JP2003118428A - Vehicle interior member and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the manufacturing cost, to prevent dew condensation and abnormal sound generation, and to absorb the noise. SOLUTION: A duct wall 52 is extended to the rear side of a base material 12 with its connected to a foam body 16 formed by foaming and hardening a foam material between the base material 12 and a surface 14, and the end part of the duct wall 52 is joined with the rear surface of the base material 12 so that an air flow passage communicated with an air conditioner unit 18 is formed in a space toward the base material 12. The duct wall 52 is integrally connected to the foam body 48 via an opening part 48 opened in a prescribed position of the base material 12.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle interior member and a method for manufacturing the same, and more specifically, a base material formed into a required shape, a skin attached to the front side of the base material, and these base materials. The present invention also relates to a vehicle interior member including a foam formed by foaming and solidifying a foaming raw material between skins, and a method for suitably manufacturing the vehicle interior member.

[0002]

2. Description of the Related Art Various vehicle interior members such as an instrument panel and a floor console are installed in a passenger compartment of a passenger car. For example, as shown in FIG. 9, an instrument panel 10 installed in front of a passenger compartment includes a synthetic resin base material 12 formed into a required shape,
It is preferable that the base material 12 has a three-layer structure including a skin 14 adhered to the front side of the base material 12 and a foam 16 formed by foaming and solidifying a foaming raw material between the base material 12 and the skin 14. (However, the upper half of the instrument panel 10 shown in FIG. 9 has a three-layer structure).

An air conditioner unit 18 whose operation is controlled by an air conditioning control panel provided at a required position of the instrument panel 10 is installed in front of the passenger compartment while being covered by the panel 10. An air outlet 20 of the air conditioner unit 18 and an air outlet (not shown) arranged at a required position of the instrument panel 10 are provided in a duct 22 provided on the back side (inside) of the panel 10. The air-conditioning unit 18 guides the temperature-controlled air adjusted to the required temperature to the air outlet through the duct 22 and then blows it out into the passenger compartment.

[0004]

By the way, the duct 2 is used.
2 is a hollow body 24 having a modified cross-sectional shape obtained by blow molding a resin material such as polyethylene (PE) or polypropylene (PP).
The hollow body 24 is assembled to the inner surface of the base material 12 or the vehicle body constituent member (line force bar) 26 with screws or the like (shown), and is formed of a gutter-shaped body obtained by injection molding the resin material. The gutter-shaped body as the base material 1
A form (not shown) in which the air flow passage is defined by being attached to the inner surface of 2 by vibration welding or the like has been put into practice. However, in the ducts of the above-mentioned and above, since it is configured as a separate member from the instrument panel 10, the molding work of the instrument panel 10, the molding work of the hollow body 24 or the gutter state, and the hollow body. 24
Alternatively, since the work of assembling the gutter-shaped body is performed in separate steps, there is an inherent problem that the manufacturing cost of the instrument panel 10 increases.

The blow-molded hollow body 24 is made of PE, PP or the like and has a relatively thin wall as described above, so that the temperature difference between the inside and the outside of the duct 22 is small. When it was large, there was a drawback that dew condensation was likely to occur.
Furthermore, when an on-vehicle component, a wire harness, or the like arranged around the duct 22 comes into contact with the hollow body 24 due to vehicle body vibration, there is a problem that an unpleasant noise such as a collision sound or a rubbing sound is generated. On the other hand, it has been pointed out that the operation sound of the air conditioner unit 18 reverberates in the duct 22 and leaks into the passenger compartment. For this reason, a method for preventing dew condensation and preventing abnormal noise by sticking a sponge or a urethane sheet on the outer surface or the inner surface of the hollow body 24 is adopted. Since the urethane sheet needs to be attached to the hollow body 24, the manufacturing cost is further increased.

[0006]

SUMMARY OF THE INVENTION The present invention has been proposed in order to suitably solve the above-mentioned problems, and when forming a foam formed by foaming and solidifying a foaming raw material between a base material and a skin, A vehicle interior member which is provided with a duct wall connected to the foam on the back side of the base material so as to reduce manufacturing cost, prevent dew condensation, prevent abnormal noise, and absorb noise, and the vehicle interior member. It is an object of the present invention to provide a method for suitably manufacturing a member.

[0007]

In order to solve the above problems and achieve the intended purpose, the present invention provides a base material formed into a required shape, and a skin attached to the front side of the base material. In a vehicle interior member made of a foam formed by foaming and solidifying a foaming raw material between the base material and the skin, the vehicle interior member is extended to the back side of the base material in a state of being connected to the foam, and its edge is It is characterized in that a duct wall defining an air flow passage communicating with the air conditioner unit is provided between the duct wall and the back surface of the base member.

In order to solve the above-mentioned problems and achieve the intended purpose, the present invention also provides a base material formed into a required shape, an epidermis attached to the front side of the base material, and the base material and the epidermis. In the method for manufacturing a vehicle interior member, which comprises a foam formed by foaming and solidifying a foaming raw material in between, the preformed skin is set in a first molding die and required on the back surface of the preformed base material. After removably attaching the shaped mold material,
The base material having this mold material attached is set in a second molding die,
A first space is defined between the mold material and the second molding die, the first molding die and the second molding die are closed, and the first space is provided between the base material and the skin. A second space communicating with the second space is defined, and the foaming raw material injected in the second space is foamed and solidified to form the foam, while the foaming raw material injected in the first space is foamed. After being solidified, a duct wall extending to the back side of the base material in a state of being integrally connected to the foam is molded, and the duct wall and the foam are removed from the mold after completion of molding, and then the duct is formed. The mold material inserted between the wall and the base material is removed from the base material, the edge portion of the duct wall is joined to the back surface of the base material, and air is circulated between the duct wall and the base material. The feature is that the road is defined.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Next, a vehicle interior member and a method for manufacturing the same according to the present invention will be described below with reference to the accompanying drawings with reference to the preferred embodiments. The vehicle interior member targeted by the present application includes a base material molded into a required shape, a skin adhered to the front side of the base material, and a foaming raw material foamed and solidified between the base material and the skin. It is assumed that the foam has a three-layer structure, and examples thereof include an instrument panel, a floor console, and a roof panel. Therefore, in the embodiment, an instrument panel will be described as an example, and the same members and parts as those of the conventional instrument panel 10 shown in FIG. 9 are designated by the same reference numerals.

FIG. 1 is a schematic perspective view of an instrument panel 30 according to a preferred embodiment of the present invention, and FIG. 2 is II- of FIG.
FIG. 4 is a sectional view taken along line II and a partial sectional view taken along line III-III in FIG. 3. The instrument panel 30 includes a base material 12 injection-molded into a desired shape using PP or the like, a skin 14 attached to the front side of the base material 12, and the base material 12
And a foam 16 formed by foaming and solidifying a foaming raw material such as urethane between the skins 14, and the basic structure is the same as that of the conventional instrument panel 10 shown in FIG. However, the skin 14 and the foam 16 are
The lower half of the base material 12 is exposed to the passenger compartment because it is attached to a substantially upper half region of the instrument panel 30.

An air outlet 32 communicating with a duct 50, which will be described later, is provided on the left end front surface and the right end front surface of the instrument panel 30, and the left end upper surface,
Another air outlet 34 is also arranged on the upper surface of the right end, and a horizontally long air outlet 35 is formed at the rear end of the upper surface.
On the other hand, on the upper surface on the left side, a double-opening type airbag door 38 corresponding to the airbag unit 36 fixed to the reinforcement bar 26 is provided, and is opened and deployed outward when the airbag unit 36 is operated. There is. In addition,
In FIG. 1, 40 is an instrument unit, 42 is a glove box, and 44 is a center console to which an audio unit, an air-conditioning control panel 46 and the like are attached.

The instrument panel 3 of the embodiment
0, as shown in FIGS. 2 and 3, the foam 16
A duct wall 52 that defines a space 54 between the base material 12 and the back surface of the base material 12 by extending the back side of the base material 12 in a state of being connected to the back surface of the base material 12. It is characterized by that. The duct wall 52 has a gutter shape whose side cross-sectional shape is substantially U-shaped as a whole, and the lower end thereof is provided on the assumption that the opening 48 is opened at a required position of the base material 12. The edge portion 52a is continuously provided to the lower edge of the back surface of the foam body 16 through the opening portion 48. Also, the upper edge 5
2b is attached to an attachment piece 49 protruding from the back surface of the base material 12 using an adhesive or the like. Such a duct wall 52
As will be described later, when the foam body 16 is molded, the foam body 16 and the foam body 16 are integrally molded at the same time.

A space 54 defined by the duct wall 52 and the base material 12 has an opening 5 provided at one end thereof.
6 is connected to the air delivery part 20 of the air conditioner unit 18, and the other end side is made to communicate with the air outlet 32 (FIG. 3). Thereby, the duct wall 5
The space 54 defined between 2 and the substrate 12 is configured to function as an air flow passage of the duct 50 that guides the temperature-controlled air sent from the air conditioner unit 18 to the air outlet 32.

As described above, in the instrument panel 30 of the embodiment, the duct wall extending to the back side of the base material 12 is integrally connected to the foam 16 formed between the base material 12 and the outer skin 14. 52 is provided, and the duct wall 52 and the substrate 12 form a space 54 that functions as an air flow passage of the duct 50. That is, as is clear from FIGS. 2 and 3, the duct 50 is formed of the foam body 16 and the duct wall 52, which have excellent heat insulating performance, soundproofing / sound absorbing performance, and the like, on the entire outer periphery. Therefore, it is possible to preferably prevent the occurrence of dew condensation due to the temperature difference between the inside and outside of the duct 50, and it is possible to preferably prevent the generation of abnormal noise due to the contact of another member with the duct wall 52, and the operation of the air conditioner unit 18. The sound can be absorbed properly.

Next, a method of manufacturing the instrument panel 30 as the vehicle interior member configured as described above will be described with reference to FIGS.

Here, the base material 12 is injection-molded into a desired shape in advance using an injection molding die (not shown). At this time, the opening 48, the engaging piece 49, etc. are formed at the required positions of the base material 12 at the same time. On the other hand, the skin 14 is preformed from a resin sheet material using a vacuum forming die, preformed from resin powder using a powder slush forming die, and polyurethane is sprayed on the forming surface of the forming die. A preformed product or the like is appropriately selected and adopted.

First, as shown in FIG. 4, the skin 14 preformed into a desired shape is set on the setting surface 64 of the first molding die 62 in the foam molding die 60. On the other hand, the mold material 70 (commonly referred to as “nesting”) 70 molded in the same shape as the shape of the space 54 was removably mounted on the back surface of the base material 12 preliminarily molded into the required shape, and then the mold material 70 was mounted. The base material 12 is set on the setting surface 68 of the second molding die 66 in the foam molding die 60. Here, on the setting surface 68 of the second molding die 66, the molding material 7 is placed at a position corresponding to the molding material 70.
A recess 72 having a size slightly larger than 0 is provided, and when the base material 12 is set on the setting surface 68,
A first space 74 for molding the duct wall 52 is defined between the mold material 70 and the recess 72. The mold material 70 is attached to the base material 12 in the form of engagement using ribs (not shown) integrally formed on the base material 12 and the engaging pieces 49. When the base material 12 is made of PP or the like, it is preferable that the surface (outer surface) of the base material 12 is subjected to a primer treatment in order to improve the adhesiveness of the foam 16 to be foam-molded. .

When the setting of the skin 14 on the first mold 62 and the setting of the base material 12 on the second mold 66 are completed, both molds 62, 66 are closed (FIG. 4). As a result, a second space 76 for molding the foam 16 is defined between the base material 12 and the skin 14. When the mold closing of the first molding die 62 and the second molding die 66 is completed, a predetermined amount of foaming raw material is injected into the first space 74 and the second space 76 by the injection nozzle 78. It should be noted that the foaming raw material is injected into the second space 76 by using the molding dies 62, 6
It is also possible to inject 6 on the back surface of the epidermis 14 before closing the mold. Further, the foaming raw material is injected into the first space 74 by using the injection port 80 provided in the second molding die 66.

Then, as the foaming raw material injected in the first space 74 is foamed and solidified, the duct wall 5
2 is formed, and the foaming material injected in the second space 76 is foamed and solidified to form the foam 16. Here, since the first space 74 and the second space 76 are spatially communicated with each other through the opening 48 provided in the base material 12, the lower end edge portion of the formed duct wall 52. 52a
The back side of the foam 16 is integrally connected through the opening 48, and the duct wall 52 extends to the back side of the substrate 12 while being integrally connected to the foam 16.

When the molding of the foam 16 and the duct wall 52 is completed, the base material 12, the outer skin 14, and the integrated base material 12,
The foam 16 and the duct wall 52 are removed from both molds 62 and 66 (FIG. 5). After demolding, the upper end edge portion 52b of the molded duct wall 52 is once separated from the engaging piece 49 formed on the base material 12 (FIG. 6), and the duct wall 52 is appropriately deformed, The mold material 70 attached to the base material 12 is removed from the base material 12 (FIG. 7). Here, when the base material 12 is made of PP, the duct wall 5
The upper edge portion 52b of No. 2 can be easily peeled off from the base material 12 (the engaging piece 49).

After the mold member 70 is completely removed, the upper edge 52b of the base material 12 is attached to the upper edge 52b of the attachment wall 49 or the duct wall 52 by applying an appropriate adhesive. Adhesive and bonded in contact with the back surface. As a result, the space 54 functioning as an airflow passage of the duct 50 is defined between the duct wall 52 and the base material 12 by removing the mold member 70 (FIG. 8).

As described above, according to the manufacturing method of the embodiment, when the foam body 16 is molded between the base material 12 and the skin 14 using the foam molding die 60, the foam body 16 is integrally connected to the foam body 16. Since the duct wall 52 extending to the back side of the base material is molded at the same time, molding of the foam 16 and molding of the duct wall 52 forming the duct 50 can be performed at the same time. It is possible to reduce the manufacturing cost due to the reduction. Further, since the duct wall 52 is formed in a state of being integrally connected to the foam body 16, there is no member to be formed separately from the instrument panel 30, and it is expected that the manufacturing cost can be reduced by reducing the number of parts. Furthermore, since the duct wall 52 can be easily and easily joined to the base material 12, the manufacturing cost can be reduced by reducing the number of assembling steps.

In the above embodiment, the case where the foaming raw material is injected into the first space 74 and the second space 76 has been described as an example, but since both spaces 74 and 76 are communicated with each other through the opening 48. Even if the foaming raw material is injected into only one of the first space 74 and the second space 76, it is possible to mold the duct wall 52 and the foam 16 integrally connected to each other. .

Further, in the above-mentioned embodiment, since the duct wall 52 formed of urethane is exposed on the back side of the base material 12, the duct wall 52 is formed when the material of the urethane is not excellent in moisture resistance. May deteriorate due to humidity. In such a case, for example, as shown in FIG. 9, if a sheet material 82 made of thin vinyl or the like is adhered to the inner surface of the duct wall 52, the duct generated by the humidity generated by the temperature difference between the inside and the outside can be used. It is possible to suitably prevent the wall 52 from deteriorating. The sheet material 82 is formed on the outer surface of the mold material 70 in advance to form the duct wall 52,
It is possible to simultaneously apply the sheet material 82 to the inner surface of the molded duct wall 52. Similarly, when moisture protection is required on the outer surface of the duct wall 52, a sheet material 82 may be attached to the outer surface of the duct wall 52. In this case as well, the concave portion 72 of the second molding die 66 is formed with the sheet material 82. By molding the duct wall 52 with the sheet material 82 set in advance,
It is possible to simultaneously apply the sheet material 82 to the outer surface of the molded duct wall 52.

Further, in the above-described embodiment, the duct wall 52 is formed at the same time when the foam body 16 is formed, so that the foam body 16 and the duct wall 52 are integrally formed. The duct wall 52 is previously attached to the foam 1
It may be molded separately from 6, and the ends of the foam 16 and the duct wall 52 may be joined to each other when the foam 16 is molded. That is, if the duct wall 52 is formed in advance into a desired shape from urethane in a separate step and set on the back side of the base material 12 together with the mold material 70, the lower end edge portion 52a of the duct wall 52 becomes the opening portion. Four
It comes to match with 8. Then, as shown in FIG. 10, when the base material 12 having the duct wall 52 set therein is set in the second molding die 66 of the foam molding die 60, the foam body 16 is molded. 16 and opening 48
The lower end edge portion 52a of the duct wall 52 facing the above is joined. In this way, the duct wall 5 formed separately is provided.
Even if the number is 2, the air conditioner unit is extended between the base material 12 and the back surface of the base material 12 by being extended to the back side of the base material 12 while being connected to the foam body 16. 1
It is possible to define an air flow passage communicating with 8.

Further, as described above, the vehicle interior member targeted by the present application is not limited to the instrument panel 30 illustrated in the embodiment, but a floor console,
Roof panels, etc. are also covered.

[0027]

As described above, according to the vehicle interior member of the present invention, the duct wall extending to the back side of the base material in a state of being connected to the foam formed between the base material and the skin is provided. Since the space that functions as an airflow passage for the duct is formed by joining the end edge of this duct wall to the back surface of the base material, the entire outer periphery of the duct has heat insulation performance, sound insulation and sound absorption. It is possible to form a foam having excellent performance. Therefore, it is possible to preferably prevent the occurrence of dew condensation due to the temperature difference between the inside and the outside of the duct, and it is possible to preferably prevent the generation of abnormal noise due to the contact of another member with the duct wall, and further to reduce the operating noise of the air conditioner unit. It has an extremely beneficial effect such that it can be suitably absorbed. The duct wall may be formed integrally with the foam, or may be formed separately from the foam and then end-joined to the foam.

Similarly, according to the method of manufacturing a vehicle interior member according to another invention, when a foam is molded between the base material and the skin using a foam molding die, the foam is integrally connected to the foam. Since the duct wall extending to the back side of the base material is molded in this state, the molding of the foam and the molding of the duct wall forming the duct can be performed at the same time, and the number of molding work steps is reduced. There is an advantage that the manufacturing cost can be reduced. Further, since the duct wall is formed integrally with the foam body, a member formed separately from the vehicle interior member is not required, and reduction in manufacturing cost due to reduction in the number of parts can be expected. Further, since the duct wall can be easily and easily joined to the base material, there is a beneficial effect such that the manufacturing cost can be reduced by reducing the number of assembling steps.

[Brief description of drawings]

FIG. 1 is a schematic perspective view of an instrument panel as an example of a vehicle interior member according to a preferred embodiment of the present invention.

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

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

FIG. 4 is a cross-sectional view of a foam molding die for manufacturing the instrument panel shown in FIG. 1, showing a first molding die having a preformed skin and a second molding die having a preformed base material. The mold is closed and the state immediately before the foaming raw material is injected into the defined first space and second space by the injection nozzle is shown.

FIG. 5: The foam mold shown in FIG. 4 was released from the mold by completion of molding of the foam and the duct wall extending to the back side of the base material while being integrally connected to the foam. It is sectional drawing of the instrument panel immediately after.

FIG. 6 is a cross-sectional view showing a state in which the upper end edge portion of the molded duct wall is once peeled from the base material.

FIG. 7 is a cross-sectional view showing a state in which the mold material attached to the base material is removed after the duct wall is separated from the base material.

FIG. 8 is a state in which a space functioning as an airflow passage of the duct is defined between the duct wall and the base material by joining the upper end edge portion of the duct wall to the back surface of the base material after removing the mold material. FIG.

FIG. 9 is a side cross-sectional view of an instrument panel illustrating that a measure against moisture is taken by applying a sheet material to the inner surface of the duct wall.

FIG. 10 is a cross-sectional view of a foaming mold for manufacturing an instrument panel, in which a duct is formed by molding a foam between a base material and a skin with a duct wall formed as a separate body set on the back side. 7 illustrates a molding method for end joining a lower edge of a wall to a foam.

FIG. 11 is a cross-sectional view of an instrument panel, which is an example of a conventional vehicle interior member, and shows an example in which the instrument panel and the duct are configured as separate members.

[Explanation of symbols]

12 Base material 14 Epidermis 16 foam 18 Air conditioner unit 48 openings 52 duct wall 62 First Mold 66 Second Mold 70 material 74 First Space 76 Second space

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) B60R 13/02 B60R 13/02 B // B29K 105: 04 B29K 105: 04 B29L 9:00 B29L 9:00 31:58 31:58 F-term (reference) 3D023 BA05 BB16 BD29 BE06 3D044 BA03 BA05 BA12 BB01 BC07 BD11 3L011 BL01 4F202 AB02 AD05 AD08 AG20 AH26 CA01 CA24 CB01 CB13 CK11 CK53 4F204 AA42 AD05 AD36 AG03 A25 AG20 AG21 AG21 AG20 AG21 AG21 AG20 AG21 AG21 AG20 AG21 AG21 EB13 EF01 EF27 EK17 EK24

Claims (6)

[Claims] 1. A base material (12) formed into a required shape, a skin (14) attached to the front side of the base material (12), and these base materials (12).
And a foam (16) formed by foaming and solidifying a foaming raw material between the skin (14) and the back surface of the base material (12) in a state of being connected to the foam (16). A duct wall (52) that defines an air flow passage communicating with the air conditioner unit (18) between the base material (12) and the base material (12) by joining the end portion to the back surface of the base material (12). ) Is provided, the vehicle interior member. 2. An opening (48) is formed at a required position of the base material (12), and the duct wall (52) and the foam body (16) are connected to each other through the opening (48). The vehicle interior member according to claim 1. 3. The vehicle interior member according to claim 1, wherein the duct wall (52) is formed integrally with the foam body (16). 4. The vehicle interior member according to claim 1, wherein the duct wall (52) is formed separately from the foam body (16) and is joined to the foam body (16) at an end portion. 5. A base material (12) formed into a required shape, a skin (14) attached to the front side of the base material (12), and these base materials (12).
And a foam (16) formed by foaming and solidifying a foaming raw material between the skin (14) and the outer skin (14), wherein the preformed skin (14) is a first molding die (62). Set on the back side of the preformed base material (12)
After detachably attaching the base material (12) to which the mold material (70) is attached, the base material (12) is set in the second molding die (66), and the base material (70) and the second molding die (66) are separated. A first space (74) is defined therebetween, and the first molding die (62) and the second molding die (66) are closed.
A second space (76) communicating with the first space (74) is defined between the base material (12) and the epidermis (14), and the second space (76) is injected into the second space (76). The foaming material is foamed and solidified to mold the foamed body (16), while the first space is formed.
(74) the foaming raw material injected in the foaming and solidification, to form a duct wall (52) extending to the back side of the base material (12) in a state of being integrally connected to the foam (16), After the mold is removed from the mold (62, 66) by the completion of molding of the duct wall (52) and the foam (16), the duct wall (52)
The mold material (70) inserted between the base material (12) and the base material (12) is removed from the base material (12), and an edge portion of the duct wall (52) is provided on the back surface of the base material (12). A method for manufacturing a vehicle interior member, characterized in that the air flow passage is defined between the duct wall (52) and the base material (12) by joining. 6. An opening (48) communicating with the first space (74) and the second space (76) is opened at a required position of the base material (12) to provide the first space. A state in which the duct wall (52) formed in (74) and the foam body (16) formed in the second space (76) are integrally connected through the opening (48). The method for manufacturing a vehicle interior member according to claim 5, wherein.