwiched between a male mold 1 and a female mold 2 and hot press molded. Simultaneously with the molding of the ceiling material body 51, a hot press mold T is provided in which a concave decorative pattern 55 by the tangible expression 4 is provided on the design surface 5a on the surface material 9 side.
In the present embodiment, as described above, the thin plate 3 with the tangible expression 4 is detachably attached and fixed to the male mold 1. Therefore, the tangible expression body 4 is opposed to the design surface 9 a of the surface material 9 related to the laminate material 6, and the hot press molding is performed by sandwiching the laminate material 6 between the thin plate 3 with the tangible expression body 4 and the female mold 2. A mold T is obtained. Even if the decorative figure 55 is added, it is an easy heating press mold T that does not lead to an increase in the burden of the molding operation.

FIG. 6 shows a hot press mold T using the thin plate 3 with the tangible expression body 4 of another embodiment different from those shown in FIGS. 1 to 5 show a hot press mold T in which the entire area of the mold surface 11 of the male mold 1 is covered with the thin plate 3 by attaching the thin plate 3 with the tangible expression body 4 to the male mold 1. However, FIG. 6 shows a hot press mold T in which the thin plate 3 covers a predetermined width in the vehicle front-rear direction of the mold surface 11 of the male mold 1. A thin plate 3 having a certain width across the vehicle width direction at the rear of the vehicle is employed. In FIG. 6 (a), the thin plate 3 is attached to the male mold 1, and a plate surface 32 opposite to the plate surface 31 appears. A plate surface 31 along the region of the molding die surface 11 of the male mold 1 closer to the rear of the vehicle, and an outer surface 36 extending from the plate surface 31 in the vehicle width direction and extending outside the zone Z of the molding die surface 11. The thin plate 3 is provided. In the ceiling material 5 formed by hot press, a step is formed at the boundary between the portion where the thin plate 3 is present and the portion where the thin plate 3 is not present, but the step is treated as a design. Reference numeral 11a denotes a ceiling surface forming portion formed by the mold surface 11, and reference numeral 11b denotes a deep drawing portion forming portion.
Other configurations are the same as those shown in FIGS. In FIG. 6, the same reference numerals as those in FIGS. 1 to 5 denote the same or corresponding parts.

(1b) Manufacturing method of vehicle ceiling material The manufacturing method of the vehicle ceiling material 5 is a method in which a laminated material 6 is charged into a heating press mold T including a male mold 1 and a female mold 2 and is heated and pressed to be molded. . This is a method for manufacturing a vehicle ceiling material 5 in which a laminated material 6 in which a surface material 9 is laminated on a base material 7 made of foam or the like is subjected to hot press molding. The ceiling material 5 is formed, for example, as follows using the hot press mold T shown in FIGS.
Prior to molding the ceiling material 5, a hot press mold T including the pair of male mold 1, female mold 2 and the thin plate 3 with the tangible expression 4 is prepared (FIGS. 1 and 2). In addition, a laminated material 6 as a material to be molded to be formed on the ceiling material 5 is prepared.

  The laminated material 6 of an Example is a sheet-like body by which the surface material 9 was laminated | stacked on the sheet-like base material 7 which consists of hard foams. Specifically, as shown in the enlarged view in a circle of FIG. 3, a laminate 6 in which a base material 7 is sandwiched between reinforcing materials 8 and a surface material 9 is placed on the reinforcing material 8 on the design surface 5a side. is there. The base material 7 is made of, for example, a hard polyurethane foam and is a plate-like body having a thickness of about 4 mm to 6 mm. Rigid polyurethane foam is generally a foam that is composed of closed cells, undergoes plastic deformation with respect to compressive force, and has low resilience to the deformation. The base material 7 is impregnated with polyisocyanate such as MDI as an adhesive, and further sprayed with amine water that promotes the curing of the adhesive, and the base material 7, the reinforcing material 8 and the surface material 9 are bonded together with heating. It has become so. In this embodiment, a mesh reinforcing material 8 made of glass fiber is placed on both surfaces of a base material 7, and a fabric surface material 9 such as a nonwoven fabric made of polyester fiber is further provided on the reinforcing material 8 on the design surface side. The laminated material 6 is formed by being placed.

The manufacturing method of the ceiling material 5 for vehicles manufactures the product of the ceiling material 5 through each process of FIGS.
First, the tangible representation 4 is placed between the male mold 1 and the female mold 2 in the mold-opened state so as to face the surface material 9, and the tangible representation 4 placed on the laminated material 6 and the male mold 1 side. The attached thin plate 3 is set. Here, the thin plate 3 with the tangible representation 4 is attached and fixed to the male mold 1 in advance (attachment process of the thin plate with the tangible representation to the male mold).
The through hole 36k of the thin plate 3 with the tangible expression 4 is aligned with the female screw hole 16n provided in the outer region surface 16 of the male mold 1. Then, the bolt B passing through the through hole 36k is screwed into the female screw hole 16n, and the thin plate 3 with the tangible expression 4 is attached to the male die 1 so that the thin plate 3 covers the molding die surface 11. Fix (Fig. 2). With this mounting and fixing, the plate surface 31 of the thin plate 3 comes into contact with the mold surface 11, and the tangible expression 4 projects toward the female die 2 on the plate surface 32 of the thin plate 3.

  Next, the prepared laminated material 6 having a predetermined size is set between the male mold 1 and the female mold 2 under the mold open state of FIG. 3 (laminated material setting step). Specifically, the tangible representation 4 is opposed to the surface material 9, and the laminated material 6 and the thin plate 3 with the tangible representation 4 placed on the male mold 1 side are set. Since the thin plate 3 with the tangible expression 4 is already attached and fixed to the male mold 1, only the laminated material 6 is disposed and set between the thin plate 3 with the tangible expression 4 and the female mold 2. As shown in FIG. 3, the surface material 9 constituting the laminated material 6 is set so as to face the plate piece surface 46 m of the plate piece 46 which is the tangible expression body 4 protruding and protruding from the plate surface 32 of the thin plate 3.

  Subsequently, the male mold 1 is lowered and the mold is closed (mold closing process), and then, as shown in FIG. 4, the laminate 6 and the thin plate 3 with the tangible expression 4 are sandwiched between the male mold 1 and the female mold 2. The process proceeds to hot press molding. Simultaneously with the molding of the ceiling material main body 51, the concave decorative figure 55 by the tangible expression 4 is molded on the design surface 5a on the surface material 9 side (heating press molding process). Since the thin plate 3 with the tangible representation 4 is attached and fixed to the male mold 1, the thin plate 3 with the tangible representation 4 and the female die 2 may be subjected to hot press molding with the laminated material 6 interposed therebetween. Become. Simultaneously with the molding of the ceiling material body 51, the decorative figure 55 is transferred and molded on the design surface 5a on the surface material 9 side. The base material 7 made of hard polyurethane foam is plastically deformed by hot press molding, and the reinforcing material 8 and the surface material 9 are also deformed following this deformation, and are formed into the shape of the ceiling material 5 with the decorative figure 55. On the design surface 5a of the ceiling material 5 formed by hot press molding from the laminated material 6, a concave decorative figure 55 according to the shape of the bear is formed by a plate piece 46 shaped like the shape of a bear provided on the thin plate 3. Transfer molded.

After finishing the heat press molding and confirming the molding and hardening from the laminated material 6 having the base material 7 made of hard foam to the ceiling material 5, the ceiling material 5 is taken out (product demolding step). The male mold 1 is moved up to open the hot press mold T, and the ceiling material 5 is removed. Thereafter, unnecessary portions 56 and burrs 59 are removed to obtain a desired ceiling material 5 in which a concave decorative figure 55 formed by the tangible expression 4 is formed on the design surface 5a on the surface material 9 side.
Thereafter, the steps from the setting process of the laminated material 6 to the product demolding process are repeated, and the ceiling material 5 having the design surface 5a provided with the concave decorative pattern 55 by the tangible expression 4 is sequentially manufactured.

(2) Embodiment 2
Whereas the first embodiment is the ceiling material 5 provided with the concave decorative figure 55 on the design surface 5a, the present embodiment is the vehicle ceiling material provided with the convex decorative figure 55 on the design surface 5a. 5 and the hot press mold T used in the manufacturing method. 7A is a plan view of a thin plate with a tangible expression body, FIG. 7B is a longitudinal sectional view of FIG. 8A, and FIG. 9 is an explanatory cross-sectional view for setting a thin plate with a tangible expression body, FIG. 9 is an explanatory cross-sectional view after mold closing and hot press molding after FIG. 8, and FIG. 10 is a view of demolding after FIG. FIG.

(2a) Heat press mold This embodiment is a tangible two-dimensional shape consisting of a human figure, a figure of a person or a geometric shape formed by hollowing out the tangible representation 4 on the plate surface 32 of the thin plate 3. It is assumed to be a formation of a physical expression. The plate piece 46 does not exist. The tangible representation 4 becomes the thin plate 3 with the tangible representation 4 in which the plate surface 32 is directly cut and formed. The tangible representation 4 is formed as a two-dimensional representation formed by penetrating the thin plate 3 as shown in FIG. 7 and having the shape of the through hole 40 shaped like a bear. The convex shape of FIG. 10 in which a portion corresponding to the thickness of the thin plate 3 is raised from the surrounding ceiling material design surface 5a in the hole area of the through hole 40 at the time of hot press molding of the ceiling material 5 to form a bear shape. A decorative figure 55 is drawn. The plate thickness t of the thin plate 3 is about 1 mm, and even if there is a spring back after hot press molding, the convex decorative figure 55 can be sufficiently visually recognized from the passenger compartment. The through hole 50 is preferably formed by drilling with a laser processing machine or the like. This is because the cut end has a sharp edge and the contour of the decorative figure 55 can be clearly displayed. Other configurations are the same as those of the first embodiment, and the description thereof is omitted. The same reference numerals as those in the first embodiment denote the same or corresponding parts.

(2b) Manufacturing method of vehicle ceiling material Prior to molding of the ceiling material 5, the pair of male mold 1, female mold 2, and the thin plate 3 with the tangible expression body 4 described above formed by hollowing out the tangible expression body 4, Are prepared (FIG. 7). In manufacturing the ceiling member 5, the thin plate 3 with the tangible representation 4 is attached and fixed to the male mold 1 in advance (the step of attaching the thin plate with the tangible representation to the male mold).

  Next, the prepared laminated material 6 having a predetermined size is set between the male mold 1, specifically, the thin plate 3 with the tangible expression 4 and the female mold 2 under the mold open state of FIG. Set process). Subsequently, the male mold 1 is lowered and the mold is closed (mold closing process), and thereafter, the laminate 6 and the thin plate 3 with the tangible expression 4 are sandwiched between the male mold 1 and the female mold 2 as shown in FIG. Shift to hot press molding. Simultaneously with the molding of the ceiling material main body 51, a convex decorative figure 55 by the tangible representation 4 is molded on the design surface 5a on the surface material 9 side (heating press molding process). On the design surface 5a of the ceiling material 5 formed by hot press molding from the laminated material 6, the decorative figure 55 of the convex portion 55u as the shape of the bear is transferred and molded by the tangible expression body 4 of the hollow hole 40.

  Finish the hot press molding and take out the ceiling material 5 (product demolding process). Thereafter, the unnecessary portion 56 and the burr 59 are removed, and the desired ceiling material 5 in which the convex decorative figure 55 by the tangible expression 4 is formed on the design surface 5a on the surface material 9 side is obtained. Other configurations are the same as those of the first embodiment, and the description thereof is omitted. The same reference numerals as those in the first embodiment denote the same or corresponding parts.

(3) Effect According to the method for manufacturing a vehicle ceiling material configured as described above and the hot press mold used for the vehicle ceiling material, using the pair of male mold 1 and female mold 2, The ceiling material 5 with the decorative figure 55 in the recess 55c and the ceiling material 5 without the decorative figure 55 can be easily made separately. Considering the cost so far that two heating press molds T had to be prepared, the initial cost is greatly reduced.
If the laminated material 6 and the thin plate 3 with the tangible expression 4 disposed on the side of the male mold 1 are sandwiched between the male mold 1 and the female mold 2 and are subjected to hot press molding, the tangible expression is expressed on the design surface 5a. The ceiling material 5 on which the concave or convex decorative figure 55 by the body 4 is transferred and molded is obtained. If only the thin plate 3 is used instead of the thin plate 3 with the tangible expression body 4, the ceiling material 5 without the decorative figure 55 can be easily manufactured. Although the thin plate 3 becomes a spacer, the thickness t of the thin plate 3 is thin, so that there is no decorative figure 55 using only the pair of male mold 1 and female mold 2 without the thin plate 3. The ceiling material 5 may be made.

  Moreover, if the thin plate 3 with the tangible representation 4 having various tangible representations 4 is prepared, the ceiling having various types of decorative figures 55 can be obtained simply by preparing a pair of male mold 1 and female mold 2. The material 5 can be manufactured at low cost. The attachment to the car is enhanced when the decorative figure 55, which is formed by the tangible expression 4 composed of the figure of the person or object of interest, is provided on the ceiling material design surface 5a. With the decorative figures 55 that children like, they can ride happily without getting bored even while the vehicle is running.

  Furthermore, since the thin plate 3 with the tangible representation 4 is a pressed product such as a thin iron plate, unlike the nesting R in FIG. 11, it can be reduced in weight and is easy to use, and the replacement operation can be smoothly performed. . There is no problem that the parting line PL appears on the ceiling design surface 5a as in the case of using the insert R. Also, unlike when digging directly, repairs in case of damage are easier. Even when it is dirty, the thin plate 3 with the tangible expression 4 can be removed, so that the dirt can be easily removed.

  In addition, a locked portion 36k formed at a portion of the thin plate 3 where the outer surface 36 is present is further provided, and the male mold 1 is thinly attached with the tangible expression 4 using the locked portion 36k. If the laminated plate 6 is detachably attached and fixed and the laminated material 6 is hot press-molded, the ceiling material 5 can be easily formed. Since the thin plate 3 with the tangible representation 4 is attached and fixed to the male mold 1, the laminated material 6 is arranged between the thin plate 3 with the tangible representation 4 and the female die 2 when the mold is opened. All you need is a set.

  The present invention is not limited to those shown in the above-described embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. The shape, size, number, material, and the like of the male mold 1, the female mold 2, the thin plate 3, the tangible expression 4, the ceiling material 5, the laminated material 6 and the like can be appropriately selected according to the application. In the present embodiment, a hard foam is used as the base material 7, but a glass fiber mixed into an aggregate of olefinic thermoplastic resin fibers such as polypropylene and polyethylene may be used as the base material. Good. Further, in the present embodiment, the tangible representation 4 that has the shape of an animal bear is used. However, for example, the tangible representation 4 that has the shape of another animal, a vehicle, or a building can be used.

DESCRIPTION OF SYMBOLS 1 Male mold 11 Mold surface 2 Female mold 3 Thin plate 31 Plate surface 32 Plate surface 36 Area outer surface 36k Locked part (through hole)
4 Tangible representation 40 Holes (through holes)
46 Plate piece 5a Design surface 51 Ceiling material body 55 Decorated figure 6 Laminated material 7 Base material 9 Surface material T Heat press mold

Claims (3)

A heating press for a vehicle ceiling material, comprising a male die (1) and a female die (2), wherein the laminated material (6) in which the surface material (9) is laminated on the base material (7) is hot-press molded. A mold,
A thin plate (3) having a plate surface (31) along the mold surface (11) of the male mold (1) and an outer surface (36) extending outward from the plate surface; and the plate surface A tangible expression (4) formed of a plate piece (46) fixed on the plate surface (32) opposite to (31) or formed by hollowing out on the plate surface (32), Equipped
The tangible representation (4) is opposed to the surface material (9), and the laminated material (6) and a thin plate (3) with a tangible representation (4) arranged on the male mold (1) side than this (3) ) Is sandwiched between the male mold (1) and the female mold (2) and subjected to hot press molding, and simultaneously with the molding of the ceiling material body (51), on the design surface (5a) on the surface material (9) side. A heating press molding die for a ceiling material for a vehicle, wherein a concave or convex decorative figure (55) by the tangible expression (4) is transferred and molded. It further includes a locked portion (36k) formed at a portion of the thin plate (3) where the outer surface (36) is present, and using the locked portion (36k), a male mold (1 2. A heating press molding die for a vehicle ceiling material according to claim 1, wherein a thin plate (3) with a tangible expression body (4) is detachably mounted and fixed to the vehicle ceiling material. A method for manufacturing a vehicular ceiling material, comprising a male mold (1) and a female mold (2), wherein a laminate (6) in which a surface material (9) is laminated on a substrate (7) is subjected to hot press molding. And
A thin plate (3) having a plate surface (31) along the mold surface (11) of the male mold (1) and an outer surface (36) extending outward from the plate surface; and the plate surface A tangible expression (4) formed of a plate piece (46) fixed on the plate surface (32) opposite to (31) or formed by hollowing out on the plate surface (32), Using the hot press mold provided,
Between the male mold (1) and the female mold (2) in the mold open state, the tangible expression body (4) is opposed to the surface material (9), and the laminated material (6) is more Set the thin plate (3) with a tangible expression (4) placed on the male mold (1) side, then close the mold, then heat press mold, simultaneously with the ceiling material body (51) molding A method for producing a vehicular ceiling material, comprising transferring and molding a concave or convex decorative figure (55) made of a tangible expression (4) on a design surface (5a) on the surface material (9) side.

Images