JP2001097168A - Skin on vehicle interior trim member having air bag door and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To open the required number of through holes along a tear- predetermined part to suitably set the tearing strength of the tear-predetermined part, and position the tear-predetermined part inwardly to shut off the respective through holes from the outside. SOLUTION: A skin 25 consists of a first skin part 26 mounted correspondingly to the external surface of a base material 11, a second skin part 27 mounted correspondingly to the external surface of an air bag door 20, and a skin connecting part 28 connecting these skin parts 26, 27. A tear-predetermined part 30 having plural through holes 31 is formed in the skin connecting part 28. The respective through holes 31 of the tear-predetermined part 30 are shut off from the outside by a first skin piece part 28A and a second skin piece part 28B which are folded to adhere closely to each other.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a skin to be mounted on an outer surface of a base material of a vehicle interior member having an airbag door at a required position, and a manufacturing method for suitably molding the skin.

[0002]

2. Description of the Related Art For example, various vehicle interior members such as an instrument panel installed in front of a passenger compartment of a vehicle, a door trim (lining member) installed inside a side door, and a pillar garnish installed in a pillar portion include: In many cases, a skin for the purpose of improving the texture is mounted on the outer surface of the resin base material formed into a required shape. FIG.
FIG. 1 is a perspective view schematically illustrating an instrument panel as an example of a vehicle interior member with a skin. In the illustrated instrument panel 10, an instrument unit 15,
An upper base 12 of a vertically divided type panel base 11 on which various in-vehicle devices and members such as a glove box 16, an air conditioning operation panel 17, and an audio unit 18 are installed.
The texture is improved by attaching a resin skin 50 to the outer surface of. The upper substrate 12 and the skin 5
As shown in FIG. 13, urethane foam 14 having elasticity is interposed between foams as shown in FIG. 13 and the tactile sensation is also improved.

Further, in the vehicle interior member, an airbag device for protecting an occupant from an impact at the time of a collision is covered. In order to allow the airbag of the airbag device to inflate and deploy into an occupant compartment. In addition, an airbag door that opens to the passenger compartment is provided. For example, in the instrument panel 10, as shown in FIG.
The airbag door 20 corresponding to the passenger airbag device 70 fixed to the reinforcement bar 76 is provided on the upper surface of the upper base 12 on the passenger seat side. The airbag door 20 is formed integrally with, for example, the upper base 12 and is configured as a part of the base material 12 before the operation of the airbag device 70, and instantly inflates under the operation of the airbag device 70. The airbag is pushed up by the breakage portion 22 formed along the contour edge of the door 20 by the pushing-up force of the airbag, so that the door 20 is bent and opened to the occupant compartment 75 side to form a deployment opening for the airbag. It has become. Note that the breakable portion 22 formed in the upper base 12 is a thin portion formed by the groove 21 extending along the contour edge of the airbag door 20, and has received the pushing force of the airbag 73. In this case, the fracture occurs at this portion where the strength is the smallest.

On the other hand, in the skin 50, as shown in FIGS.
A cleavage target portion 54 is formed at a site along the
When the airbag door 20 is opened by the opening 3, the airbag door 20 is allowed to open and the airbag 73 is allowed to bulge by being ruptured at the cleavable portion 54. Here, the skin 50 in the illustrated example is formed by using a powder slash forming die 56 shown in FIG. The powder slush molding die 56 is
7 has a molding surface 58 for molding the skin 50, and a temperature control pipe 59 through which a heat medium for heating and cooling the molding surface 58 flows outside the shell 57.
And the bucket 42 containing the thermoplastic powder P is attached to the opening 57a of the shell 57. Also, on the molding surface 58,
A ridge 6 extending along the contour shape of the airbag door 20
0 protrudes into the mold.

[0005] Such a powder slush molding die 56
As shown in FIG. 14 (b), the skin 50 formed by the first skin portion 51 formed into a shape along the shape of the outer surface of the upper base 12 and the first skin portion 51 corresponding to the airbag door 20. The two skin portions 52 are integrally connected to each other by a connection skin portion 53 formed by the protrusions 60. In addition, since the tip portion of the ridge 60 is formed at an acute angle, the center tip of the connecting skin portion 53 is formed thinner than other portions, and the thin portion functions as the scheduled cleavage portion 54. Become like

[0006]

By the way, in the molding of the skin 50 using the powder slush molding die 56 described above, the to-be-cleaved portion 5 formed by the ridge 60 is formed.
No. 4 has a problem that even if the thickness (thickness) of this portion becomes thinner than other portions, it is extremely difficult to delicately control the thickness. That is, the thickness tends to vary depending on molding conditions such as the outer shape of the instrument panel 10, the contour shape of the airbag door 20, and the forming position, and it is impossible to stably mold to the set thickness. For example, if the tearable portion 54 is formed to be thicker than the set thickness, the tearing strength against the opening operation of the airbag door 20 becomes high, which hinders the deployment of the airbag 73 that is inflated by the operation of the airbag device 70. In the worst case, there is a serious problem that the airbag 73 cannot be inflated and deployed into the passenger compartment 75 within a set time. Further, when the planned tearing portion 54 is formed thinner than the set thickness, the tearing strength is low, so that the opening of the airbag door 20 is sufficiently ensured. Occasionally, cracks are likely to occur in the cleavage target portion 54, and the urethane foam 1
Inconveniences, such as cracking from the cracked portion due to the foaming pressure at the time of foaming of 4, occur.

If the thickness of the portion to be cleaved 54 is to be reduced, the thickness of the entire skin 50 is inevitably reduced. If the thickness of the portion to be cleaved 54 is to be increased, the thickness of the entire skin 50 is also reduced. There is also a problem that it becomes inevitably larger. Further, in the skin 50, since the connecting skin portion 53 is formed in a U-shape, a gap corresponding to the thickness of the ridge 60 is formed between the edge portions of the first skin portion 51 and the second skin portion 52. There are inconveniences that can be achieved. That is, the upper substrate 12
When the urethane foam 14 is foam-formed between the first skin portion 50 and the second skin portion 52, when the urethane foam 14 is foam-formed between the first skin portion 51 and the second skin portion 52, As shown in FIG. 16, a large curved surface is formed at the edge portions of both skin portions 51 and 52, and it is visually recognized as if there is a large gap, resulting in a deterioration in texture.

On the other hand, separately from the skin 50, as shown in FIGS. 17 and 18, a single skin 61 in which a first skin portion 62 and a second skin portion 63 are continuously provided is provided. ,
Using a laser or the like, a plurality of through holes 64 are formed at predetermined intervals along the breakable portion 22, and each of the through holes 64 is formed.
In some cases, the to-be-cleaved portion 65 is formed. However, in such a form, the through-hole 64 is exposed on the outer surface of the instrument panel 10. Therefore, if the opening diameter is set to be large, the existence of the through-hole 64 can be easily visually observed, which causes a deterioration in texture. Together with the urethane foam 14
In some cases, urethane may leak during foam molding, and in order to prevent this, it is necessary to close the through holes 64 with a foam tape or the like. Further, when the opening diameter of the through hole 64 is set to be small, there is an inherent problem that a desired cleavage strength cannot be obtained even if there is an advantage that urethane does not leak from the through hole 64.

[0009]

SUMMARY OF THE INVENTION The present invention has been proposed to suitably solve the above-mentioned problem, and a required number of through-holes are opened along a prospective cleavage portion to appropriately set the tearing strength of the prospective cleavage portion. A skin to be mounted on a vehicle interior member having an airbag door in which the to-be-cleaved portion is positioned inside and the through holes are shielded from the outside to prevent leakage of urethane; It is an object of the present invention to provide a production method for suitably molding a.

[0010]

In order to solve the above-mentioned problems and to achieve the intended object, a skin of a vehicle interior member having an airbag door according to the present invention has an airbag door defined at a required position. A vehicle interior member, a skin that is mounted on an outer surface of a base material constituting the member via urethane foam formed by foam molding, and the skin is mounted corresponding to an outer surface of the base material. A first skin portion, a second skin portion corresponding to the outer surface of the airbag door, and a connecting skin portion connecting the skin portions, and the connecting skin portion is an intermediate portion thereof. It is characterized in that it is extended to the back side of each of the skin portions in a state of being folded and closely attached to each other, and a bent portion having a plurality of through holes is formed in the bent portion.

Further, in order to solve the above-mentioned problems and achieve the intended object, a method for manufacturing a skin of a vehicle interior member having an airbag door according to another invention defines an airbag door at a required position. With respect to the vehicle interior member, when manufacturing a skin to be mounted on the outer surface of the base material constituting the member via urethane foam by foam molding, a first skin portion corresponding to the outer surface of the base material, The intermediate skin comprising a second skin portion corresponding to the outer surface of the airbag door and a connecting skin portion which is formed by connecting the second skin portion to the first skin portion in a state of being appropriately recessed is formed in a predetermined shape. A predetermined portion is formed by forming a plurality of through-holes in a middle portion of the connection skin portion using a required hole-opening tool, and the connection skin portion is formed by the mold. 2 The folding, and by inverting deform the second skin portion, said first skin portion and said second skin portion is characterized in that so as to mold the skin in alignment.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, a skin of a vehicle interior member having an airbag door according to the present invention and a method of manufacturing the same will be described below with reference to the accompanying drawings by way of preferred embodiments. In this embodiment, the instrument panel 10 shown in FIG. 12 is exemplified as a vehicle interior member having an airbag door.
A description will be given of the epidermis to be attached to No. 0. Further, the same members as those already described will be described with the same reference numerals.

(Instrument Panel) First, an instrument panel 10 on which the skin of the present embodiment is mounted is shown.
An example will be described briefly. The instrument panel 10 is a base for installing various in-vehicle devices and members such as an instrument unit 15, a glove box 16, an air conditioning operation panel 17, and an audio unit 18. The upper base 12 and the lower base 13 are vertically assembled. Panel substrate 11 formed by
And a skin 25 attached to the outer surface of the upper base 12
And a urethane foam 14 interposed between the upper base 12 and the skin 25. The instrument panel 10 of the embodiment is provided with the panel base material 1.
The upper substrate 12 and the lower substrate 13 in 1 are formed into a required shape in advance by injection molding or the like,
The skin 25 is formed into a required shape in advance by powder slush molding as described later, and then formed using a foaming mold (not shown). That is, the upper substrate 12 and the skin 25 formed in a required shape in the previous process.
Is set in a foaming mold, and the urethane stock solution is foamed and solidified in the space defined between the both 12 and 25, so that the urethane foam 14 is interposed between the upper base 12 and the skin 25. .

Such an instrument panel 10
Is a combination of the upper substrate 12 and the lower substrate 13,
As shown in FIG. 13, the rear end portion 10a is fixed to the vehicle body by using an appropriate fixing means while approaching the lower edge portion of the windshield 78. Thereby, the passenger compartment 75
Various in-vehicle devices such as an air conditioner unit 77 disposed in front of the vehicle and an airbag device 70 for a front passenger seat fixed to the reinforcement bar 76 are in a state of being embedded by the instrument panel 10. Note that the instrument panel targeted by the present embodiment is not limited to the instrument panel 10 in which the skin 25 is mounted only on the upper base 12 shown in FIG. The type with the epidermis 25 attached,
An instrument panel or the like in which a skin 25 is attached to the entire outer surface of the panel substrate 11 in which the upper substrate 12 and the lower substrate 13 are integrally formed is also a target.

(Panel substrate) The upper substrate 12 and the lower substrate 13 of the panel substrate 11 are made of, for example, polypropylene.
As shown in FIG. 1, the airbag device 70 is formed by injection molding from an olefin resin material such as (PP).
A groove 21 having a substantially V-shaped cross section extending along the opening 72 of the case body 71 is formed. That is, the instrument panel 10 of the present embodiment includes the panel base 11
The groove 21 is formed to reveal the contour edge of the airbag door 20 integrally formed with the upper base 12.

(Airbag Door) The airbag door 20
Is the upper substrate 12 before the airbag device 70 is activated.
And the airbag device 70
During operation, the upper base 12 is partially separated and opened. That is, since the portion where the groove 21 is formed is thinner than the other portions, a thin portion formed along the groove 21 is set as the rupture scheduled portion 22, and the rupture scheduled portion 22 breaks. This allows the airbag door 20 to exhibit its original function.
Note that the breakable portion 22 is formed by the groove 2 extending in a rectangular shape.
1 extends in a plane U-shape along the front, left and right extending portions. The extending portion on the rear side (left side in FIG. 1) of the groove 21 is such that the airbag door 20 is tilted. It functions as a hinge point at the time of opening displacement.

(Skin) The skin 25 of the present embodiment mounted on the instrument panel 10 is formed by powder slush molding from an olefin-based thermoplastic powder represented by, for example, polypropylene (PP). A first skin portion 26 corresponding to the outer surface of the base 12, a second skin portion 27 corresponding to the outer surface of the airbag door 20, and a connecting skin portion 28 connecting the two skin portions 26, 27 therebetween. It has a shape and size that cover the entire outer surface of the upper base 12 including the airbag door 20. As will be described later, the skin 25 is formed by a powder slash molding die 56 shown in FIG.
The intermediate skin 25A formed into the shape shown in FIG.
Is a so-called “reversal deformation type” obtained by reversing the shape shown in FIG.
It is in the form of protruding into the urethane foam 14 in a folded state. Therefore, the connecting skin portion 28 is
The upper part (first skin piece part) 28A and the lower part (second skin piece part) 2 are formed by the foamed and cured urethane foam 14.
8B is pressed from both sides of the side surface so as to be partially or completely adhered to each other, and the boundary edge between the inner edge of the contour of the first skin portion 26 and the outer edge of the contour of the second skin portion 27 is suitably joined to each other. And looks to the passenger compartment 75 like an outer skin
(FIG. 1).

(Section to be Cleaved) The connecting skin portion 28 has a substantially rectangular frame shape along the portion to be broken 22 (outer edge of the airbag door 20) formed on the upper base 12. A to-be-cleaved portion 30 is formed at the bent edge portion (lower end). As shown in FIG. 2 and FIG. 3, the scheduled cleavage portion 30 is formed at a position recessed inward from the outer surfaces of the first skin portion 26 and the second skin portion 27. while being set to a small thickness H ₂ than the thickness H _1, a plurality of through holes 31 are formed open at every predetermined interval. That opening tear strength of the cleavage scheduled portion 30 includes a thickness of H ₂ epidermis 25, a setting can be changed by conditions such as the aperture size and form number of Kakutsuana 31 (formation interval), the air of the air bag device 70 It is premised that conditions such as not disturbing the opening operation of the airbag door 20 that is opened by receiving the pressing force of the bag 73 and preventing tearing due to foaming pressure or the like during molding of the urethane foam 14 are suitably satisfied. Is set as In the present embodiment, a portion that is cleaved when the airbag door 20 is opened, that is, the front side 28 of the connecting skin portion 28 is opened.
a, the through hole 31 is formed in each of the folded portions on the left side 28b and the right side 28c (FIG. 7), and since the folded portion on the rear side 28d faces the hinge point and is not actually split, The case where the through hole 31 is not formed will be exemplified. However, even if the through hole 31 is formed in this portion, there is no hindrance to the opening operation of the airbag door 20.

In the instrument panel 10 of the present embodiment having the above-described configuration, when the airbag device 70 is operated and the airbag 73 is inflated, the airbag door 20 is pushed by the pushing-up force of the airbag 73. Is pushed up from below, firstly, a rupture occurs in the to-be-ruptured portion 22 formed in the upper base 12, thereby causing the airbag door 2 to break.
0 is gradually released from the front side (the right side in FIG. 1). Next, the second skin portion 27 is pushed upward through the urethane foam 14 by the opening displacement of the airbag door 20, and thus the tearable portion 30 formed in the connection skin portion 28 is formed.
(FIG. 3), whereby the opening displacement of the airbag door 20 toward the passenger compartment 75 is allowed. In addition, since the airbag door 20 is gradually opened and displaced from the front side, the rupture of the skin 25 at the cleavable portion 30 is first started from a portion corresponding to the front side 28a of the connected skin portion 28, and then the left side of the skin portion 28 It gradually expands to a portion corresponding to 28b and the right side 28c.

Next, a method of manufacturing the outer skin 25 mounted on the instrument panel 10 will be described. In the present embodiment, as described above, the so-called “reverse deformation type” skin 25 is implemented, and is molded using the powder slash molding die 35 shown in FIG. So first,
The configuration of the powder slush mold 35 will be schematically described.

(Powder Slash Mold) This powder slush mold 35 is used to mold the intermediate skin 25A (FIG. 4A) before being inverted and deformed.
Molding surface 37 formed in the shape of the intermediate skin 25A inside
And a molding surface 37 outside the shell 36.
Temperature control pipe 4 through which heat medium for heating and cooling
1, and a bucket 42 in which the thermoplastic powder P is stored can be aligned and mounted in the opening 36b of the shell 36. The molding surface 3
7 is formed with a projection 36a which is formed in a shape conforming to the contour shape of the airbag door 20, and thereby the molding surface 37 is formed by the first molding for molding the first skin portion 26. It has a surface 38, a second molding surface 39 for molding the second skin portion 27, and a third molding surface 40 for forming the connecting skin portion 28. The protrusion 36a
In the third molding surface 40, a ridge 43 having a substantially triangular cross section protruding outward and outward is provided in a ring shape over the entire circumference.

(Intermediate Skin Forming Step) First, the intermediate skin 25A shown in FIG. 4 is formed by using the powder slash forming mold 35 configured as described above. That is, as shown in FIG. 11, a bucket 42 into which a predetermined amount of plastic powder P is charged is clamped in the opening 36b, and a heating medium is circulated in the temperature control pipe 41 so that the molding surface 37 is heated to a predetermined temperature. By rotating the entire mold at a constant speed while heating, the plastic powder P comes into contact with each of the molding surfaces 38a, 38b and 38c, gradually heats and gels, and eventually adheres with a substantially constant thickness. After a certain time, the bucket 42 is opened to discharge the non-gelled plastic powder P out of the mold, and the temperature control pipe 4
By cooling the molding surface 37 by circulating a cooling medium through 1, the adhered and formed resin is solidified. Here, the molding surface 37
The resin that has been peeled off from the mold is the intermediate skin 25A.

As shown in FIG. 4 (a), the intermediate skin 25A formed by the powder slush forming mold 35 is made of a first material.
Skin portion 26, second skin portion 27, and connected skin portion 2
8 is integrally formed with a required thickness H ₁ , and the second skin portion 27 is connected to the first skin portion 26 by a connecting skin portion 28 so as to be appropriately recessed. A groove 29 having a triangular cross section in which the shape of the ridge 43 protruding from the protrusion 36a is transferred is formed at a substantially central portion in the upper and lower portions of the connecting skin portion 28 so as to extend in the lateral direction. Is done. Moreover in the portion of the groove 29, as shown enlarged in FIG. 4 (b), the thickness of H ₂ skin in the deepest portion corresponding to the top of the ridge 43, the thickness H of the general portions other than the groove 29 _It is smaller than ₁ , and this thinnest portion is the aforementioned scheduled cleavage portion 30. Further, as shown in FIG. 4B, in the connection skin portion 28 formed by the recess of the second skin portion 27, the inner dimension W ₁ of the upper portion 28A bordering the groove 29 is formed.
With an inner dimension W ₂ of the lower portion 28B is set to the same as the height dimension Wa and the lower portion of the upper portion 28A 2
The height Wb of 8B is set to be the same.

(Pore Forming Step) Next, the deepest portion of the groove 29 in the intermediate skin 25A formed as described above.
A predetermined number of through holes 31 are formed in (the thinnest portion). As shown in FIG. 5 and FIG. 6, for example, this through-hole 31 can be inserted into a predetermined position of the groove 29 by inserting a needle-shaped opening tool 45 into the hole 29 or an existing opening device using a laser or the like. It is formed by utilizing the above. The opening size (inner diameter) of the through hole 31
And the forming interval (pitch) varies in the thickness H ₂ in the groove 29 and the deployed shape (shape at the time of inflation) of the airbag 73.
Generally, the opening size is 0.3 to 1.
It is desirable that the distance is about 0 mm and the forming interval is about 1 to 3 mm. In addition, various embodiments can be adopted as the arrangement of the through-holes 31, such as forming the through-hole 31 uniformly over the entirety of the portion 30 to be cleaved or forming only the portion that is difficult to be cleaved. In any case, the tear strength of the tearable portion 30 is, as described above, the skin 25
Is determined by the conditions such as the thickness H ₂ of the groove 29 in the groove 29, the opening size and the number of the through holes 31, and the air bag is opened by receiving the pressing force of the air bag 73 of the air bag device 70. The opening size and the number of the through holes 31 are set on the condition that the opening operation of the door 20 is not hindered, and that the opening of the urethane foam 14 is prevented from being torn due to foaming pressure or the like at the time of molding, etc. It is determined. In this embodiment, as shown in FIG.
The case where the through holes 31 are formed at required intervals in the grooves 29 located on the front side 28a, the left side 28b, and the right side 28c of the connecting skin portion 28 will be exemplified.

(Reversing Deformation Step) When the forming operation of the through hole 31 by the required opening tool 45 is completed, the second skin portion 27 is reversed and transformed. That is, first, the intermediate skin 25A in the state shown in FIG. 6A is inserted into the groove 2 as shown in FIGS. 8A and 8B.
9 as a hinge point for turning back, the groove 2
9 are brought into close contact with each other. Then
As shown in FIGS. 9A and 9B, the lower portion 28 </ b> B of the connected skin portion 28 is folded back, and at the same time, the bending direction of the second skin portion 27 with respect to the connected skin portion 28 is reversed. Thereby, the connecting skin portion 28 is connected to the upper portion 28.
A and the lower portion 28B are folded into two, while the respective inner dimensions are set to W ₁ = W ₂ and the respective height dimensions are set to Wa = Wb, so that the second skin portion 27 becomes the first skin portion. 26 and are aligned on the same plane (FIG. 10).

As shown in FIGS. 9 and 10, the outer skin 25 of the present embodiment formed as described above has an upper portion 28A and a lower portion 28B of the two-folded connected skin portion 28. facing surface 29a of the groove 29, in close contact with the 29a with each other with so-called "self-sealing condition" is formed, the inner dimensions of the inner dimensions W ₁ and the lower portion 28B of the upper portion 28A of the second skin section 27 W ₂ Are set to be the same, the upper end portions of the upper portion 28A and the lower portion 28B are also in close contact with each other. In other words, the connection skin portion 28 is in a self-sealing state because at least the portions near the lower end and the upper end of the upper portion 28A and the lower portion 28B are in close contact. Particularly, the vicinity of the groove 29 is forcibly elastically deformed, so that the adhesion between the opposing surfaces 29a, 29a of the groove 29 is enhanced, and a suitable sealing action can be expected. . In addition, the connecting skin portion 28
When the upper portion 28A and the lower portion 28B of the first embodiment come into close contact with each other, further improvement of the sealing effect is expected.

As described above, in the skin 25 of the present embodiment, the portion 30 to be cleaved is composed of the first skin portion 26 and the second skin portion 27.
Are located on the inside (back side) of these
The scheduled cleavage portion 30 is not visible from the outside of 7. Moreover,
Since the connecting skin portion 28 is folded in two and is in a state of being partially or completely adhered, the plurality of through-holes 31 formed in the planned to-be-cleaved portion 30 can be provided in each of the skin portions without any special measures. It is in a state of being cut off from the outside of 26 and 27, and can be handled in the same manner as a skin having no through hole 31. Thus, when the urethane foam 14 is foam-formed between the skin 25 and the upper base 12 using a foaming mold, the upper portion 28 of the connected skin portion 28 is formed.
The close contact between A and the lower portion 28B suitably prevents the urethane foam from leaking from the through holes 31 without attaching a foam tape or the like. In addition, the upper portion 28A and the lower portion 28
B is partially or completely adhered,
The boundary edges between the inner edge of the contour of the first skin portion 26 and the outer edge of the contour of the second skin portion 27 are preferably joined to each other.

In the experiment conducted by the applicant, the through holes 31
In setting conditions in which the formation arrangement interval between 1 to 2 mm, the thickness of H ₂ skin 25 in the cleavage scheduled portion 30 is 0.3
mm or less, the opening diameter of the through hole 31 is 0.5 mm.
The following could prevent urethane from leaking out. Also in the same setting conditions, when the thickness of H ₂ skin 25 in the cleavage scheduled portion 30 is not less than 0.3 mm, the opening diameter of the through hole 31 was possible also preventing leakage of urethane as 0.8 mm.

In the above-described embodiment, the instrument panel 10 is exemplified as a vehicle interior member having an airbag door. However, the vehicle interior member is not limited to this, and the vehicle interior member is not limited to the above-described door panel or pillar garnish. All vehicle interior components that define the door and are fitted with a skin are covered.

In the above embodiment, the airbag door 20
Is formed integrally with the panel base material 11 (the upper base body 12). However, the panel base material 11 and the airbag door 20 are separately formed and formed on the panel base material 11. The airbag door 20 may be attached to the opening in a later process.

In the above-described embodiment, the skin 25 made of powder slush molding is exemplified. However, the skin 25 is not limited to this. For example, the skin 25 is made of vacuum molding using a vacuum mold. Is also good.

[0032]

As described above, the skin of the vehicle interior member having the airbag door according to the present invention is formed such that the portion to be split is located inside (the back side) of the first skin portion and the second skin portion. Therefore, there is an advantage that the portion to be cleaved is not visible from outside of these skin portions. In addition, since the connecting skin portion is folded into two and is in close contact with each other, the plurality of through holes formed in the portion to be cleaved are appropriately shielded from the outside of each skin portion, and the through holes are formed. There is also an advantage that it can be treated equally as an unformed epidermis. Thereby, when the urethane foam is foam-formed between the skin and the substrate using a foaming mold, the urethane foam is preferably prevented from leaking from the through holes, and a foam tape is attached. This has a beneficial effect such that the operation can be omitted and the operation efficiency can be improved.

According to another aspect of the present invention, there is provided a method of manufacturing a skin of a vehicle interior member having an airbag door, wherein the second skin portion corresponding to the airbag door is formed into a stepped state that is appropriately recessed from the first skin portion. After a predetermined number of through-holes are formed in the connected skin portion in the intermediate skin state to form a portion to be cleaved, the second skin portion is reversely deformed. For this reason, in the epidermis formed by inversion deformation, the connecting epidermis connecting the first epidermis and the second epidermis is in a two-fold tight contact state. There is an advantage that each through hole of the portion can be formed in a state where it is suitably shielded from the outside without any special measures.

[Brief description of the drawings]

FIG. 1 is a side view showing an instrument panel to which an outer skin is mounted according to an embodiment of the present invention, which is broken at an airbag door.

FIG. 2 is an enlarged view of a main part of FIG. 1, showing details of a scheduled break portion formed on a panel base material and a planned tear portion formed on a skin.

FIG. 3 is a fragmentary cross-sectional view showing a state in which the rupture of a portion to be ruptured of the panel base material and the rupture of a portion to be ruptured in the skin progress due to inflation of the airbag, and the airbag door is being opened.

4 (a) is a cross-sectional view of an intermediate skin formed by the powder slush molding die shown in FIG. 11, and FIG. 4 (b) shows a groove formed integrally with a connected skin portion in the intermediate skin shown in FIG. 4 (a). It is sectional drawing.

FIG. 5 is an enlarged view of a main part showing a state in which a through hole is formed in a groove formed in the intermediate skin using a required drilling tool.

FIG. 6A is a sectional view of a main part of an intermediate skin in which a through hole is opened in a groove to form a portion to be broken, and FIG. 6B is an enlarged sectional view of the portion to be broken.

FIG. 7 is a perspective view of a main part of an intermediate skin in which a portion to be broken is formed.

FIGS. 8A and 8B are explanatory views showing a state in which the intermediate skin is reverse-molded, wherein FIG. 8A shows a state in which a connected skin portion is bent at a portion to be cleaved, and FIG. The state shown is enlarged.

FIG. 9 is an explanatory view showing a state in which the reverse molding of the intermediate skin has been completed, and FIG. 9 (a) shows that the connected skin portion is folded and adhered, and the first skin portion and the second skin portion are on the same plane. (B) shows that the connected skin portion is folded in two and partially adhered, resulting in a self-sealing state.

FIG. 10 is a cross-sectional view of a skin formed by reverse-molding an intermediate skin.

FIG. 11 is a schematic cross-sectional view of a powder slush mold shown in a state where an intermediate skin is being formed.

FIG. 12 is a perspective view illustrating an instrument panel as a vehicle interior member having an airbag door to which a skin according to the present embodiment is mounted.

FIG. 13 is a side cross-sectional view showing the instrument panel shown in FIG. 11 in a state where the instrument panel is installed in a vehicle with an airbag device and the like inside.

FIG. 14A is a schematic cross-sectional view of a powder slush molding die showing a state of molding a skin according to a conventional technique, and FIG.
It is a principal part sectional view which shows the state in which the to-be-cleaved part was formed in the skin by the protrusion provided in the molding die of (a).

15 is a side cross-sectional view showing a conventional instrument panel having a skin formed by the molding die of FIG. 14 at an airbag door.

FIG. 16 is an enlarged view of a main part of FIG. 15, showing a planned rupture portion formed on the panel base material and a conventional planned rupture portion formed on the skin.

FIG. 17 is a side view showing a conventional instrument panel to which another type of skin is mounted, which is cut away at a portion of an airbag door.

FIG. 18 is an enlarged view of a main part of FIG. 17, which shows a scheduled break portion formed on a panel base material and a scheduled tear portion formed on another conventional skin.

[Explanation of symbols]

 Reference Signs List 11 panel base material (base material) 14 urethane foam 20 airbag door 25 skin 25A intermediate skin 26 first skin portion 27 second skin portion 28 connected skin portion 28A upper portion (first skin piece portion) 28B lower portion (first (2 skin pieces) 30 scheduled to be cleaved 31 through hole 45 drilling tool 56 powder slash mold

 ────────────────────────────────────────────────── ─── Continued on the front page (72) Inventor Toshiyuki Koyama 3-36 Imaike-cho, Anjo-shi, Aichi Pref. Inoac Corporation Anjo Office (72) Inventor Kuma ▲ Saki ▼ Hiroyuki Imaike-cho, Anjo-shi, Aichi 1-36 Chome F-term (reference) in Inoac Corporation Anjo Office 3D054 AA03 AA14 AA17 AA18 BB09 FF17

Claims (6)

[Claims] 1. A vehicle interior member having an airbag door (20) defined at a required position, which is mounted on an outer surface of a base material (11) constituting the member via a foamed urethane foam (14). A skin (25), wherein the skin (25) comprises a first skin portion (26) correspondingly mounted on an outer surface of the base material (11), and the airbag door (20).
A second skin portion (27) correspondingly attached to the outer surface of the
A connecting skin portion (28) for connecting these skin portions (26, 27) in a continuous manner. The connecting skin portion (28) is folded in two at an intermediate portion thereof and brought into close contact with each of the skin portions (28). A vehicle interior member having an airbag door, characterized in that it is extended to the back side of (26, 27), and a bent portion (30) having a plurality of through holes (31) is formed in a bent portion thereof. Epidermis. 2. The connecting skin portion (28) includes a first skin piece portion (28A) and a second skin piece portion (28B) sandwiching the to-be-cleaved portion (30).
2. The skin of a vehicle interior member having an airbag door according to claim 1, wherein the through holes (31) are shut off from the outside by bringing the airbag door into close contact. 3. When the urethane foam (14) is foamed between the base material (11) and the skin (25), the first skin piece (28A) and the second skin piece (28B) are formed. The interior skin of a vehicle interior member having an airbag door according to claim 2, wherein leakage of urethane foam from said through hole (31) is prevented by bringing said airbag door into close contact. 4. A vehicle interior member in which an airbag door (20) is defined at a required position is mounted on an outer surface of a base material (11) constituting the member via a foamed urethane foam (14). A first skin portion (26) corresponding to the outer surface of the base material (11) when manufacturing the outer skin (25).
And a second corresponding to the outer surface of the airbag door (20).
An intermediate skin (25A) comprising a skin portion (27) and a connected skin portion (28) which is connected to the second skin portion (27) in a stepped state appropriately recessed with respect to the first skin portion (26). The specified mold (5
6), a plurality of through-holes (31) are formed in the intermediate portion of the connecting skin portion (28) using a required hole-forming tool (45), and the portion to be cleaved (30) is formed. By forming the connected skin portion (28) into two at the scheduled cleavage portion (30) and by inverting the second skin portion (27), the second skin portion (27) and A method of manufacturing a skin of a vehicle interior member having an airbag door, wherein a skin (25) aligned with the first skin portion (26) is formed. 5. The first skin piece (28A) and the second skin piece (28B) are brought into close contact with each other with respect to the connected skin part (28) folded in two at the part to be cleaved (30). 5. The method for manufacturing a skin of a vehicle interior member having an airbag door according to claim 4, wherein each of the through holes (31) is blocked from the outside. 6. The method for manufacturing a skin of a vehicle interior member having an airbag door according to claim 4, wherein the intermediate skin (25A) is formed by a powder slash forming die (56).