JP2001315237A - Molded article and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the weight of a molded article wherein a surface layer is laminated on a core material through a cushion layer. SOLUTION: A door trim 10 (molded article) consists of the core material 11 and the surface layer 13 laminated on the core material 11 through the cushion layer 12. The core material 11 is formed of a foamed molded object.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded product in which a surface layer is laminated on a core material via a cushion layer, and a method for producing the same.

[0002]

2. Description of the Related Art For example, a molded product such as an instrument panel or a door trim of a vehicle interior has a surface layer laminated on a core material via a cushion layer. In general, an injection molded body obtained by injection molding a polypropylene resin or the like is used as the core material.

[0003]

However, there is a problem that the core material made of the injection molded body is heavy.

[0004]

Means for Solving the Problems In order to solve the above problems, a molded article according to the present invention comprises a core material formed of a foamed molded product, a cushion layer laminated on the core material, and a cushion layer formed on the core material. And a laminated surface layer.
Here, an auxiliary plate having a higher hardness than the core material is provided at the edge of the core material so as to protrude from the core material, and a part of the cushion layer and the surface layer is also extended and laminated on this auxiliary plate. It may be.

In the method of manufacturing a molded article according to the present invention, a surface layer and a cushion layer are laminated in a sheet shape, a core material is foamed, and then the surface layer and the cushion layer are firstly formed.
While the surface layer is arranged between the second molds such that the surface layer faces the molding surface of the first mold, the core material is placed in the second mold.
Attach to the mold, apply an adhesive to the surface of the core material facing the cushion layer, and then form a vacuum between the surface layer and the first mold to form the surface layer and the cushion layer. In addition, the first and second molds are closed, and the cushion layer and the core material are bonded with the adhesive. Here, the auxiliary plate is fixed to the edge of the core material by placing the auxiliary plate on a mold for foam molding of the core material and then foaming the core material, and is also bonded to the auxiliary plate. The surface layer and the cushion layer may be laminated with the agent applied. Further, after foam molding of the core material, an auxiliary plate may be fixed to the core material by bonding, and the core material may be attached to the second molding die with an adhesive applied to the auxiliary plate.

[0006]

An embodiment of the present invention will be described below with reference to the drawings. FIGS. 1 to 3 show a door trim 10 (molded product) attached to a vehicle door. The door trim 10 includes a core 11, a cushion layer 12 laminated on a surface of the core 11 on the vehicle interior side, and a surface layer 13 laminated on the cushion layer 12, and has a substantially rectangular shape. The core material 11 relates to a characteristic portion of the present invention, and will be described later in detail. Cushion layer 12
Is formed of a soft foamed resin such as a polypropylene foam. Its thickness is 2.0 mm to 4.0 mm (preferably 3.0 mm). The surface layer 13 is formed of a resin such as a polyolefin-based thermoplastic elastomer.
Its thickness is about 0.6 mm. The surface layer 13 and the cushion layer 12 are laminated with each other by extrusion lamination, and given a predetermined shape by vacuum forming.

The core 11 will be described. The core material 11 is
It is formed of a rigid foamed molded article obtained by foaming resin beads such as polypropylene about 25 times. Many irregularities 11 a are formed on the surface of the core material 11. These irregularities 11a are traces of steam holes in a mold (not shown) for foam molding. The core material 11 and the cushion layer 12 are bonded with, for example, a chloropyrene-based rubber adhesive (not shown).

[0008] A plurality of clip seats 1
4 are embedded at intervals. The end surface of the clip seat 14 is exposed flush with the surface of the core member 11 on the door body side. A clip 19 is fitted into the clip seat 14, and the door trim 10 is attached to the door body by the clip 19. An auxiliary plate 15 is provided along the upper edge and the rear edge (right in FIG. 1) of the core material 11. The auxiliary plate 15 is formed so as to have a higher hardness than the core material 11 by, for example, injection molding a resin such as polypropylene, and is bonded to the core material 11 with a hot melt adhesive (not shown). The auxiliary plate 15 protrudes from the edge of the core material 11. The upper end and the rear end of the cushion layer 12 and the surface layer 13 are also extended and laminated on the auxiliary plate 15. The shapes of the ends of the cushion layer 12 and the surface layer 13 are maintained by the auxiliary plate 15. The thickness of the auxiliary plate 15 is smaller than the core material 11 and is about 2 mm. Therefore, the door trim 10
The upper end portion and the rear end portion are thin with a thickness of about 5 mm to 6 mm.

A method for manufacturing the door trim 10 will be described. First, as shown in FIG. 4, the core material 11 is formed by foam molding. In molding, the clip seat 14 is arranged in advance on a mold for foam molding. Thus, the clip seat 14 is embedded in the core 11 at the same time as the molding of the core 11.
After forming the core material 11, the auxiliary plate 15 is bonded. The auxiliary plate 15 may be fixed to the core 11 at the same time as the molding of the core 11 by disposing the auxiliary plate 15 in a foaming mold in advance similarly to the clip seat 14.

Aside from the foaming of the core material 11, the surface layer 13 and the cushion layer 12 are laminated by extrusion lamination (see FIG. 5). At this stage, the surface layer 13 and the cushion layer 12 have a sheet shape.

Next, as shown in FIG.
And the surface layer 13 and the cushion layer 12 are formed by the vacuum forming apparatus 2
Send to 0. The vacuum forming apparatus 20 includes a pair of first and second forming dies 21 and 22 facing up and down, and a pair of holding frames 2.
And 3. The outer edges of the surface layer 13 and the cushion layer 12 are held by the holding frame 23, and the surface layer 13 is heated and softened by a heater (heating means) not shown. Then, the surface layer 13 and the cushion layer 12 are arranged between the first and second molding dies 21 and 22 such that the surface layer 13 faces the molding surface 21a of the first molding die 21 (female mold).

The molding surface 21a of the first molding die 21 is
1 has almost the same shape as the surface to be directed to the passenger compartment side (note that the unevenness corresponding to the unevenness 11a is not formed). On the other hand, the molding surface 22a of the second molding die 22 is
1 has the same shape as the surface to which the door body should face (however, as in the case described above, no unevenness corresponding to the unevenness 11a is formed). The core material 11 is placed on the second molding die 22 so that the molding surface 22a and the door material side surface of the core material 11 are brought into close contact with each other. (Note that the core material 11 in FIGS.
The illustration of the unevenness 11a on the side of the door body is omitted. Next, an adhesive is applied to the surface of the core member 11 on the vehicle interior side. An adhesive is also applied to the auxiliary plate 15.

Next, as shown in FIG.
2 Bring them closer together. Thereby, the cushion layer 1
2 corresponds to the core material 11, and the surface layer 13 and the cushion layer 12
Is deformed toward the molding surface 21 a of the first molding die 21. Further, by the surface layer 13 hitting the first mold 21, the closed space 20 is formed between the surface layer 13 and the molding surface 21 a.
a is formed.

Subsequently, while pressing the molding dies 21 and 22 in the approaching direction, suction means (not shown) is used.
The closed space 20a is evacuated through a number of small holes (not shown) formed in the first mold 21. by this,
As shown in FIG. 7, the molds 21 and 22 are clamped, and the surface layer 13 is in close contact with the molding surface 21a, so that the surface layer 13 and the cushion layer 12 are molded. Further, the cushion layer 12 and the core material 11 are bonded. Of course, cushion layer 1
2 and the auxiliary plate 15 are also bonded. Further, the molds 21 and 22
The cushion layer 12 is compressed by the mold clamping pressure, and is deformed so as to conform to the unevenness 11 a of the core material 11. As a result, the cushion layer 12 adheres tightly to the side surface of the core material 11 without any gap.

Next, the holding frame 23 is removed, the molds 21 and 22 are opened, and the integrated core 11, the cushion layer 12, and the surface layer 13 are removed. Thereafter, trimming (cutting) of the peripheral ends of the surface layer 13 and the cushion layer 12 and winding of the core material 11 toward the side of the door body are performed. Thereby, the door trim 10 is completed.

The operation will be described. Door trim 10
Since the core material 11 is formed of a foamed molded body, the weight can be reduced as compared with that of a conventional injection molded body.
For example, in the case of a door trim of a front side door of a normal passenger car, the conventional product weighs about 1.5 kg, whereas the product applied to the present invention weighs about 0.7 kg, which is about half the weight. . The surface of the cushion layer 12 facing the core material 11 is deformed according to the irregularities 11a, but the surface layer 13 is sucked by the first molding die 21 which is a female mold, and the molding surface 21a
Therefore, the above deformation does not extend to the surface layer 13 and no irregularities appear on the surface layer 13. Even if there is a dimensional error in the core material 11, it can be absorbed by the cushion layer 12, so that high precision is not required at the time of foam molding. Even if the cell is roughened (the boundary between the fused resin beads appears in a narrow groove shape) on the surface of the core material 11 made of the foam molded body, the surface layer 13 covers the core material 11 so that it cannot be seen from the passenger compartment side. can do. Door trim 1
The upper end and the rear end of 0 can be made thinner by holding the shapes of the surface layer 13 and the cushion layer 12 with the auxiliary plate 15 instead of the core material 11. The seam between the core material 11 and the auxiliary plate 15 is invisible from the passenger compartment because the cushion layer 12 and the surface layer 13 cover the seam. Moreover,
Since the surface layer 13 is sucked into the first molding die 21 and molded, no dent is formed in the surface layer 13 due to the seam.

The present invention can adopt various forms irrespective of the above embodiment. For example, the auxiliary plate
In addition to injection molding, it may be formed by vacuum molding or the like. After applying the adhesive to the surface of the core material facing the cushion layer, the core material may be attached to the second mold. The present invention is also applicable to vehicle interiors other than door trims such as instrument panels, pillars and console boxes, and other molded products.

[0018]

As described above, in the first invention,
The weight of the molded article can be reduced. In the second invention,
The ends of the molded product can be made thin by maintaining the shapes of the surface layer and the cushion layer with an auxiliary plate instead of the core material made of the foamed molded product. In the third aspect, the weight of the molded product can be reduced. In addition, it is possible to prevent unevenness due to steam hole marks on the surface of the core material from appearing on the surface layer. In the fourth and fifth aspects, the auxiliary plate can be easily attached to the core material. In addition, the end and the like of the molded article can be made thin.

[Brief description of the drawings]

FIG. 1 is a view of a door trim according to an embodiment of the present invention, as viewed from a passenger compartment side.

FIG. 2 is a sectional view taken along the line II-II in FIG.

FIG. 3 is a sectional view taken along the line III-III in FIG. 1;

FIG. 4 is a cross-sectional view showing a method of manufacturing the door trim in a state where an auxiliary material is attached to a foam-molded core material.

FIG. 5 is a cross-sectional view showing the door trim manufacturing method in a state where a core material, a surface layer and a cushion layer are set in a vacuum forming apparatus.

FIG. 6 is a cross-sectional view showing a method of manufacturing the door trim in a state where first and second molds are close to each other.

FIG. 7 is a cross-sectional view showing the method of manufacturing the door trim in a state where first and second molds are closed.

[Explanation of symbols]

 Reference Signs List 10 Door trim (molded product) 11 Core material 12 Cushion layer 13 Surface layer 15 Auxiliary plate 21 First molding die 21a Molding surface 22 Second molding die 22a Molding surface

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) // B29K 105: 04 B29K 105: 04 B29L 9:00 B29L 9:00 (72) Inventor Tsutomu Iwaida Gunma 330F, Yura-cho, Ota-shi F-term (reference) in Shigeru Kogyo Co., Ltd. AG03 AG20 AH23 AH26 MA01 MA05 MB01 MB11 MB22 MC03 MG05 MG11 MG23 MJ22 MK15 4F213 AA03 AA11 AA45 AC04 AD08 AH23 AH26 WA08 WA18 WA43 WA52 WA83 WB01 WB11 WB22 WC01 WE06 WF05 WK02 WK03 WW01 WW50

Claims (5)

[Claims] 1. A molded article comprising: a core material formed of a foamed molded body; a cushion layer laminated on the core material; and a surface layer laminated on the cushion layer. 2. An auxiliary plate having a higher hardness than the core material is provided at an edge of the core material so as to protrude from the core material, and a part of the cushion layer and the surface layer is also extended and laminated on the auxiliary plate. The molded article according to claim 1, wherein: 3. A surface layer and a cushion layer are laminated in a sheet shape, and a core material is foam-molded. Then, the surface layer and the cushion layer are sandwiched between first and second molds. While being arranged so as to face the molding surface of one mold, the core is attached to the second mold,
An adhesive is applied to a surface of the core material facing the cushion layer, and then the surface layer and the cushion layer are formed by evacuating the surface layer and the first molding die. Closing the second mold and adhering the cushion layer and the core material with the adhesive. 4. An auxiliary plate is placed on a mold for foam molding of the core material, and then the core material is foam-molded to fix the auxiliary plate to an edge of the core material. The method for producing a molded product according to claim 3, wherein the surface layer and the cushion layer are laminated with the adhesive applied. 5. The method according to claim 5, wherein after the foaming of the core material, an auxiliary plate is fixed to the core material by bonding, and the core material is attached to the second molding die with an adhesive applied to the auxiliary plate. The method for producing a molded article according to claim 3, wherein