JP2000229327A - Production of panel for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a panel for a vehicle constituted by integrating a skin layer, a cushioning layer, a substrate layer and a duct member without requiring an adhesive or a tapping screw and restricting the kind of a resin material. SOLUTION: A skin layer 12, a substrate layer 13 and a duct member 15 are preformed to be set in a mold 17 and a non-foamed resin material 21 prepared by mixing a foaming agent 24 and a microwave absorbing material 25 is arranged between the skin layer 12 and the substrate layer 13 and a microwave absorbing material 26 is arranged between the substrate layer 13 and the duct member 15. The mold 17 is irradiated with a microwave from the outside to generate heat in the microwave absorbing materials 25, 26 and the non-foamed resin material 21 containing the foaming agent 24 is heated and foamed not only to mold a cushioning layer 14 welded to the skin layer 12 and the substrate layer 13 but also to weld the duct member 15 to the substrate layer 13.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a skin material layer made of a thermoplastic resin, a base material layer made of a thermoplastic resin, and a thermoplastic resin sandwiched and integrally welded between the skin material layer and the base material layer. And a duct member made of a thermoplastic resin which is welded to the back surface of the base material layer and forms a duct with the base material layer.

[0002]

2. Description of the Related Art Generally, an instrument panel for an automobile has a three-layer structure in which a skin layer, a cushion layer and a base layer made of resin are laminated. As the Japanese Patent Publication 63-47
No. 76 is known.

In the above-mentioned conventional manufacturing method, a skin material layer is formed from a material obtained by blending an olefin-based thermoplastic elastomer with a polypropylene resin, and an adhesive is applied to the skin material layer, followed by heating to a polypropylene foam cushion material layer. Then, it is formed into a predetermined shape by a vacuum forming die. Then, a base layer made of an ABS resin to which an adhesive has been applied in advance is bonded to the laminate of the skin material layer and the cushion material layer to obtain an instrument panel having a three-layer structure.

An air conditioning duct member is attached to the back side of the instrument panel. Conventionally, this duct member has been attached to a boss formed on a base material of the instrument panel by using a tapping screw.

[0005]

In the above-mentioned publication, the skin material layer and the cushion material layer are bonded by bonding, and the laminate of the skin material layer and the cushion material layer is bonded to the base material layer. In order to join by adhesion, a primer application step as a pretreatment of adhesion, an adhesive application step,
There is a problem that the number of steps is increased due to the necessity of a bonding step.

Further, in the above publication, a cushion material is formed by injecting and foaming a urethane resin between a skin material layer and a base material layer in a state where a preformed skin material layer and a base material layer are set inside a molding die. Although a method of obtaining an instrument panel having a three-layer structure by forming a layer is also disclosed, in this method, an olefin-based resin in which a foamed resin is unlikely to flow in a molding die is selected as a material of a cushion material layer. However, there is a problem that the degree of freedom in selecting a material is hindered.

In addition, when a tapping screw is used to attach an air conditioning duct member to an instrument panel, there is a problem that the number of steps and the number of parts are increased.

The present invention has been made in view of the above circumstances, and requires a vehicle panel comprising a skin material layer, a cushion material layer, a base material layer, and a duct member integrated with an adhesive or a tapping screw. It is an object of the present invention to provide a method for producing a resin material without limiting the type of the resin material.

[0009]

In order to achieve the above object, according to the first aspect of the present invention, a skin material layer made of a thermoplastic resin, a base material layer made of a thermoplastic resin,
A cushion material layer made of a thermoplastic resin foam sandwiched and integrally welded between a skin material layer and a base material layer, and a duct formed between the cushion material layer and the base material layer welded to the back surface of the base material layer A method for manufacturing a vehicle panel including a duct member made of a thermoplastic resin, comprising setting a preformed skin material layer, a base material layer, and a duct member inside a mold, and forming the skin material layer and the base material layer. Interposing an unfoamed resin material in which a foaming agent and a microwave absorbing material are mixed together, and interposing a microwave absorbing material at a contact portion between the base material layer and the duct member; Heating the microwave-absorbing material contained in the unfoamed resin material and the microwave-absorbing material interposed between the base layer and the abutting portion of the duct member;
Heating and foaming with the heat of the microwave absorbing material contained therein to form a cushion material layer; and welding the cushion material layer to the skin material layer and the base material layer by the heat of the molten cushion material layer; Welding the duct member to the base material layer by the heat generated by the microwave absorbing material interposed between the base material layer and the abutment portion of the duct member. .

[0010] According to the above configuration, the skin material layer, the base material layer, and the duct member, which have been molded in advance, and the unfoamed resin material in which the foaming agent and the microwave absorbing material are mixed are set inside the mold. Irradiation of microwaves to foam the unfoamed resin material to form the cushion material layer and weld the cushion material layer to the skin material layer and the base material layer, and at the same time, between the base material layer and the duct member. Since the microwave absorbing material interposed in the tube can generate heat and weld the duct member to the base material layer, the cushion material layer can be integrated with the skin material layer and the base material layer using an adhesive or There is no need to integrate the member into the base material layer, and the vehicle panel can be obtained with a small number of steps and a small number of parts. In addition, since the base material layer, the skin material layer, the cushion material layer, and the duct member may be made of a thermoplastic resin, the degree of freedom in selecting the material is increased.

According to the second aspect of the present invention,
In addition to the configuration of claim 1, a space is formed between the skin material layer and the base material layer where the foaming of the unfoamed resin material is allowed in a state where the skin material layer and the base material layer are set inside the mold. A method for manufacturing a vehicle panel is proposed.

According to the above construction, the unfoamed resin material is foamed in the space formed between the skin material layer and the base material layer, so that the molding resin is not deformed by the foaming pressure, and excess resin is removed. A vehicle panel can be formed without discharging to the outside of a mold.

According to the third aspect of the present invention,
In addition to the configuration of the first aspect, there is proposed a method for manufacturing a vehicle panel, wherein the skin material layer, the base material layer, the cushion material layer, and the duct member are all made of an olefin resin.

According to the above construction, since the skin layer, the base layer, the cushion layer and the duct member of the vehicle panel are all made of an olefin resin, the skin layer, the base layer, the cushion layer and the duct member are formed. Can be easily recycled without separation.

According to the invention described in claim 4,
In addition to the configuration of the first aspect, there is proposed a method for manufacturing a vehicle panel, wherein the skin material layer is a slush molded product.

According to the above configuration, by forming the skin material layer by slush molding, a skin material layer having a complicated shape having sharp corners can be obtained.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described based on embodiments of the present invention shown in the accompanying drawings.

1 to 4 show an embodiment of the present invention. FIG. 1 shows a state in which a skin material layer, a base material layer, a duct member and an unfoamed resin material are set in an opened mold. FIG. 2 is a view showing a state in which a cushion material layer is formed in a closed mold, FIG. 3 is a view showing a state in which an outer peripheral portion of an instrument panel is trimmed, and FIG. 4 is a cross-sectional structure of the instrument panel. FIG.

FIG. 4 shows a cross section of an instrument panel 11 for an automobile manufactured by the manufacturing method of the present invention. The instrument panel 11 includes a skin material layer 12 located on the front side and facing a vehicle compartment. A base layer 13 that is located on the back side and forms a strength member that maintains the shape of the instrument panel 11, and is formed of a flexible foam and is sandwiched between the skin material layer 12 and the base layer 13. And a cushion material layer 14 laminated in three layers.
Has a structure in which a duct member 15 is welded to a rear surface of the air conditioner to form an air conditioning duct 16. Since the skin material layer 12, the base material layer 13, the cushion material layer 14, and the duct member 15 are all made of an olefin-based thermoplastic resin, each layer 1
Even if the 2, 3, 14 and the duct member 15 are finely broken and recycled without being separated without separating, a high-quality recycled material containing no different kinds of resin can be obtained. Further, as described later, the skin material layer 12, the base material layer 13,
When the cushion material layer 14 and the duct member 15 are integrally welded, since they are made of the same material, they are easily fused to each other, and the strength is increased. Examples of the olefin-based thermoplastic resin include polypropylene, polyethylene, and a polyolefin such as a copolymer of propylene and ethylene.

As shown in FIG. 1, a molding die 17 for molding the instrument panel 11 is made of a non-metallic material that transmits microwaves. 19 and an upper mold 20.
In the cavity of the lower mold 19, the skin material layer 12 and the base material 13
And the unfoamed resin material 2 which is the material of the cushion material layer 14
1 is set with the pin 22 positioned, and the duct member 15 is set in the cavity of the upper mold 20. As a material of the molding die 17, a super-engineering plastic having high heat resistance (for example, polyimide or polyetheretherketone) is used.

The skin material layer 12 is slush-molded in advance with an olefin-based thermoplastic resin. By using an olefin-based resin, it is possible to give a calm feeling and color tone required for the skin material layer 12 of the instrument panel 11, and by performing slush molding,
It can be formed into a complicated shape with a precise grain pattern and sharp corners. Skin material layer 12
An unfoamed resin material 21 serving as a material of the cushioning material layer 14 has an inner surface (a surface facing the base material layer 13)
Are attached so that a space 23 exists between them. The unfoamed resin material 21 is obtained by mixing a foaming agent 24 and a microwave absorbing material 25 with a material obtained by forming an olefin-based thermoplastic resin into a powder or a granule.

The microwave absorbing material 25 includes carbon black, oxide ceramic particles, fine indium oxide, fine particles of aniline-based polymer (surface-treated with a titanate-based coupling agent or an aluminum-based coupling agent), zinc oxide (The metal surface is treated), glass beads (metal surface is treated), and titanium oxide (metal surface is treated). As the foaming agent 24, an ADCA-based or OBSH-based foaming agent is used.

The duct member 15 set on the upper mold 20
A microwave absorbing material 26 which is the same as the microwave absorbing material 25 contained in the unfoamed resin material 21 is previously attached to the welded portion. Note that instead of attaching the microwave absorbing material 26 to the duct member 15 side, it is also possible to attach the microwave absorbing material 26 to the instrument panel 11 side.

Subsequently, as shown in FIG. 2, the lower mold 19 and the upper mold 20 of the mold 17 are clamped. In this state, upper mold 2
The duct member 15 set to 0 contacts the back surface of the base material layer 13 via the microwave absorbing material 26 attached to the duct member 15. Next, the mold 17 is placed inside the microwave irradiation device 27, and the lower mold 19 and the upper mold 20 are irradiated with microwaves while being pressed in the mold clamping direction.

The microwave radiated from the microwave radiating device 27 passes through the non-metallic mold 17, the microwave absorbing material 25 contained in the unfoamed resin material 21, the base material layer 13 and the duct member 15. Acts on the microwave absorbing material 26 interposed therebetween, and the microwave absorbing material 25,
26 is heated. As a result, the microwave absorbing material 25
Is generated, the thermoplastic resin of the unfoamed resin material 21 is melted and the foaming agent 24 is decomposed to generate gas,
The thermoplastic resin melted by this gas foams and expands to fill the space 23 between the skin material layer 12 and the base material layer 13. The surfaces of the skin material layer 12 and the base material layer 13 in contact with the thermoplastic resin of the melted unfoamed resin material 21 are melted, and the thermoplastic resin of the unfoamed resin material 21 is cooled and solidified to form the cushion material layer 14. In this case, the skin material layer 12 and the base material layer 13 are welded to both surfaces of the cushion material layer 14.

At the same time, the microwave absorbing material 26 interposed between the base material layer 13 and the duct member 15 generates heat, so that the contact surface between the base material layer 13 made of thermoplastic resin and the duct member 15 is melted. Welded together.

Thus, it is possible to integrate the cushion material layer 14 into the skin material layer 12 and the base material layer 13 and to integrate the duct member 15 and the base material layer 13 without using an adhesive or a tapping screw. As a result, the number of steps and the number of parts can be significantly reduced. In addition, since the unfoamed resin material 21 is foamed inside the mold 17, it is possible to employ an olefin resin as the unfoamed resin material 21, thereby increasing the degree of freedom in selecting a material. Further, since the space 23 for the unfoamed resin material 21 to expand and expand is formed inside the molding die 17, the surplus unfoamed resin material 21 does not escape to the outside of the molding die 17, and the molding is performed. The cushion material layer 14 can be formed without applying a large internal pressure to the mold 17.

As described above, the skin material layer 12 and the base material layer 1
3 and the cushioning material layer 14 to the duct member 15
When an integrated product is formed, as shown in FIG.
An unnecessary portion on the outer periphery is trimmed by a water jet to complete the instrument panel 11.

Although the embodiments of the present invention have been described in detail, various design changes can be made in the present invention without departing from the gist thereof.

For example, in the embodiment, the skin material layer 12, the base material layer 13, the cushion material layer 14, and the duct member 15 are made of a thermoplastic olefin resin. Even with a thermoplastic resin, sufficient welding performance can be ensured.

"Polystyrene", "polyvinyl chloride",
"Polyvinylidene chloride", "Polymethyl methacrylate", "Copolymers of styrene, vinyl chloride, methyl methacrylate, vinylidene chloride, etc.", "Condensed engineering plastics such as polycarbonate, polyamide, polyester, polyimide"

The present invention also relates to an instrument panel 1
The invention can be applied to a vehicle panel other than the one described above, and the duct formed by the duct member 15 is not limited to the one for air conditioning, but may be for any other purpose.

The structure of the molding die 17 is not limited to that of the embodiment, and a pair of dies may be opened and closed by moving in a vertical or horizontal direction in parallel.

[0034]

As described above, according to the first aspect of the present invention, an unfoamed resin material obtained by mixing a preformed skin material layer, a base material layer and a duct member with a foaming agent and a microwave absorbing material. Is set inside the mold, and the mold is irradiated with microwaves to foam the unfoamed resin material to form the cushion material layer and weld the cushion material layer to the skin material layer and the base material layer At the same time, the microwave absorbing material interposed between the base material layer and the duct member can be heated to weld the duct member to the base material layer, so that the cushion material layer is formed using an adhesive or a tapping screw. There is no need to integrate the skin layer and the base material layer or the duct member with the base material layer, and the vehicle panel can be obtained with a small number of steps and a small number of parts. Moreover, since the base material layer, the skin material layer, the cushion material layer, and the duct member may be a thermoplastic resin,
The degree of freedom in selecting the material is increased.

According to the second aspect of the present invention,
Since the unfoamed resin material is foamed inside the space formed between the skin material layer and the base material layer, without deforming the mold due to the foaming pressure, and without discharging excess resin to the outside of the mold. Vehicle panels can be molded.

According to the third aspect of the present invention,
Since the skin layer, base layer, cushion layer and duct member of the vehicle panel are all olefinic resin, the skin layer, base layer, cushion layer and duct member can be easily recycled without separation. be able to.

According to the fourth aspect of the present invention,
By performing the slash molding of the skin material layer, a skin material layer having a complicated shape having sharp corners can be obtained.

[Brief description of the drawings]

FIG. 1 is a view showing a state in which a skin material layer, a base material layer, a duct member, and an unfoamed resin material are set in an opened mold.

FIG. 2 is a diagram showing a state in which a cushion material layer is formed in a closed mold.

FIG. 3 is a diagram showing a state where an outer peripheral portion of the instrument panel is trimmed.

FIG. 4 is a diagram showing a cross-sectional structure of an instrument panel.

[Explanation of symbols]

 12 skin material layer 13 base material layer 14 cushion material layer 15 duct member 16 air-conditioning duct (duct) 17 mold 21 unfoamed resin material 23 space 24 foaming agent 25 microwave absorbing material 26 microwave absorbing material

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F212 AA03 AB02 AB16 AB18 AD05 AD08 AD20 AG03 AG20 AH25 UA10 UB01 UB13 UG02 UG05 UG07 UN08

Claims (4)

[Claims] 1. A skin layer (12) made of a thermoplastic resin.
And a base material layer (13) made of a thermoplastic resin, and a cushion material layer (made of a thermoplastic resin foam sandwiched and integrally welded between the skin material layer (12) and the base material layer (13)) 14) and a duct member (15) made of a thermoplastic resin which is welded to the back surface of the base material layer (13) to form a duct (16) between the base material layer (13) and the vehicle. A method of manufacturing a panel, comprising a preformed skin material layer (1) inside a forming die (17).
2) The base material layer (13) and the duct member (15) were set, and the foaming agent (24) and the microwave absorbing material (25) were mixed between the skin material layer (12) and the base material layer (13). A step of interposing an unfoamed resin material (21) and interposing a microwave absorbing material (26) in a contact portion between the base material layer (13) and the duct member (15);
7) Irradiation of microwave to unfoamed resin material (21)
The microwave absorbing material (25) contained in the base material layer (1)
3) a step of generating heat with the microwave absorbing material (26) interposed in the contact portion of the duct member (15); Heating and foaming by the heat generated by the wave absorbing material (25) to form the cushion material layer (14); and heating the cushion material layer (14) by the heat of the melted cushion material layer (14). ) And the step of welding to the base material layer (13); and the base material layer (13) and the duct member (1).
Microwave absorbing material (26) interposed in the contact portion of (5)
Welding the duct member (15) to the base material layer (13) by the heat generated by the method. 2. A skin material layer (1) inside a molding die (17).
With the 2) and the base material layer (13) set, a space (23) is formed between the skin material layer (12) and the base material layer (13) that allows the unfoamed resin material (21) to foam. The method for manufacturing a vehicle panel according to claim 1, wherein: 3. The material according to claim 1, wherein the skin material layer (12), the base material layer (13), the cushion material layer (14), and the duct member (15) are all olefin-based resins. A method for manufacturing a vehicle panel. 4. The method for manufacturing a vehicle panel according to claim 1, wherein the skin material layer (12) is a slush molded product.