JPH05200873A - Manufacture of molded product with ornament - Google Patents

Abstract

PURPOSE:To reduce labor, time and cost by manufacturing a molded product with an ornament stuck on a part of a synthetic resin skin material in a small number of processes. CONSTITUTION:An ornament 30 with a hotmelt film bonding agent on its rear face is pressure molded by an ornament molding site 4 of a first breathable molding tool 1 and a second molding tool 12 and sucked and retained on the ornament molding site 4. A base 34 with a bonding agent coated on its surface is set in a third molding tool 18. A heated synthetic resin skin material 37 is pressure molded by the first breathable molding tool 1 and the third molding tool 18 and vacuum molded by the first breathable molding tool 1, and simultaneously the synthetic resin skin material 37 is pressurized and stuck on the surface of the base 34 by means of a bonding agent, and the ornament 30 is pressurized snd stuck on a part of the surface of the synthetic resin skin material 37 by a hotmelt film bonding agent 32.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a molded article such as an automobile door trim having an ornament attached to a part of its surface.

[0002]

2. Description of the Related Art Most of automobile door trims are made by attaching a synthetic resin skin material with a grain pattern on the surface of a base material for decoration. An ornament made of a woven or knitted fabric is attached to the center of the resin skin material. Conventionally, such a door trim is manufactured by forming and sticking a synthetic resin skin material on a base material in advance, as shown in Japanese Patent Laid-Open No. 2-111526, and then applying it to the surface of the synthetic resin skin material. It was done by molding and sticking ornaments by processing.

[0003]

However, in this method of manufacturing a door trim, the steps of forming and attaching the synthetic resin skin material and the step of attaching the ornament are separated, so that the number of steps is large and therefore a great deal of labor is required. There was a problem that it took time and cost.

An object of the present invention is to produce a molded article in which an ornament is attached to a part of a synthetic resin skin material in a small number of steps, and thus to save labor, time and cost. An object of the present invention is to provide a method for manufacturing a molded article with an ornament.

[0005]

In order to achieve the above object, a method for producing a molded article with an ornament according to the present invention comprises an ornament having a hot melt adhesive on the back surface thereof, and an ornament molding of a first breathable molding die. The part is pressed with the second mold and the suction is held in the ornament molding part. At the same time, the trimming of the marginal excess part of the ornament is performed, and the base material with the adhesive applied to the surface is used as the third mold. The step of setting and the heated synthetic resin skin material are pressure-molded by the first breathable molding die that holds the ornament by suction and the third molding die that sets the base material, and by the first breathable molding die. Vacuum forming, and at the same time, pressurize the synthetic resin skin material on the surface of the base material and stick with the adhesive, and press the ornament on a part of the surface of the synthetic resin skin material before And configured to include a step of attaching a hot-melt adhesive.

Examples of the material of the "ornament" include woven fabric, knitted fabric, natural leather, synthetic leather and the like.
The "hot melt adhesive" is preferably provided so as to make the ornament non-breathable or low breathable, and for example, a hot melt film adhesive can be used.
The material of the "synthetic resin skin material" is a general thermoplastic resin, and may have a single-layer structure or a multi-layer structure including a foamed synthetic resin sheet or the like. Examples of the material of the "base material" include wood board, synthetic resin, rubber and the like.

[0007]

According to the method for producing a molded article with an ornament of the present invention, the molding of the synthetic resin skin material and the sticking to the base material, and the sticking of the ornament to the synthetic resin skin material,
Since the steps can be performed simultaneously in one step, the number of steps is reduced.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment in which the present invention is embodied in a method for manufacturing an automobile door trim will be described below with reference to the drawings. First, the apparatus used in this embodiment will be described. As shown in FIGS. 1 and 2, the first breathable mold 1
A breathable electroformed shell 2 is used for. The air-permeable electroformed shell 2 is manufactured, for example, by the method disclosed in Japanese Patent Publication No. 2-14434, and a large number of vent holes 3 whose diameter is increased toward the back side are formed simultaneously with electroforming. In addition, a grain pattern is formed on the molding surface, and a convex strip 5 is formed around the convex ornament molding portion 4 in the center of the molding surface.

A support frame 6 is provided on the rear peripheral portion of the air-permeable electroformed shell 2.
Is attached, and its upper end is closed by the base 7, thereby forming a decompression chamber on the back surface of the air-permeable electroformed shell 2.
This decompression chamber is provided with a partition plate 9 for the ornament molding portion 4
It is divided into a first decompression chamber 8a on the back side and a remaining second decompression chamber 8b, and a decompression device 22 such as a vacuum pump is connected to each decompression chamber 8a, 8b via a valve 24 or the like. . The back surface of the air-permeable electroformed shell 2 is a filler in which a large number of metal balls 10 (for example, steel balls) are hardened with an epoxy resin so as not to lose air permeability between the balls (for convenience of drawing, some of them are omitted for illustration. Backed up). In addition, a cooling pipe 1 through which cooling water flows is provided on a rear surface of the breathable electroformed shell 2.
1 is provided.

As shown in FIGS. 1 and 2, the second molding die 12 for ornament molding is made of an epoxy resin having a molding surface having a shape corresponding to the ornament molding portion 4 of the first breathable molding die 1. A mold body 13 is provided, and the mold body 13 is a base 1.
4 is supported by a guide member 15 and a spring 16 so as to be vertically movable. A cutting blade 17 with a heater for heating, which is fixed to a base 14, is arranged around the mold body 13. As shown in FIGS. 4 and 5, the third molding die 18 for the base material set includes a mold body 19 made of epoxy resin having a molding surface having a shape corresponding to that of the first breathable molding die 1. A concave groove 20 is formed in a portion of the breathable mold 1 corresponding to the ridge 5. The back surface of the mold body 19 is supported by the base 21.

Now, a method of manufacturing a door trim, which is carried out by using the above apparatus, will be described in the order of steps. (1) Ornament Molding Step As shown in FIG. 1, an ornament 30 having a chucked peripheral edge is set between the ornament molding portion 4 of the first breathable molding die 1 and the second molding die 12. This ornament 30 is composed of a woven fabric 31 having a thickness of about 1 mm and a non-breathable hot melt film adhesive 32 having a thickness of about 0.05 mm and attached to the back surface thereof. The hot melt film adhesive 32 is set in the mold 1 so as to face the second mold 12. Then, as shown in FIG. 2, the two molding dies 1 and 12 are put together, and the following steps 1 to 3 are performed at the same time.

The ornament 30 is pressure-molded into a three-dimensional shape. The decompression device 22 decompresses the first decompression chamber 8a of the first breathable mold 1, and the ornament 30 is suction-held at the ornament molding site 4. At this time, since the ornament 30 is made non-breathable by the hot melt film adhesive 32, it is surely sucked. The peripheral edge surplus portion 33 of the ornament 30 is trimmed by the cutting blade 17 with the heater for heating which hits the ridge 5.

(2) Base Material Setting Step As shown in FIG. 4, the base material 34 is set on the upper surface of the third molding die 18. The base material 34 is formed of a breathable wood board having a thickness of about 2 mm, and a groove 36 is formed around a concave ornament attachment portion 35 at the center of the surface. An adhesive (not shown) is applied to the surface of the base material 34 in advance.

(3) Steps of forming / attaching synthetic resin skin material and attaching ornaments The synthetic resin skin material 37 having the peripheral edge chucked is heated by the heater 23 as shown in FIG. As shown, it is set between the first breathable mold 1 and the third mold 18. The synthetic resin skin material 37 has a thickness of about 0.
A thermoplastic synthetic resin sheet 38 having a thickness of 3 mm and a foam synthetic resin sheet 39 having a thickness of about 3 mm attached to the back surface thereof are used. The thermoplastic synthetic resin sheet 38 is used as the first breathable mold 1 and the foam synthetic resin. The sheets 39 are set toward the third molding dies 18, respectively. Subsequently, as shown in FIGS. 5 and 6, the two molding dies 1 and 18 are combined and the following steps 1 to 5 are simultaneously performed.

The synthetic resin skin material 37 is pressure-molded into a three-dimensional shape. The second decompression chamber 8b of the first air-permeable mold 1 is decompressed by the decompression device 22, the synthetic resin skin material 37 is recessed and vacuum-formed in the first air-permeable mold 1, and the embossed pattern is transferred and shaped. The synthetic resin skin material 37 is pressed onto the surface of the base material 34, and is adhered by an adhesive on the surface. The ornament 30 is pressed onto the surface of the synthetic resin skin material 37, and is adhered by the hot melt film adhesive 32 melted by the heat of the synthetic resin skin material 37. The ridge 5 of the first breathable mold 1 and the groove 36 of the base material 34
By fitting with the
Wrap around the inner wall of the. Therefore, the ornament 30 can be attached with good positioning accuracy and neatly.

(4) Mold release process When the first breathable mold 1 and the third mold 18 are opened, a door trim 40 as shown in FIG. 7 is obtained. The peripheral marginal portion of the synthetic resin skin material 37 is trimmed at the time of mold matching in the previous step or after mold release.

The present invention is not limited to the configuration of the above-described embodiment, but may be embodied by being modified without departing from the spirit of the invention, for example, as follows. (1) As the first breathable mold, for example, an electroforming mold having a vent hole subjected to laser processing, a breathable ceramic mold, or the like can be used. (2) The present invention can also be embodied in automobile interior products other than door trims, furniture, electric appliance cases, and other various molded products.

[0018]

EFFECTS OF THE INVENTION Since the method for producing a molded article with an ornament of the present invention is configured as described above, it is possible to manufacture a molded article in which an ornament is attached to a part of a synthetic resin skin material with a small number of steps. Therefore, there is an excellent effect that labor, time and cost can be reduced.

[Brief description of drawings]

FIG. 1 is a cross-sectional view before mold matching in a step of forming an ornament according to an embodiment.

FIG. 2 is a cross-sectional view during mold matching in the same process.

FIG. 3 is a cross-sectional view of a synthetic resin skin material during heating.

FIG. 4 is a cross-sectional view of a synthetic resin skin material before molding, in a step of forming / sticking and in a step of sticking an ornament.

FIG. 5 is a cross-sectional view at the time of mold matching in the same process.

6 is an enlarged cross-sectional view of a main part in FIG.

FIG. 7 is a cross-sectional view of the manufactured door trim.

[Explanation of symbols]

1 First Breathable Mold 4 Ornament Molding Part 12 Second Mold 18 Third Mold 30 Ornament 31 Textile 32 Hot Melt Film Adhesive 33 Peripheral Excess 34 Base Material 37 Synthetic Resin Skin 38 Thermoplastic Synthetic Resin Sheet 39 Foam synthetic resin sheet 40 Door trim

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI Technical display area B29L 9:00 4F 31:58 4F

Claims (1)

[Claims] 1. An ornament having a hot melt adhesive on its back surface is pressure-molded by an ornament molding portion of a first breathable molding die and a second molding die and is suction-held at the ornament molding portion, at the same time. The step of trimming the peripheral marginal part of the ornament, the step of setting the base material with the adhesive applied to the surface in the third molding die, the first breathable molding in which the heated synthetic resin skin material is sucked and held by the ornament The adhesive is obtained by pressure-forming with a mold and a third molding die in which the base material is set and vacuum-forming with the first breathable molding die, and at the same time, pressing a synthetic resin skin material on the surface of the base material. And a step of applying an ornament to a part of the surface of the synthetic resin skin material and adhering it with the hot melt adhesive.