JP2004182068A - Manufacturing method of interior component for automobile - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve the weight reduction and the cost reduction of an interior component for an automobile, and simply form mounting holes of an attachment such as an inside handle escutcheon or the like with excellent workability. <P>SOLUTION: A door trim body 11 of a door trim 10 is composed of a light-weight foam resin substrate 20 having a shape keeping a property and a resin rib 30 laminated and integrated on the inner surface side along a predetermined pattern. A foam resin sheet S is molded in a cavity shape in a mold die 40 to obtain the foam resin substrate 20. Molten resin M is filled in the cavity from an injection machine 43 to integrally mold the resin rib 30. A plurality of openings 22 are formed in predetermined places of the door rim body 11 in the same mold die 40 by operating a cutting mechanism 50 provided on a lower mold die 42. The cost is reduced by shortening man-hour and eliminating a separate cutting device. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to interior parts for automobiles such as door trims, rear parcel shelves, floor trims, trunk trims, rear side trims and the like, and in particular, can be reduced in weight, can be manufactured at low cost, and easily form openings for attaching accessory parts. The present invention relates to a method for manufacturing interior parts for automobiles.
[0002]
[Prior art]
For example, the configuration of an interior part for an automobile will be described with reference to FIGS. 11 and 12 exemplifying a door trim. The door trim 1 is configured by laminating and integrating a skin 3 having an excellent surface appearance on a surface of a resin core material 2 having shape retention and rigidity for mounting to a vehicle body panel.
[0003]
The resin core material 2 is made of a polypropylene-based resin mixed with talc, and the skin 3 itself does not have a shape-retaining property, and a polyethylene foam or the like is formed on the back surface of a synthetic resin sheet such as a PVC sheet. A laminated sheet material in which a cushion material is laminated is used, and recently, a cushion material such as polyethylene foam is laminated on the back surface of an elastomer sheet such as a TPO (thermoplastic olefin) sheet in consideration of the environment and recycling. Sheet materials tend to be heavily used.
[0004]
Next, a conventional example of a method of forming the door trim 1 will be described with reference to FIG. First, a molding die 4 for molding the door trim 1 is connected to a molding upper die 5 that can move up and down by a predetermined stroke, a fixed lower molding die 6 that forms a pair with the molding upper die 5, and a molding lower die 6. It is generally constituted by an injection machine 7.
[0005]
When the upper and lower molds 5 and 6 are clamped, a cavity 5a is formed in the upper mold 5 and a core 6a is provided in the lower mold 6 to form the product shape of the door trim 1. I have. In order to move the upper molding die 5 up and down by a predetermined stroke, an elevating cylinder 5b is connected, and the lower molding die 6 is provided with a manifold 6b and a gate 6c serving as a passage for the molten resin from the injection machine 7.
[0006]
The upper mold 5 that moves up and down is provided with guide posts 6d at four corners of the lower mold 6 in order to maintain a proper posture, and the upper mold 5 corresponds to the guide posts 6d. A bush 5c is provided.
[0007]
Therefore, when the upper and lower molds 5 and 6 are in the mold open state, the skin 3 is set in the mold, and thereafter, the timing of immediately before or after the mold upper and lower molds 5 and 6 are clamped. By injection-filling the molten resin M from the injection machine 7 through the manifold 6b and the gate 6c into the product cavity between the two molds, the resin core material 2 is formed into a required curved surface shape, and the surface of the resin core material 2 is formed. The skin 3 is integrally formed (see, for example, Patent Document 1).
[0008]
In FIG. 13, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6a in an open state, but as described above, the molten resin M is supplied to the cavity after the mold upper and lower dies 5, 6 are clamped. It may be filled by injection.
[0009]
Further, in order to attach an accessory such as an inside handle escutcheon to the door trim 1, first, as shown in FIG. 14, a piercing process is performed on the resin core material 2 and the skin 3 at the attaching portion with a piercing cut blade 8, and FIG. As shown, an opening 9a having a predetermined size is opened. Thereafter, as shown in FIG. 16, various accessory parts are attached to the door trim 1 by fitting the inside handle escutcheon 9 into the opening 9a.
[0010]
[Patent Document 1]
JP-A-10-138268 (page 2, FIG. 3, FIG. 4)
[0011]
[Problems to be solved by the invention]
However, it has been pointed out that the conventional door trim 1 has a problem that the projected area of the resin core 2 is large, so that the material cost is high and the product is heavy.
[0012]
In addition, since the projected area of the resin core material 2 is large, the injection pressure at the time of molding must be set high, and a mold structure that can withstand the high injection pressure is required. In addition, since a large amount of molten resin is cooled and solidified, the molding cycle is prolonged, which is a major factor in lowering productivity.
[0013]
Further, it is necessary to open a plurality of openings at the attachment parts such as an opening 9a for attaching an accessory such as an inside handle escutcheon 9 to be attached to the door trim 1, which requires a piercing and cutting device in addition to a molding die. It has been pointed out that the facility cost is increased and a piercing step is added, which leads to an increase in man-hours and an increase in cost.
[0014]
The present invention has been made in view of such circumstances, and it is possible to provide a method of manufacturing an automobile interior part which can promote weight reduction, achieve high rigidity and reduce cost, and additionally provide a mounting portion such as an inside handle escutcheon. It is an object of the present invention to provide a method of manufacturing interior parts for automobiles, in which the cost of equipment can be reduced and the number of manufacturing steps can be reduced by simply and inexpensively forming an opening in the vehicle.
[0015]
[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. In places where rigidity is required, that is, at the periphery of the product, the panel, or where parts are attached, and where loads are applied, resin ribs with increased rigidity are used to cope with the problem. The present invention has been completed by opening the openings for the attachment parts and the like at the same time as the molding of the interior trim.
[0016]
In other words, the present invention is directed to an automotive vehicle comprising an interior trim body including a foamed resin base material having shape-retaining properties, and a resin rib laminated and integrated on the back surface of the foamed resin base material, with attached parts. In the method of manufacturing an interior part, in a molding die, a setting step of a foamed resin sheet for setting a foamed resin sheet, which is a material of a foamed resin base material, and clamping the molding dies together to form a molding die Along with forming the foamed resin base material into a required shape along the cavity shape, at any timing before or after the mold clamping of the molding die, the molding lower mold is formed along the resin rib arrangement pattern. Injecting and filling a molten resin through a resin passage from an injection machine into a formed groove, and forming a resin rib on a back surface of the foam resin substrate by laminating and integrating a resin rib, Decorated in a mold By driving the cylinder of the cutting mechanism, the cutting blade is made to penetrate into the foamed resin base material, and among the accessory parts, a cutting step of an opening for opening at least one part. It is characterized by becoming.
[0017]
Here, the interior parts for automobiles to which the method of the present invention is applied can be applied to door trim, rear parcel shelf, floor trim, luggage trim, trunk trim, rear side trim and the like.
[0018]
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 heated and softened, and then formed into a desired curved shape in a molding die, thereby maintaining that shape. If the product shape includes a high expansion rate, the foamed resin sheet is heated and softened, and then a vacuum suction mechanism is arranged in the molding die to vacuum-suction the foamed resin sheet along the inner surface of the molding die. A force may be applied.
[0019]
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.
[0020]
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.
[0021]
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 2.0 mm, and the thickness is preferably 0.5 to 30 mm, and more preferably 1 to 10 mm.
[0022]
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 resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, ionomer resins, polyamide resins, acrylonitrile / butadiene / styrene (ABS). Resin, polycarbonate resin and the like can be used. 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.
[0023]
Further, in order to enhance the appearance design, a skin may be laminated and integrated on the surface of the foamed resin base material. As the skin, a woven fabric, a nonwoven fabric, a knitted fabric, a sheet, a film, a foam, a mesh, and 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 make use of the sound absorbing performance of the foamed resin base material.
[0024]
Further, as accessory parts to be attached to the interior trim main body, there are an inside handle escutcheon, a pull handle, a power window switch finisher, a pocket escutcheon, a speaker grill and the like, and an opening is opened at a predetermined position of the interior trim main body.
[0025]
Next, a molding die used when manufacturing these interior parts is a vertically movable upper die, a lower molding die located below the upper molding die, and an injection machine connected to the lower molding die. The molten resin supplied from the injection machine is supplied onto the mold surface of the lower mold through a resin passage such as a manifold and a gate provided in the lower mold, but the upper mold descends to the bottom dead center. Then, the molten resin is injected and filled into the cavity at a predetermined injection pressure immediately before or after the mold upper and lower molds are clamped.
[0026]
Therefore, the foamed resin sheet is molded along the shape of the mold surface of the molding die, and the molten resin is injected and filled into the groove formed in the mold surface of the lower molding die by closing the upper and lower molds. Thereby, the resin rib is laminated and integrated on the back surface side of the foamed resin base material.
[0027]
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.
[0028]
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. .
[0029]
Therefore, resin ribs can be laminated and integrated on the back surface of a lightweight foamed resin base material having shape retention properties. 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.
[0030]
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.
[0031]
Further, the lower mold is provided with a cutting mechanism corresponding to a portion to be opened in the interior trim main body. For example, a simple cutting mechanism with a die blade attached to the tip of the piston rod of the cylinder is molded corresponding to the inside handle escutcheon attachment, pull handle attachment, power window switch finisher attachment, or speaker grill attachment It is decorated in a lower mold. Note that a configuration in which a cutting blade is attached to the outer periphery of the support block instead of the mold blade may be used.
[0032]
The drive timing of the cutting mechanism may be performed in a post-process of forming the foamed resin base material and a process of integrating the resin ribs on the back surface of the foamed resin base material. At the same time, the cutting process may be performed by driving the cylinder.
[0033]
Therefore, according to the method of the present invention, since only the resin ribs need to be molded as compared with the conventional resin core material having a large projected area, the load on the molding die can be reduced, the amount of resin is small, and the material cost is reduced. Savings are possible, and the cooling time is shorter than that of the conventional resin core material, so that the molding cycle of the product can be greatly shortened.
[0034]
The porous sound absorbing function of the foamed resin base material provides a laminated structure excellent in sound absorption performance capable of effectively absorbing noise inside and outside the vehicle cabin, and a polyolefin resin as a material of the foamed resin base material and the resin rib. When is used, since all olefin resins are unified, the separation process can be eliminated and the recycling operation can be simplified.
[0035]
In addition, the rib thickness of the resin rib can be appropriately changed, for example, by setting the rib thickness thicker in a portion where a large external force is applied to the product, and thinning the rib thickness in a portion where a relatively small external force is applied. it can. Therefore, it is sufficient to use the minimum necessary resin material, which can contribute to a reduction in the weight and cost of the product. Also, a clip seat or a mounting seat or mounting boss for mounting various escutcheon parts can be integrally formed with the resin rib.
[0036]
Furthermore, according to the method of the present invention, the opening formed in the interior trim main body is provided with a cutting mechanism on a molding die for the interior trim composed of a foamed resin base material and a resin rib, so that a piercing cut device can be separately provided. The number of steps can be made unnecessary, and the number of steps can be significantly reduced by performing the cutting step in a series of forming steps that are continuous with the forming step or by performing the cutting step simultaneously with the forming step.
[0037]
Further, the cutting mechanism used in the method of the present invention is for cutting a foamed resin base material, and compared with a conventional cutting blade for cutting and cutting a hard resin core material, a cylinder for performing a piercing cut. The capacity is small and the equipment cost can be reduced.
[0038]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, a preferred embodiment of a method for manufacturing an automobile interior component according to the present invention will be described by exemplifying an automobile door trim.
[0039]
1 to 10 show an embodiment of a method of manufacturing a door trim for a vehicle to which the method of the present invention is applied, FIG. 1 is a front view showing a door trim for a vehicle manufactured by the method of the present invention, and FIG. 3 is a front view showing the shape of a resin rib in the vehicle door trim, and FIG. 4 is a cross-sectional view showing an inside handle escutcheon mounting portion in the door trim. 5 and 6 show a molding die used for carrying out the method of the present invention. FIG. 5 is an overall view, and FIG. 6 is an explanatory diagram showing an arrangement configuration of a cutting mechanism in the molding die. 7 to 10 show a method of manufacturing a door trim. FIG. 7 shows a preheating step of the foamed resin sheet, FIG. 8 shows a setting step of the foamed resin sheet, FIG. 9 shows a molding step of the door trim, and FIG. It is explanatory drawing shown respectively.
[0040]
First, a configuration of an automobile door trim 10 manufactured by applying the method of the present invention will be described with reference to FIGS. 1 and 2, an automobile door trim 10 includes a power window switch finisher 14 and an inside handle escutcheon 12 on an armrest portion 13 of the door trim main body 11 with respect to a door trim main body 11 formed into a desired curved shape. Attached parts of the pull handle 15 are attached, a pocket opening 16 is opened below the armrest portion 13, a pocket escutcheon 17 is fitted and fixed around the pocket opening 16, and a speaker grill 18 is attached to the front side thereof. .
[0041]
More specifically, as shown in FIG. 2, the door trim main body 11 is formed into a desired curved surface shape, and is laminated and integrated on a foam resin base material 20 having shape retaining properties and on the back side of the foam resin base material 20. And a skin 21 having a decorative function, which is laminated and integrated on the surface side of the foamed resin base material 20.
[0042]
Further, the foamed resin base material 20 is subjected to heat softening treatment of the foamed resin sheet so as to have shape retention properties, and then thermoformed into a required shape, for example, cold press molding 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. In the case of a flat component such as a lid component such as a jack lid, the foamed resin sheet can be formed into a flat shape without performing a heat softening treatment.
[0043]
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 polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, and chloride resin. A vinyl resin, an ionomer resin, an acrylonitrile / butadiene / styrene (ABS) resin or the like can be used. As a foaming agent, an organic foaming agent such as azodicarbonamide or an inorganic foaming agent such as sodium bicarbonate can be used. In this embodiment, a foamed resin sheet obtained by appropriately adding sodium bicarbonate as a foaming agent to a polypropylene resin is used. The expansion ratio of the foamed resin base material 20 is set to 2 to 10 times, and the thickness is set to 0.5 to 30 mm, particularly 1 to 10 mm.
[0044]
Next, the resin ribs 30 are arranged on the back surface side of the foamed resin base material 20, and are particularly set in a lattice pattern extending in the vertical and horizontal directions as shown in FIG. The resin rib 30 is made of a general-purpose synthetic resin molded body, and is preferably a synthetic resin that can be preferably used as a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin, The resin may be appropriately selected from an ionomer resin, a polyamide resin, an acrylonitrile / butadiene / styrene (ABS) resin, a polycarbonate resin, and the like. In the present embodiment, a polypropylene resin is used in consideration of the environment and recycling. .
[0045]
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.
[0046]
Further, in the present embodiment, a configuration is adopted in which the number of resin ribs 30 is increased in the rigidity enhancing portion of the door trim main body 11, but the outer ribs are set along the outer peripheral edge of the door trim main body 11. Alternatively, a configuration of the resin rib 30 in which the outer peripheral ribs are connected by a bridging rib may be employed. When the outer peripheral ribs are provided, the shape retention of the door trim main body 11 can be maintained satisfactorily, and the alignment management with the vehicle body panel and the mating component can be performed with high accuracy.
[0047]
As described above, the door trim main body 11 includes the foamed resin base material 20 having shape-retaining properties, the resin ribs 30 laminated and integrated on the back surface of the foamed resin base material 20, and the decorative skin 21. Therefore, the resin core material occupying the entire surface of the product as in the related art can be eliminated, and the weight of the product is reduced by 40% compared to the conventional example because the lightweight foamed resin base material 20 is used. The above reduction in weight can be achieved, and the amount of resin material can be greatly reduced, contributing to cost reduction.
[0048]
Furthermore, since the foamed resin base material 20 has a porous structure, the door trim main body 11 is excellent in sound absorbing performance and can reduce noise inside and outside the vehicle interior. Further, in order to enhance the sound absorbing performance of the foamed resin base material 20 for the noise in the passenger compartment, the skin 21 laminated and integrated on the surface of the foamed resin base material 20 is made of a woven fabric, a nonwoven fabric, a knitted fabric or the like. A sheet material having properties is preferred. The skin 21 is made of a synthetic resin sheet such as a PVC sheet or a TPO sheet in addition to a breathable sheet such as a woven fabric, a nonwoven fabric, or a knitted fabric, or a laminate in which a cushion material such as a polyethylene foam is laminated on the back of the synthetic resin sheet. Sheet materials, synthetic resin films, foams, nets, and the like can be used. In addition, when the TPO sheet is used, since all the olefin resins can be used, the separation step in recycling can be eliminated, and the recycling operation can be easily performed.
[0049]
Next, on the door trim body 11, various accessory parts such as an inside handle escutcheon 12, an inside handle escutcheon 12, a power window switch finisher 14, a pull handle 15, a pocket escutcheon 17, and a speaker grill 18 are attached.
[0050]
For example, as shown in FIG. 4, the inside handle escutcheon 12 is provided with an opening 22 for fitting the inside handle escutcheon, and the inside handle escutsion 12 is inserted into the opening 22 on the back side of the door trim body 11. To fit.
[0051]
Around the opening 22, a mounting boss 31 is provided upright with the resin rib 30. After the mounting boss 31 is inserted into the mounting hole 12 b formed in the flange 12 a of the inside handle escutche 12, The tip of the mounting boss 31 is caulked by heat caulking or ultrasonic welding caulking, and the inside handle escutcheon 12 is mounted on the door trim main body 11.
[0052]
Next, a method of manufacturing the door trim 10 will be described. First, the overall configuration of the molding die 40 used in the method of manufacturing the door trim 10 and the configuration of the cutting mechanism in the molding die 40 will be described with reference to FIGS.
[0053]
In FIG. 5, a molding die 40 used for molding the door trim 10 includes a molding upper die 41 that can move up and down by a predetermined stroke, a fixed lower molding die 42 paired with the molding upper die 41, and a molding lower die 42. And an injection machine 43 connected to the main body.
[0054]
More specifically, the upper molding die 41 is formed with a cavity 411 conforming to the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 412 connected to the upper surface of the upper molding die 41. At four corners of the upper mold 41, guide bushes 413 serving as a guide mechanism are provided.
[0055]
On the other hand, the lower molding die 42 is provided with a core portion 421 corresponding to the cavity portion 411 of the upper molding die 41. Further, a manifold 422 and a gate 423 are provided to supply the molten resin to the mold surface of the core portion 421. The molten resin M supplied from the injection machine 43 through the resin passage of the manifold 422 and the gate 423 is provided. Is supplied to the groove 424 on the upper surface of the core 421.
[0056]
Guide posts 425 serving as a guide mechanism project from four corners of the lower molding die 42. The guide posts 425 are guided into the guide bush 413 when the upper and lower molding dies 41 and 42 are clamped. Thus, the pressing posture of the upper mold 41 can be properly maintained.
[0057]
Next, as shown in FIG. 6, a cutting mechanism 50 for opening the plurality of openings 22 in the door trim main body 11 is attached to the lower molding die 42. In FIG. 6, a cut mechanism 50 (a cut mechanism 50a for an inside handle escussion, a cut mechanism 50a for a pull handle) for opening three openings 22 corresponding to the inside handle escutcheon 12, the pull handle 15, and the speaker grille 18, respectively. Although shown as a cutting mechanism 50b and a speaker grill cutting mechanism 50c), a cutting mechanism for the power window switch finisher 14 and the pocket opening 16 (not shown) is also provided.
[0058]
And since the structure of each cutting mechanism part 50a, 50b, 50c is the same, the structure of the cutting mechanism part 50a for the inside handle escutche 12 is demonstrated for convenience of explanation. First, the cutting mechanism 50a is configured such that a mold blade 53a is attached to the tip of a piston rod 52a of a cylinder 51a such as an air cylinder, and an edge-like cutting edge extends in the extension direction of the cylinder 51a on the outer peripheral edge of the mold blade 53a. ing. The receiving pad 54a is embedded in the upper mold 41 corresponding to the cutting edge of the mold blade 53a. The cut mechanism 50b for the pull handle and the cut mechanism 50c for the speaker grill have the same configuration, although the dimensions and the cylinder direction are different.
[0059]
Next, each step of the method for manufacturing the door trim 10 will be described. First, as shown in FIG. 7, a foamed resin sheet S (on which the skin 21 is laminated) is put into a heater device 60, and subjected to a heat softening treatment. As the foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumika Plustech Co., Ltd., trade name: Sumicellar foam PP sheet, foaming ratio = 3 times, thickness 2 mm) is used.
[0060]
Further, as shown in FIG. 8, the foamed resin sheet S subjected to the heat softening treatment is set in a molding die 40. At this time, the corresponding cylinders 51a, 51b, 51c of the cutting mechanisms 50a, 50b, 50c housed in the lower molding die 42 are kept in a contracted state. Then, after setting the foamed resin sheet S, the elevating cylinder 412 of the upper mold 41 is operated, and as shown in FIG. Then, the foamed resin sheet S is shaped along a desired mold surface shape, and the foamed resin base material 20 is molded along the cavity shape with the skin 21 laminated on the surface side. The molten resin M is injected and filled into the groove 424 provided in the core portion 421 of the lower molding die 42 from the injection machine 43 through the manifold 422 and the gate 423 either immediately before or after the mold clamping of the molds 41 and 42. Then, a resin rib 30 having a predetermined pattern is integrally formed on the inner surface side of the foamed resin base material 20. As the molten resin M, Sumitomo Noblen AX568 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 minutes) is used.
[0061]
Next, after the resin rib 30 is integrally formed on the inner surface of the foamed resin base material 20, as shown in FIG. 10, each of the cylinders 51a, 51b of the cut mechanism units 50a, 50b, 50c housed in the lower molding die 42. , 51c are operated, and the mold blades 53a, 53b, 53c perform an ascending operation and a sliding operation, and the foamed resin base material 20 and the skin 21 formed into a required shape are cut by the mold blades 53a, 53b, 53c. An opening 22 having a predetermined size for attaching the inside handle escutcheon 12, the pull handle 15, and the speaker grill 18 is formed in the foamed resin base material 20 and the skin 21 of the door trim main body 11.
[0062]
Therefore, since the cutting process is performed in the same molding die 40 without using a separate trim cutting device as in the related art, the facility cost can be reduced and the man-hour can be reduced. Further, if the drive timing of the cutting mechanisms 50a, 50b, 50c is set at the same time as the step of molding the resin rib 30, the molding cycle can be further shortened, and the productivity can be further increased.
[0063]
Further, in the method of the present invention, the cutting mechanism 50a, 50b, 50c is provided in the lower molding die 42 of the molding die 40, and the opening scheduled portions of the foamed resin base material 20 and the skin 21 are cut. Since the foamed resin base material 20 is a soft material as compared with the hard resin core material described above, the load applied to the mold blades 53a, 53b, 53c is small, and the life of the cutting mechanisms 50a, 50b, 50c can be prolonged. The cylinders 51a, 51b, 51c also have a small capacity, which is advantageous in that they are practical.
[0064]
【The invention's effect】
As described above, the method for manufacturing an automobile interior part according to the present invention is a method of laminating and integrating a lightweight and shape-retaining foamed resin base material and a portion of the back surface of the foamed resin base material where rigidity is required. The resin rib is a resin molded body because the opening for attachment of the accessory is opened by a cutting mechanism provided in the molding die at the same time as the molding or after the molding process. Because the projected area of is small, compared to the conventional resin core material, the load on the molding die is small, the cooling time can be shortened, and the yield can be increased. This has the effect of reducing costs.
[0065]
Further, the method for manufacturing an automobile interior part according to the present invention is to form an opening for attaching an accessory part in the same molding die simultaneously with or after the resin rib molding step. Therefore, the cutting device can be eliminated separately, the cost of equipment cost can be reduced, and the trim main body can be specified in a series of processes that are continuous with the molding process in the same mold or at the same time as the molding process. Since an opening can be opened at a location, there is an effect that the total number of steps can be reduced.
[0066]
In addition, the method for manufacturing an automobile interior part according to the present invention is characterized in that a hard resin core material is not trimmed but is cut by a cutting mechanism provided with a soft foamed resin base material or a skin in a molding die. Since the processing is performed, the cylinder of the cutting mechanism needs to have a small capacity, the load applied to the mold blade can be reduced, the durability of the cutting mechanism can be increased, and the life can be prolonged.
[Brief description of the drawings]
FIG. 1 is a front view showing an automobile door trim manufactured by applying the method of the present invention.
FIG. 2 is a sectional view taken along line II-II in FIG.
FIG. 3 is a front view showing a shape of a resin rib in the automobile door trim shown in FIG. 1;
FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. 1, and is a cross-sectional view showing a mounting portion of an inside handle escutcheon.
FIG. 5 is an overall view showing a molding die used in the method for manufacturing the door trim shown in FIG.
FIG. 6 is a configuration explanatory view showing an example of the arrangement of a cutting mechanism attached to the molding die shown in FIG. 5;
FIG. 7 is an explanatory view showing a preheating step of the foamed resin sheet in the door trim manufacturing method shown in FIG.
FIG. 8 is an explanatory view showing a step of setting a foamed resin sheet in a mold in the method of manufacturing the door trim shown in FIG.
FIG. 9 is an explanatory view showing a molding step of a foamed resin base material and a molding step of a resin rib in the door trim shown in FIG. 1;
FIG. 10 is an explanatory view showing a step of cutting an opening in the door trim shown in FIG. 1;
FIG. 11 is a front view showing a conventional door trim.
12 is a sectional view taken along line XII-XII in FIG.
FIG. 13 is an explanatory view showing a conventional mold press molding method for door trim.
FIG. 14 is an explanatory view showing a piercing cut step in a conventional door trim.
FIG. 15 is an explanatory view showing a state in which an opening is opened in a door trim main body in a conventional piercing cut step.
FIG. 16 is an explanatory view showing a state where an inside handle escutcheon is attached to an opening of a conventional door trim.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Car door trim 11 Door trim main body 12 Inside handle escutcheon 13 Armrest part 14 Power window switch finisher 15 Pull handle 16 Pocket opening 17 Pocket escutcheon 18 Speaker grill 20 Foam resin base material 21 Skin 22 Opening 30 Resin rib 31 Mounting boss 40 Molding metal Mold 41 Upper mold 42 Lower mold 43 Injecting machine 50 (50a, 50b, 50c) Cutting mechanism 51 (51a, 51b, 51c) Cylinder 52 (52a, 52b, 52c) Piston rod 53 (53a, 53b, 53c) Mold blade 54 (54a, 54b, 54c) Receiving pad 60 Heating device S Foamed resin sheet M Molten resin

Claims (2)

An interior trim body (11) including a foamed resin base material (20) having shape retention properties and a resin rib (30) laminated and integrated on the back surface of the foamed resin base material (20) is provided with an accessory part ( 12, 14, 15, 17, 18), a method of manufacturing an interior part (10) for an automobile, comprising:
A setting step of a foamed resin sheet (S) for setting a foamed resin sheet (S) as a material of the foamed resin base material (20) in a molding die (41, 42);
The molding dies (41, 42) are clamped together to form the foamed resin substrate (20) into a required shape along the cavity shape of the molding dies (41, 42). , 42) is injected into the groove (424) formed in the lower mold (42) along the arrangement pattern of the resin ribs (30) either before or after the mold clamping. Resin (M) is injected and filled from a machine (43) through resin passages (422, 423), and a resin rib (30) is laminated and integrated on the back surface of the foamed resin substrate (20). Rib forming process,
The cylinder (51) of the cutting mechanism (50) contained in the lower mold (42) is driven to cause the cutting blade (53) to penetrate into the foamed resin base material (20). A step of cutting an opening (22) for opening an opening (22) for mounting at least one of the parts (12, 14, 15, 17, 18);
A method for manufacturing an automobile interior part, comprising: The method for manufacturing an interior part for an automobile according to claim 1, wherein the step of cutting the opening (22) is performed simultaneously with the step of forming the foamed resin base material (20) and the resin rib (30). .

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