JP6215023B2 - Method for manufacturing vehicle interior material - Google Patents

Method for manufacturing vehicle interior material Download PDF

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JP6215023B2
JP6215023B2 JP2013245987A JP2013245987A JP6215023B2 JP 6215023 B2 JP6215023 B2 JP 6215023B2 JP 2013245987 A JP2013245987 A JP 2013245987A JP 2013245987 A JP2013245987 A JP 2013245987A JP 6215023 B2 JP6215023 B2 JP 6215023B2
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skin material
mold
skin
thermoplastic resin
molding
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JP2015101079A (en
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長尾　誠
誠 長尾
悠大 児島
悠大 児島
圭 岡
圭 岡
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Nanjo Auto Interior Co Ltd
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  • Injection Moulding Of Plastics Or The Like (AREA)

Description

本発明は、ドアトリムやインストルメントパネル等の車両用内装材の製造方法に関する。   The present invention relates to a method for manufacturing a vehicle interior material such as a door trim or an instrument panel.

従来より、車両用内装材には、パネル状の基材表面を表皮材で覆って形成したものが知られ、例えば、特許文献１では、シボ模様を表面に有する表皮材本体を樹脂で成形するとともに、該表皮材本体に縫糸でステッチ（刺繍）を施して表皮材を得た後、他の工程で射出成形した基材を接着剤等で上記表皮材の裏面側に貼り付けて車両用内装材を得ている。   2. Description of the Related Art Conventionally, vehicle interior materials are known in which a panel-like base material surface is covered with a skin material. For example, in Patent Document 1, a skin material body having a texture pattern on the surface is molded with a resin. In addition, after the skin material is stitched (embroidered) with a thread, the skin material is obtained, and then the base material injection-molded in another process is attached to the back surface side of the skin material with an adhesive or the like. I have the material.

特開２０１３−２１６２４２号公報JP 2013-216242 A

ところで、特許文献１では、表皮材と基材とを別々の工程で得た後、表皮材の裏面に接着剤等で基材を貼り付けて車両用内装材を得るので、製造に手間がかかり煩雑である。   By the way, in patent document 1, after obtaining a skin material and a base material by a separate process, a base material is affixed with the adhesive agent etc. on the back surface of a skin material, and an interior material for vehicles is obtained, Therefore A manufacturing takes time. It is complicated.

これに対応するために、例えば、表皮材本体にステッチを施して表皮材を得た後、型開きした射出成形型の一方の型に上記表皮材をセットするとともに、型閉じ後の射出成形型のキャビティに熱可塑性樹脂を充填して基材を得ることにより、基材を射出成形すると同時に表皮材と基材とを一体にする方法が考えられる。   In order to cope with this, for example, after the skin material body is stitched to obtain the skin material, the skin material is set in one of the molds of the injection-molded mold that is opened, and the injection mold after the mold is closed A method of consolidating the skin material and the base material simultaneously with injection molding of the base material is conceivable by filling the cavity with a thermoplastic resin to obtain the base material.

しかし、上述の方法を採用すると、表皮材本体には、縫糸でステッチを施す際に多数の針孔が形成されているので、射出成形型のキャビティ内に熱可塑性樹脂を充填する際に針孔周縁部と縫糸との間が広い隙間（例えば、曲率半径の小さいコーナー部に施したステッチの針孔）から樹脂が表皮材の表面側に漏れ出してしまい、射出成形後の車両用内装材の意匠性が低下してしまうおそれがある。   However, when the above-described method is adopted, since a large number of needle holes are formed in the skin material body when stitching with a sewing thread, the needle holes are used when filling the cavity of the injection mold with the thermoplastic resin. The resin leaks out to the surface side of the skin material from the wide gap between the peripheral edge and the sewing thread (for example, the needle hole of the stitch made in the corner portion with a small radius of curvature), and the interior of the vehicle interior material after injection molding There is a possibility that the designability is lowered.

さらに、上述の如きステッチが施された車両用内装材に対して、長い期間使用しても縫糸が緩むことなく高い意匠性を維持したいという要求もある。   Furthermore, there is also a demand for maintaining a high design without causing the sewing thread to loosen even when used for a long period of time for a vehicular interior material that has been stitched as described above.

本発明は、斯かる点に鑑みてなされたものであり、その目的とするところは、高い意匠性を長い期間維持することができ、しかも、効率良く製造できる車両用内装材の製造方法を提供することにある。   The present invention has been made in view of such a point, and an object of the present invention is to provide a method for manufacturing a vehicle interior material that can maintain high designability for a long period of time and can be manufactured efficiently. There is to do.

上記の目的を達成するために、本発明は、基材を射出成形する際に当該基材と表皮材とを一体にするとともに、表皮材本体の針孔を介して熱可塑性樹脂が表皮材の表面側に移動しないよう工夫を凝らしたことを特徴とする。   In order to achieve the above object, the present invention integrates the base material and the skin material when the base material is injection-molded, and the thermoplastic resin is made of the skin material through the needle holes of the skin material body. The feature is that it has been devised not to move to the surface side.

具体的には、パネル状の基材と、該基材の表面側を覆う可撓性表皮材とを備えた車両用内装材の製造方法において、次のような解決手段を講じた。   Specifically, the following solution was taken in a method for manufacturing an interior material for a vehicle including a panel-like base material and a flexible skin material covering the surface side of the base material.

すなわち、第１の発明では、表皮材成形型で熱可塑性樹脂からなる表皮材本体を成形した後、上記表皮材成形型を型開きして上記表皮材本体を取り出し、その後、上記表皮材本体に縫糸でステッチを施して上記表皮材とし、次いで、上記表皮材をセットする第１型と、該第１型に対向配置され、上記基材の裏面側の形状に対応する成形面を有する第２型とを備えた射出成形型を用意し、該射出成形型を型開きした状態で、上記表皮材裏面側におけるステッチ形成部分の少なくとも一部を液漏防止手段で覆った上記表皮材を上記液漏防止手段が上記第２型に向くよう上記第１型にセットするか、又は、上記表皮材を上記第１型にセットした後、上記表皮材裏面側におけるステッチ形成部分の少なくとも一部を上記液漏防止手段で覆い、しかる後、上記射出成形型を型閉じして上記第１型にセットされた表皮材裏面と上記第２型の成形面との間に形成されたキャビティ内に熱可塑性樹脂を充填して上記基材を得ることを特徴とする。 That is, in the first invention, after molding the skin material body made of thermoplastic resin with the skin material molding die, the skin material molding die is opened and the skin material body is taken out, and then the skin material body A first die for setting the skin material by stitching with a sewing thread, and a second mold having a molding surface corresponding to the shape on the back surface side of the base material, which is disposed opposite to the first mold. An injection mold having a mold is prepared, and in the state where the injection mold is opened, the skin material in which at least a part of the stitch forming portion on the back surface side of the skin material is covered with a liquid leakage preventing means is used as the liquid. After setting the first mold so that the leakage prevention means is directed to the second mold, or after setting the skin material to the first mold, at least a part of the stitch formation portion on the back side of the skin material is the above Cover with liquid leakage prevention means, and then The injection mold is closed and a thermoplastic resin is filled into a cavity formed between the back surface of the skin material set on the first mold and the molding surface of the second mold to obtain the substrate. It is characterized by that.

第２の発明では、第１の発明において、上記表皮材裏面側におけるステッチ形成部分の全体のうちの一部のみを液漏防止手段で覆うことを特徴とする。The second invention is characterized in that, in the first invention, only a part of the entire stitch forming portion on the back surface side of the skin material is covered with the liquid leakage preventing means.

第３の発明では、第１又は第２の発明において、上記液漏防止手段は、上記表皮材裏面側におけるステッチ形成部分の一部に貼り付ける熱可塑性の樹脂シート材であることを特徴とする。 In a third invention, in the first or second invention, the liquid leakage preventing means is a thermoplastic resin sheet material to be attached to a part of the stitch forming portion on the back surface side of the skin material. .

第１及び第２の発明では、射出成形型内で基材を射出成形すると同時に、表皮材と基材とが一体になるので、表皮材と基材とを別々の工程で得た後、表皮材裏面に接着剤等で基材を貼り付けるといった煩雑な作業を回避することができ、効率良く車両用内装材を製造することができる。また、基材を射出成形する際、射出成形型のキャビティに充填する熱可塑性樹脂が針孔を通過して表皮材本体の表面側に移動するのを液漏防止手段が防ぐので、表皮材本体の表面側に熱可塑性樹脂が漏れて成形後の車両用内装材の意匠性が低下してしまうといったことがない。さらに、表皮材本体に施したステッチの表皮材裏面側が基材で固定されるので、縫糸が緩むことなく高い意匠性を維持したまま車両用内装材を長い期間使用できる。 In the first and second inventions, since the base material is injection-molded in the injection mold and the skin material and the base material are integrated, the skin material and the base material are obtained in separate steps, and then the skin is obtained. It is possible to avoid a complicated operation of attaching a base material to the back surface of the material with an adhesive or the like, and to efficiently manufacture an interior material for a vehicle. In addition, when the base material is injection molded, the liquid leakage preventing means prevents the thermoplastic resin filling the cavity of the injection mold from passing through the needle hole and moving to the surface side of the skin material body. This prevents the thermoplastic resin from leaking to the surface side of the vehicle and the design of the molded vehicle interior material from being deteriorated. Furthermore, since the back surface side of the skin material of the stitches applied to the skin material body is fixed by the base material, the vehicle interior material can be used for a long period of time while maintaining a high design without loosening the sewing thread.

第３の発明では、ステッチの表皮材本体裏面側を覆う作業を定量的に、且つ、簡単に行えるようになり、製造する内装材の品質がばらつき難くなるとともに、作業者の作業工数を低減させることができる。 In the third invention, the work of covering the back side of the skin material body of the stitch can be performed quantitatively and easily, the quality of the interior material to be manufactured is less likely to vary, and the number of work steps of the operator is reduced. be able to.

車両用ドアを車室内側から見た斜視図である。It is the perspective view which looked at the door for vehicles from the vehicle interior side. （ａ）は、図１のＡ−Ａ線における断面図であり、（ｂ）は、（ａ）のＣ部拡大図である。(A) is sectional drawing in the AA of FIG. 1, (b) is the C section enlarged view of (a). （ａ）は、図１のＢ−Ｂ線における断面図であり、（ｂ）は、（ａ）のＤ部拡大図であり、（ｃ）は、（ｂ）のＨ−Ｈ線における断面図である。(A) is sectional drawing in the BB line of FIG. 1, (b) is the D section enlarged view of (a), (c) is sectional drawing in the HH line of (b). It is. 本発明の実施形態に係る車両用内装材の製造方法の手順を示すブロック図である。It is a block diagram which shows the procedure of the manufacturing method of the vehicle interior material which concerns on embodiment of this invention. 本発明の実施形態に係る表皮材本体を成形する真空成形型の断面図であり、（ａ）は、真空成形している途中の状態を、（ｂ）は、（ａ）のＥ部拡大図を示す。It is sectional drawing of the vacuum forming die which shape | molds the skin material main body which concerns on embodiment of this invention, (a) is the state in the middle of vacuum forming, (b) is the E section enlarged view of (a). Indicates. 本発明の実施形態に係る車両用内装材を成形する射出成形型の断面図であり、（ａ）は、射出成形型に表皮材をセットした直後の状態を、（ｂ）は、（ａ）のＦ部拡大図を示す。It is sectional drawing of the injection mold which shape | molds the vehicle interior material which concerns on embodiment of this invention, (a) is the state immediately after setting a skin material to an injection mold, (b) is (a). The F section enlarged view of is shown. 射出成形型を型閉じし、キャビティに熱可塑性樹脂を注入した直後の状態を示す。The state immediately after the injection mold is closed and the thermoplastic resin is injected into the cavity is shown. （ａ）は、射出成形型で基材を射出成形した直後の状態を、（ｂ）は、（ａ）のＧ部拡大図を示す。(A) shows the state immediately after injection-molding a base material with an injection mold, (b) shows the G section enlarged view of (a). 射出成形型を型開きし、車両用内装材を射出成形型から取り出した直後の状態を示す。The state immediately after opening the injection mold and taking out the vehicle interior material from the injection mold is shown.

以下、本発明の実施形態を図面に基づいて詳細に説明する。尚、以下の好ましい実施形態の説明は、本質的に例示に過ぎない。   Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiment is merely exemplary in nature.

図１は、本発明の実施形態の製造方法で製造されたドアトリム１（車両用内装材）を備えた車両用ドアＷを示す。上記ドアトリム１は、車両前後方向に延びるパネル状をなし、車室内側に面するようにドアパネル上部（図示せず）に取り付けられ、車両前後方向の前側部分には、ドアレバーＷ２用の開口１ａが形成されている。尚、車両用ドアＷのおけるドアトリム１の下方には、車両前後方向に延びるアームレストＹが配設され、該アームレストＹの車両前側には、ウインドウスイッチＹ１が、上記アームレストＹの車両後側の凹陥部Ｙ２には、乗員が把持する把持部Ｙ３がそれぞれ設けられている。   FIG. 1 shows a vehicle door W provided with a door trim 1 (vehicle interior material) manufactured by the manufacturing method of the embodiment of the present invention. The door trim 1 has a panel shape extending in the vehicle front-rear direction and is attached to an upper portion of the door panel (not shown) so as to face the vehicle interior side. An opening 1a for the door lever W2 is provided at the front side portion in the vehicle front-rear direction. Is formed. An armrest Y extending in the vehicle front-rear direction is disposed below the door trim 1 of the vehicle door W. A window switch Y1 is provided on the vehicle front side of the armrest Y, and a recess on the vehicle rear side of the armrest Y is provided. The portion Y2 is provided with a gripping portion Y3 that the occupant grips.

上記ドアトリム１は、その上部が車両上方に行くにつれて車室外側に緩やかに湾曲しており、図２及び図３に示すように、パネル状の樹脂製基材２と、該基材２の表面側（車室内側）を覆う可撓性表皮材３とを備え、上記表皮材３の裏面側に上記基材２が一体となっている。   The upper part of the door trim 1 is gently curved toward the vehicle exterior as the vehicle goes upward. As shown in FIGS. 2 and 3, a panel-shaped resin base material 2 and the surface of the base material 2 are provided. A flexible skin material 3 covering the side (vehicle interior side), and the base material 2 is integrated with the back surface side of the skin material 3.

上記表皮材３は、熱可塑性樹脂９からなる表皮材本体３０を備えている。該表皮材本体３０は、当該表皮材本体３０の表面を構成する表皮３ａと、該表皮３ａの裏面側を覆う発泡体３ｂとを備え、上記表皮３ａと上記発泡体３ｂとは接着剤等で一体にされている。   The skin material 3 includes a skin material body 30 made of a thermoplastic resin 9. The skin material body 30 includes a skin 3a constituting the surface of the skin material body 30 and a foam 3b covering the back side of the skin 3a. The skin 3a and the foam 3b are made of an adhesive or the like. It is united.

上記表皮３ａの上部には、車両前後方向に延びる線状の凹条溝３ｃが凹陥形成され、図１乃至図３に示すように、上記表皮材本体３０の上記凹条溝３ｃに縫糸４でステッチ４０を施して上記表皮材３を得るようになっている。   A linear groove 3c extending in the vehicle front-rear direction is formed in the upper portion of the skin 3a. As shown in FIGS. 1 to 3, the groove 4c of the skin main body 30 is threaded into the groove 3c. The skin material 3 is obtained by applying the stitch 40.

上記ドアトリム１は、図４に示すように、真空成形する第１成形工程１０ａと、縫製を行う縫製工程１０ｂと、加工を施す加工工程１０ｃと、射出成形する第２成形工程１０ｄとを順に経て製造されるようになっている。   As shown in FIG. 4, the door trim 1 is subjected to a first molding step 10a for vacuum molding, a sewing step 10b for sewing, a processing step 10c for processing, and a second molding step 10d for injection molding in order. It has come to be manufactured.

上記第１成形工程１０ａの真空成形型６（表皮材成形型）は、図５に示すように、互いに進退可能に対向配置された上型６２及び下型６１を備えている。   As shown in FIG. 5, the vacuum forming die 6 (skin material forming die) of the first forming step 10a includes an upper die 62 and a lower die 61 that face each other so as to be able to advance and retreat.

上記上型６２は、上記表皮材本体３０の表面側を成形する成形面６２ａを有し、該成形面６２ａには、図５（ｂ）に示すように、上記凹条溝３ｃを形成する突条部６２ｃが下方に向かって突設されている。   The upper mold 62 has a molding surface 62a for molding the surface side of the skin material body 30, and the molding surface 62a has a protrusion for forming the concave groove 3c as shown in FIG. 5 (b). A strip 62c projects downward.

また、上記成形面６２ａには、表皮材本体３０の表面に形成されるシボ模様に対応する細かな凹凸が形成されるとともに、図示しない孔が多数形成されている。   The molding surface 62a is formed with fine irregularities corresponding to the embossed pattern formed on the surface of the skin material main body 30 and a number of holes (not shown).

一方、上記下型６１は、上記表皮材本体３０の裏面側を成形する成形面６１ａを有し、該成形面６１ａには、上記突条部６２ｃに対応する形状をなし、型閉じ時に上記表皮材本体３０を逃がす逃がし凹部６１ｃが形成されている。   On the other hand, the lower mold 61 has a molding surface 61a for molding the back side of the skin material main body 30, and the molding surface 61a has a shape corresponding to the protrusion 62c, and the skin is closed when the mold is closed. An escape recess 61c that allows the material body 30 to escape is formed.

そして、加熱して軟化させたシート状の上記表皮材本体３０を上記上型６２と上記下型６１との間にセットするとともに、上記真空成形型６を型閉じして上記成形面６１ａと上記成形面６２ａとで上記表皮材本体３０を挟持し、且つ、上記上型６２の成形面６２ａに形成された図示しない多数の孔から真空引きを行うことにより、表面にシボ模様と上記凹条溝３ｃとが形成された表皮材本体３０を成形するようになっている。   Then, the sheet-shaped skin material body 30 softened by heating is set between the upper mold 62 and the lower mold 61, and the vacuum forming mold 6 is closed to form the molding surface 61a and the mold. The skin material main body 30 is sandwiched between the molding surface 62a and vacuuming is performed from a large number of holes (not shown) formed in the molding surface 62a of the upper mold 62 so that the surface has a texture pattern and the concave groove. The skin material main body 30 formed with 3c is molded.

上記加工工程１０ｃでは、上記真空成形型６で成形した表皮材本体３０の不要部分を切断するとともに、図２に示すように、上記表皮材３裏面側におけるステッチ４０形成部分の一部、例えば、曲率半径の小さいコーナー部に施したステッチ４０形成部分に熱可塑性の樹脂シート材５（液漏防止手段）を貼り付けるようになっている。   In the processing step 10c, an unnecessary portion of the skin material body 30 formed by the vacuum forming die 6 is cut, and as shown in FIG. 2, a part of the stitch 40 forming portion on the back surface side of the skin material 3, for example, A thermoplastic resin sheet material 5 (liquid leakage prevention means) is affixed to a stitch 40 forming portion formed at a corner portion having a small curvature radius.

上記第２成形工程１０ｄの射出成形型７（表皮材成形型）は、図６乃至図９に示すように、固定された下型７１（第２型）と、該下型７１に対して進退可能に対向配置された上型７２（第１型）とを備えている。   The injection molding die 7 (skin material molding die) in the second molding step 10d includes a fixed lower die 71 (second die) and advancing and retreating with respect to the lower die 71 as shown in FIGS. An upper mold 72 (first mold) is provided so as to face each other.

上記下型７１は、上記ドアトリム１の裏面側（基材２の裏面側）の形状に対応する成形面７１ａと、該成形面７１ａに連続する分割面７１ｂとを有している。   The lower mold 71 has a molding surface 71a corresponding to the shape of the back surface side (the back surface side of the base material 2) of the door trim 1, and a split surface 71b continuous with the molding surface 71a.

一方、上記上型７２は、上記ドアトリム１の表面側（表皮材３の表面側）の形状に対応するとともに、上記表皮材３をセットするセット面７２ａと、該セット面７２ａに連続する分割面７２ｂとを有し、該分割面７２ｂは、射出成形型７の型閉じ状態で上記下型７１の成形面７１ａと合わされるようになっている（図７及び図８参照）。   On the other hand, the upper mold 72 corresponds to the shape of the surface side of the door trim 1 (the surface side of the skin material 3), a set surface 72a for setting the skin material 3, and a divided surface continuous to the set surface 72a. 72b, and the split surface 72b is adapted to be matched with the molding surface 71a of the lower mold 71 in the closed state of the injection mold 7 (see FIGS. 7 and 8).

上記表皮材３の裏面側を下型７１側にして上記表皮材３を上記セット面７２ａにセットすると、ステッチ４０形成部分を除く表皮材３表面と上記セット面７２ａとが当接するようになっている。   When the skin material 3 is set on the set surface 72a with the back surface side of the skin material 3 facing the lower mold 71, the surface of the skin material 3 excluding the stitch 40 forming portion and the set surface 72a come into contact with each other. Yes.

そして、図７に示すように、上記射出成形型７の型閉じ状態で、上記上型７２のセット面７２ａにセットされた表皮材３裏面と上記下型７１の成形面７１ａとの間にキャビティ８が形成され、該キャビティ８内に熱可塑性樹脂９を充填することにより上記基材２を成形するようになっている。   As shown in FIG. 7, with the injection mold 7 closed, a cavity is formed between the back surface of the skin material 3 set on the set surface 72a of the upper mold 72 and the molding surface 71a of the lower mold 71. 8 is formed, and the base material 2 is formed by filling the cavity 8 with the thermoplastic resin 9.

次に、上記ドアトリム１の製造方法について説明する。   Next, a method for manufacturing the door trim 1 will be described.

まず初めに、上記真空成形型６を用意し、加熱して軟化させたシート状の表皮材本体３０を型開きした真空成形型６における上型６２と下型６１との間にセットする。   First, the vacuum forming die 6 is prepared, and the sheet-like skin material body 30 softened by heating is set between the upper die 62 and the lower die 61 in the opened vacuum forming die 6.

次いで、図５に示すように、上記真空成形型６を型閉じし、上記上型６２の成形面６２ａと上記下型６１の成形面６１ａとで上記表皮材本体３０を挟持するとともに、上記上型６２の成形面６２ａに形成された図示しない多数の孔から真空引きを行って、表面にシボ模様と上記凹条溝３ｃとが形成された表皮材本体３０を成形する。   Next, as shown in FIG. 5, the vacuum forming die 6 is closed, the skin material body 30 is sandwiched between the forming surface 62a of the upper die 62 and the forming surface 61a of the lower die 61, and the upper Vacuuming is performed from a large number of holes (not shown) formed on the molding surface 62a of the mold 62, and the skin material body 30 having a texture pattern and the groove 3c formed on the surface is molded.

しかる後、該表皮材本体３０を上記真空成形型６から脱型し、且つ、表皮材本体３０の不要部分を切断した後、上記表皮材本体３０の凹条溝３ｃに縫糸４でステッチ４０を施し、表皮材３を得る。   Thereafter, the skin material body 30 is removed from the vacuum forming die 6 and unnecessary portions of the skin material body 30 are cut, and then stitches 40 are formed on the concave grooves 3c of the skin material body 30 with the sewing thread 4. The skin material 3 is obtained.

その後、表皮材３裏面のステッチ４０形成部分の一部に熱可塑性の樹脂シート材５を貼り付ける。   Thereafter, the thermoplastic resin sheet material 5 is affixed to a part of the stitch 40 forming portion on the back surface of the skin material 3.

次に、上記射出成形型７を用意し、図６に示すように、上記射出成形型７を型開きした状態で、上記表皮材３を熱可塑性の樹脂シート材５が下型７１側に向くように上型７２のセット面７２ａにセットする。尚、上記表皮材３を上記上型７２のセット面７２ａにセットした後、上記表皮材３の裏面側におけるステッチ４０形成部分の一部に熱可塑性の樹脂シート材５を貼り付けても良い。   Next, the injection mold 7 is prepared. As shown in FIG. 6, the thermoplastic resin sheet material 5 faces the lower mold 71 side of the skin material 3 with the injection mold 7 opened. In this way, the upper mold 72 is set on the set surface 72a. Note that after setting the skin material 3 on the set surface 72 a of the upper mold 72, the thermoplastic resin sheet material 5 may be attached to a part of the stitch 40 forming portion on the back surface side of the skin material 3.

次いで、図７に示すように、射出成形型７を型閉じした後、表皮材３の裏面側と下型７１の成形面７１ａとの間に形成されたキャビティ８内に熱可塑性樹脂９を射出機（図示せず）で射出注入し、図８に示すように、キャビティ８内を隙間無く熱可塑性樹脂９で充填して基材２を得る。その際、表皮材３裏面側のステッチ４０形成部分において、熱可塑性の樹脂シート材５で覆われている箇所は、針孔４ａ（図７（ｂ）参照）から表皮材３表面側に熱可塑性樹脂９が漏れない（図２参照）。一方、表皮材３裏面側のステッチ４０形成部分において、熱可塑性の樹脂シート材５で覆われていない箇所は、注入した熱可塑性樹脂９によって縫糸４が表皮材３裏面に固定される（図３（ｂ），（ｃ）参照）。   Next, as shown in FIG. 7, after the injection mold 7 is closed, the thermoplastic resin 9 is injected into the cavity 8 formed between the back surface side of the skin material 3 and the molding surface 71 a of the lower mold 71. As shown in FIG. 8, the cavity 8 is filled with a thermoplastic resin 9 without a gap to obtain the base material 2. At that time, the portion covered with the thermoplastic resin sheet material 5 in the stitch 40 forming portion on the back surface side of the skin material 3 is thermoplastic from the needle hole 4a (see FIG. 7 (b)) to the surface side of the skin material 3. The resin 9 does not leak (see FIG. 2). On the other hand, in the portion where the stitch 40 is formed on the back surface side of the skin material 3, the sewing thread 4 is fixed to the back surface of the skin material 3 by the injected thermoplastic resin 9 in the portion not covered with the thermoplastic resin sheet material 5 (FIG. 3). (See (b) and (c)).

その後、図９に示すように、上型７２を下型７１から後退させて射出成形型７を型開きし、表皮材３に基材２が一体となったドアトリム１を脱型する。   Thereafter, as shown in FIG. 9, the upper mold 72 is retracted from the lower mold 71 to open the injection mold 7, and the door trim 1 in which the base material 2 is integrated with the skin material 3 is removed.

以上より、本発明の実施形態によると、射出成形型７内で基材２を射出成形すると同時に、表皮材３と基材２とが一体になるので、表皮材３と基材２とを別々の工程で得た後、表皮材３裏面に接着剤等で基材２を貼り付けるといった煩雑な作業を回避することができ、効率良くドアトリム１を製造することができる。また、基材２を射出成形する際、射出成形型７のキャビティ８に充填する熱可塑性樹脂９が針孔４ａを通過して表皮材本体３０の表面側に移動するのを樹脂シート材５で防ぐので、表皮材本体３０の表面側に熱可塑性樹脂９が漏れて成形後のドアトリム１の意匠性が低下してしまうといったことがない。さらに、表皮材本体３０に施したステッチ４０の表皮材３裏面側が基材２で固定されるので、縫糸４が緩むことなく高い意匠性を維持したままドアトリム１を長い期間使用できる。   As described above, according to the embodiment of the present invention, since the base material 2 is injection-molded in the injection mold 7 and the skin material 3 and the base material 2 are integrated, the skin material 3 and the base material 2 are separately provided. After being obtained in this step, it is possible to avoid a troublesome operation of attaching the base material 2 to the back surface of the skin material 3 with an adhesive or the like, and the door trim 1 can be manufactured efficiently. Further, when the base material 2 is injection-molded, it is the resin sheet material 5 that the thermoplastic resin 9 filling the cavity 8 of the injection mold 7 passes through the needle holes 4a and moves to the surface side of the skin material body 30. This prevents the thermoplastic resin 9 from leaking to the surface side of the skin material body 30, and the design of the door trim 1 after molding does not deteriorate. Furthermore, since the back surface side of the skin material 3 of the stitch 40 applied to the skin material body 30 is fixed by the base material 2, the door trim 1 can be used for a long period of time while maintaining high design without the sewing thread 4 loosening.

また、表皮材３裏面側のステッチ４０形成部分の一部を熱可塑性の樹脂シート材５を貼り付けることで覆うので、ステッチ４０の表皮材本体３０裏面側を覆う作業を定量的に、且つ、簡単に行えるようになり、製造するドアトリム１の品質がばらつき難くなるとともに、作業者の作業工数を低減させることができる。   Further, since a part of the stitch 40 forming portion on the back surface side of the skin material 3 is covered by attaching the thermoplastic resin sheet material 5, the work of covering the back surface side of the skin material body 30 of the stitch 40 is quantitatively performed, and As a result, the quality of the door trim 1 to be manufactured is less likely to vary, and the number of man-hours for the operator can be reduced.

尚、本発明の実施形態では、射出成形時において熱可塑性樹脂９が表皮材３の表面側に漏れるのを防ぐために、表皮材３裏面側のステッチ４０形成部分に熱可塑性の樹脂シート材５を貼り付けているが、これに限らず、例えば、液状や粉体の樹脂材を塗布して液漏れを防いでもよい。   In the embodiment of the present invention, in order to prevent the thermoplastic resin 9 from leaking to the surface side of the skin material 3 at the time of injection molding, the thermoplastic resin sheet material 5 is applied to the stitch 40 forming portion on the back surface side of the skin material 3. However, the present invention is not limited to this. For example, a liquid or powdery resin material may be applied to prevent liquid leakage.

また、本発明の実施形態では、ステッチ４０が１つしかないが、複数のステッチ４０を有するドアトリム１を製造する場合にも本発明の実施形態の製造方法を適用することができる。   In the embodiment of the present invention, there is only one stitch 40. However, the manufacturing method according to the embodiment of the present invention can be applied to manufacturing the door trim 1 having a plurality of stitches 40.

また、本発明の実施形態では、表皮材本体３０に形成した凹条溝３ｃに縫糸４でステッチ４０を施しているが、凹条溝３ｃが形成されていない箇所に縫糸４でステッチ４０を施してもよい。   In the embodiment of the present invention, the stitch 40 is applied to the concave groove 3c formed in the skin material body 30 with the sewing thread 4, but the stitch 40 is applied to the portion where the concave groove 3c is not formed. May be.

さらに、本発明の実施形態では、ドアトリム１の製造に本発明を適用したが、その他の車両用内装材、例えば、インストルメントパネル等の製造に本発明の製造方法を適用できる。   Furthermore, in the embodiment of the present invention, the present invention is applied to the manufacture of the door trim 1, but the manufacturing method of the present invention can be applied to the manufacture of other vehicle interior materials such as instrument panels.

それに加えて、本発明では、表皮材本体３０を真空成形により成形したが、射出成形やトランスファー成形等で成形してもよい。   In addition, in the present invention, the skin material body 30 is formed by vacuum forming, but may be formed by injection molding, transfer molding, or the like.

そして、本発明の実施形態では、射出成形型７の上型７２に表皮材３をセットする構造であったが、下型７１に表皮材３をセットする構造であってもよい。   In the embodiment of the present invention, the skin material 3 is set on the upper mold 72 of the injection mold 7. However, the skin material 3 may be set on the lower mold 71.

本発明は、ドアトリムやインストルメントパネル等の車両用内装材の製造方法に適している。   The present invention is suitable for a method for manufacturing a vehicle interior material such as a door trim or an instrument panel.

１ ドアトリム（車両用内装材）
２ 基材
３ 表皮材
４ 縫糸
５ 樹脂シート材（液漏防止手段）
６ 真空成形型（表皮材成形型）
７ 射出成形型
８ キャビティ
９ 熱可塑性樹脂
３０ 表皮材本体
４０ ステッチ
７１ 下型（第２型）
７１ａ 成形面
７２ 上型（第１型） 1 Door trim (vehicle interior material)
2 Base material 3 Skin material 4 Sewing thread 5 Resin sheet material (Liquid leakage prevention means)
6 Vacuum mold (skin material mold)
7 Injection mold 8 Cavity 9 Thermoplastic resin 30 Skin body 40 Stitch 71 Lower mold (second mold)
71a Molding surface 72 Upper mold (first mold)

Claims (3)

パネル状の基材と、該基材の表面側を覆う可撓性表皮材とを備えた車両用内装材の製造方法であって、
表皮材成形型で熱可塑性樹脂からなる表皮材本体を成形した後、上記表皮材成形型を型開きして上記表皮材本体を取り出し、その後、上記表皮材本体に縫糸でステッチを施して上記表皮材とし、
次いで、上記表皮材をセットする第１型と、該第１型に対向配置され、上記基材の裏面側の形状に対応する成形面を有する第２型とを備えた射出成形型を用意し、該射出成形型を型開きした状態で、上記表皮材裏面側におけるステッチ形成部分の少なくとも一部を液漏防止手段で覆った上記表皮材を上記液漏防止手段が上記第２型に向くよう上記第１型にセットするか、又は、上記表皮材を上記第１型にセットした後、上記表皮材裏面側におけるステッチ形成部分の少なくとも一部を上記液漏防止手段で覆い、
しかる後、上記射出成形型を型閉じして上記第１型にセットされた表皮材裏面と上記第２型の成形面との間に形成されたキャビティ内に熱可塑性樹脂を充填して上記基材を得ることを特徴とする車両用内装材の製造方法。 A method for producing a vehicle interior material comprising a panel-shaped base material and a flexible skin material covering the surface side of the base material,
After the skin material body made of thermoplastic resin is molded with the skin material molding die, the skin material molding die is opened and the skin material body is taken out, and then the skin material body is stitched with a sewing thread and then the skin Material,
Next, an injection mold comprising a first mold for setting the skin material and a second mold disposed opposite to the first mold and having a molding surface corresponding to the shape of the back side of the base material is prepared. In the state where the injection mold is opened, the liquid leakage preventing means faces the second mold with the skin material covering at least a part of the stitch forming portion on the back surface side of the skin material with the liquid leakage preventing means. After setting the first mold, or after setting the skin material to the first mold, cover at least part of the stitch formation portion on the back side of the skin material with the liquid leakage prevention means,
Thereafter, the injection mold is closed and a thermoplastic resin is filled into a cavity formed between the back surface of the skin material set in the first mold and the molding surface of the second mold, and the base is formed. A method for producing an interior material for a vehicle, characterized in that the material is obtained. 請求項１に記載の車両用内装材の製造方法において、In the manufacturing method of the interior material for vehicles according to claim 1,
上記表皮材裏面側におけるステッチ形成部分の全体のうちの一部のみを液漏防止手段で覆うことを特徴とする車両用内装材の製造方法。A method for manufacturing a vehicular interior material, characterized in that only a part of the entire stitch formation portion on the back side of the skin material is covered with a liquid leakage prevention means. 請求項１又は２に記載の車両用内装材の製造方法において、
上記液漏防止手段は、上記表皮材裏面側におけるステッチ形成部分の一部に貼り付ける熱可塑性の樹脂シート材であることを特徴とする車両用内装材の製造方法。 In the manufacturing method of the interior material for vehicles according to claim 1 or 2 ,
The method for manufacturing an interior material for a vehicle, wherein the liquid leakage preventing means is a thermoplastic resin sheet material to be attached to a part of a stitch forming portion on the back surface side of the skin material.
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