JP2003220854A - Interior decoration member for vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent a foam body to be foamed between a surface leather and a base material from leaking out by appropriately forming a sealed state. <P>SOLUTION: On the outer surface of the base material 12, hook-engaging channels 24 are extendedly disposed along the periphery edge lines of a disposing region 20 for the surface leather 14. At the edges of the general portion 40 of the surface leather 14, surface leather edges 42 are formed that are tightly inserted into the foregoing hook-engaging channels at the time of setting the surface leather 14 on the disposing region 20. The foam body 16 in the process of foaming reaction between these base material 12 and surface leather 14 is prevented from leaking out from between the surface leather edges 42 and the base material 12, by inserting the surface leather edges 42 into the hook- engaging channels 24 to form a sealed state between the surface leather 14 and the base material 12. <P>COPYRIGHT: (C)2003,JPO

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 more specifically, to a base material formed in a required shape, a skin partially disposed on the outer surface of the base material, and a member between the two members. The present invention relates to a vehicle interior member including a foam body which is foamed and interposed.

[0002]

2. Description of the Related Art Various vehicle interior members represented by instrument panels and floor consoles are installed in passenger compartments of passenger cars and the like. For example, an instrument panel is composed of a synthetic resin base material and is a single layer type in which the base material is entirely exposed, and a synthetic resin base material, and an outer surface of the base material is attached to form a decorative surface. It is roughly classified into a three-layer type including an eggplant skin and a foam having elasticity by being interposed between the base material and the skin. In the case of a three-layer type instrument panel, (a) a soft surface type covering the outer surface of the base material so as to cover the entire outer surface of the base material, and (b) partially covering the outer surface of the base material. It is roughly classified into a partial soft type in which a skin and a foam are adhered.
Partial soft type instrument panel 70
For example, as shown in FIG. 12, in a base material 12 made of a synthetic resin injection-molded into a required shape, the outer surface of the base material 12 is covered with a skin in a required area facing the passenger seat side (for example, about 2/3). 14 and the foam 16 are partially arranged.

Further, the instrument panel 70 of the partial soft type described above is (1) a skin 1 formed in a separate process.
The foam 16 with 4 is attached to the base material 12 (FIG. 11), and (2) the foam 16 is interposed between the base material 12 and the skin 14 (FIG. 12). ) And are roughly divided. In the instrument panel 70 of (1), the foamed body 16 is molded between the mounting base material 72 and the outer skin 14 in a separate process, and is preformed in a subsequent process.
By attaching the attachment base material 72 to the second installation portion 74 with the screw 76, the outer skin of the base material 12 and the foam 16 are attached to the outer surface of the base material 12 to be manufactured. In addition, in the instrument panel 70 of (2), as shown in FIG. 13, the skin 14 and the second skin 14 set in the first molding die 62 of the foam molding die 60.
The foam 16 is provided between the base materials 12 set in the molding die 64.
By foaming and intervening, the outer skin of the base material 12 and the foamed body 16 are adhered to manufacture.

[0004]

By the way, each of the instrument panels 70 manufactured by the methods (1) and (2) has various problems inherent in any of the forms. First, in the instrument panel 70 of (1), a mounting base 72 used when molding the foam 16 in a separate process, and a plurality of mounting bases 72 used when mounting the mounting base 72 on the base 12. Since the screws 76 are required, there is an inherent problem that the cost is increased due to the increase in the number of parts and the cost is increased due to the increase in the assembly work process of the mounting base 72. In addition, when the molding accuracy of each member is poor or the assembling work is inappropriate, a gap or a step is generated at the joint (boundary) between the base material 12 and the outer skin 14, which causes a deterioration in texture. There is also an inconvenience.

On the other hand, in the instrument panel 70 of (2), the step of molding the foam 16 and the step of mounting the foam 16 on the base material 12 are performed at the same time.
Cost reduction is expected by rationalizing molding work and reducing man-hours. However, there is an inherent defect that the skin end portion 42 of the skin 14 and the base material 12 cannot be properly sealed. That is, as is clear from FIG. 13, when the first molding die 62 and the second molding die 64 of the foam molding die 60 are closed, even if the skin end portion 42 comes into close contact with the base material 12, the arrow shown in the figure No flexural deformation is restricted in the A direction. Therefore, during foam molding of the foam body 16,
When the skin end portion 42 is flexibly deformed by the pressure of the foam 16 during the foaming reaction, a gap is formed between the skin end portion 42 and the base material 12, and the foaming reaction occurs. There is a problem that the foam body 16 in progress is exposed from the gap to the outer surface of the instrument panel 70 and hardens, and the texture of the instrument panel 70 deteriorates.
In some cases, when the foaming mold 60 is closed, the tip of the skin end portion 42 catches on the base material 12 and rolls up, so that the sealing state between the skin end portion 42 and the base material 12 is not formed at all. possible.

[0006]

DISCLOSURE OF THE INVENTION The present invention has been proposed in order to suitably solve the above-mentioned problems, and by ensuring that the sealing state between the surface skin and the base material is appropriately formed, the base material and the surface skin are protected. It is an object of the present invention to provide a vehicle interior member capable of preventing leakage of foam that is foam-molded in between.

[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 partially disposed on the outer surface of the base material. In the vehicle interior member including a foam body that is foamed between both members, an engagement groove that is formed on an outer surface of the base material and extends along an outer edge line in a region where the skin is disposed, A skin end portion formed along an edge of the skin and inserted into the engaging groove when the skin is set in the disposition region. By inserting into the groove and forming a sealed state, it is possible to prevent the foam, which is undergoing the foaming reaction between the base material and the skin, from leaking from between the skin end portion and the base material. It is characterized in that it is configured to be able to.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION Next, a vehicle interior member according to the present invention will be described below with reference to the accompanying drawings with reference to preferred embodiments. The vehicle interior member targeted by the present application is, for example, an instrument panel installed in front of a vehicle passenger compartment.

FIG. 1 is a schematic perspective view illustrating an instrument panel 10 as a vehicle interior member according to a preferred embodiment of the present application, FIG. 2 is a sectional view taken along line II-II of FIG. 1, and FIG.
It is a III-III sectional view taken on the line. The instrument panel 10 of the embodiment is a partial soft type, and a base material 12 injection-molded into a required shape, and the base material 1
An outer skin 14 that partially adheres to the outer surface of 2 to form a decorative surface,
It is of a three-layer type including a foam 16 interposed between the base material 12 and the skin 14. For convenience of explanation, the windshield 18 side is the front side of the instrument panel 10, and the passenger seat side is the rear side of the panel 10.

The base material 12 is, for example, polypropylene.
An instrument panel 1 of the present embodiment, which is formed by injection molding an olefin resin material such as (PP).
It is integrally formed based on the overall shape of 0.
As shown in FIGS. 1 and 2, the outer surface of the base material 12 has a disposition region 20 to which the skin 14 and the foam 16 are applied and covered, and the skin 14 and the foam 16.
Is not covered and is exposed to the outside, and is divided into a non-disposed region 22. Of these, the disposed region 20 has an area of about 2/3 of the entire outer surface of the instrument panel 10. The front upper surface and the rear rear surface of the panel 10 are non-disposed areas 22. The arrangement area 20 is formed in a state of being recessed from the non-arrangement area 22 in consideration of the thickness of the foam 16. Also the base material 1
On the outer surface of No. 2, the engaging groove 24 extending along the outer edge line of the disposing region 20 is provided at the boundary between the disposing region 20 and the non-disposing region 22 of the skin 14.

In the non-arranged area 22 exposed on the upper surface of the front side of the instrument panel 10, an air outlet 26 for blowing out air used for defrosting the windshield 18 is provided, and the panel 10 is also provided. An installation port 28 for a glove box (not shown), an insertion hole 30 for a steering column (not shown), etc. are formed in the non-arranged region 22 exposed on the rear surface of the rear side. On the other hand, in the arrangement area 20,
Air outlet 32 that blows out air used for air conditioning in the passenger compartment
Alternatively, an air outlet 34 for blowing out air used for defrosting a side window glass (not shown) is opened,
A meter hood 36 is formed. However, separately formed air outlets are retrofitted to the air outlet 32 and the air outlet 34.

The skin 14 is pre-formed into the design shape required for the instrument panel 10. For example, based on (a) urethane spray molding, the molding surface 52 of the skin molding die 50 has a urethane material U. Molded by spraying (Fig. 4), (b) Molded by melting and adhering resin powder to the molding surface of the skin forming mold based on the powder slush molding method (not shown), etc. Is preferably adopted. The skin 14 preformed in this manner is integrally molded into a general portion 40 which is exposed to the outer surface of the instrument panel 10 to form a design surface thereof and a shape bent along the edge of the general portion 40. The outer surface of the general portion 40 is textured to give the texture of genuine leather or the like to improve the texture of the instrument panel 10. There is. The material is PU (polyurethane) etc. by the urethane spray molding method, and TPO (olefin), PVC, by the powder slush molding method.
TPU (urethane type) etc.

The foamed body 16 is preformed by using the foaming mold 60 shown in FIGS. 5 to 8 and setting it in the first molding die 62 of the foaming mold 60, as will be described later. The urethane raw material is interposed between the members 12 and 14 by foaming and curing the urethane raw material between the outer skin 14 and the preformed base material 12 set in the second molding die 64. That is, since the foam body 16 has an appropriate elasticity, when the appropriate portion of the outer skin 14 is pressed with a fingertip, the portion corresponding to the foam portion is compressed and deformed into a concave shape, and the instrument panel 10 has a concave shape. It is designed to improve the touch. Further, in the event of a collision accident, if a passenger thrown forward collides with the instrument panel 10, a function is provided to absorb the shock.

The instrument panel 1 of the embodiment
At 0, it is formed on the outer surface of the base material 12, and is formed along the engaging groove 24 extending along the outer edge line in the disposition region 20 of the outer skin 14 and the edge portion of the general portion 40 of the outer skin 14. Due to the outer skin end portion 42 thus formed, a sealed state can be suitably formed between the base material 12 and the outer skin 14 when the foam 16 is foam-molded. That is, as will be described later, the base material 12 in which a foam molding die 60 for foam-molding the foam body 16 is preformed
And by closing the mold with the epidermis 14 set,
The outer skin end portion 42 is adapted to be closely inserted while being aligned with the engaging groove 24, and when the mold closing is completed, the outer skin end portion 42 is deformed and closely adheres to the engaging groove 24 so that a sealing state is obtained. Is formed. Thereby, the base material 1
Since the foamed body 16 is molded under the condition where the sealing state between the skin 2 and the skin 14 is formed, the foamed body 16 in which the foaming reaction is proceeding between the base material 12 and the skin 14 is the skin end portion. Leakage between 42 and the substrate 12 can be prevented. The engagement groove 24, as shown in FIG.
The opening side is wider than the bottom side, and the cross-sectional shape has an included angle V
It is formed in a shape, and is designed so that the skin end portion 42 can be easily inserted. Further, the skin end portion 42 is appropriately thicker than the general portion 40, so that the skin end portion 42 is unlikely to be bent or bent when it is inserted into the engaging groove 24.

As a result, in the instrument panel 10 of the embodiment, the foam body 16 foam-molded between the base material 12 and the outer skin 14 is formed between the outer skin end portion 42 of the outer skin 14 and the base material 12. Since it can prevent leaking appropriately,
It is possible to avoid the problem that a part of the foam 16 is hardened while leaking to the outer surface of the instrument panel 10. Therefore, the instrument panel 10
The post-work for removing the foam 16 that has leaked to the outer surface of the instrument and has hardened is not necessary, and deterioration of the texture of the instrument panel 10 is avoided.

Next, the method of manufacturing the vehicle interior member having the above-described structure according to this embodiment will be described specifically and in detail.

The base material 12 is injection molded by a base material molding die (not shown). And this base material 1
At the time of preforming of No. 2, the engaging groove 24 is also extended along the outer edge line of the disposing region 22 at the boundary between the disposing region 20 and the non-disposing region 22 to which the skin 14 is adhered. It

As described above, the skin 14 is formed by the urethane spray molding method or the powder slush molding method. For example, when the urethane spray molding method is used, the skin shown in FIG. 4 is used. A mold 50 is used. The outer skin forming die 50 is an electroforming mold which is formed based on the shape of the outer skin 14 and has a forming surface 52 which is surface-textured or the like, and is a urethane material sprayed to a required thickness by a spray gun 54. U
By curing, the urethane skin 14 having a thickness of about 1 mm can be molded, and the pattern of the molding surface 52 can be faithfully reproduced on the surface of the general portion 40 of the molded skin 14. In addition, the masking jig 56 used when forming the skin end portion 42 into a thick wall is
It is arranged so as to be able to move closer to and away from 2. Further, on the back side of the molding surface 52, a heating pipe 58 through which a heat medium such as water or oil flows is laid in a meandering shape, and the surface temperature of the molding surface 52 is set to the optimum temperature for curing the urethane material U ( For example, it can be heated to about 65 ° C. The masking jig 56 has a tray shape, and the side wall portion 56a enables the skin end portion 42 to be thickened (bulged) and shaped.

In the urethane spray molding method using the skin molding die 50, the spray gun 54 is moved at a predetermined speed while the heating medium is supplied to the heating pipe 58 to heat and maintain the molding surface 52 at a required temperature. Then, the urethane material U is sprayed onto the molding surface 52 (FIG. 4A). When the molding of the general portion 40 is completed by uniformly spraying the urethane material U onto the molding surface 52, the masking jig 56 is moved toward the molding surface 52, and under this condition, the skin end portion 42 is moved. By further adding and spraying the urethane material U to the portion corresponding to the molding surface 52 and the side wall portion 5
A skin end portion 42 having a required thickness is formed between the end portion 6 and 6a (FIG. 4 (b)).

Here, the urethane material U includes a non-foaming type and a foaming type which are colored in a required color. Assuming that the urethane material U is used as a skin of the instrument panel 10, it is excellent in durability. And soft type is preferably used. When the uncolored urethane material U is used, it is necessary to apply urethane paint or the like of a desired color to the molding surface 52 before spraying the urethane material U.

Since the urethane material U sprayed on the surface of the molding surface 52 is heated to the above-mentioned temperature, the curing is accelerated immediately after the spraying and the curing is completed in a short time. To do. Thus, the skin forming mold 50
In the skin 14 preformed by the above, a general portion 40 having an outer surface shape of the instrument panel 10 and a thick skin end portion 42 along the outer edge of the general portion 40 are integrally formed ( FIG. 4 (c)).

Next, the foam 16 is formed between the base material 12 and the skin 14. First, as a forming preparation step of the foam body 16, the skin 14 preformed on the set surface 62a of the first molding die 62 in the foam molding die 60 opened.
(FIG. 5B), and the preformed base material 12 is set on the setting surface 64a of the second molding die 64 of the foam molding die 60 (FIG. 5A). Then, when the setting of the skin 14 and the base material 12 is completed, as shown in FIG. 6, the first molding die 62 and the second molding die 64 are closed. Here, in the foam molding die 60 of the embodiment, the second molding die 64 on which the base material 12 is set is closed while being displaced leftward in FIG. 6 with respect to the first molding die 62 on which the skin 14 is set. Therefore, the tip of the skin end portion 42 is appropriately and surely inserted into the engaging groove 24 having a V-shaped cross section from an oblique direction.

That is, when the second molding die 64 is designed to be vertically (vertically) closed with respect to the first molding die 62 in FIG. 6, the tip of the skin end portion 42 is not arranged on the base material 12. There is a possibility that the skin end portion 42 may be bent or deformed by being caught by the edge corner portion of the installation region 22, but the foam molding die 60 of the embodiment preferably avoids such an inconvenience. It The mold closing angle R of the second molding die 64 with respect to the first molding die 62 is approximately 15 degrees with respect to the vertical as shown in FIG. However, this mold closing angle R
If is set to 5 degrees or more, the above-mentioned inconvenience can be avoided.

When the second molding die 64 is completely closed with respect to the first molding die 62, the skin end portion 42 is inserted into the engaging groove 24 while receiving an appropriate pressing force. As shown in FIG. 7, the tip portion of the skin end portion 42 is appropriately deformed into the shape of the engaging groove 24. As a result, a suitable sealed state is formed between the skin end portion 42 and the engagement groove 24, and the foam space 66 defined between the skin 14 and the base material 12 is sealed.

With the foam molding die 60 closed,
Foaming space 66 defined between the skin 14 and the substrate 12.
The foam 16 is molded therein (FIG. 8). At this time, since the sealing state is formed between the skin end portion 42 and the engaging groove 24, the foam 16 in which the foaming reaction is in progress,
Leakage from the gap between the skin end portion 42 and the base material 12 is preferably prevented. The urethane raw material for molding the foam 16 is injected into the back surface of the skin 14 set in the first molding die 62 before the first molding die 62 and the second molding die 64 are closed. deep.

When the molding of the foam body 16 by the foam molding die 60 is completed, the second molding die 64 is released from the first molding die 62, and the manufactured instrument panel 10 is demolded.

As described above, according to the manufacturing method of the embodiment, the skin 1
4 is inserted into the engaging groove 24 of the base material 12 to form a sealed state between the skin end portion 42 and the base material 12, and the foaming is performed between the skin 14 and the base material 12. Body 1
Since 6 is foamed / molded, it is possible to preferably avoid the inconvenience that the foam 16 in which the foaming reaction is in progress leaks from the gap between the skin 14 and the base material 12. Therefore, the foam 16
Will not leak to the outer surface of the instrument panel 10 and harden, resulting in defective products and deterioration in texture, and the production cost will not increase because the work of removing the leaked foam is unnecessary.

Further, the skin end portion 4 with respect to the engaging groove 24
Since the insertion of No. 2 is performed at the same time as the mold closing of the foam molding die 60, there is no need for troublesome work and troublesome work when preparing the molding of the foam body 16. Moreover, since the skin end portion 42 is formed to be thicker than the general portion 40, the skin end portion 42 is unlikely to be deformed when it is inserted into the engaging groove 24, and the sealing state between the skin end portion 42 and the base material 12 is reliable. Is formed.

(Modification) FIGS. 9 and 10 exemplify an instrument panel 10 as a vehicle interior member according to a modification, in which an installation area 20 on the outer surface of the base material 12 is shown.
At the boundary between the non-disposition area 22 and the disposition area 20,
By extending the projecting piece 68 along the outer edge line, the engaging groove 24 into which the skin end portion 42 of the skin 14 is inserted is defined. The engaging groove 24 has a cross section of V
The skin end portion 42 has a letter-like shape, and the cross-sectional shape of the skin end portion 42 has a tapered shape that is closely inserted into the engaging groove 24. The projecting piece 68 may be continuously extended along the boundary line between the disposition region 20 and the non-disposition region 22, or may have a required length and be intermittently extended at appropriate intervals. It may be provided.

When the skin 14 is molded by the powder slush molding method, the general portion 40 and the general portion 40 are controlled by controlling the temperature partially on the molding surface of the skin molding die. It is possible to form the skin 14 having the skin end portion 42 that is thick. That is, on the molding surface, if the skin 14 is molded under temperature control such that the temperature of the portion where the skin end portion 42 is molded is higher than the temperature of the portion where the general portion 40 is molded, the The terminal portion 42 can be formed thick. Further, when it is necessary to accurately shape and dimension the skin end portion 42 (thickness, etc.), a separately prepared molding jig can be pressed immediately after molding (before curing), and the skin end portion 4 can be formed.
2 can be molded in an appropriate shape.

Although the instrument panel 10 is exemplified as the vehicle interior member in the above-mentioned embodiment, the vehicle interior member targeted by the present application is the base material 12, the skin 14, and the foam 1.
A floor console and a door panel having a three-layer structure of No. 6 are also included.

[0032]

As described above, according to the vehicle interior member of the present invention, the skin end portion formed on the skin is inserted into the engaging groove formed on the base material to form the end portion of the skin and the base material. Since the foam is foamed / molded between the skin and the base material under the sealed state, the foam in which the foaming reaction is in progress leaks from the gap between the skin and the base material. The beneficial effect of avoiding inconvenience can be obtained. Therefore, the foam does not leak to the outer surface of the vehicle interior member and hardens, which does not lead to defective products or deterioration in texture.
Further, since the skin end portion is inserted into the engaging groove at the same time when the foaming mold is closed, there is no need for troublesome work or troublesome work in preparing the foamed body. Further, since the skin end portion is formed to be thicker than the general portion, it is difficult to deform when it is inserted into the engaging portion,
The sealing state between the end portion of the epidermis and the base material is reliably formed.

[Brief description of drawings]

FIG. 1 is a schematic perspective view illustrating an instrument panel as 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.

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

FIG. 4 is an explanatory cross-sectional view showing a step of forming a skin with a skin forming die based on the urethane spray molding method over time, in which (a) shows a general portion obtained by spraying a urethane material on a molding surface. The state of molding is shown, (b) shows the state in which the skin end portion is bulgingly formed under the setting of the masking jig, and (c) shows that the general portion and the skin end portion are integrated. 2 shows a state in which the formed epidermis is demolded.

FIG. 5A is a cross-sectional view showing a state in which a preformed base material is set in a second molding die of a foam molding die, and FIG.
FIG. 4 is a cross-sectional view showing a state in which a preformed skin is set on a first molding die of the foam molding die.

FIG. 6 is a cross-sectional view showing a state in which a second molding die in which a base material is set is closed with respect to a first molding die in which a skin is set.

FIG. 7 is a partially enlarged cross-sectional view showing a state in which the end portion of the skin is inserted into the locking groove when the mold closing of the foam molding die is completed, and a sealing state between the base material and the skin is formed.

FIG. 8 is a cross-sectional view showing a state in which a foam is being molded between the base material and the skin, with the foam molding die being closed.

FIG. 9 is a partial cross-sectional view of an instrument panel according to a modification.

FIG. 10 is a partial cross-sectional view of an instrument panel according to a modified example.

FIG. 11 is a schematic cross-sectional view illustrating an instrument panel manufactured by separately molding a base material, a skin and a foam, and then assembling the foam with a screw on the base material.

FIG. 12 is a schematic cross-sectional view illustrating an instrument panel manufactured by foam molding a foam between a base material and a skin.

13 is an explanatory cross-sectional view showing a state in which the instrument panel shown in FIG. 12 is manufactured, and FIG. 13 (a) is a second molding die in which a base material is set to a first molding die in which a skin is set. Shows a state in which the foam is closed, and (b) shows a state in which the foam is molded between the base material and the skin under the closed mold of the foam molding die.

[Explanation of symbols]

10 Instrument panel (vehicle interior material) 12 Base material 14 Epidermis 16 foam 20 installation area 24 Locking groove 40 General part 42 Skin terminal part 60 foam mold

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Claims (4)

[Claims] 1. A base material (12) formed into a required shape, a skin (14) partially disposed on an outer surface of the base material (12), and both members (1).
In a vehicle interior member consisting of a foam (16) which is foamed and interposed between the two (14), is formed on the outer surface of the base material (12), in the disposition region (20) of the skin (14) Locking groove (24) extending along the outer edge line
And a skin terminal which is formed along the edge of the skin (14) and is closely inserted into the engagement groove (24) when the skin (14) is set in the disposition region (20). Part (42), by inserting the skin end portion (42) of the skin (14) into the engagement groove (24) to form a sealed state, the base material (12) and the skin (14) The foam (16) in which a foaming reaction is in progress with the (16) is configured to prevent leakage from between the skin end portion (42) and the base material (12). Vehicle interior parts to be. 2. A foam molding die (60) for foam-molding the foam (16) is closed by setting the preformed base material (12) and skin (14), Skin terminal part
The vehicle interior member according to claim 1, wherein the (42) is adapted to be inserted into the engagement groove (24). 3. The epidermal terminal portion (42) comprises the epidermis (14).
The thicker portion than the general portion (40) of the above, which is difficult to be deformed when being inserted into the engagement groove (24).
The vehicle interior member described. 4. The vehicle interior member according to claim 1, wherein the vehicle interior member is an instrument panel (10).