JP2005059632A - Interior parts for automobile and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an interior part for an automobile and its manufacturing method for lightening the part, reducing costs, simplifying a molding die, and simplifying a mold releasing operation after molding. <P>SOLUTION: This interior part (door trim) 10 comprises a light foamed resin base material 20 having a form retaining property, and a hard resin layer 30 inserted inside the foamed resin base material 20 only at a portion requiring rigidity of the interior part 10. Accordingly, the light foamed resin base material 20 is used, and an amount of resin used for the hard resin layer 30 is reduced, so as to lighten the part and reduce costs. Also, the hard resin layer 30 is inserted inside the foamed resin base material 20, so as to make a product thin, simplify a manhour of processing the molding die, and improve a mold releasing property. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, rear side trims, and manufacturing methods thereof, and in particular, is lightweight, excellent in formability, and mold cost and equipment of a molding die. The present invention relates to an automobile interior part that can be reduced in cost and excellent in demolding property, and a method for manufacturing the same.
[0002]
[Prior art]
For example, the configuration of automobile interior parts will be described with reference to FIGS. 14 and 15 exemplifying door trims. The door trim 1 has shape retention and attachment rigidity to a vehicle body panel, and is configured by laminating and integrating a skin 3 excellent in surface appearance on the surface of a resin core material 2 extending over almost the entire product surface. .
[0003]
The resin core material 2 is made of a polypropylene resin mixed with talc, and the skin 3 does not have shape retention itself, such as polyethylene foam on the back surface of a synthetic resin sheet such as a vinyl chloride sheet. In recent years, a cushioning material such as polyethylene foam is laminated on the back side of an elastomer sheet such as a TPO (thermoplastic olefin) sheet in consideration of environmental and recycling aspects. The laminated sheet material tends to be frequently used.
[0004]
Next, a conventional example of the method for forming the door trim 1 will be described with reference to FIG. First, a molding die 4 that molds the door trim 1 is connected to a molding upper die 5 that can move up and down by a predetermined stroke, a molding lower die 6 that forms a pair with the molding upper die 5, and a molding lower die 6. It is generally composed of the injection machine 7.
[0005]
When the upper and lower molds 5 and 6 are clamped, a cavity portion 5a is formed in the molded upper mold 5 and a core section 6a is provided in the molded lower mold 6 in order to shape the product shape of the door trim 1. Yes. In order to move the upper molding die 5 up and down by a predetermined stroke, an elevating cylinder 5b is connected, and the molding lower die 6 is provided with a manifold 6b and a gate 6c that serve as a passage for molten resin from the injection machine 7.
[0006]
Further, in order to maintain an appropriate posture, the upper molding die 5 that moves up and down is provided with guide posts 6d at the four corners of the lower molding die 6, and the molding upper die 5 has guides corresponding 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 then the upper and lower molds 5 and 6 are clamped and then injected into the product cavity between the two molds. By injecting and filling the molten resin M from the machine 7 through the manifold 6b and the gate 6c, the resin core material 2 is formed into a required curved shape, and the skin 3 is integrally formed on the surface of the resin core material 2 (for example, , See Patent Document 1).
[0008]
In FIG. 16, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state. However, the molten resin M is injected and filled into the cavity after the mold upper and lower molds 5 and 6 are clamped. May be.
[0009]
Recently, as interior parts for automobiles such as automobile ceilings and doors, thermoplastic foams such as bosses, clips, hooks, etc., which are ribs for reinforcement and attachments to other parts, are used. There is also known a molding method in which a resin functional member is fused and integrated (for example, see Patent Document 2).
[0010]
[Patent Document 1]
Japanese Patent Laid-Open No. 10-138268 (Page 2, FIGS. 3 and 4)
[0011]
[Patent Document 2]
JP 2001-121561 A (Page 6, FIGS. 6 to 9)
[0012]
[Problems to be solved by the invention]
However, in the conventional door trim 1, the resin core material 2 is provided over the entire area of the back surface of the product, and since the projected area is large, there are problems that the material cost is high and the product is heavy. ing.
[0013]
In addition, since the projected area of the resin core material 2 is large, it is necessary to set the injection pressure at the time of molding high, and a mold structure that can withstand the high injection pressure is required, and the production cost of the mold is increased, In addition, since a large amount of molten resin is cooled and solidified, the molding cycle becomes longer, which is a major factor for reducing productivity.
[0014]
Furthermore, when the configuration in which the functional member is fused and integrated with the foamed resin sheet is adopted, when the molded product is removed from the molding die, the functional member and the molding die are likely to interfere with each other. There was a problem of being inferior.
[0015]
The present invention has been made in view of such circumstances, and can provide an interior part for automobiles that can promote weight reduction, can be reduced in cost with high rigidity, can reduce the cost of a molding die, and can be molded. It is an object to provide an interior part for automobiles excellent in demoldability from the above and a method for producing the same.
[0016]
[Means for Solving the Problems]
As a result of earnest research, the present inventors have given the function as a core material by imparting shape retention to the foamed resin sheet that has been used conventionally as the skin, and more. The resin core material with a large projected area can be obtained by infiltrating the hard resin inside the foamed resin sheet at the parts where rigidity is required, that is, at the peripheral part of the product, the panel, or the part mounting part and the part where the load is applied. In addition to providing interior trim parts that are lighter and less expensive, and by inserting a hard resin layer, the resistance of the interior trim parts to the molding die is reduced and the mold release is improved when the product is removed. As a result, the present invention has been completed.
[0017]
That is, the automotive interior part according to the present invention is molded into a desired curved shape, is lightweight and has a shape-retaining foamed resin base material, and is inserted into the foamed resin base material in a portion where rigidity is required. And a hard resin layer.
[0018]
Here, the interior parts for automobiles can be applied to door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, and the like.
[0019]
A foamed resin base material having shape retention can be obtained by molding after molding, even if there is no reinforcing material such as ribs, by molding the foamed resin sheet into a desired curved surface shape after heating and softening treatment. Even if it is removed from the mold, it has such rigidity (shape retention) that it retains its shape. Also, if the product shape includes a high expansion ratio part, after the foamed resin sheet is heat-softened, a vacuum suction mechanism is provided in the molding die and the foamed resin sheet is vacuumed along the inner surface of the molding die. By applying a suction force, the shape of the product shape is improved, and it is advantageous for transferring a drawn pattern or the like engraved in the upper mold.
[0020]
As the foamed resin sheet, a material obtained by adding a foaming agent to a thermoplastic resin is used. The thermoplastic resin may be one type of thermoplastic resin or two or more types of thermoplastic resins. Preferably, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / Styrene (ABS) resin or the like can be used.
[0021]
As the foaming agent, an organic foaming agent such as an azo compound, a sulfohydrazide compound, a nitroso compound or an azide compound, or an inorganic foaming agent such as sodium bicarbonate can be used.
[0022]
The foamed resin base material obtained by molding the foamed resin sheet into a required shape after heat softening treatment preferably has a foaming ratio of 2 to 10 times in consideration of the balance between the weight and strength of the product. The cell diameter of the foamed resin base material at that time is preferably in the range of 0.1 μm to 2.0 mm, and the thickness is 0.5 to 30 mm, preferably 1 to 10 mm.
[0023]
Moreover, in order to improve external appearance designability, you may laminate | stack a decorating material on the surface of a foamed resin base material. As the decorating material, a woven fabric, a non-woven fabric, a knitted fabric, a sheet, a film, a foam, a net-like material, or the like can be used. Although the material which comprises these decorating materials is not specifically limited, It is more preferable to use the raw material which has air permeability, such as a woven fabric, a nonwoven fabric, and a knitted fabric, in order to utilize the sound absorption performance of a foamed resin base material.
[0024]
On the other hand, the thermoplastic resin material used as the hard resin layer can be appropriately selected from a wide range of thermoplastic resins. Usually usable as polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, polyamide resin, polyacetal resin, acrylonitrile / butadiene / Styrene (ABS) resin, polycarbonate resin and the like can be used.
[0025]
Moreover, you may mix various fillers 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. Moreover, various additives, such as antioxidant, a ultraviolet absorber, a coloring agent, a flame retardant, and a low shrinkage agent, may be mix | blended.
[0026]
Furthermore, as a preferable aspect of the automobile interior part according to the present invention, a plate body or a resin rib set so that a part of the soft resin layer protrudes outward from the foamed resin base material is provided. It is characterized by.
[0027]
And according to the interior parts for automobiles according to the present invention, since the hard resin layer is inserted in a sense to reinforce the rigidity inside a part of the foamed resin base material having shape retention, The resin core material occupied over the entire surface can be eliminated. Therefore, by eliminating the conventional resin core material having a very large projected area, the weight of the product can be reduced and the resin material can be saved, so that the material cost can be reduced at the same time.
[0028]
In addition, the porous sound absorbing function of the foamed resin base material provides interior parts with excellent sound absorbing performance. When a polyolefin resin is used as the material for the foamed resin base material and the hard resin layer, Since it is unified, the separation process can be abolished and the recycling work can be simplified.
[0029]
Furthermore, since the hard resin layer is introduced into the foamed resin base material, for example, compared to the case where the foamed layer and the hard resin layer are bonded together, material destruction is less likely to occur, and high rigidity is obtained. Further, since the hard resin layer is thin, the thickness of the entire product is reduced, so that the mating relationship with the counterpart part and the vehicle body panel can be maintained well.
[0030]
In addition, for example, since there is no shape that easily catches on the mold such as a rib shape, when the mold is removed from the mold after molding, the molded product can be easily removed without deformation or breakage of the molded product. The
[0031]
Moreover, if the thickness of the foamed resin base material around the hard resin layer is compressed to be thin, the hard resin layer can be set at an appropriate position.
[0032]
Next, a method for manufacturing an automotive interior part according to the present invention includes a foamed resin base material that is lightweight and has shape retention, and a hard resin layer that is inserted into the foamed resin base material in a portion that requires rigidity. In the method for manufacturing an interior part for an automobile, the foamed resin sheet, which is the material of the foamed resin base material, is heated and softened and then set in a molding die, and between the molding dies. By clamping, the foamed resin sheet is made to conform to the cavity shape of the molding die and press-molded into the required shape, and the molten resin that is the material of the hard resin layer is permeated into the inside from the back side of the foamed resin sheet, It comprises a molding step of a foamed resin base material that introduces a hard resin layer into the foamed resin base material.
[0033]
Here, the molding die is composed of a molding upper mold that can move up and down, a molding lower mold that is a fixed side located below the molding upper mold, and an injection machine that is connected to the molding lower mold. .
[0034]
The molten resin supplied from the injection machine is supplied into the mold upper and lower mold cavities through resin passages such as a manifold and a gate provided in the mold lower mold. Further, the forming upper mold may be provided with a vacuum suction mechanism for improving the shapeability of the product, enabling a sharp shape, and improving the drawing transferability.
[0035]
In addition, the foamed resin sheet is shaped along the mold surface shape of the molding die by clamping the molding die, but the foamed resin sheet is heated and softened by a heater or the like before the molding process. Applied and set in a molding die in a heat-softened state. The heating temperature of the foamed resin sheet at this time is preferably heated at 170 to 200 ° C. Moreover, the resin temperature of the hard resin introduced into the foamed resin base material from the back side of the foamed resin base material through the manifold and gate from the injection machine is set to 190 to 240 ° C.
[0036]
In the foamed resin base material, the hard resin layer is partially inserted only in a portion where rigidity is required. At that time, as a method for controlling the insert area, the mold clearance is narrowed along the periphery of the insert area. In order to adjust the penetration of the hard resin, a method of suppressing the penetration range of the hard resin, or a temperature change for each part of the foamed resin sheet, and maintaining the insert area of the hard resin layer at a high temperature state. Anyway.
[0037]
Therefore, according to the method of the present invention, compared with the conventional resin core material having a large projected area, it is only necessary to insert a hard resin layer partially inside the foamed resin base material. Can be set lower than in the prior art, so that the load on the molding upper die can be reduced.
[0038]
Further, when the molded product is removed from the molding die, it is only necessary to handle the foamed resin base material in which the hard resin layer is inserted, so that the removal can be easily performed and the removal time can be shortened.
[0039]
DETAILED DESCRIPTION OF THE INVENTION
BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of an automotive interior part and a method for manufacturing the same according to the present invention will be described below by exemplifying a vehicle door trim and a method for manufacturing the same.
[0040]
1 to 9 show a first embodiment in which the present invention is applied to an automobile door trim and a method for manufacturing the same, FIG. 1 is a front view showing the automobile door trim, and FIG. 2 is a sectional view showing the configuration of the automobile door trim. 3 is an overall view of a molding die used in the method for manufacturing the automobile door trim, FIG. 4 is a cross-sectional view showing the main part of the molding die, and FIGS. 5 to 9 are methods for manufacturing the door trim for the automobile. It is explanatory drawing which shows each process. FIGS. 10 to 13 show a second embodiment in which the present invention is applied to an automobile door trim. FIG. 10 is a sectional view showing the configuration of the automobile door trim in the second embodiment. FIGS. FIG. 13 is a cross-sectional view of an automotive door trim showing a modification of the second embodiment.
[0041]
In FIG. 1, a door trim 10 for an automobile is molded into a desired curved surface shape. As functional parts to be mounted on the door trim 10, an inside handle escutcheon 11 and an armrest 12 formed in a bulging shape at the center include power. A window switch finisher 13 and a pull handle 14 are attached, a pocket escutcheon 16 is attached to the periphery of the door pocket 15 below the armrest 12, and a speaker grill 17 is provided integrally or separately on the front side. .
[0042]
As shown in FIG. 2, the automobile door trim 10 is lightweight and has a foamed resin base material 20 that is molded into a desired curved surface shape and has shape retention, and a portion that requires rigidity in the door trim 10. And the hard resin layer 30 inserted in the foamed resin base material 20 in FIG. A decorating material 21 is affixed to the surface of the foamed resin base material 20.
[0043]
The foamed resin substrate 20 is thermoformed into a required shape after heat-softening the foamed resin sheet so as to have shape retention. For example, although cold press molding is performed with a molding die having a desired mold surface, the portion with a higher development ratio may be shaped by using vacuum molding in combination.
[0044]
The foamed resin sheet has a structure in which a foaming agent is added to a general-purpose thermoplastic resin. The thermoplastic resin includes a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a chloride resin. Vinyl resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, acrylonitrile / butadiene / styrene (ABS) resins, and the like can be used. Moreover, as a foaming agent, organic foaming agents, such as azodicarbonamide, and inorganic foaming agents, such as sodium bicarbonate, can be used. In this embodiment, a foamed resin sheet in which sodium bicarbonate is appropriately added as a foaming agent to a polypropylene resin is used. Moreover, 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 preferably 1 to 10 mm.
[0045]
Next, the hard resin layer 30 inserted into the foamed resin base material 20 is made of a general-purpose synthetic resin molded body, and a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene resin can be preferably used as a synthetic resin. The terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, polyamide resin, polyacetal resin, acrylonitrile / butadiene / styrene (ABS) resin, polycarbonate resin, etc. In view of environmental and recycling aspects, polypropylene resins are used.
[0046]
In addition, fillers such as inorganic fibers such as glass fibers and carbon fibers, and inorganic particles such as talc, clay, silica, and calcium carbonate are appropriately mixed in the thermoplastic resin used for the hard resin layer 30. May be.
[0047]
Thus, the door trim 10 described above is lightweight and has a foamed resin base material 20 having shape retention, and the hard resin layer 30 inserted only in a portion where rigidity is required in the foamed resin base material 20. Because it is configured, the resin core material occupied over the entire surface of the product can be abolished and the lightweight foamed resin base material 20 is used while the hard resin layer 30 is partially inserted. As a result, the weight of the product can be reduced by 40% or more compared to the conventional example, the resin material can be saved significantly, and the cost can be reduced.
[0048]
Furthermore, since the foamed resin base material 20 has a porous structure, it has excellent sound absorption performance and can reduce noise inside and outside the vehicle interior. Moreover, in order to improve the sound absorption performance for the vehicle interior noise in the foamed resin base material 20, the decorating material 21 laminated and integrated on the surface of the foamed resin base material 20 is a woven fabric, a nonwoven fabric, a knitted fabric, or the like. A sheet material having air permeability as described above is preferable. The decorative material 21 is not only a breathable sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric, but also a synthetic resin sheet such as a vinyl chloride sheet, a TPO (thermoplastic olefin) sheet, or a cushion layer such as a polyolefin foam on the back surface thereof. It is also possible to use a laminated sheet material backed with Moreover, a synthetic resin film, a foam, a net-like body, etc. can be used.
[0049]
At this time, if the materials of the foamed resin base material 20 and the decorating material 21 are unified like a polyolefin resin, recycling can be easily performed. In addition, as a low-cost configuration, the decorative material 21 may be omitted, and the surface of the foamed resin base material 20 may be subjected to painting or printing processing.
[0050]
Furthermore, as a feature of the door trim 10 according to the present invention, since the hard resin layer 30 is inserted into the foamed resin base material 20 at a location where rigidity is required, the thickness of the entire product can be reduced. It is possible to increase the alignment accuracy without interfering with adjacent parts and body panels. In addition, since the flat foamed resin base material 20 surface is located on the back surface of the door trim 10, the mold can be easily removed from the mold, and the time required for removing the mold can be shortened.
[0051]
Next, a method for manufacturing the door trim 10 will be described below. First, based on FIG. 3, FIG. 4, the structure of the shaping die 40 is demonstrated. In FIG. 3, a molding die 40 used for molding the door trim 10 includes a molding upper mold 41 that can move up and down by a predetermined stroke, a molding lower mold 42 that is paired with the molding upper mold 41, and a molding lower mold 42. And an injection machine 43 connected to the main body.
[0052]
More specifically, the molding upper die 41 has a cavity portion 411 that matches 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 molding upper die 41. In addition, guide bushes 413 serving as a guide mechanism are provided at the four corners of the molding upper die 41.
[0053]
On the other hand, the molding lower die 42 is provided with a core portion 421 corresponding to the cavity portion 411 of the molding upper die 41. In addition, 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 passages of the manifold 422 and the gate 423 is provided. Is supplied to the upper surface of the core portion 421. In addition, since the hard resin layer 30 is set in a portion where rigidity is required, the setting location of the gate 423 corresponds to that.
[0054]
In addition, guide posts 424 serving as a guide mechanism protrude from the four corners of the lower molding die 42. The guide posts 424 are guided into the guide bush 413 when the molding upper and lower dies 41 and 42 are clamped. As a result, the pressing posture of the molding upper die 41 can be properly maintained.
[0055]
Furthermore, in the molding die 40 used in the present invention, as shown in FIG. 4, it is necessary to accurately define the insert area (indicated by reference symbol A in FIG. 4) of the hard resin layer 30. Therefore, the protrusion 425 protrudes from the molding lower mold 42 so that the mold clearance is set small along the peripheral edge of the insert area A.
[0056]
Therefore, when the upper and lower molds 41 and 42 are clamped, the protrusion 425 can prevent the foamed resin sheet S along the periphery of the insert area A from being excessively compressed and prevent the molten resin from penetrating outside the insert area A. The hard resin layer 30 can be formed with high accuracy.
[0057]
Next, a method for manufacturing the door trim 10 will be described. First, as shown in FIG. 5, the heater device 50 heats and softens the laminate of the decorating material 21 on one surface of the foamed resin sheet S at a predetermined temperature. The heating temperature of the foamed resin sheet S at this time is set to 170 to 220 ° C. In this embodiment, as the foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumika Plustech, trade name: Sumiceller foam PP sheet, expansion ratio = 3 times, thickness 3 mm) is used.
[0058]
Next, as shown in FIG. 6, the heat-softened foamed resin sheet S (with the decorative material 21 laminated) is set on the core portion 421 of the molded lower mold 42.
[0059]
Thereafter, as shown in FIG. 7, the raising / lowering cylinder 412 of the molding upper die 41 is operated, the molding upper die 41 is lowered by a predetermined stroke, the molding upper and lower dies 41 and 42 are clamped, and the foamed resin sheet S is formed into a cavity shape. Are pressed into the required shape.
[0060]
At this time, when the foamed resin sheet S is still in the preheated state, the molten resin M is introduced into the foamed resin sheet S through the injection machine 43, the manifold 422, and the gate 423.
[0061]
In particular, as shown in FIG. 8, since the protrusion 425 is formed on the molded lower mold 42 so as to surround the insert area A of the hard resin layer 30, the foamed resin sheet S is formed at the peripheral portion of the insert area A. In the over-compressed state, the molten resin M does not penetrate from the insert area A to the outside, and the hard resin layer 30 is inserted into the foamed resin base material 20 only in a limited portion.
[0062]
Thereafter, as shown in FIG. 9, the door trim 10 may be removed after the lifting cylinder 412 is driven to raise the molding upper die 41 and the molding upper and lower dies 41 and 42 are opened. In the demolding operation of the door trim 10, the portion that comes into contact with the molded lower mold 42 is a smooth surface of the foamed resin base material 20, so that there is no interference between the door trim 10 and the molded lower mold 42, and it is easy. In addition, the door trim 10 can be quickly removed.
[0063]
In addition, the insert area A of the hard resin layer 30 was accurately adjusted along the periphery of the insert area A by the sealing performance by the compression action, but the permeation of the molten resin M is controlled by giving the foamed resin sheet S a temperature distribution. You may make it do.
[0064]
Next, FIG. 10 to FIG. 13 show a second embodiment in which the present invention is applied to an automobile door trim 10. As shown in FIG. 10, the door trim 10 is molded into a desired curved shape, is lightweight, In order to improve the appearance performance, the decorative material 21 is composed of a foamed resin base material 20 having shape retention and a hard resin layer 30 inserted into the foamed resin base material 20 at a portion where rigidity is required. May be affixed to the surface of the foamed resin substrate 20.
[0065]
In the door trim 10 according to the second embodiment, an inner seal mounting flange 31 for mounting a door inner seal (not shown) is formed integrally with the hard resin layer 30.
[0066]
Therefore, the inner seal mounting flange 31 can be integrated at the same time as the door trim 10 is formed, as compared with the conventional case where the inner seal mounting flange is formed in a separate process and retrofitted to the door trim. Can be shortened.
[0067]
In order to integrate the inner seal mounting flange 31 with the hard resin layer 30, a temperature distribution is set in the foamed resin sheet S as shown in FIG. That is, the inner seal mounting flange 31 setting portion is set to a high temperature portion B that is equal to or higher than the normal heating temperature. For example, when heating a general part to 170-220 degreeC, the high temperature part B is set to 200-250 degreeC.
[0068]
Accordingly, as shown in FIG. 12, when the foamed resin sheet S is press-molded by clamping the molding upper and lower molds 41 and 42, the molten resin M, which is the material of the hard resin layer 30, is placed inside the foamed resin sheet S through the gate 423. Infiltrate. Then, as described above, the molten resin M penetrates into the insert area A with high accuracy due to the sealing performance by the protrusions 425. In particular, in the high temperature portion B, the foamed resin sheet S is pierced and corresponds to the inner seal mounting flange 31. The molten resin M is introduced into the groove portion 426 of the molded lower mold 42 to be formed, so that the inner seal mounting flange 31 is integrally formed integrally with the hard resin layer 30 as shown in FIG.
[0069]
In addition to the inner seal mounting flange 31, as shown in FIG. 13, the hard resin layer 30 and the resin rib 32 can be integrally formed. In the case of integration, the hard resin layer 30 and the resin rib 32 can be integrated.
[0070]
Further, if the hard resin layer 30 is provided at a portion corresponding to the clip seat for attaching the door trim 10 to the vehicle body panel, the force for knocking the clip seat when the door trim 10 is attached to the vehicle body panel, or the door trim 10 is removed from the vehicle body panel. The force at that time is reliably transmitted to the clip seat through the hard resin layer 30. Further, the clip seat may be integrally formed with the hard resin layer 30 or may be a separate body.
[0071]
【The invention's effect】
As described above, the automotive interior part according to the present invention is a lightweight and shape-retaining foamed resin base material, and a hard resin layer inserted into the foamed resin base material in a portion where rigidity is required. Because it is made up of a conventional material, it can eliminate the conventional heavy resin core material, so it is lightweight, low-cost, and is a porous material. In addition, there is an effect that it is possible to provide an automotive interior part that is excellent in demoldability.
[0072]
Furthermore, the method for manufacturing an automotive interior part according to the present invention is to form a foamed resin base material into a required shape along the cavity shape of a molding die and simultaneously introduce a hard resin into the foamed resin sheet. Since the projected area is small, the load applied to the molding die is smaller and the cooling time can be shortened compared to the conventional resin core material, the yield can be increased, the work efficiency can be increased, and The cost can be reduced.
[0073]
In addition, an automotive interior part and a method for manufacturing the same according to the present invention include the step of press-molding a foamed resin base material into a required shape along the cavity shape of a molding die, and at the same time, a hard resin layer inside the foamed resin base material. Since the back surface side of the interior part is a smooth surface, the mold can be easily and quickly removed from the mold.
[Brief description of the drawings]
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 cross-sectional view taken along the line II-II in FIG.
3 is an explanatory view showing an overall configuration of a molding die used when molding the automobile door trim shown in FIG. 1; FIG.
4 is a cross-sectional view showing a main part of the molding die shown in FIG. 3. FIG.
FIG. 5 is an explanatory view showing a preheating step of the foamed resin sheet in the method for manufacturing the automobile door trim shown in FIG. 1;
6 is an explanatory view showing a foamed resin sheet setting step in the door trim manufacturing method shown in FIG. 1. FIG.
7 is an explanatory view showing a molding step of a foamed resin base material and a hard resin layer in the door trim manufacturing method shown in FIG. 1; FIG.
8 is an explanatory view showing an insert state of the hard resin layer shown in FIG. 7;
9 is an explanatory view showing a demolding step in the method of manufacturing the automobile door trim shown in FIG. 1. FIG.
FIG. 10 is a cross-sectional view showing a second embodiment in which the automotive interior part according to the present invention is applied to a vehicle door trim.
FIG. 11 is an explanatory view showing a foamed resin sheet setting step in the method for manufacturing the automobile door trim shown in FIG. 10;
12 is an explanatory view showing a molding step of a foamed resin base material and a hard resin layer in the method for manufacturing the automobile door trim shown in FIG.
13 is a cross-sectional view showing a modification of the automobile door trim shown in FIG.
FIG. 14 is a front view showing a conventional door trim.
15 is a cross-sectional view taken along line XV-XV in FIG.
FIG. 16 is an explanatory view of a molding die used when molding a conventional door trim.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Automotive door trim 20 Foamed resin base material 21 Decorating material 30 Hard resin layer 31 Inner seal mounting flange 32 Resin rib 40 Molding die 41 Molding upper die 412 Lifting cylinder 42 Molding lower die 421 Core part 422 Manifold 423 Gate 424 Guide Post 425 Projection 426 Groove 43 Injector 50 Heater device S Foamed resin sheet M Molten resin A Insert area B High temperature part

Claims (7)

A foamed resin base material (20) that is molded into a desired curved surface shape, is lightweight and has shape retention, and a hard resin layer (30) that is inserted into the foamed resin base material (20) inside a portion that requires rigidity. An automotive interior part characterized by comprising: A part of the hard resin layer (30) includes a plate body (31) or a resin rib (32) set so as to protrude outside from the back surface side of the foamed resin base material (20). The interior part for automobiles according to claim 1. The automotive interior part according to claim 1 or 2, wherein the thickness of the foamed resin base material (20) around the hard resin layer (30) is compressed to be thin. Automotive interior parts comprising a foamed resin base material (20) that is lightweight and has shape-retaining properties, and a hard resin layer (30) that is inserted into the foamed resin base material (20) at a portion where rigidity is required. In the manufacturing method of (10),
A step of setting the foamed resin sheet (S) to be set in the molding die (41, 42) after heat-softening the foamed resin sheet (S) which is the material of the foamed resin base material (20);
By clamping the molding dies (41, 42) to each other, the foamed resin sheet (S) is made to conform to the cavity shape of the molding dies (41, 42), press-molded into a required shape, and the hard resin layer (30). A foamed resin base material (30) which introduces a hard resin layer (30) into the inside of the foamed resin base material (20) by infiltrating the molten resin (M) which is a material of the above into the inside from the back side of the foamed resin sheet (S). 20) a molding process;
A method for producing an interior part for an automobile, comprising: When the foamed resin sheet (S) is press-molded by clamping the molding dies (41, 42), the mold clearance is set small along the periphery of the insert area (A) of the hard resin layer (30). The method for producing an automotive interior part according to claim 4, wherein the formation location of the hard resin layer (30) is adjusted. The insert area (A) of the hard resin layer (30) is a high temperature part (B) in which the temperature of the foamed resin sheet (S) is set higher than that of the general part, and is a material of the hard resin layer (30). The method for manufacturing an interior part for an automobile according to claim 4, wherein introduction of the molten resin (M) into the foamed resin sheet (S) is promoted. The high temperature part (B) of the foamed resin sheet (S) is provided at a joint part with the plate body (31) integrated with the back surface of the foamed resin base material (20) or the resin rib (32). The manufacturing method of the interior component for motor vehicles of Claim 6 characterized by the above-mentioned.

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