CN101659238A - Inner-decoration component for automobile and method for the production thereof - Google Patents

Inner-decoration component for automobile and method for the production thereof Download PDF

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Publication number
CN101659238A
CN101659238A CN200810173956A CN200810173956A CN101659238A CN 101659238 A CN101659238 A CN 101659238A CN 200810173956 A CN200810173956 A CN 200810173956A CN 200810173956 A CN200810173956 A CN 200810173956A CN 101659238 A CN101659238 A CN 101659238A
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China
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lit
involved
par
miscellaneous part
structure body
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Granted
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CN200810173956A
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Chinese (zh)
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CN101659238B (en
Inventor
中川浩成
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Kasai Kogyo Co Ltd
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Kasai Kogyo Co Ltd
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Publication of CN101659238A publication Critical patent/CN101659238A/en
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Publication of CN101659238B publication Critical patent/CN101659238B/en
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  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

Provided are an installation structure on a light decorated back face, used for simply and cheaply installing other parts to the whole or a part of inner-decoration component for automobile and an installation method. A door decoration upper portion-forepart (a laminating structure) (30) of a door decoration (20) is formed by a light laminating body with a foamex substrate (31) with the conformality and a rigid resin rib (31) which is integrated with the substrate and arranged on the back face, and is taken as a structure for installing a waist ornament (other components) (50) on the back side, a part of waist ornament is fused to be integrated by a hump (34) used for fusion splicing and integrated on the resin rib (32), and the part of the waist ornament, corresponding to the end edge portion of the door decoration upper portion-forepart uses the coiling process by means of the coiling material (35) at the circumference of the foamex substrate, the upper terminal (50a) of the waist ornament is kept by the coiling of the coiling material, thus simplifying the conformality shape of the waist ornament.

Description

Inner-decoration component for automobile and manufacture method thereof
Technical field
The present invention relates to inner-decoration component for automobile and manufacture methods thereof such as a decoration, Rear Parcel Shelf, floor decorative, rear platform decoration, baggage container decoration, ceiling decoration, rear side decoration, particularly can be with miscellaneous parts such as decorative fitting, carriage, liners simple and cheap and outward appearance be installed in the inner-decoration component for automobile and the manufacture method thereof of the rear side of lit-par-lit structure body well.
Background technology
For example, the illustration door is decorated, and the structure of inner-decoration component for automobile is described based on Figure 21, Figure 22.Door is decorated 1 and is possessed conformality and to the installation rigidity of door face board, and the epidermis 3 that stacked appearance is good on the surface of roughly whole the resin core 2 that spreads all over the goods face is also integrated and constitute.As above-mentioned resin core 2, to sneak into talcous polypropylene-based resin as the base material, in addition, epidermis 3 himself does not possess conformality, use is at the lamination sheets material of the padded coamings such as the stacked polyethylene in the back side of the single sheet material of synthetic resin sheets such as vinyl chloride sheet or synthetic resin sheet, recently, consider environment aspect and recirculation aspect, the tendency that adopts elastomeric sheets such as TPO (TPO) sheet is arranged morely.
Then, based on Figure 23 the example in the past of the manufacturing process of above-mentioned door decoration 1 is described.At first, formed door decorate 1 forming metal mould 4 substantially by can be with the shaping patrix 5 of predetermined stroke up-and-down movement, constitute with the forming lower die 6 of shaping patrix 5 double-type fixation side with forming lower die 6 bonded assembly injector 7.And, with shaping upper and lower mould 5,6 matched moulds the time,, on shaping patrix 5, form the cavity 5a of portion in order to form an article shape of decoration 1, core 6a is set on forming lower die 6.Link lift cylinders 5b in order to make above-mentioned shaping patrix 5 knee-action predetermined strokes, in forming lower die 6, be provided with collector 6b, the cast gate 6c of conduct from the path of the molten resin of injector 7.In addition, on the shaping patrix 5 of knee-action, on 4 bights of forming lower die 6, guide posts 6d is set, on shaping patrix 5, is provided with guiding sleeve 5c corresponding to this guide posts 6d in order to keep correct body position.
Thereby, when shaping upper and lower mould 5,6 is in die opening state, by epidermis 3 is arranged in the metal paattern, molten resin M is injected in the goods cavity that is filled between two metal paattern from injector 7 by collector 6b, cast gate 6c sometime before shaping upper and lower mould 5,6 is just wanted matched moulds or behind the matched moulds then, resin core 2 is configured as the curve form that needs, and epidermis 3 is integrally formed on the surface of resin core 2 (for example with reference to patent documentation 1).In addition, in Figure 23, for convenience of explanation, the die face of core 6a is supplied with molten resin M under the state of opening, be filled in the cavity but also molten resin M can be injected behind the matched moulds of shaping upper and lower mould 5,6.
And recently as Figure 24, shown in Figure 25, having proposed can light weight and the door decoration 10 of the light-type made at an easy rate.The door of this light-type is decorated 10 and is formed with light weight that the pressure forming of Foamex sheet is formed for the shape that needs and the foamed resin substrate 11 with conformality, in the peripheral part of this foamed resin substrate 11 and on the part that needs to strengthen with grid shape etc., hollow out that shape is set resin rib 12 and integrated, and the integrated door that is used for keeping well light-type is decorated 10 the surface texturisation and the epidermis 13 of sense of touch on the surface of foamed resin substrate 11.Decorate 10 structure and manufacture method, expression at length in patent documentation 2 for the door of this light-type.In addition, decorate in 10 at the door of this light-type, for miscellaneous parts 14 such as decorative fitting, carriage, liner are fixed on the assigned position, for example as shown in figure 26, implemented since in the past from the back side of resin rib 12 upright establish welding with projection 15, insert the protruding hole 14a that lead to miscellaneous part 14 in projection 15 this welding after, by ultrasonic machining etc. welding is fixed with protruding 15 front end ca(u)lk or such as shown in figure 27 back side that miscellaneous part 14 is bonded in foamed resin substrate 11 via hot melt class bond layer 16 on and incorporate method.
[patent documentation 1] spy opens flat 10-138268 communique
[patent documentation 2] spy opens the 2005-28722 communique
Like this, the door of the resin rib 12 integrated light-types on the back side of foamed resin substrate 11 of predetermined pattern shape is decorated 10 and possessed light weight and characteristic that can low-cost production.But, for with decorative fitting, carriage, miscellaneous parts such as liner 14 install and fix the rear side of door decoration 10, can consider for example by the welding fixture construction of welding with projection 15, or the structure that is adhesively fixed by hot melt class bond layer 16, but in the method for using welding with projection 15, because to aspect the mould processing of forming metal mould, welding is restricted with the setting position of projection 15, so the desired location of miscellaneous part 14 is limited, has the undesirable condition that Design freedom is restricted, and because welding is set in a plurality of positions with projection 15, each welding is processed with protruding 15 ca(u)lks, so processing is complicated, spend more production time etc., in operation, have problems.
In addition, in the method for using hot melt class bond layer 16 shown in Figure 27, need the working procedure of coating of hot melt class bond layer 16 equally, have the man-hour number and increase and cause cost to rise and preferred problem on operating environment.
Summary of the invention
The present invention In view of the foregoing makes, purpose provide a kind of in the inner-decoration component of light-type that with the foamed resin substrate is substrate, when miscellaneous parts such as decorative fitting, carriage, liner being installed to the rear side of base material, can be simply and cheap and outward appearance is installed well and the position that is provided with of miscellaneous part is not restricted and can be set to optional position etc., can improves the inner-decoration component for automobile and the manufacture method thereof of appearance degree of freedom.
The present inventor is in order to address the above problem, carried out wholwe-hearted research, the result, be conceived to handle structure, being involved in material (volume Write body シ ロ) thermoplastic and being involved in when handling on the main body side back side, wrapping into and fix, can replace with the protruding fixture construction of projection simply and the character of cheaply miscellaneous part being fixed on making a part that is located at periphery complete cycle or periphery, finished the present invention by welding by the end portion of miscellaneous part is involved in material with this as the end of lit-par-lit structure body.
Promptly, the present invention is the inner-decoration component for automobile that adopts the lit-par-lit structure body to form in an integral body or a part, described lit-par-lit structure body possesses the shape that is configured as needs, light weight and have the foamed resin substrate of conformality, the resin rib of integrated predetermined pattern shape on the back side of this foamed resin substrate, it is characterized in that, the foamed resin substrate of above-mentioned lit-par-lit structure body between the shaping upper and lower mould by pressure forming, and integrated resin rib on the back side of this foamed resin substrate is molten resin injection is filled in the slot part of forming lower die and is shaped, and then, at foamed resin substrate, the rear side configuration miscellaneous part of resin rib, the material that is involved in of the periphery end of the stacked tectosome of end portion of this miscellaneous part is involved in supporting.
Here, as the purposes of inner-decoration component for automobile, can be used for a decoration, Rear Parcel Shelf, floor decorative, rear platform decoration, baggage container decoration, ceiling decoration, rear side decoration etc.In addition, also relevant lit-par-lit structure body of the present invention can be applied in the unitary construction of inner-decoration component for automobile, but also can be only door in the part of inner-decoration component for automobile, during for example the door of two dividing bodies is decorated up and down decorate and use relevant lit-par-lit structure body of the present invention in the top, perhaps decorate under the situation about also constituting in the top, also can only decorate top-toe lateral and use the lit-par-lit structure body at door by front and back two dividing bodies anterior, the rear portion at door.
And then, foamed resin substrate with conformality is by handling the thermoplastic of Foamex sheet the back at the curve form of forming metal mould internal shaping for wishing, even have the rigidity (conformality) that also keeps the degree of shape even without strengthening parts such as ribs after shaping from moulding/demoulding.In addition, the semifinished piece shape comprises under the situation of high sheetage part, also the thermoplastic of Foamex sheet can handled the back, vacuum attraction mechanism is provided in the forming metal mould, along the inner face of forming metal mould pull of vacuum is acted on the Foamex sheet.
As above-mentioned Foamex sheet, use the base material that in thermoplastic base resin, has added foaming agent.In addition, thermoplastic base resin both can also can be made of two or more thermoplastic base resins a kind of thermoplastic base resin.Preferably can use polythylene resin, polypropylene-based resin, polystyrene resins, polyethylene terephthalate resinoid, polyvinyl alcohol resin, vinyl chloride resin, polyamide-based resin, poly-acetal resin, polycarbonate resin, ionomer resinoid, acrylonitrile-butadiene-styrene (ABS) resin etc.In addition, as foaming agent, can use inorganic foaming agents such as organic foaming agents such as azo-compound, sulfohydrazide cmpd, nitroso compound, triazo-compound or sodium bicarbonate.The back is being handled in above-mentioned Foamex sheet thermoplastic, be configured as the shape that needs and the foamed resin substrate that obtains considered to be preferably 2~10 times expansion ratio under the situation of the weight of goods and intensity balance.The element diameter of foamed resin substrate of this moment is preferably the scope of 0.1 μ m~2.0mm, and thickness can be 0.5~30mm, be preferably the scope of 1~10mm.
Then, in order to improve the outward appearance intention of lit-par-lit structure body, also can be on the surface of foamed resin substrate stacked epidermis and integrated.As this epidermis, material does not limit, but can be made of top layer that improves appearance and the lamination sheets material of giving the cushion layer of cushion characteristic yet.As top layer, can use cloth quality sheets such as synthetic resin sheets such as TPO (TPO) sheet, thermoplastic polyurethane (TPU) sheet, vinyl chloride sheet or woven, nonwoven fabrics, woven cloth etc., as cushion layer, can use polypropylene foam, polyethylene, isocyanurate foam etc.
On the other hand, the thermoplastic base resin that uses as the resin rib can suitably be selected from large-scale thermoplastic base resin.As the material that can preferably use usually, polythylene resin, polypropylene-based resin, polystyrene resins, polyethylene terephthalate resinoid, polyvinyl alcohol resin, vinyl chloride resin, polyamide-based resin, poly-acetal resin, polycarbonate resin, ionomer resinoid, acrylonitrile-butadiene-styrene (ABS) resin etc. are arranged.In addition, also can in these thermoplastic base resins, sneak into various extending agents.As the extending agent that can use, inorganic particulates such as inorganic fibres such as glass fibre, carbon fiber, french talc, clay, silica, calcium carbonate etc. are arranged.In addition, also can cooperate various additives such as oxidation inhibitor, ultraviolet absorbent, colorant, fire retardant, shrinking agent.And then above-mentioned resin rib is configured on the back side of foamed resin substrate along the pattern form of regulation.As the configuration position, partly be configured in the circumference of easy generation buckling deformation, ripple distortion etc. and apply the waist of load easily and the position that the armrest part even load is concentrated.
And then, miscellaneous part as the rear side that is installed in the lit-par-lit structure body, decorative fitting, carriage, liner etc. are arranged, in the past, generally be to fix, fix by the welding of hot melt class lining cement by the welding of projection, but in the present invention, it is characterized in that, in a part, adopt protruding welding to fix, and on the end portion of miscellaneous part, by being involved in processing by the material that is involved in along the periphery end of foamed resin substrate, the end of implementing the lit-par-lit structure body is simultaneously handled and the end processing of miscellaneous part.
And, the lit-par-lit structure body that can make at low cost owing in its part, adopt light weight according to relevant inner-decoration component for automobile of the present invention, so can realize the lightweight of goods, and can reduce the goods cost, in addition, installation constitution for the miscellaneous part of the rear side that is provided in the lit-par-lit structure body, since adopted along the periphery of lit-par-lit structure body terminal set be involved in the terminal treatment process of material the time end portion of miscellaneous part is involved in affixed structure to embrace shape, so can reduce the setting position of welding with projection, can be reduced in the expense of middle costs such as metal paattern processing, and the cut-out of the end portion of miscellaneous part wood mouth is involved in material and coats, cosmetic look improves, and also can improve the appearance degree of freedom.
Then, in the preferred embodiment of relevant inner-decoration component for automobile of the present invention, it is characterized in that, above-mentioned lit-par-lit structure body be involved in material except the end portion that is involved in the supporting miscellaneous part, also welding integratedly is fixed on and inserts on the welding lead in the protruding hole of the miscellaneous part side with the front end face of projection and miscellaneous part.
And, according to this embodiment, since be the goods of the foamed resin substrate in the lit-par-lit structure body terminal be provided be involved in material by bend roughly 90 ° of operations, welding on the side of miscellaneous part, simultaneously insert in the protruding hole that leads at miscellaneous part welding with protruding front end face also with the stickup face of miscellaneous part integratedly with the structure that is involved in the material welding, so, have the fixing effect of more failure-free that the positional precision that miscellaneous part is installed improves and can realize miscellaneous part by setting projection.
Then, the manufacture method of relevant inner-decoration component for automobile of the present invention, it is the manufacture method of the inner-decoration component for automobile that employing lit-par-lit structure body forms in an integral body or a part, described lit-par-lit structure body possesses the shape that is configured as needs, light weight and have the foamed resin substrate of conformality, the resin rib of integrated predetermined pattern shape on the back side of this foamed resin substrate, it is characterized in that, additional have a following operation: above-mentioned lit-par-lit structure body will be after will handling as the Foamex sheet thermoplastic of the base material of foamed resin substrate, put in the forming metal mould, matched moulds by forming metal mould, with the shape of foamed resin substrate pressure forming for needing, and behind the matched moulds of above-mentioned forming metal mould, the molten resin injection is filled in the slot part of forming lower die, at the integrated and resin rib of shaping predetermined pattern shape of the rear side of foamed resin substrate, then, with the lit-par-lit structure body behind the form metal moulding/demoulding, miscellaneous part is configured in the rear side of lit-par-lit structure body, will be on the resin rib incorporate welding is inserted in the protruding hole of miscellaneous part with projection after, by welding is processed with protruding ca(u)lk, miscellaneous part is integrated on the rear side assigned position of foamed resin substrate and resin rib, then, after the heated jig thermoplastic of the rear side that is involved in material by terminal processing equipment that is set in the periphery terminal part of lit-par-lit structure body handled, the advance and retreat operation of the portion of mechanism that is involved in by terminal processing equipment will be involved in material bending operation so that the end portion of miscellaneous part is wrapped into, thereby handle the end portion of miscellaneous part is terminal.
And, the inventive method is as a part that constitutes inner-decoration component for automobile or the manufacture method of single-piece lit-par-lit structure body, by the forming process of lit-par-lit structure body and from forming metal mould with the demoulding of lit-par-lit structure body after, two operations of installation procedure that the miscellaneous part of miscellaneous part is installed at the back side of lit-par-lit structure body constitute, particularly, fixedly operation and the treatment process that is involved in that is involved in material constitute the installation procedure of miscellaneous part by the welding of projection.
Here, the forming metal mould that uses in the manufacturing process of lit-par-lit structure body is for example in the forming metal mould of die sinking direction setting as the specification of above-below direction, by shaping patrix that can up-and-down movement, be positioned at the constituting of lower side of shaping patrix as the forming lower die of fixation side and the injector that is attached on the forming lower die, be fed in the slot part that wears the predetermined pattern shape of processing on the die face of forming lower die via being located at resin passage such as collector on the forming lower die, cast gate from the injector molten resin supplied.In addition, if wish, also can on the shaping patrix, set up vacuum attraction mechanism, when the drawing and forming of foamed resin substrate, by making the pull of vacuum effect, improve the plastic property of article shape, and be favourable for the transfer printing of pull and stretch decorative pattern etc. from the shaping patrix.On the other hand, also can set up air blown mechanism on forming lower die, air blown mechanism is by shortening the cooling cycle in the shaping of foamed resin substrate time winding-up cooling with gas.
Thereby, after will carrying out thermoplastic by temperature booster etc. as the Foamex sheet of the base material of foamed resin substrate and handling, the Foamex sheet is put in the forming metal mould, then by with shaping upper and lower mould matched moulds, with the shape of foamed resin substrate pressure forming for needing, and with the shaping of foamed resin substrate simultaneously, after perhaps setting some time differences, for the foamed resin substrate back side from injector with molten resin via collector, resin passage such as cast gate supply in the slot part of forming lower die, can the resin rib of predetermined pattern shape is integrated on the back side of foamed resin substrate.In addition, if wish, then also can by in advance paste epidermis on the Foamex sheet or when being shaped with skin-integrated, stacked epidermis on the surface of foamed resin substrate.
Then, as the equipment that uses in the installation constitution on the back side that miscellaneous part is installed to the lit-par-lit structure body, the ca(u)lk device that uses in the ca(u)lk processing of projection in welding is arranged, be involved in and handle so that embrace the terminal processing equipment of the end portion of miscellaneous part by being involved in material.As the ca(u)lk device, use to settle as the welding jig of the lit-par-lit structure body of processing object and will implement the ultrasonic horn that ultrasonic machining uses with projection to be attached at the structure that forms on the compression machine corresponding to the welding that is wholely set with the resin rib.In addition, terminal processing equipment by the lit-par-lit structure body after settle being shaped accept anchor clamps, will being involved in the heated jig that the material thermoplastic handles and will being involved in material and constitute corresponding to the end edge portion of lit-par-lit structure body to the rear side of the foamed resin substrate main body portion of mechanism that is involved in that handles of turning back.Above-mentioned accept anchor clamps by the arrangement platform that is used for settling stacked tectosome, be used for constituting with being placed in the fixing liner of the lit-par-lit structure body settled on the platform and accepting anchor clamps pushing portion.In addition, as heated jig, also can adopt the temperature booster supporting mass that possesses box-like temperature booster can be along horizontal slip and structure that also can lifting with respect to above-below direction.And then, as being involved in portion of mechanism, driving along the horizontal direction advance and retreat with the be involved in screw die of cylinder by advance and retreat, and drive the bench board that the supporting advance and retreat are used cylinder with cylinder along above-below direction by the bench board driving with rectangular shape.
Thereby, if the shaping of lit-par-lit structure body finishes, then after taking out, the lit-par-lit structure body is placed on the welding jig of ca(u)lk device, thereon the miscellaneous part mounting with the forming metal mould die sinking and with the lit-par-lit structure body.At this moment, the upright welding that is located on the resin rib is inserted with projection leads in the protruding hole of miscellaneous part, the ultrasonic horn that is attached on the compression machine is descended and welding is carried out welding processing with the front end of projection, via the welding on the resin rib that is located at the lit-par-lit structure body with protruding with miscellaneous part partly welding fix.
Then, the lit-par-lit structure body of integrated miscellaneous part is placed in the arrangement of terminal processing equipment with on the anchor clamps, make by heated jig and to be involved in the thermoplastic of the material back side corresponding to the periphery end of the foamed resin substrate of lit-par-lit structure body, then, drive by cylinder and to be involved in screw die and will to be involved in material and to be involved in operation, be involved in processing, the end portion of miscellaneous part wrapped into to be involved in material by this.
Like this, according to the inventive method, the manufacture method of lit-par-lit structure body has been added the installation procedure that needs the lit-par-lit structure of shape body that the miscellaneous part of miscellaneous part is installed to being configured as, the installation procedure of this miscellaneous part is by the welding ca(u)lk operation of welding with projection, with the material that is involved in the terminal treatment process that the end portion of miscellaneous part is involved in is constituted by foamed resin substrate, compare with projection weld fixing means in the past, relaxed the restriction at protruding setting position, and also can reduce the number of projection, welding processing operation is oversimplified, and owing to be involved in by the end portion of foamed resin substrate with miscellaneous part, so cosmetic look also improves, particularly owing to utilizing the general terminal treatment process that is involved in material of foamed resin substrate, so can suppress number increase in man-hour.
And then, the inventive method preferred embodiment in, it is characterized in that, in the terminal treatment process that is involved in material of the periphery end that is set in the lit-par-lit structure body, the end portion of miscellaneous part disposes to vertical direction from the back side of lit-par-lit structure body, to be involved in roughly 90 ° of material bending operations, thereby welding is fixed on the miscellaneous part, and with welding with the side of the front end face of projection and miscellaneous part and be involved in material welding integratedly.
And, in this embodiment, end portion by miscellaneous part is involved in material clamping and facial with to be involved in the material welding integrated with the front end of projection from the upright welding of establishing of resin rib by resin rib and foamed resin substrate, can by the resin rib be involved in the end portion that material keeps miscellaneous part reliably.In addition, having can be by setting the effect that projection improves the positional precision that miscellaneous part is installed.
As described above, according to relevant inner-decoration component for automobile of the present invention and manufacture method thereof, because the whole or a part of lit-par-lit structure body that constitutes inner-decoration component for automobile is by light weight and have the foamed resin substrate of conformality, constitute with the resin rib on the position that needs rigidity at the integrated back side at this foamed resin substrate, so from being configured to the angle of the very high resin core of past weight, can light weight and inner-decoration component for automobile is provided at low cost, and for the decorative fitting on the back side that is installed in the lit-par-lit structure body, carriage, miscellaneous parts such as liner, because the end that is involved in material on being set in the periphery terminal part of lit-par-lit structure body is involved in the end portion of handling miscellaneous part integratedly when handling, so compare with in the past protruding welding process and hot melt adhesion method, the number of can reducing work hours, because the end portion of miscellaneous part is coated by the material that is involved in of foamed resin substrate at short notice, so have the effect that can improve the aesthetic property of end portion with cheap method.
Description of drawings
Fig. 1 is the front elevation of the automobile door decoration of the expression structure of having used relevant inner-decoration component for automobile of the present invention.
Fig. 2 is the front elevation that the door of expression automobile door decoration shown in Figure 1 is decorated top.
Fig. 3 is an III-III line cutaway view among Fig. 2.
Fig. 4 is an IV-IV line cutaway view among Fig. 2.
Fig. 5 is the integrally-built instruction diagram of expression forming metal mould of use for door shown in Figure 2 being decorated top-front portion shaping.
Fig. 6 is the instruction diagram of arrangement operation of the base material of the expression door shown in Figure 2 manufacturing process of decorating top-front portion.
Fig. 7 is the instruction diagram of forming process of the foamed resin substrate of the expression door shown in Figure 2 manufacturing process of decorating top-front portion.
Fig. 8 is the instruction diagram of forming process of the resin rib of the expression door shown in Figure 2 manufacturing process of decorating top-front portion.
Fig. 9 is that expression is arranged to the instruction diagram that door shown in Figure 2 is decorated the state on top-front portion with waist decorative fitting (ウ エ ス ト ガ one ニ Star シ ユ).
Figure 10 is that expression is fixed to the instruction diagram that door shown in Figure 2 is decorated the state on top-front portion with the welding of waist decorative fitting projection.
Figure 11 is the integrally-built instruction diagram that the terminal processing equipment of the end processing that door shown in Figure 2 decorates top-front portion is carried out in expression.
Figure 12 is that expression uses terminal processing equipment shown in Figure 11 to make an instruction diagram that is involved in the thermoplastic operation of material of decorating top-front portion.
Figure 13 is that expression uses terminal processing equipment shown in Figure 11 door to be decorated the instruction diagram that material is involved in the operation of processing that is involved in of top-front portion.
Figure 14 is that expression uses terminal processing equipment shown in Figure 11 door to be decorated the instruction diagram that material is involved in the operation of processing that is involved in of top-front portion.
Figure 15 is illustrated in door shown in Figure 2 to decorate the cutaway view that the state of the waist decorative fitting that has changed shape is installed on top-front portion.
Figure 16 is the instruction diagram that door decoration top-front portion that expression will be shown in Figure 15 and waist decorative fitting are arranged to the state on the welding jig.
Figure 17 is the instruction diagram that expression door shown in Figure 15 is decorated the welding stationary state of top-front portion and waist decorative fitting.
Figure 18 is the instruction diagram that the terminal processing equipment of the end processing that door shown in Figure 15 decorates top-front portion is carried out in expression.
Figure 19 is the instruction diagram that is involved in the material heating soft state that expression door shown in Figure 15 is decorated top-front portion.
Figure 20 is the instruction diagram that is involved in treatment process that is involved in material that expression door shown in Figure 15 is decorated top-front portion.
Figure 21 is a front elevation of representing that automobile door is in the past decorated.
Figure 22 is the XXII-XXII line cutaway view among Figure 21.
Figure 23 is the integrally-built instruction diagram of the expression forming metal mould that door in the past is decorated formed.
Figure 24 is a front elevation of representing the automobile door decoration of light-type in the past.
Figure 25 is an XXV-XXV line cutaway view among Figure 24.
Figure 26 is that the automobile door that is illustrated in light-type is in the past decorated the fixedly cutaway view of the state of miscellaneous part of upward projection welding.
Figure 27 is that the automobile door that is illustrated in light-type in the past decorate to be gone up by the be adhesively fixed cutaway view of state of miscellaneous part of hot melt class lining cement.
Description of reference numerals
20 automobile doors are decorated
The 20A door is decorated top
The 20B door is decorated the bottom
Decorate top-front portion for 30
31 foamed resin substrates
32 resin ribs
33 epidermises
34 weldings are with protruding
35 are involved in material
Decorate top-rear portion for 40
50 waist decorative fittings
50a upside end
51,51a, 51b projection hole
60 forming metal moulds
61 shaping patrixes
612 lift cylinders
62 forming lower dies
622 collectors
623 cast gates
624 slot parts
63 injector
70 ca(u)lk devices
71 welding jigs
72 ultrasonic horns
80 terminal processing equipment
81 arrangement anchor clamps
81a settles platform
The 81b distance piece
81c accepts anchor clamps pushing portion
82 heated jigs
The 82a temperature booster
82b temperature booster supporting mass
82c drives and uses cylinder
83 are involved in portion of mechanism
83a is involved in screw die
83b advance and retreat cylinder
The 83c bench board
83d knee-action cylinder
The M molten resin
S Foamex sheet
The specific embodiment
Below, explain with reference to the preferred embodiment of accompanying drawing relevant inner-decoration component for automobile of the present invention and manufacture method thereof.In addition, it is pointed out that purport of the present invention is documented in claims, below the content of Shuo Ming embodiment is only merely represented an example of the present invention.
[embodiment]
Fig. 1 to Figure 20 is the figure of expression one embodiment of the invention.Fig. 1 is the front elevation that the expression automobile door is decorated, Fig. 2 is the front elevation that the door of this decoration of expression is decorated top, Fig. 3 is the cutaway view of the structure on this decoration top of expression, Fig. 4 is that the door on this decoration top of expression is decorated the cutaway view of the structure of top-front portion, Fig. 5 is the overall diagram that is illustrated in the structure of the forming metal mould that uses in the shaping of this decoration top-front portion, Fig. 6 to Fig. 8 is each instruction diagram of the forming process of this decoration top-front portion of expression, Fig. 9 to Figure 14 is the figure that expression is installed in miscellaneous part each operation on this decoration top-front portion, Fig. 9, Figure 10 is expression welding each instruction diagram with the ca(u)lk manufacturing procedure of projection, Figure 11 to Figure 14 be represent respectively to support miscellaneous part end portion be involved in that material heating is softening to be handled, be involved in each instruction diagram of processing, Figure 15 to Figure 20 is the figure of expression variation of the present invention, Figure 15 is the cutaway view that has changed the shape of miscellaneous part, and Figure 16 to Figure 20 is that expression is installed in an instruction diagram of decorating each operation on top-front portion with miscellaneous part shown in Figure 15.
Based on Fig. 1 to Fig. 4, the automobile door of having used relevant inner-decoration component for automobile of the present invention decorated 20 structure and describe.As shown in Figure 1, automobile door is decorated 20 two dividing bodies up and down by door decoration top 20A and door decoration bottom 20B and is constituted, and decorates on the 20A of top at door, and the installed in front of connecting portion has inside handle unit 21 therebetween.On the other hand, on door is decorated bottom 20B, be formed with handrail 22, on the upper surface of handrail 22, be provided with switch panel 23, the tractive handle unit 24 of automatic window switch etc. to the indoor protuberance.And then, below handrail 22, be provided with the door bag 25 that can accommodate spare unit, in the front side of this bag 25, be provided with loudspeaker grid 26 with door with decorating bottom 20B one or split.
Like this, used automobile door decoration 20 of the present invention and constituted with two dividing bodies up and down of door decoration bottom 20B, improved intention by apparent contrast effect, and can realize the densification of forming metal mould by door decoration top 20A.And then, in the present invention, decorate top 20A for door and also on fore-and-aft direction, adopt two segmenting structures.That is, to shown in Figure 4, decorate top 20A, decorate top-front portion 30 by door and constitute with front and back two dividing bodies that door is decorated top-rear portion 40 for door as Fig. 2.In addition, decorate top-front portion 30 and door at door and decorate on both lower edges of top-rear portion 40, be set with and be used for the joint flange 27 that engages with door decoration bottom 20B.And, decorate the structure of top-front portion 30 as door, the structure of the lit-par-lit structure body that adopts light weight and can make at low cost, and dispose in its rear side under the situation of miscellaneous parts such as decorative fitting, carriage, liner for example, waist decorative fitting 50 is installed in the present embodiment, feature be can be simply and cheap and outward appearance also carry out the installation of waist decorative fitting 50 well.
Then, the concrete structure at opposite house decoration top-front portion 30 and door decoration top-rear portion 40 describes.At first, the door that constitutes by the lit-par-lit structure body decorate top-front portion 30 cardinal principles by the curve form that is configured as hope and have conformality foamed resin substrate 31, integrated rear side at this foamed resin substrate 31, give rigidity resin rib 32 and integrated at foamed resin substrate 31 face side and epidermis 33 with decoration functions constitutes.
Above-mentioned foamed resin substrate 31 is thermoformed into the shape that needs after the thermoplastic of Foamex sheet is handled, and for example the forming metal mould cold pressure of the die face by having hope is shaped and gives shape, so that it possesses conformality.Above-mentioned Foamex sheet is the structure of having added foaming agent in the general-duty thermoplastic base resin, as thermoplastic base resin, can use polythylene resin, polypropylene-based resin, polystyrene resins, polyethylene terephthalate resinoid, polyvinyl alcohol resin, vinyl chloride resin, polyamide-based resin, poly-acetal resin, polycarbonate resin, ionomer resinoid, acrylonitrile-butadiene-styrene (ABS) resin etc., as foaming agent, can use inorganic foaming agents such as organic foaming agents such as azodicarbonamide and sodium bicarbonate.In this embodiment, use the Foamex sheet that in polypropylene-based resin, has suitably added sodium bicarbonate as foaming agent.In addition, the expansion ratio of this foamed resin substrate 31 is set at 2~10 times, and thickness setting is 0.5~30mm, is preferably set in the scope of 1~10mm especially.
Then, resin rib 32 is set at the grid-like pattern of extending at direction or direction of tilt etc. in length and breadth.And, this resin rib 32 is by having added glass fibre, the general-duty synthetic resin forming body of reinforcings fiber such as natural fiber constitutes, usually the synthetic resin that can preferably use can be from polythylene resin, polypropylene-based resin, polystyrene resins, the polyethylene terephthalate resinoid, polyvinyl alcohol resin, vinyl chloride resin, polyamide-based resin, the poly-acetal resin, polycarbonate resin, the ionomer resinoid, suitably select in acrylonitrile-butadiene-styrene (ABS) resin etc., in the present embodiment, consider the environment aspect, recirculation aspect and use polypropylene-based resin.
Like this, constituted as the door of lit-par-lit structure body and decorated top-front portion 30, constitute by the body that is injected into of synthetic resin and decorate top-anterior 30 bonded assembly doors decoration top-rear portion 40 with this, as the base material that uses, can use the identical base material of resin rib 32 of decorating top-front portion 30 with door, decorate top-front portion 30 and door by door and decorate the apparent emphasis effect at top-rear portion 40 to guarantee that good surface appearance intention this point and door are decorated the relation of a top 20A and a decoration bottom 20B identical.
And then, decorate in 20 at relevant automobile door of the present invention, decorate the rear side of top-front portion 30 at door waist decorative fitting 50 is installed, but the installation constitution of this waist decorative fitting 50 is oversimplified.Promptly, as shown in Figure 4, waist decorative fitting 50 is overlapped a rear side of decorating top-front portion 30, to be inserted in the protruding hole 51 of waist decorative fitting 50 with projection 34 to the edge-on welding of establishing in the back side from resin rib 32, by welding is processed with the fore-end ca(u)lk of projection 34, the latter half of waist decorative fitting 50 is fixed on the back side of decorating top-front portion 30, and for the first half of waist decorative fitting 50, the material 35 that is involved in of the terminal part by being located at foamed resin substrate 31 is involved in the terminal 50a of the upside of waist decorative fitting 50 affixed.
Thereby, need not set protruding welding position at upper portion, be used for installing the number of the welding of waist decorative fitting 50 so can reduce with projection 34, can cut down metal paattern machining period number, because the operation that is involved in that is involved in material of foamed resin substrate 31 can be adopted simultaneously with the terminal treatment process of common peripheral part, so can not bring number increase in man-hour yet, owing to by being involved in material 35 the terminal 50a of the upside of waist decorative fitting 50 is coated, so also be preferred on appearance looks elegant.
Then, decorate the structure of the forming metal mould 60 that uses on top-anterior 30 o'clock at formed door based on Fig. 5 explanation.Forming metal mould 60 substantially by can be with the shaping patrix 61 of predetermined stroke up-and-down movement, constitute with the forming lower die 62 of shaping patrix 61 double-type fixation side and the injector 63 that is connected on the forming lower die 62.More particularly, shaping patrix 61 is formed with the cavity portion 611 consistent with article shape, and the lift cylinders 612 that is attached on the upper surface of shaping patrix 61 drives up and down with predetermined stroke.In addition, be provided with guiding sleeve 613 in 4 bights of shaping patrix 61.
On the other hand, on forming lower die 62, be provided with core 621 corresponding to the cavity portion 611 of shaping patrix 61.In addition, for with molten resin supplying on the die face of this core 621, on forming lower die 62, be provided with collector 622, cast gate 623,, will supply on the upper surface of core 621 from injector 63 molten resin supplied M via the resin passage of this collector 622, cast gate 623.In addition, in order to form resin rib 32, on core 621 upper surfaces, be equipped with the slot part 624 of supplying with molten resin M.In addition, on 4 bights of forming lower die 62, be equipped with guide posts 625 as guide mechanism, this guide posts 625 is with shaping upper and lower mould 61,62 matched moulds the time, by guide posts 625 being directed in the guiding sleeve 613 of shaping patrix 61, can suitably keep the pressure of shaping patrix 61.
Then, each operation that above-mentioned door is decorated the manufacturing process of top-front portion 30 describes.At first, by not shown heating arrangement will be on the face of Foamex sheet S stacked the base material of epidermis 33 carry out thermoplastic and handle, when shaping upper and lower mould 61,62 is in die opening state, put in the mould.In this embodiment, as Foamex sheet S, use polypropylene system foaming sheet (firmly changing プ ラ ス テ Star Network system, trade name: ス ミ セ ラ one foaming PP sheet, expansion ratio=3 times, thickness 3mm).In addition,, also can be arranged as, Foamex sheet S and epidermis 33 are overlapped onto respectively in the forming metal mould 60 according to hope.And after settling Foamex sheet S, the driving by lift cylinders 612 makes shaping patrix 61 decline predetermined strokes, with shaping upper and lower mould 61,62 matched moulds, with the die face shape figuration (with reference to Fig. 7) of Foamex sheet S along hope.
And then, with the shaping of foamed resin substrate 31 simultaneously or after after a while, carry out the injection moulding of resin rib 32.That is, when shaping upper and lower mould 61,62 is in the matched moulds state, via collector 622, cast gate 623 molten resin M injection is filled in the slot part 624, resin rib 32 is configured as the predetermined pattern shape from injector 63.In addition, as this molten resin M, use Sumitomo ノ one Block レ Application BUE81E6 (Sumitomo Chemical system polypropylene, fusion index=80g/10 minute).In addition, in molten resin M, also can sneak into fillers such as french talc with proper proportion.
As described above, door is decorated the shape that top-front portion 30 is configured as to be needed, finish if be shaped, then with 61,62 die sinkings of shaping upper and lower mould, take out door from forming metal mould 60 and decorate top-front portions 30, door is decorated on the welding jig 71 that top-front portion 30 is placed in ca(u)lk device 70 shown in Figure 9.Then, waist decorative fitting 50 is positioned at a rear side of decorating top-front portion 30, at this moment, by with integrated in door is decorated welding on the resin rib 32 of top-front portion 30 is inserted into waist decorative fitting 50 with projection 34 protruding hole 51, use ultrasonic horn 72 ca(u)lks to process with protruding 34 fore-end welding, as shown in figure 10, the latter half of waist decorative fitting 50 is fixed on the rear side assigned position of decorating top-front portion 30 by the ca(u)lk joint of welding with projection 34.At this moment, the end portion of foamed resin substrate 31 extends to than the terminal 50a of the upside of waist decorative fitting 50 by the top.And this part is equivalent to be involved in material 35.
Then, decorating top-front portion 30 for opposite house finishes the installation of waist decorative fitting 50, uses terminal processing equipment 80 shown in Figure 11.This end processing equipment 80 substantially by the arrangement of settling door to decorate top-front portion 30 with anchor clamps 81, make being involved in material 35 thermoplastic heated jigs 82 and will being involved in material 35 and constituting of a decoration top-front portion 30 to the portion of mechanism 83 that is involved in that the rear side of main body is involved in processing.
More particularly, settle with anchor clamps 81 by being used for settling an arrangement platform 81a of decoration top-front portion 30, being used for door is decorated top-anterior 30 positioning and fixing to the distance piece 81b of assigned position with accept the anchor clamps pushing 81c of portion and constitute.Then, as heated jig 82, the temperature booster supporting mass 82b that supports temperature booster 82a is attached at driving with on the cylinder 82c, the back side thermoplastic that is involved in material 35 of door being decorated top-front portion 30 by the temperature booster 82a of this heated jig 82.And then, for the action that is involved in portion of mechanism 83, to be involved in cylinder 83b by advance and retreat and to handle the screw die 83a that is involved in be involved in material 35 and drive, and with cylinder 83d the bench board 83c that advances and retreat with cylinder 83b will be installed by knee-action and drive predetermined stroke along above-below direction along the horizontal direction advance and retreat.
Thereby in order to carry out semi-finished terminal processing the shown in Figure 10, as shown in figure 11, the arrangement that is arranged to terminal processing equipment 80 under the incorporate state of the latter half of door being decorated top-front portion 30 and waist decorative fitting 50 is with on the arrangement platform 81a of anchor clamps 81.Then, by distance piece 81b, accept the anchor clamps pushing 81c of portion after assigned position is fixing, as shown in figure 12, heated jig 82 is driven into assigned position, the rear side thermoplastic that is involved in material 35 that will set along the peripheral part of foamed resin substrate 31 by temperature booster 82a.
Then, as shown in figure 13, the temperature booster supporting mass 82b of supporting temperature booster 82a retreats by the driving that drives with cylinder 82c, replace it and be involved in portion of mechanism 83 be involved in screw die 83a by advance and retreat with the action of cylinder 83b sliding action, to be involved in roughly 90 ° of bending operations of material 35, terminal 50a is that basic point is involved in processing with the upside of waist decorative fitting 50.At this moment, as shown in figure 14, by advance and retreat with cylinder 83b and knee-action with both actions of cylinder 83d, be involved in material 35 and can be involved in processing with 180 ° bending angle roughly.And, because being involved in the end processing action of material 35 carries out along the periphery of door decoration top-front portion 30 usually, so also can handle action with common being involved in of end processing carrying out simultaneously waist decorative fitting 50, so can newly not add the number in man-hour, in addition, can reduce the number of projection, and also can improve cosmetic look etc., can expect bigger action effect.
Then, Figure 15 to Figure 20 is the figure of expression variation of the present invention, as shown in figure 15, also uses decorating the form that waist decorative fitting 50 is installed on top-front portion 30 at the door of door decoration 20 in this variation.And, by accompanying drawing as can be known, waist decorative fitting 50 is set at curved shape, (establishing upside projection hole is 51a to be formed with protruding hole 51a, 51b on a plurality of positions separately of upper and lower, setting side projection hole is 51b), corresponding to this, also set cooresponding welding with protruding 34a, 34b for resin rib 12.And, downside for waist decorative fitting 50, welding is inserted among the protruding hole 51b of waist decorative fitting 50 with projection 34, by the latter half projection of waist decorative fitting 50 is fixed in the processing of front end ca(u)lk, and the upper end side that comprises the terminal 50a of upside of waist decorative fitting 50 is clamped and fixed in resin rib 32 and is involved between the material 35, and then, be involved in material 35 and fix with the front end face welding of protruding 34a with welding.
Thereby, by setting the protruding 34a of welding, can further improve the positional precision that waist decorative fitting 50 is installed, can be reliably and firmly fix with end portion.For this situation, also as shown in figure 16, door is being decorated after top-front portion 30 is placed on the welding jig 71, each protruding 34a, 34b are inserted protruding hole 51a, the 51b of logical waist decorative fitting 50 respectively and settle, owing to set protruding hole 51a, 51b respectively at the upper and lower sides of waist decorative fitting 50, so can critically control accuracy of positioning with positioning function.And, as shown in figure 17,, the latter half of waist decorative fitting 50 can be fixed on the decoration top-front portion 30 by the welding of downside is processed by ultrasonic horn 72 weldings with the front end of protruding 34b.
Then, as shown in figure 18, door is being decorated arrangement that top-front portion 30 is placed in terminal processing equipment 80 with after on the anchor clamps 81, as shown in figure 19, make the back side heating and melting that is involved in material 35 of front end of foamed resin substrate 31 by heated jig 82 after, as shown in figure 20, if with the driving of cylinder 83b the screw die 83a advance and retreat that are involved in that are involved in portion of mechanism 83 are moved by advance and retreat, to be involved in the face of weld bending operation of material 35 along waist decorative fitting 50, then can be by the terminal 50a of the upside that is involved in clamping waist decorative fitting 50 between material 35 and the resin rib 32, and then, since welding with the front end face of protruding 34a with to be involved in material 35 weldings integrated, so can realize more firm maintenance by the anchor combination.
Thereby, in this variation, also utilize the method for edge treatment of foamed resin substrate 31, by with resin rib 32 be involved in the terminal 50a of upside that material 35 grips waist decorative fitting 50, and with welding with protruding 34a with to be involved in material 35 integrated, become the anchor structure, can realize more firm maintenance etc., make simple structureization, on the other hand, can also guarantee the failure-free installation strength, and be involved in material 35 and can carry out roughly 90 ° bending operation, the action that is involved in portion of mechanism 83 is only just enough with cylinder 83b by advance and retreat, so the operation that is involved in that is involved in material 35 is oversimplified.
Industrial applicibility
More than Shuo Ming embodiment decorates top 20A with door to decorate the type that bottom 20B engages with door, and decorate the structure of decorating the relevant lit-par-lit structure body of the present invention of employing in top-front portion 30 that top 20A is partitioned into by front and back two at door, and be applied in the structure that miscellaneous parts such as waist decorative fitting 50 simply and cheaply are installed, decorate among the 20A of top but the lit-par-lit structure body can be applied to whole door, perhaps decorate at one-piece type door, or door is decorated inner-decoration component in addition, Rear Parcel Shelf for example, floor decorative, rear platform is decorated, baggage container is decorated, ceiling is decorated, rear side decoration etc., during decorating, adopt all interior trims structure of the present invention and method of the present invention.

Claims (4)

1, a kind of inner-decoration component for automobile, it is the inner-decoration component for automobile (20) that in an integral body or a part, adopts lit-par-lit structure body (30) to form, described lit-par-lit structure body (30) possesses shape, the light weight that is configured as needs and has the foamed resin substrate (31) of conformality, the resin rib (32) of integrated predetermined pattern shape on the back side of this foamed resin substrate (31), it is characterized in that
The foamed resin substrate (31) of above-mentioned lit-par-lit structure body (30) between shaping upper and lower mould (61,62) by pressure forming, and integrated resin rib (32) on the back side of this foamed resin substrate (31) is molten resin (M) injection to be filled in the slot part (624) of forming lower die (62) and shaping, and then, at the rear side configuration miscellaneous part (50) of foamed resin substrate (31), resin rib (32), the material (35) that is involved in of the periphery end of the stacked tectosome of end portion (50a) (30) of this miscellaneous part (50) is involved in supporting.
2, inner-decoration component for automobile as claimed in claim 1, it is characterized in that, above-mentioned lit-par-lit structure body (30) be involved in material (35) except the end portion (50a) that is involved in supporting miscellaneous part (50), also welding integratedly is fixed on and inserts on the welding lead in the protruding hole (51) of miscellaneous part (50) side with the front end face of projection (34a) and miscellaneous part (50).
3, a kind of manufacture method of inner-decoration component for automobile, it is the manufacture method of the inner-decoration component for automobile (20) that employing lit-par-lit structure body (30) forms in an integral body or a part, described lit-par-lit structure body (30) possesses shape, the light weight that is configured as needs and has the foamed resin substrate (31) of conformality, the resin rib (32) of integrated predetermined pattern shape on the back side of this foamed resin substrate (31), it is characterized in that
Additional have a following operation: above-mentioned lit-par-lit structure body (30) will be after will handling as Foamex sheet (S) thermoplastic of the base material of foamed resin substrate (31), put into forming metal mould (61,62) in, by forming metal mould (61,62) matched moulds, with the shape of foamed resin substrate (31) pressure forming for needing, and at above-mentioned forming metal mould (61,62) behind the matched moulds, molten resin (M) injection is filled in the slot part (624) of forming lower die (62), at the integrated and resin rib (32) of shaping predetermined pattern shape of the rear side of foamed resin substrate (31), then, with lit-par-lit structure body (30) from forming metal mould (61,62) after the demoulding, miscellaneous part (50) is configured in the rear side of lit-par-lit structure body (30), to go up incorporate welding is inserted in the protruding hole (51) of miscellaneous part (50) with protruding (34) after at resin rib (32), by welding is processed with projection (34) ca(u)lk, miscellaneous part (50) is integrated on the rear side assigned position of foamed resin substrate (31) and resin rib (32), then, after heated jig (82) thermoplastic of the rear side that is involved in material (35) by terminal processing equipment (80) that will be set in the periphery terminal part of lit-par-lit structure body (30) handled, the advance and retreat operation of the portion of mechanism that is involved in (83) by terminal processing equipment (80) will be involved in material (35) bending operation so that the end portion (50a) of miscellaneous part (50) is wrapped into, thereby handle the end portion (50a) of miscellaneous part (50) is terminal.
4, the manufacture method of inner-decoration component for automobile as claimed in claim 3, it is characterized in that, in the terminal treatment process that is involved in material (35) of the periphery end that is set in lit-par-lit structure body (30), the end portion (50a) of miscellaneous part (50) disposes to vertical direction from the back side of lit-par-lit structure body (30), to be involved in roughly 90 ° of material (35) bending operations, thereby welding is fixed on the miscellaneous part (50), and with welding with the side of front end face and the miscellaneous part (50) of projection (34a) and be involved in material (35) welding integratedly.
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