JP2004106600A - Interior component for automobile and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce weight, man-hour and cost, by integrating a side impact absorbing body with an interior component body side, in an interior component for an automobile mounted to a side wall of a vehicle and its manufacturing method. <P>SOLUTION: A door trim 10 comprises a lightweight foamed resin base material 20 having shape retention, a resin rib 30 along a predetermined pattern integrally laminated on the inner surface side of the foamed resin base material 20, and the side projection shock absorbing body 40 integrated with the resin rib 30. By using the lightweight foamed resin base material 20 and reducing projection area of the resin rib 30 comparing with a conventional resin core material, the weight and cost are reduced. The shock absorbing body 40 is molded integrally with the resin rib 30, thereby reducing molding processes and mounting man-hour of a side projection pat. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a vehicle interior component mounted on a side wall panel of a vehicle, such as a door trim and a rear side trim, and a method of manufacturing the same, and more particularly to a vehicle interior component that is lightweight and can reduce the number of mounting steps, and a method of manufacturing the same.
[0002]
[Prior art]
Normally, various interior parts for automobiles are mounted in the vehicle interior, and a representative example of the interior parts is an automobile door trim mounted on a side wall panel of the vehicle.
[0003]
The configuration of the car door trim will be described with reference to FIGS. 12 and 13. The car door trim 1 bulges into the interior of the vehicle, and the armrest 1 a is positioned substantially at the center of the car door trim so that the occupant can rest on his elbow. A door pocket 1b for accommodating equipment is formed below the speaker pocket 1b, and a speaker grill 1c is formed on the front side thereof.
[0004]
As shown in FIG. 13, the automotive door trim 1 is formed into a required shape, laminated with a resin core material 3 having shape-retaining property and rigidity for mounting to the door panel 2, and laminated on the surface side thereof to obtain a good surface texture and And a skin 4 having a touch feeling.
[0005]
Further, a side impact pad 5 is fixed to the rear surface of the door trim 1 at a position where the occupant's waist and shoulders are likely to collide when a shock is applied to the vehicle from the side. As the side bump pad 5, a molded foam molded article or a synthetic resin molded article molded in a block shape such as urethane foam or foamed bead molded article, or a synthetic resin molded article has been conventionally used. (For example, see Patent Document 1).
[0006]
As means for fixing the side protrusion pad 5 to the rear surface of the door trim 1, heat welding fixing, hot melt welding fixing, screw fixing and the like are employed. The outline of the manufacturing method of the door trim 1 is as follows. A raw sheet of the skin 4 is set in a molding die in advance, and after closing the mold, a molten resin is injected and filled into a product cavity to obtain a required curved surface shape. The door trim 1 is manufactured by molding the resin core material 3 and laminating and integrating the skin 4 on the surface side of the resin core material 3.
[0007]
[Patent Document 1]
JP-A-10-278709 (page 2, FIG. 8, FIG. 9)
[0008]
[Problems to be solved by the invention]
As described above, in the conventional door trim 1, the skin 4 is laminated and integrated on the surface of the resin core material 3, and in the impact area where the occupant's waist or shoulder is likely to collide, the side collision pad 5 is provided on the back side thereof. Since it is configured to be attached, the number of parts is large, and a molding die for molding the side protrusion pad 5 is required in addition to the molding die for the door trim 1. This requires a lot of molding equipment, increases the number of mounting steps, and costs. It has been pointed out that the problem of inviting upswing is caused.
[0009]
Further, since the door trim 1 uses a heavy resin core material 3 and a heavy mold urethane as a material of the side collision pads 5, the entire door trim 1 is heavy and the door trim 1 is heavy. In other words, there is a problem in that the workability of mounting to the door panel 2 is hindered and the fuel efficiency is reduced. In addition, when a polyolefin resin is used as the resin core material 3 and a mold urethane is used as the side collision pad 5, it is difficult to perform a batch process for recycling, and it is necessary to separate both. There is a problem that the recycling cost increases.
[0010]
The present invention has been made in view of such circumstances, and relates to an automobile interior component to be mounted on a side wall panel of a vehicle and a method of manufacturing the same, which can reduce the number of components, reduce the number of mounting steps, and reduce the weight. It is an object of the present invention to provide an automotive interior part which can be manufactured and is suitable in terms of recycling, and a method of manufacturing the same.
[0011]
[Means for Solving the Problems]
The present inventors have conducted intensive studies to solve the above-mentioned problems, and as a result of imparting shape retention to a foamed resin sheet conventionally used as a skin, have a function as a core material. The present invention has been completed by arranging a resin rib in a portion requiring high rigidity and providing a side impact shock absorber integrally with the resin rib.
[0012]
That is, the automotive interior part according to the present invention includes a foamed resin base material having shape-retaining properties, a resin rib along a predetermined pattern laminated and integrated on the back surface of the foamed resin base material, and an integrated resin rib. And a side collision shock absorber that abuts or faces the vehicle body panel and absorbs a shock in a side collision.
[0013]
Here, as interior parts for automobiles, the present invention can be applied to door trims, rear side trims, and the like mounted on side wall panels of vehicles.
[0014]
When the foamed resin base material having shape retention properties is close to a flat shape, the heating softening step is omitted, and the molded resin is molded into a desired shape. Is heat-softened, then molded into a desired curved surface shape in a molding die, and the shape is maintained. Also, when the product shape includes a high expansion rate, after heating and softening the foamed resin sheet, a vacuum suction mechanism is arranged in the molding die, and vacuum suction is performed along the inner surface of the molding die with a vacuum suction force. A force may be applied.
[0015]
As the foamed resin sheet, a material obtained by adding a foaming agent to a thermoplastic resin is used. Incidentally, the thermoplastic resin may be composed of one kind of thermoplastic resin or two or more kinds of thermoplastic resins. Preferably, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin and the like can be used.
[0016]
As the foaming agent, an organic foaming agent such as an azo compound, a sulfohydrazide compound, a nitroso compound, and an azide compound, or an inorganic foaming agent such as sodium bicarbonate can be used.
[0017]
The foamed resin substrate obtained by molding the foamed resin sheet into a required shape after the heat softening treatment has a foaming ratio of 2 to 10 times in consideration of the balance between the weight and the strength of the product. The cell diameter of the foamed resin substrate at that time is preferably in the range of 0.1 μm to 2 mm, and the thickness is preferably 0.5 to 30 mm, and more preferably 1 to 10 mm.
[0018]
On the other hand, the thermoplastic resin material used as the resin rib can be appropriately selected from a wide range of thermoplastic resins. Usually preferred are polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, polyamide resin, acrylonitrile / butadiene / styrene (ABS). Resin, polycarbonate resin and the like can be used.
[0019]
Various fillers may be mixed in these thermoplastic resins. Examples of the filler that can be used include inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica, and calcium carbonate. Further, various additives such as an antioxidant, an ultraviolet absorber, a coloring agent, a flame retardant, and a low shrinkage agent may be blended.
[0020]
According to the automotive interior part of the present invention, the foamed resin base material has shape-retaining properties, and the resin ribs and the side impact shock absorbers are laminated and integrated on the back surface side of the foamed resin base material. In addition, by eliminating the conventional resin core material having a very large projected area, the weight can be reduced and the resin material can be saved. In addition, the side impact shock absorber is integrally molded with the resin rib instead of the side impact pad that was conventionally separately molded and attached by hot melt, welding, screwing, etc., so molding equipment can be saved, the number of parts and mounting Man-hours can also be reduced.
[0021]
In addition, the porous sound-absorbing function of the foamed resin base makes it possible to obtain automotive interior parts with excellent sound-absorbing performance, and uses a polyolefin-based resin as a material for the foamed resin base, resin ribs, and side impact shock absorbers. In this case, the separation step can be abolished by the all-olefin resin, so that the recycling operation can be simplified.
[0022]
Further, as a preferred embodiment of the present invention, the resin rib may have an L-shaped cross-section or an inverted T-shaped cross-section so that the contact portion on the back surface of the foamed resin substrate becomes a plate portion. In addition, no streaks appear on the surface of the interior parts, the appearance is good, and the shape retention of the product can be enhanced.
[0023]
Furthermore, the rib thickness of the resin rib is appropriately changed, for example, by setting the rib thickness to be thicker at a portion where external force is greatly applied to the interior component, and by thinning the rib thickness at a portion to which relatively less external force is applied. be able to. Therefore, it is sufficient to use the minimum necessary amount of resin material, which can contribute to weight reduction and cost reduction of the product.
[0024]
In addition, a clip seat or a mounting seat for mounting various escutcheon parts can be integrally formed with the resin rib. Further, a skin that enhances the appearance design can be laminated on the surface of the foamed resin substrate. As the skin, a woven fabric, a nonwoven fabric, a knitted fabric, a sheet, a film, a foam, a mesh, or the like can be used. Although the material constituting these skins is not particularly limited, it is preferable to use a material having air permeability such as a woven fabric, a nonwoven fabric, or a knitted fabric in order to utilize the sound absorbing performance of the foamed resin base material.
[0025]
Next, as the side impact shock absorber integrated with the resin rib, a lattice-shaped rib integrally formed of the same material as the resin rib may be formed, or an elastomer of a different material from the resin rib may be used. Is also good.
[0026]
In the case of a lattice-shaped rib, the resin rib is integrally formed at the time of injection molding, and the lattice-shaped rib is erected so as to extend in the vertical and horizontal directions protruding toward the vehicle body panel from a plate portion abutting on the back surface of the foamed resin base material. ing.
[0027]
When an elastomer is used, a case in which an opening facing the panel side is provided integrally with the resin rib is formed, and the inside of the case is filled with an elastomer material such as a foam.
[0028]
Next, the method for manufacturing an automobile interior part according to the present invention comprises a foamed resin base material having shape-retaining properties, a resin rib and a side impact shock absorber laminated and integrated on the back surface of the foamed resin base material. In a method of manufacturing an interior part for an automobile, a foaming resin sheet setting step of setting a foaming resin sheet, which is a material of a foamed resin base material, in a molding die, and clamping of the molding dies to form a molding die In addition to molding the foamed resin base material into the required shape along the cavity shape of the above, the molten resin is injected and filled into the cavity of the molding die, so that the resin ribs and the plate portion and the grid-like ribs are on the back side of the foamed resin base material. And an integration step of laminating and integrating the components.
[0029]
Here, the molding die is composed of a molding upper mold that can move up and down, a molding lower mold located below the molding upper mold, and an injection machine connected to the molding lower mold, and is supplied from the injection machine. The molten resin is supplied onto the mold surface of the lower mold through resin passages such as manifolds and gates provided in the lower mold, but the upper mold descends to the bottom dead center and clamps the upper and lower molds. After that, the molten resin is injected and filled into the cavity at a predetermined injection pressure.
[0030]
Therefore, the foamed resin sheet is molded along the mold surface shape of the molding die by clamping the upper and lower molds, and the molten resin is injected and filled into the cavity, thereby absorbing the resin ribs and side impact shock. A body is formed, and these resin ribs and side impact shock absorbers are laminated and integrated on the back side of the foamed resin base material.
[0031]
Then, when the product shape is set to a three-dimensional shape, after performing heat softening treatment by a heater or the like in the previous step, the foamed resin sheet is set in a molding die.
[0032]
Furthermore, after supplying the foamed resin sheet in a heat-softened state into the molding die, if the molding die is clamped, the foamed resin sheet is formed into a required shape, and a foamed resin base material having shape retention properties is obtained. .
[0033]
Therefore, the resin rib and the side impact absorber can be laminated and integrated on the back surface of the lightweight foamed resin base material having shape-retaining property. If the final product has a highly developed shape, the mold should be clamped a plurality of times to inject the molten resin in the final mold clamping step.
[0034]
Further, when the product shape includes a high expansion rate portion, a vacuum suction mechanism is provided on the upper mold, and the foamed resin base material is formed into a required shape by a vacuum suction force along the mold surface of the upper mold. You may do it.
[0035]
Therefore, according to the method of the present invention, since only the resin rib and the side impact shock absorber are molded as compared with the conventional resin core material having a large projected area, the load on the molding die is small and the amount of resin is small. In addition, the material cost can be saved, and the cooling time is shorter than that of the conventional resin core material, so that the molding cycle of the product can be shortened.
[0036]
Furthermore, according to the method of the present invention, since the grid-like rib is integrally formed as a side impact shock absorber integrally with the resin rib, the side bump pad formed in a separate step as in the related art is formed in a separate step after forming the interior component. The installation work is omitted, the number of mold facilities is reduced, and the man-hour can be reduced.
[0037]
Next, another embodiment of the method of the present invention is formed by filling an elastomer into a foamed resin base material having shape-retaining properties, a resin rib laminated and integrated on the back surface of the foamed resin base material, and a resin case body. In a method for manufacturing an automobile interior part comprising a side impact absorber, a foaming resin sheet setting step of setting a foaming resin sheet, which is a material of a foaming resin base material, in a molding die; The mold is clamped to form the foamed resin base material into a required shape along the cavity shape of the molding die, and the molten resin is supplied to the back surface of the foamed resin base material through the resin passage from the first injection machine. A step of laminating and integrating a resin rib and a case body connected thereto on the back surface of the foamed resin base material, and injecting and filling a foamable molten resin into the case body via a resin passage from a second injection machine; Elastomer loaded in the body In Rukoto, characterized forming a side collision impact absorbing body, in that it consists of.
[0038]
According to this embodiment, one-shot integral molding with two cylinders is employed, and the side impact shock absorber is configured such that an elastomer such as a foam is filled into a case body integrally molded with a resin rib. By using an elastomer resin excellent in shock absorption, it is possible to cope with high shock absorption.
[0039]
BEST MODE FOR CARRYING OUT THE INVENTION
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of an automotive interior component and a method for manufacturing the same according to the present invention will be described below by exemplifying an automobile door trim and a method for manufacturing the same.
[0040]
1 to 8 show a first embodiment of the present invention. FIG. 1 is a front view showing a first embodiment in which an automobile interior part according to the present invention is applied to an automobile door trim. FIG. 2 is a configuration of the door trim. FIG. 3 is a front view showing the shapes of the resin ribs and the side impact shock absorber after removing the foamed resin base material in the door trim, and FIG. 4 is a cross-sectional view showing the configuration of the side impact absorber in the door trim. It is. FIG. 5 is an overall view showing a configuration of a molding die for molding the automobile door trim, and FIGS. 6 to 8 show respective steps in a molding process of the automobile door trim. FIG. FIG. 7 is an explanatory view showing a heat softening step, FIG. 7 is an explanatory view showing a setting step of a foamed resin sheet, and FIG. 8 is an explanatory view showing a molding step of the automobile door trim.
[0041]
A first embodiment of the present invention will be described with reference to FIGS. First, in FIGS. 1 to 4, an automobile door trim 10 includes a foamed resin base material 20 having a shape-retaining property formed into a desired curved surface shape, and a vertical and horizontal direction laminated on the back side of the foamed resin base material 20. The resin ribs 30 each extend in a cross shape, and the side impact absorbers 40 integrated with the resin ribs 30.
[0042]
More specifically, a skin 21 for imparting decorativeness is laminated on the entire surface of the foamed resin base material 20, but may be partially adhered to a part of the surface of the foamed resin base material 20. Various resin parts such as an inside handle escutcheon 11, a power window switch finisher 12, a speaker grille 13, and a pocket escutcheon 14 are attached to the door trim 10.
[0043]
By the way, the foamed resin base material 20 is subjected to heat softening treatment of the foamed resin sheet so as to have shape-retaining properties, then thermoformed into a desired shape, for example, cold-pressed with a molding die having a desired mold surface. Further, the foamed resin base material 20 may be shaped by vacuum molding for a portion having a higher expansion rate.
[0044]
The foamed resin sheet has a configuration in which a foaming agent is added to a general-purpose thermoplastic resin. Examples of the thermoplastic resin include a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, and a chloride resin. Vinyl-based resins, ionomer-based resins, acrylonitrile / butadiene / styrene (ABS) resins, and the like can be used. As the foaming agent, an organic foaming agent such as azodicarbonamide and an inorganic foaming agent such as sodium bicarbonate can be used. In this embodiment, a foamed resin sheet obtained by appropriately adding sodium bicarbonate to a polypropylene resin is used. The expansion ratio of the foamed resin substrate 20 is set to 2 to 10 times, and the thickness is set to 0.5 to 30 mm, particularly 1 to 10 mm.
[0045]
Next, the resin rib 30 is formed of a general-purpose synthetic resin molded body, and as a synthetic resin that can be preferably used, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin , An ionomer-based resin, a polyamide-based resin, an acrylonitrile / butadiene / styrene (ABS) resin, a polycarbonate resin, or the like. In the present embodiment, a polypropylene-based resin is used in consideration of the environment and recycling. I have.
[0046]
In addition, fillers such as inorganic fibers such as glass fibers and carbon fibers and fillers such as inorganic particles such as talc, clay, silica and calcium carbonate are mixed into the thermoplastic ribs. May be.
[0047]
Further, as shown in FIG. 3, the resin ribs 30 are disposed so as to extend in the vertical and horizontal directions over substantially the entire surface of the product when the foamed resin base material 20 is removed. An outer peripheral frame along the outer peripheral edge of the door trim 10 may be added to reinforce the rigidity of the peripheral part of the door trim 10, and in this case, a gap or the like does not occur between the door trim 10 and the vehicle body panel 50.
[0048]
Further, as shown in FIG. 3, when forming the resin ribs 30 extending in the vertical and horizontal directions, for example, mounting for attaching functional parts such as an inside handle escutcheon 11, a power window switch finisher 12, a speaker grille 13, a pocket escutcheon 14, and the like. A seat (not shown) can be formed integrally, and a clip seat for attaching a clip to be attached to the vehicle body panel 50 can be integrally formed on the back side of the resin rib 30.
[0049]
By the way, in the door trim 10 shown in the first embodiment according to the present invention, the side impact absorber 40 is integrated with the resin rib 30. As shown in FIGS. 3 and 4, the side impact shock absorber 40 has a plate portion 41 abutting on the back surface of the foamed resin base material 20 and protrudes from the back surface of the plate portion 41 toward the vehicle body panel 50. Grid-like ribs (encoded as vertical ribs 42 and horizontal ribs 43) extending in the vertical and horizontal directions are formed.
[0050]
Therefore, by appropriately adjusting the rib thickness, rib height, rib interval, and the like of the grid-like ribs 42 and 43, the impact load at the time of a side collision can be effectively controlled. In addition, even if the side impact shock absorber 40 is broken at the time of a side collision, the plate portion 41 prevents the sharp edges of the grid-like ribs 42 and 43 from piercing the skin 21.
[0051]
As described above, the door trim 10 shown in FIGS. 1 to 4 includes a foamed resin base material 20 having shape-retaining properties, a resin rib 30 and a side impact shock absorber 40 laminated and integrated on the back surface of the foamed resin base material 20. Since the resin core material occupied over the entire surface of the product as in the related art can be eliminated, and the use of the lightweight foamed resin base material 20, the weight of the product is smaller than that of the conventional example. The weight can be reduced by 40% or more, and the resin material can be largely saved, which can contribute to cost reduction.
[0052]
In addition, since the side collision shock absorber 40 is integrally formed with the resin rib 30, a step of forming the side collision pad with a molding die and a step of attaching the side collision pad to the door trim are separately performed as in the related art. Since it can be abolished and is configured based on the grid-like ribs 42 and 43, the weight can be reduced as compared with the conventional molded urethane and the like, and the recyclability is excellent.
[0053]
Furthermore, since the foamed resin base material 20 has a porous structure, the door trim 10 has excellent sound absorbing performance and can reduce noise in the vehicle interior. Further, in order to maintain the sound absorbing property of the foamed resin base material 20, the skin 21 laminated and integrated on the surface of the foamed resin base material 20 is made of a permeable material such as woven fabric, nonwoven fabric, or knitted fabric. preferable. The skin 21 may be made of a synthetic resin sheet, a synthetic resin film, a foam, a net, or the like, in addition to a breathable sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric.
[0054]
Next, one embodiment of a method of manufacturing the door trim 10 for an automobile will be described with reference to FIGS. First, as shown in FIG. 5, a molding die 60 used for molding the door trim 10 includes a molding upper die 61 that can move up and down by a predetermined stroke, and a fixed lower molding die 62 that forms a pair with the molding upper die 61. , And an injection machine 63 connected to the lower molding die 62.
[0055]
More specifically, the upper molding die 61 has a cavity 611 conforming to the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 612 connected to the upper surface of the upper molding die 61. Further, guide bushes 613 serving as a guide mechanism are provided at four corners of the upper mold 61.
[0056]
On the other hand, the lower molding die 62 is provided with a core portion 621 corresponding to the cavity portion 611 of the upper molding die 61. Further, a manifold 622 and a gate 623 are provided to supply the molten resin to the mold surface of the core portion 621. The molten resin M supplied from the injection machine 63 through the resin passage of the manifold 622 and the gate 623 is provided. Is supplied to the upper surface of the core portion 621. A groove 624 corresponding to the pattern of the resin rib 30 is formed on the upper surface of the core portion 621, and the plate portion 41 and the grid-like rib 42 of the side impact absorber 40 integrally formed with the resin rib 30 are formed. , 43 are fitted in the lower molding die 62.
[0057]
Guide posts 625 serving as a guide mechanism project from four corners of the lower molding die 62, and guide the guide posts 625 into the guide bushes 613 when the molding upper and lower dies 61 and 62 are clamped. Thus, the pressing posture of the upper mold 61 can be properly maintained.
[0058]
First, as a first step of molding the door trim 10, when the upper and lower molds 61 and 62 are in a mold open state, the foamed resin sheet S, which is the material of the foamed resin base material 20, is opened. In this embodiment, as the foamed resin sheet S, a polypropylene foamed sheet (manufactured by Sumitomo Chemical Co., Ltd., trade name: Sumicellar foamed PP sheet, foaming ratio = 3 times, thickness 2 mm) is used, and FIG. As shown in the drawing, the foamed resin sheet S is supplied into the upper and lower molds 61 and 62 in a state where the foamed resin sheet S has been heated and softened to 130 ° C. by the heater device 65.
[0059]
Next, after the foamed resin sheet S is supplied into the upper and lower molds 61 and 62 (see FIG. 7), the elevating cylinder 612 is driven, and the upper mold 61 is lowered by a predetermined stroke, as shown in FIG. When the upper molding die 61 is lowered to the bottom dead center and the upper and lower molding dies 61 and 62 are clamped, the injection rib 63 passes through the manifold 622 and the gate 623 to the resin rib 30 and the side impact absorber in the door trim 10. Molten resin M for molding 40 is supplied.
[0060]
As the molten resin M, talc is appropriately mixed in with Sumitomo Noblen AX568 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 minutes).
[0061]
Therefore, in the mold-clamped state by the upper and lower molds 61 and 62, the foamed resin sheet S is shaped according to the shape of the cavity 611 of the upper mold 61, and the foamed resin base material 20 is molded into a desired shape. At the same time, the resin rib 30 and the side impact absorber 40 are laminated and integrated on the inner surface side of the foamed resin substrate 20.
[0062]
As described above, the molding of the foamed resin base material 20, the resin ribs 30, and the side impact shock absorbers 40 can be performed in one molding step. Since the supply amount of the molten resin M is sufficient for molding the resin, the amount of the molten resin can be saved, and at the same time, the load on the molding upper and lower dies 61 and 62 can be reduced. Can be achieved. In the specification in which the skin 21 is laminated on the surface of the foamed resin base material 20, the raw sheet of the skin 21 may be preliminarily laminated on one side of the foamed resin sheet S.
[0063]
When the foamed resin base material 20 is molded from the foamed resin sheet S, after heating and softening to a predetermined temperature by the heater device 65 in advance as described above, the molten resin M can be formed into a required shape at the time of injection of M. However, when a complicated curved surface shape with a higher expansion rate is required, a vacuum suction mechanism is attached to the upper mold 61 and the upper and lower molds 61 and 62 are formed. Before or during the mold clamping, a vacuum suction force may be applied from the upper mold 61 to form the foamed resin base material 20 in a vacuum.
[0064]
Further, the upper mold 61 can be controlled in two stages. That is, the foamed resin sheet S is press-molded by clamping the upper and lower molds 61 and 62 in the first stage, and the foamed resin base material 20 is primarily molded. By lowering the mold 61 and injecting and filling the molten resin M into the cavity in the second molding step, the resin rib 30 and the side impact absorber 40 can be integrally molded with the foamed resin base material 20.
[0065]
Next, FIGS. 9 to 11 show a second embodiment of the present invention. FIG. 9 is a perspective view of the foamed resin base material 20 of the automobile door trim 10 according to the second embodiment. FIG. 10 is a perspective front view showing the configuration of the impact shock absorber 40, FIG. 10 is a cross-sectional view showing the configuration of the second embodiment of the same impact absorber 40, and FIG. 11 shows a method of forming the door trim 10 in the second embodiment. FIG. In the second embodiment, the same parts as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.
[0066]
In the second embodiment, since only the configuration of the side impact absorber 40 is changed, the other configurations of the foamed resin base material 20 and the resin rib 30 are exactly the same as those of the first embodiment.
[0067]
That is, the side collision shock absorber 40 according to the second embodiment includes a case body 44 having an opening toward the vehicle body panel 50 and an elastomer 45 filled in the case body 44. The case body 44 is integrated with the resin rib 30 and is integrally formed at the time of injection molding of the resin rib 30. After the molding of the case body 44 is completed, the material of the elastomer 45 is placed in the internal space of the case body 44. It is constituted by injecting a foamed resin liquid as follows.
[0068]
Therefore, in the second embodiment, by using the elastomer 45 having an excellent shock absorbing function, the shock absorbing function at the time of a side collision can be enhanced, and a lightweight material based on a foamed resin is used. Thus, a lightweight side impact shock absorber 40 can be provided.
[0069]
Next, based on FIG. 11, an outline of a molding process of the door trim 10 in the second embodiment, particularly a molding method of the case body 44 and the elastomer 45 constituting the side impact shock absorber 40 will be mainly described. It should be noted that, with respect to the molding die 60, only the differences will be described.
[0070]
That is, the molding die 60 used in the second embodiment uses the molding upper die 61 having the same structure as that of the first embodiment for the molding upper die 61. As in the first embodiment, a groove 624 is formed in the portion 621 according to the arrangement pattern of the resin ribs 30, and a case body forming a part of the side impact shock absorber 40 so as to communicate with the groove 624. A groove 66 corresponding to 44 is provided in the core portion 621, and a slide block 67 is provided in the groove 66 so as to be able to advance and retreat by driving a cylinder (not shown).
[0071]
Two injection machines 63a and 63b are connected to the lower molding die 62, and the first injection machine 63a supplies the resin rib 30 and the side body impact absorber 40, which is a material of the case body 44. The resin M1 is supplied through the manifold 622a and the gate 623a.
[0072]
On the other hand, from the second injection machine 63b, the foamable molten resin M2, which is the raw material of the elastomer 45 filled in the case body 44, is supplied through the manifold 622b and the gate 623b. The supply of the molten resin M1 and the foamable molten resin M2 from the two injection machines 63a and 63b is performed when the molding upper and lower dies 61 and 62 are closed. M1 is supplied into the mold, and the resin rib 30 and the case body 44 are integrally formed along the desired pattern shape on the back surface side of the foamed resin base material 20 formed into a required shape.
[0073]
Thereafter, at a certain interval, the foamable molten resin M2 is supplied from the second injection machine 63b through the manifold 622b and the gate 623b. At this time, the slide block 67 retreats to form an internal space of the case body 44, The foamable molten resin M2 is supplied into this space and foamed and hardened, so that the resin ribs 30, the case body 44, and the side impact absorbers 40 made of the elastomer 45 are integrally formed on the back surface of the foamed resin base material 20. Is done.
[0074]
The above-described door trim 10 is of a type in which an upper portion and a lower portion are integrally formed. For example, the present invention is applied to a two-ton type door trim in which a door trim upper portion is formed of a laminated structure and a door trim lower portion is formed of a resin molded body. In this case, the door trim upper portion is composed of a foamed resin base material 20 and resin ribs 30 extending in the vertical and horizontal directions which are laminated and integrated on the back side thereof. What is necessary is just to employ | adopt the structure which integrally molds the above-mentioned side collision shock absorber 40 with a molded object.
[0075]
Further, also for the rear side trim, the configuration of the door trim 10 described in the first and second embodiments can be applied mutatis mutandis.
[0076]
【The invention's effect】
As described above, the automotive interior part according to the present invention has a configuration in which the side impact shock absorber is integrated with the resin rib laminated on the back surface of the lightweight and shape-retaining foamed resin base material. In addition, the conventional heavy resin core material can be eliminated, and the need for a separately formed side impact pad is eliminated, so that it is possible to provide an automobile interior part that is lightweight, low-cost and excellent in sound absorption performance.
[0077]
Further, the method for manufacturing an automobile interior part according to the present invention employs a process of molding a foamed resin base material into a required shape and simultaneously integrating a resin rib and a side impact absorber on the back surface side of the foamed resin base material. Because the projected area of the resin ribs and side impact absorbers is smaller than the conventional resin core material, the load on the molding die is small, and the cooling time can be shortened. Compared with the method of bonding the side collision pads to the back of interior parts or mechanically fixing them, the work efficiency can be improved, and the cost can be significantly reduced due to the simplification of the mold equipment and the reduction of man-hours. Having.
[Brief description of the drawings]
FIG. 1 is a front view showing a first embodiment of a door trim to which the present invention is applied.
FIG. 2 is a sectional view taken along line II-II in FIG.
FIG. 3 is a front view showing an arrangement pattern of resin ribs and a side impact shock absorber in the automotive door trim shown in FIG. 1 from which a foamed resin base material is removed.
FIG. 4 is a cross-sectional view showing a configuration of a side impact shock absorber in the door trim shown in FIG.
FIG. 5 is an explanatory view showing an entire configuration of a molding die for molding the door trim shown in FIG.
FIG. 6 is an explanatory view showing a heating and softening step of the foamed resin sheet in the method of manufacturing the door trim shown in FIG.
FIG. 7 is an explanatory view showing a setting step of a foamed resin sheet in the door trim manufacturing method shown in FIG.
FIG. 8 is an explanatory view showing an injection molding step in the method of manufacturing the door trim shown in FIG.
FIG. 9 is a front view showing an arrangement pattern of resin ribs and a side impact shock absorber in a door trim according to a second embodiment of the present invention.
FIG. 10 is a cross-sectional view illustrating a configuration of a side impact shock absorber according to a second embodiment of the present invention.
FIG. 11 is an explanatory diagram illustrating an outline of a method for manufacturing a door trim according to a second embodiment of the present invention.
FIG. 12 is a front view showing a conventional door trim.
FIG. 13 is a sectional view taken along line XIII-XIII in FIG. 12;
[Explanation of symbols]
10 Door trim
20 Foam resin base material
21 epidermis
30 resin ribs
40 Side impact absorber
41 Plate part
42, 43 Lattice rib
44 Case body
45 Elastomer
50 Body panel
60 Mold
61 Upper mold
611 Cavity
612 lifting cylinder
62 lower mold
621 core
622 manifold
623 gate
63 injection machine
63a first injection machine
63b Second injection machine
64 nested type
65 heater device
66 Groove
67 slide blocks
M, M1 molten resin
M2 foamable molten resin
S foam resin sheet

Claims (8)

A foamed resin base material (20) having shape retention properties, a resin rib (30) along a predetermined pattern laminated and integrated on the back surface of the foamed resin base material (20), and an integral part of the resin rib (30) An interior part for an automobile, comprising: a side impact shock absorber (40) which is formed into a body and abuts or confronts a vehicle body panel (50) to absorb an impact at the time of a side collision. The side impact absorber (40) is provided with a plate portion (41) in contact with the back surface of the foamed resin base material (20), and is erected from the plate portion (41) toward the vehicle body panel (50). The automotive interior part according to claim 1, wherein the interior part comprises a grid-shaped rib (42, 43) extending in the vertical and horizontal directions. The side impact absorber (40) is composed of a case body (44) having an opening on the vehicle body panel (50) side, and an elastomer (45) filled in the case body (44). The automotive interior part according to claim 1, wherein: The automotive interior part according to any one of claims 1 to 3, wherein a skin (21) is integrally laminated on a surface of the foamed resin base material (20). Interior for automobiles comprising a foamed resin base material (20) having shape-retaining properties, a resin rib (30) laminated and integrated on the back surface of the foamed resin base material (20), and a side impact shock absorber (40) In the method of manufacturing parts,
Setting a foamed resin sheet (S) for setting a foamed resin sheet (S) as a material of a foamed resin base material (20) in a molding die (61, 62);
The molding dies (61, 62) are clamped together to form the foamed resin substrate (20) into a required shape along the shape of the cavity (C) of the molding dies (61, 62). The molten resin (M) is injected and filled into the cavity (C) of the (61, 62), and the resin rib (30), the plate portion (41) and the grid-like ribs (42, 43) are formed into a foamed resin base material (20). ), An integration step of laminating and integrating on the back side;
A method for manufacturing an automobile interior part, comprising: An elastomer (45) is filled in a foamed resin base material (20) having shape retaining properties, a resin rib (30) laminated and integrated on the back surface of the foamed resin base material (20), and a case body (44). A method for manufacturing an automobile interior part (10) comprising a side impact shock absorber (40) comprising:
Setting a foamed resin sheet (S) for setting a foamed resin sheet (S) as a material of a foamed resin base material (20) in a molding die (61, 62);
The molding dies (61, 62) are clamped together to form the foamed resin base material (20) into a required shape along the cavity shape of the molding dies (61, 62), and the first injection machine ( From 63a), the molten resin (M1) is supplied to the back surface of the foamed resin base material (20) through the resin passage, and the resin ribs (30) and the case body (45) connected to the resin ribs (30) are formed. 20) The step of laminating and integrating the back surface of the case body (44), the foaming molten resin (M2) being injected and filled into the case body (44) via the resin passage from the second injection machine (63b), and the case body (44) Forming a side impact shock absorber (40) by loading an elastomer (45) therein;
A method for manufacturing an automobile interior part, comprising: Prior to the setting step of the foamed resin sheet (S), the foamed resin sheet (S) is heated and softened in a preheating step, and when the molding dies (61, 62) are closed, the foamed resin sheet (S) is Is formed into a required shape to form a foamed resin base material (20) having shape-retaining properties, and a resin rib (30) and a side impact shock absorber ( The method for producing an interior component for an automobile according to claim 5 or 6, wherein (40) is laminated and integrated. A vacuum suction mechanism is attached to the molding die (61), and the foamed resin sheet (S) that has been subjected to the heat softening treatment is used to mold the molding die (61, 62) when the molding die (61, 62) is clamped. 8. The method according to claim 5, further comprising a step of operating the vacuum suction mechanism to form the foamed resin base material into a required shape by vacuum suction when the shape is formed along the shape. A method for producing an automobile interior part according to any one of the above.

Images