JP2000127862A - Manufacture of automobile trim and molding die therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing an automobile trim and a molding die reducing a manufacturing cost and improving quality. SOLUTION: A molding die 5 to be used comprises a cavity die 50 having a first front side molding face 51 and a second front side molding face 52, and a core die 60 having a first back side molding face 61, a second back side molding face 62 and a freely advancing/retreating core slide 7. The core slide 7 is advanced to partition a first cavity 71 and a second cavity 72 by the core slide 7, and first resin material 81 is injected into the first cavity 71 to mold a first member 11. The core slide 7 is then retreated to release the partition between the first cavity 71 and the second cavity 72, and second resin material 82 is injected into the second cavity 72 to mold a second member 12. The second member 12 is bonded to the first member 11 to integrate both members 11, 12.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an automobile trim and a mold.

[0002]

2. Description of the Related Art A trim (automobile trim) for covering an inner surface of a door panel is provided on a door of an automobile. As shown in FIG. 10, the conventional automobile trim 9 has an upper member 91.
And the lower member 92. The upper member 91 and the lower member 92 are made of, for example, resin materials of the same material but of different colors, or resin materials of different materials themselves.
Molded with different kinds of resin materials. FIG.
As shown in FIG. 7, a decoration material 93 may be provided on the upper member 91 or the lower member 92 in some cases.

In manufacturing the conventional automobile trim 9, as shown in FIGS. 10 and 11, an upper member 91 and a lower member 92 are separately formed, and a boss 920 is mounted on the lower member 92 and an upper member 91 is formed. The member 91 has a through hole 9
10 are provided. Then, the upper member 91 and the lower member 92 are integrated by inserting the boss 920 into the through hole 910 and heat-staking the tip of the boss 920.

[0004]

However, the above-mentioned conventional method of manufacturing a trim for an automobile has the following problems. That is, in the conventional automobile trim 9, as described above, the upper member 91 and the lower member 92 are separately formed, and then they are assembled and integrated. Therefore, the number of assembly steps is large, and it is difficult to rationalize the manufacturing cost. Further, there may be a quality problem that a slight dimensional error between the upper member 91 and the lower member 92 appears as a gap or a shift at the boundary between them. In this case, the repair work is required, which further increases the manufacturing cost.

The present invention has been made in view of such conventional problems, and an object of the present invention is to provide a method of manufacturing a trim for an automobile and a mold capable of reducing the manufacturing cost and improving the quality.

[0006]

According to a first aspect of the present invention, a first member made of a first resin material and a second member made of a second resin material different from the first resin material are integrally formed. A method for manufacturing an automotive trim, comprising: a mold having a first surface forming surface for forming a surface shape of the first member and a second surface forming surface for forming a surface shape of the second member;
A first back forming surface provided to face the mold and forming a back shape of the first member; and a second back forming surface forming a back shape of the second member, and the first back forming surface. A mold having a core mold having a retractable core slide provided between the first mold and the second back molding surface, and moving the core slide forward to make contact with the mold, thereby forming the first mold. A first cavity formed between the front molding surface and the first back molding surface and a second cavity formed between the second front molding surface and the second back molding surface; The first member is molded by injecting the first resin material into the first cavity, and then the core slide is retracted to form the first member.
The space between the cavity and the second cavity is opened to expose the first member to the second cavity, and then a second resin material is injected into the second cavity to mold the second member and A method of manufacturing a trim for an automobile, wherein a second member is bonded to the first member to integrate the first member and the second member.

The most remarkable point in the present invention is that a mold having the above-mentioned mold and a core having the above-mentioned core slide is used, and the advancing and retreating operation of the above-mentioned core slide is carried out as described above, so that the first cavity is inserted into the first cavity. One resin material is injected to form the first member, and then a second resin material is injected into the second cavity to form the second member and integrate them.

Next, the function and effect of the present invention will be described.
In the present invention, the first cavity and the second cavity are first defined by advancing the core slide using the mold. Both the first cavity and the second cavity have the same shape and capacity as the cavity when the first member or the second member is molded alone. In addition, each cavity does not require a complicated shape for providing a connection boss or a through-hole, which is required in the related art, and can be formed in a smooth shape.

[0009] Therefore, when the first resin material is injected into the first cavity, the first resin material injected into the first cavity flows more smoothly than in the past, and has high quality with excellent dimensional accuracy and appearance. Molded into a first member. Then,
By retracting the core slide, a gap between the first cavity and the second cavity is opened without the weir of the core slide, and the first member is exposed in the second cavity.

By injecting the second resin material into the second cavity in this state, the second resin material, which has flowed more smoothly than in the prior art as described above, becomes a high-quality second resin material having excellent dimensional accuracy and appearance. It becomes two members. Further, the second resin material contacts and adheres to the first member exposed in the second cavity in a molten state. Thereby, the second member is molded in a state of being integrally joined to the first member.

[0011] Then, in the obtained automobile trim, the first member and the second member are integrally formed in the molding die, so that the joining operation of the two members, which has been conventionally required, is completely eliminated. This makes it possible to streamline the process and reduce costs. In addition, the above-mentioned integral molding can solve the problem of the quality of the joint portion, which has been a problem in the past, and can manufacture an automobile trim with excellent quality.

Therefore, according to the present invention, it is possible to provide a method of manufacturing a trim for an automobile which can reduce the manufacturing cost and improve the quality.

Further, as in the second aspect of the present invention, a skin material can be previously disposed on at least one of the first surface forming surface and the second surface forming surface of the mold. In this case, it is possible to easily obtain an automobile trim in which the skin material is disposed on the surface of the first member or the second member, and it is possible to improve the surface decoration effect. Further, it is preferable that the skin material is arranged in the mold by preforming. Here, the preforming means forming the skin material by, for example, vacuum forming.

Next, according to a third aspect of the present invention, a first member made of a first resin material and a second member made of a second resin material different from the first resin material are integrally formed. A molding die for molding an automotive trim, comprising: a first molding surface for molding a surface shape of the first member;
A mold having a second surface forming surface for molding the surface shape of the member, a first back molding surface provided opposite to the mold for molding the back surface of the first member, and a back surface of the second member; A core mold having a second back molding surface for shaping a shape, and a retractable core slide provided between the first back molding surface and the second back molding surface of the core mold; The core slide abuts on the mold in its advanced state, and has a first cavity formed between the first front molding surface and the first back molding surface; a second cavity formed between the first front molding surface and the second back molding surface; A second cavity formed between the back molding surface and the second cavity;
In the retracted state, the first cavity and the second cavity are configured to communicate with each other.
A first step of injecting the first resin material into the first cavity;
A mold for automotive trim, comprising: a nozzle; and a second nozzle for injecting the second resin material into the second cavity.

The most notable point of the mold of the present invention is that the mold includes the mold, the core, and the core slide, and the first and second cavities are formed by moving the core slide forward and backward. Are configured so that they can be divided or communicated with each other. The use of the mold of the present invention makes it possible to easily carry out the above-mentioned excellent production method.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments A method for manufacturing a trim for automobiles and a mold according to an embodiment of the present invention will be described with reference to FIGS. First, the automotive trim 1 manufactured in this example is shown in FIG.
As shown in FIGS. 2 and 8, an upper member as a first member 11 made of a first resin material 81 and a lower member as a second member 12 made of a second resin material 82 different from the first resin material 81. Are integrally molded. In this example, PP (polypropylene) was used as the first resin material 81 and PP was used as the second resin material 82. These resins differ in their color. Further, on the surface of the first member 11, a skin material 15 made of fabric skin + PP foam or vinyl chloride skin + PP foam or the like is arranged in an island shape to enhance decorativeness.

Next, as shown in FIG. 4, the molding die 5 of the present embodiment has a first front molding surface 5 for molding the surface shape of the first member 11.
Surface molding surface 5 for molding the surface shapes of the first and second members 12
2, a first back forming surface 61 provided opposite to the mold 50 for forming the back surface of the first member 11, and a second back forming surface for forming the back surface of the second member 12. 62 and a core mold 60 having the same.

The first back molding surface 61 of the core mold 60 and the second
The core slide 7 which can move forward and backward is provided between the back molding surface 62. Further, a boundary portion between the first surface forming surface 51 and the second surface forming surface 52 of the mold 50 is formed as a contact portion 55 protruding inward and in contact with the core slide 7.

As shown in FIGS. 6 and 7, the core slide 7 abuts on the abutment portion 55 of the mold 50 in its advanced state, and the first front molding surface 51 and the first back molding surface 61 come into contact with each other. And a second cavity formed between the second front molding surface 52 and the second back molding surface 62.
The first cavity 71 and the second cavity 72 are configured to communicate with each other when the cavity 72 is partitioned.

As shown in FIG. 4, a first nozzle 65 for injecting the first resin material 81 into the first cavity 71 and a second resin material 82 in the second cavity 72 are injected into the core mold 60. A second nozzle 66 is provided. The core slide 7 is connected to a hydraulic cylinder 78, as shown in FIGS. 4 and 9, and is configured to perform an advance / retreat operation by the operation of the hydraulic cylinder 78. The hydraulic cylinder 78 has a front chamber 781 and a rear chamber 7 located before and after a piston plate 75 provided at the base end of the core slide 7.
A run-around circuit 79 communicating with 82 is provided, and a mechanism for preventing breakage of the hydraulic cylinder 78 due to the clamping force between the mold 50 and the core 60 described later is provided.

Next, in forming the automotive trim 1, first, as shown in FIG.
The skin material 15 was arranged on the front molding surface 51. This skin material 15
In a separate process, a sheet in which a fabric skin and a PP foam (cushion material) are bonded with an adhesive in advance is heated and vacuum-formed, and unnecessary portions are removed to form a substantially product shape. The skin material 15 was disposed by adsorbing the skin material 15 to the mold 50 by vacuum from a number of small holes provided in the mold 50.

Next, as shown in FIG. 6, the mold mold 50 and the core mold 60 are closed to a slightly open state, that is, to a small opening amount that can be formed by low pressure, for example, a state of 30 mm before the bottom dead center of the mold clamping. The core slide 7 is moved to the hydraulic cylinder 78
To make contact with the contact portion 55 of the mold 50. Thereby, the first front molding surface 51 and the first back molding surface 6
1 and a second cavity 72 formed between the second front molding surface 52 and the second back molding surface 62 are defined by the core slide 7.

Next, as shown in FIG. 6, in this state, the first resin material 81 is injected from the first nozzle 65 into the first cavity 71, and then the mold is clamped to the bottom dead center at the timing of the completion of the injection. Thus, the first member 11 is formed. The first resin material 8 in the slightly opened state
The reason for injecting No. 1 is to reduce damage to the PP foam used for the skin material due to the injection pressure.

In closing the mold to the bottom dead center, the run-around circuit of the hydraulic cylinder 78 is opened. Accordingly, it is possible to prevent the hydraulic cylinder 78 from being damaged due to the retreat of the core slide 7.

Next, as shown in FIG. 8, the core slide 7 is retracted, the space between the first cavity 71 and the second cavity 72 is opened, and the first member 11 is moved to the second cavity 7.
Exposure to 2. Next, as shown in FIG.
The second resin material 82 is supplied from the nozzle 66 to the second cavity 72.
To form the second member 12 and the second member 1
2 is adhered to the first member 11 to integrate the first member 11 and the second member 12. Thereby, as shown in FIG.
An automobile trim 1 obtained by integrally molding an upper member as the first member 11 and a lower member as the second member is obtained.

First member 11 of obtained automobile trim 1
2 and 3 show the cross-sectional structure of the bonding surface at the boundary between the first member 12 and the second member 12. As can be seen from the figure, it can be seen that an adhesive surface 19 formed by fusing the first member 11 and the second member 12 is thinly formed on the boundary surface between the first member 11 and the second member 12 and is joined without a gap.

As described above, in the present embodiment, the first member 11 and the second member 12 can easily be integrally molded in two colors by performing the above-described manufacturing method using the molding die 5. . Therefore, the joining work of the two members, which was conventionally required, can be completely eliminated, and the process can be streamlined and the cost can be reduced. Further, it is not necessary to provide the molding die 5 with a complicated shape for molding a connection boss or a through hole. Therefore, at the time of the above-mentioned molding, a smoother resin flow can be obtained than before, and the moldability can be improved. In addition, the integral molding can eliminate the quality problem of the joint portion, which has been a problem in the past. Therefore, according to this example, it is possible to manufacture the automobile trim 1 of excellent quality at low cost.

[0028]

As described above, according to the present invention, it is possible to provide a method of manufacturing a trim for an automobile and a mold capable of reducing the manufacturing cost and improving the quality.

[Brief description of the drawings]

FIG. 1 is a front view of a vehicle trim according to an embodiment.

FIG. 2 is a cross-sectional view of the automotive trim according to the embodiment (a cross-sectional view taken along line AA of FIG. 1).

FIG. 3 is an enlarged view of a joint between a first member and a second member in the embodiment.

FIG. 4 is an explanatory view showing a configuration of a molding die in the embodiment.

FIG. 5 is an explanatory view showing a state in which a skin material is set on a molding die in the embodiment.

FIG. 6 is an explanatory diagram showing a state in which a first resin material is injected into a first cavity in the embodiment.

FIG. 7 is an explanatory view showing a state in which molding of a first member is completed in the embodiment.

FIG. 8 is an explanatory view showing a state in which the molding of the second member is completed in the embodiment.

FIG. 9 is an explanatory view showing a configuration of a hydraulic cylinder for core slide in the embodiment.

FIG. 10 is a front view of an upper member and a lower member of an automotive trim in a conventional example.

11A is a cross-sectional view of an upper member and a lower member in a conventional example, and FIG. 11B is an explanatory diagram showing a joint state between the upper member and the lower member.

[Explanation of symbols]

 1. . . 10. automotive trim, . . 11. first member (upper member); . . 14. second member (lower member); . . Skin material, 5. . . Mold, 50. . . Mold type, 51. . . Table 1 molding surface, 52. . . Table 2, molding surface, . . Core type, 61. . . First back molding surface, 62. . . Second back molding surface, 65. . . First nozzle, 66. . . 6. Nozzle 7, . . Core slides, 71. . . First cavity, 72. . . Second cavity, 81. . . First resin material, 82. . . Second resin material,

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Torao Kanayama 100 Kanayama, Ichiriyama-cho, Kariya-shi, Aichi F-term (reference) 3D023 BA01 BB08 BC00 BD03 BE04 BE06 BE16 BE31 4F202 AA11 AD17 AD20 AH23 CA11 CB01 CB16 CB28 CK18 CK23 CK54 CQ06 4F206 AA11 AD17 AD20 AH23 JA07 JB15 JB28 JN12 JN25 JN33 JQ81

Claims (3)

[Claims] 1. A method for manufacturing an automotive trim, comprising integrally molding a first member made of a first resin material and a second member made of a second resin material different in type from the first resin material. A mold having a first surface molding surface for molding the surface shape of the first member and a second surface molding surface for molding the surface shape of the second member; It has a first back molding surface for molding the back surface shape of one member and a second back molding surface for molding the back surface shape of the second member, and is provided between the first back molding surface and the second back molding surface. A core mold having a core slide having a retractable core slide provided is used, and the core slide is advanced and brought into contact with the mold, thereby forming the first front molding surface and the first back molding surface. Between the first cavity formed between the first surface and the second surface forming surface. A second cavity formed between the second back molding surface and the second cavity is defined by the core slide;
Next, the first resin material is injected into the first cavity to form the first member, and then the core slide is retracted to open the space between the first cavity and the second cavity. Exposing the first member to the second cavity, injecting a second resin material into the second cavity to mold the second member, and bonding the second member to the first member. A method for manufacturing an automotive trim, comprising: integrating the first member and the second member. 2. A method of manufacturing a trim for an automobile according to claim 1, wherein a skin material is previously arranged on at least one of the first surface forming surface and the second surface forming surface of the mold. . 3. A molding die for molding an automotive trim formed by integrally molding a first member made of a first resin material and a second member made of a second resin material different from the first resin material. A first molding surface for molding the surface shape of the first member and a second molding surface for molding the surface shape of the second member.
A mold having a front molding surface, a first back molding surface provided opposite to the mold to mold the back surface of the first member, and a second back molding surface molding the back surface of the second member; And a core slide which is provided between the first back molding surface and the second back molding surface of the core mold, and is capable of moving back and forth. A first cavity formed in contact with the mold and formed between the first front molding surface and the first back molding surface, and formed between the second front molding surface and the second back molding surface. The second cavity is partitioned from the first cavity while the first cavity is in communication with the second cavity when the second cavity is retracted.
A mold for automotive trim, comprising: a first nozzle for injecting a resin material; and a second nozzle for injecting the second resin material into the second cavity.