JP2003251669A - Molding base material for door trim and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding base material for a door trim which can be surely fitted on an inner panel without being rickety even if number of parts is reduced and a method for manufacturing the same. <P>SOLUTION: In the molding base material in which a base material main body 11 is held by inserting a hook part 12 provided on its back face into a fitting hole of the inner panel, a seal seat 13 whose foaming magnification is higher than those of the base material main body 11 and the hook part 12 and which has a shape sealing the fitting hole is integrally molded on the base part of the hook part 12 on the back face of the base material main body 11. A split-cavity mold in which one of a pair of molds is registered to the other mold during molding and which consists of a fixed main block and a sub-block being freely forward and backward movable is provided, and after the base material main body with a low foaming magnification and the hook part on the back face are molded under a condition where this sub-block is forwarded, only the sub-block is retreated to expand the base part of the hook part molded in advance and to obtain the seal seat with a high foaming magnification. <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 door trim molding base material used as a core material of a vehicle door trim and a method for manufacturing the same.

[0002]

2. Description of the Related Art In a vehicle door trim, a decorative skin material 52 is joined to the front side of a molded base material 51 as shown in FIG. 6, but a hook portion 53 is provided in the middle of the back surface of the molded base material 51. The mounting hole 55 is provided on the inner panel 54.
It is normally mounted and held inside the door by inserting it into the door, but a large gap remains between the mounting hole 55 and the hook portion 53, which deteriorates the sealing performance with the outside of the vehicle. , Vibration may cause the door trim to rattle and generate abnormal noise. Therefore, by using a separately prepared sealing material 56, the sealing performance with the outside of the vehicle is improved,
The rubber pad 57 is used to block the mounting hole 55 to prevent the generation of abnormal noise. As described above, conventionally, there has been a problem that the manufacturing cost is increased because various different members are used for attaching and holding the door trim.

[0003]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems, and a molded base material for a door trim which can be securely attached and held to the inner panel without rattling even if the number of parts is reduced, and It was made in order to provide the manufacturing method.

[0004]

SUMMARY OF THE INVENTION The present invention, which has been made to solve the above-mentioned problems, provides a base body having a hook portion integrally formed on the back surface thereof, and a mounting hole provided in the inner panel with the hook portion. In the molded base material for door trim used for the interior of the inner panel, the foaming ratio is increased only at the base of the hook portion on the back surface of the base material body from the base material body and the hook portion so that the mounting hole is from the front side. Molded base material for door trim, which is provided with a seal seat integrally molded in a sealing shape, and a method for mass-producing such a molded base material for door trim at low cost, that is, formed between a pair of molds. For door trims, in which foamed synthetic resin raw material is filled in the cavity to be foam-molded in this cavity with the hook part integrally molded on the back surface of the base material body In the method for producing a shaped substrate, one of the above-mentioned pair of molds is placed in a peripheral position of a main block which is matched with the other mold during molding and is held at a fixed position, and a hook portion to be molded. It is set as a split mold consisting of a sub block that can be moved back and forth and is placed on the back surface of the substrate main body with a cavity between both main blocks and one of the above molds with the main block and the sub block advanced to a predetermined position. A base portion of a hook portion formed by forming a formed base material in which hook portions are continuously provided, and subsequently retracting only the sub-block described above to a required position before the foaming of the base material body and the hook portion is completed. Molding for door trims characterized by expanding the peripheral cavity to expand the base of the hook part that was previously molded to provide a seal seat with a higher expansion ratio than the base material body and the hook part. In which the more the manufacturing process of wood.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is an enlarged cross-sectional view in the vicinity of a hook portion of a molding die used for manufacturing a molding base material for a door trim of the present invention, in which 1 is a fixed side molding die which is one of the molding dies and 2 is a fixed side molding die. It is a movable side molding die that forms a pair with the mold 1. The movable mold 2 is a split mold composed of a main block 2a and two sub-blocks 3a and 3b which are nests. The main block 2a described above is for mainly forming the main cavity 4 for molding the base material main body when the main block 2a is fitted to the stationary mold 1, and the main block 2a is always formed during foam molding. It is held at a fixed position matched with the stationary mold 1. On the other hand, the two sub blocks 3a and 3b are the main blocks 2a.
The sub-blocks 3a and 3b form a hook cavity 5 between the sub-blocks 3a and 3b and the fixed-side molding die 1. The sub-blocks 3a and 3b are attached to the tip of a cylinder rod 6 which is hydraulically driven, and can move forward and backward independently of the main block 2.

In order to manufacture a molding substrate with the fixed-side mold 1 and the movable-side mold 2, the main block 2a and the sub-blocks 3a and 3 are first prepared for the fixed-side mold 1.
The movable-side molding die 2 composed of b and two sub-blocks 3
Molds a and 3b are advanced to the foremost position, and a cavity composed of a main cavity 4 and a hook cavity 5 formed between the molds has a foaming property from a nozzle of an injection molding machine (not shown). A predetermined amount of synthetic resin raw material is injected and filled. When the synthetic resin raw material is filled in the capacity in this way, the synthetic resin raw material starts foaming. However, when the synthetic resin raw material is foamed to a relatively low predetermined expansion ratio, the cavity is filled with the cavity. A molded base material is formed in which hook portions are continuously provided on the back surface of the base material body according to the shape. In this way, if the synthetic resin raw material is foamed to a relatively low predetermined foaming ratio and the base material body having the hook portion on the back surface is molded with a low foaming degree, then with a slight time lag, Before the foam molding of the base material body and the hook portion is completed, the sub block 3a,
3b is retracted to a predetermined position as shown in FIG. That is, in the figure, the upper sub-block 3a is retracted in the horizontal direction, and the lower sub-block 3b is retracted in the vertical direction. When the sub blocks 3a and 3b are retracted in this manner, the cavity around the base of the molded hook portion is expanded, so that the pressing force applied to the hook portion cavity 5 is reduced,
The base portion of the previously molded hook portion expands and the base material main body 11
The seal seat 13 foamed at a higher magnification is molded. The seal seat 13 may have any shape as long as it seals the mounting hole provided in the inner panel from the front side.

In this way, if the synthetic resin resin raw material is foamed and hardened in the cavity composed of the main cavity 4 and the hook portion cavity 5, if both molds are opened, the base material main body as shown in FIG. It is possible to obtain a molded base material in which the hook portion 12 having the seal seat 13 higher in foaming than the base material main body 11 at the base portion is provided on the back surface of the base material 11, and thereafter the same as the conventional molded base material is obtained. A door trim as shown in FIGS. 4 and 5 may be obtained by applying post-processing such as covering the front surface of the base material main body 11 with a means by means.
When the door trim obtained in this manner is used for the interior of the inner panel 24 by inserting it into the mounting hole 25 provided in the inner panel 24, the seal seat 13 is compressed and deformed by its elasticity. Since the door trim can be securely attached and held to the inner panel 24, the door trim is not rattled and no abnormal noise is generated. Also. Since the foam cells formed on the molding base material 21 are independent foam cells that do not communicate with each other, the door trim can be attached to the inner panel 24 with a high sealing property without leaving a gap with the inner panel 24.
Can be attached to.

If the skin material 22 is set in advance at a desired position of the fixed-side molding die 1 and the synthetic resin raw material is filled in the cavity and foamed, the skin material 22 is integrally bonded to the molding base material 21. Molded door trim can be obtained. As a synthetic resin raw material, polypropylene resin,
In addition to polyolefin resins such as polyethylene resin, foamable thermoplastic resins such as polyamide resin and polystyrene resin can be used, and as the foaming agent added to such thermoplastic resin, sodium bicarbonate, bicarbonate Inorganic foaming agents such as ammonium, nitroso compounds,
A general compound such as an azo compound or a sulfonyl hydrazide may be used. In this case, the amount of the foaming agent added is set to about 0.1 to 5% with respect to the thermoplastic resin, so that high foaming as described above is achieved. It is possible to manufacture the molded substrate 21 in which the hook portion 12 having the portion 13 is provided on the back surface of the substrate body 11.

[0009]

As described above, in the molded base material for door trim of the present invention, the base material body in which the hook portion is integrally molded on the back surface is installed in the mounting hole provided in the inner panel with the hook portion. In the molded base material for door trim that is inserted to be used for the interior of the inner panel, only the expansion ratio is made higher than the base material body and the hook portion at the base of the hook portion on the back surface of the base material body to seal the mounting hole from the front side. Since a seal seat integrally molded to the inner panel is provided, when the hook part is inserted into the mounting hole of the inner panel and the door trim is attached and held on the inner panel, the seal seat is elastically deformed and mounted. By closing the holes, the door trim can be securely attached to and retained on the inner panel with a high sealing property without rattling, which is necessary for conventional door trim installation. The member such as a sealing material and a rubber pad that had be omitted. Further, the method for producing a molded base material for door trim of the present invention has an advantage that the molded base material for door trim as described above can be mass-produced at low cost. Therefore, the present invention has extremely great industrial value as a solution to the problems of the conventional molded base material for door trim and the manufacturing method thereof.

[Brief description of drawings]

FIG. 1 is an enlarged cross-sectional view of a main part of a molding die used for manufacturing a door trim molding base material of the present invention.

FIG. 2 is an enlarged cross-sectional view of a main part of a molding die shown in a state where a sub block is retracted.

FIG. 3 is an enlarged perspective view of the vicinity of a hook portion.

FIG. 4 is a front view of a door trim using the molded base material for door trim of the present invention.

FIG. 5 is a cross-sectional view of essential parts showing a state in which a door trim using the molded base material for door trim of the present invention is mounted on an inner panel.

FIG. 6 is a cross-sectional view of a main part showing a state in which a door trim using a conventional molding substrate is mounted on an inner panel.

[Explanation of symbols]

1 Fixed mold 2 Movable mold 2a Main block 3 sub blocks 11 Base material body 12 Hook part 13 Seal seat

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 4F202 AB02 AG20 AG28 AH23 CA11                       CB01 CK19 CK52                 4F206 AB02 AG20 AG28 AH23 JA04                       JF04 JL02 JM04 JM05 JN11                       JQ81

Claims (2)

[Claims] 1. A molded base material for door trim, which is used for the interior of an inner panel by inserting a base material body having a hook portion integrally molded on the back surface into the mounting hole provided in the inner panel with the hook portion as described above. It is characterized in that the base of the hook portion on the back surface of the material main body is provided with a seal seat integrally formed in a shape that seals the mounting hole from the front side by making only the expansion ratio higher than that of the base material main body and the hook portion. Molding base material for door trim. 2. A foamed synthetic resin material is filled in a cavity formed between a pair of molds, and a molded base material having a hook portion integrally molded on the back surface of the base material body is foam-molded in the cavity. In the method for producing a molded base material for door trim described above, one of the above-mentioned pair of molds is joined to the other mold during molding, the main block is held at a fixed position, and the hook part to be molded is formed. It is a split type consisting of a sub block that can be moved back and forth in the peripheral position,
In a state where the main block and the sub block are advanced to a predetermined position, a molding base material in which a hook portion is continuously provided on the back surface of the base material main body is molded in the cavity between both blocks and the one mold described above, and subsequently, Before the foam molding of the base material body and the hook portion is completed, only the above-mentioned sub-block is retracted to the required position to expand the cavity around the base portion of the formed hook portion, thereby forming the base portion of the hook portion previously molded. Is provided to provide a seal seat having a higher expansion ratio than the base material main body and the hook portion, and a method for manufacturing a molded base material for door trim.