JP2006168267A - Trims for automobile and manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide trims for automobile which attain lightweight and cost reduction, improve the appearance of the peripheral edge portions and simplify the edge processing work, and to provide a manufacturing method therefor. <P>SOLUTION: A door trim upper 20 in a two-tone type door trim 10 or a one-piece type door trim 100 is formed of a foamed resin base material 21 that is light and has shape retaining property, a resin rib 22 that is integrated with its inner face side, and a decorative material 23 that is laminated onto the surface of the foamed resin base material 21. By the use of the lightweight foamed resin base material 21 and the reduction of the projected area by the resin rib 22, lightweight and cost reduction are achieved. The edge material 21a of the foamed resin base material 21 is cut and eliminated in the shear edge portion A between the molding dies 41, 42 and then the margin 23a to be enfolded of the decorative material 23, which is provided so as to extend outward from the cut line, is rolled in the rear face of the foamed resin base material 21. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to interior parts for automobiles such as door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and methods for manufacturing the same. The present invention relates to an automobile interior part that can be easily and inexpensively processed along a terminal, and a method of manufacturing the same.

  For example, the configuration of automobile interior parts will be described with reference to FIGS. The door trim 1 has a shape retaining property and a mounting rigidity to a vehicle body panel, and is formed by laminating and integrating a skin 3 excellent in surface appearance on the surface of a resin core material 2 that extends over almost the entire product surface. Yes. The resin core material 2 is made of a polypropylene resin mixed with talc, and the skin 3 does not have shape retention itself, and the back surface of the synthetic resin sheet such as a vinyl chloride sheet is made of polyethylene foam or the like. A laminated sheet material in which a cushion material is laminated is used, and recently, an elastomer sheet such as a thermoplastic olefin (hereinafter referred to as TPO) sheet tends to be frequently used in consideration of environmental aspects and recycling aspects.

  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. 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 molding upper 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 of molten resin from the injection machine 7. 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.

  Therefore, when the molding upper and lower molds 5 and 6 are in the mold open state, either the skin 3 is set in the mold, and then either immediately before or after the molding upper and lower molds 5 and 6 are clamped The molten resin M is injected and filled from the injection machine 7 through the manifold 6b and the gate 6c into the product cavity between the molds at the timing, thereby forming the resin core material 2 into a required curved shape and the resin core material 2 The skin 3 is integrally formed on the surface (for example, see Patent Document 1). In FIG. 20, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state. Actually, however, the molten resin M is injected into the cavity after the mold upper and lower molds 5 and 6 are clamped. It may be filled.

  Furthermore, as shown in FIG. 21, the outer peripheral terminal of the door trim 1 product is subjected to simultaneous press molding of the skin 3 on the surface of the core material 2, and then pierced in a separate process after the mold blade in the mold or molding. Cut processing is performed. Further, as shown in FIG. 22, after the core material 2 is press-molded, the skin 3 is integrated by vacuum pressing, press-bonding or the like in a separate process, and then the terminal 3 a of the skin 3 is wound around the back surface side of the core material 2. Processing is also conventionally performed.

Japanese Patent Laid-Open No. 10-138268 (Page 2, FIGS. 3 and 4)

  However, in the conventional door trim 1, since the projected area of the resin core material 2 is large, there are problems that the material cost is high and the product is heavy. 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.

  Furthermore, at the outer peripheral edge of the door trim 1, as shown in FIG. 21, when the outer skin simultaneous press molding is performed, the outer peripheral terminal processing is difficult, and in the case of the skin 3 of the skin 3 or the skin 3 of the laminated sheet material specification, In addition to the appearance of the foam layer being exposed to the outside and the disadvantage of reducing the appearance performance, as shown in FIG. 22, the process of winding the skin 3 in a separate process requires a lot of man-hours and costs. Up is inevitable.

  The present invention has been made in view of such circumstances, and can provide an automotive interior part that can promote weight reduction, can achieve high rigidity, and can reduce costs, and in particular, can enhance the appearance of a product outer peripheral terminal portion. Another object of the present invention is to provide an automobile interior part with improved appearance performance that can easily perform terminal processing work and a method for manufacturing the same.

  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. High rigidity is required at places where rigidity is required, that is, at the peripheral part of the product, the panel, the mating part with the mating part, or where a certain clearance is secured, or where the part is attached and where the load is applied By arranging resin ribs, the weight of the product is reduced compared to the conventional resin core material with a large projected area, and the terminal of the outer periphery of the product is a beautiful terminal by devising the mold shape. It has been found that processing can be achieved, and the present invention has been completed.

  That is, an automotive interior part according to the present invention is a resin resin having a predetermined pattern shape that is molded into a required shape, is lightweight and has shape retention, and is laminated and integrated on the back surface of the foam resin substrate. In an interior part for an automobile in which a laminated structure composed of a rib and a decorating material attached to the surface of the foamed resin base material is employed in whole or in part, the laminated structure comprises a foamed resin base material The foamed resin sheet, which is a material of the above, is heat-softened to a high temperature and put into a molding die, and the decorative material that has been subjected to the heat treatment is omitted or the low-temperature heat treatment is placed on the upper surface, and the foam The foamed resin base material is molded into the required shape with a low press pressure due to the residual heat of the resin sheet and mold clamping, and the decorative material is integrated on the surface, and the shear edge part of the molding die In the foamed resin group The end material of the outer peripheral terminal portion or the opening terminal portion is cut and removed, and the winding of the decorating material is wound on the back surface of the foamed resin base material based on the cut line in the shear edge portion. And

  Here, the interior parts for automobiles can be applied to door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and the like. And if the foamed resin base material that is lightweight and has shape retention properties is close to a flat shape, the heat softening step is omitted and it is molded into a desired shape by a mold, but it is applied to a three-dimensional product. In this case, after the foamed resin sheet is heat-softened, the foamed resin sheet is molded into a required curved shape in a molding die, and the shape is maintained. Here, “shape retention” refers to having rigidity enough to retain the shape when the mold is removed after molding, even without a reinforcing material such as a rib. 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. A suction force may be applied.

  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. 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. 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.

  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, those that can be preferably used include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, Acrylonitrile / butadiene / styrene (ABS) resin or the like can be used. 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.

  And in order to improve an external appearance design property, the decorating material is integrated with the surface of the foamed resin base material. As this decorating material, a thermoplastic resin sheet such as TPO, thermoplastic urethane (TPU), PVC, or a fabric sheet such as a woven fabric, a non-woven fabric, a knitted fabric, or the like, or these thermoplastic resin sheet, woven fabric, A foam sheet such as polyurethane foam, polyethylene foam, or polypropylene foam can be laminated and integrated as a cushion layer on the back surface of a fabric sheet such as nonwoven fabric or knitted fabric. In addition, if TPO sheet or polyethylene foam is used as the material of the decorating material and olefin resin is used as the material of the foamed resin base material or resin rib, all materials can be unified into the olefin resin and recycled. Above preferred.

  Further, the configuration of the outer peripheral terminal portion and the open terminal portion in the laminated structure is characterized in that the end material of the foamed resin base material is cut and removed at the shear edge portion of the product mold. Therefore, in this shear edge portion, the mold clearance of the upper and lower molds is set to be as narrow as 0 to 1 mm. In addition, for the product terminal part, the part from the shear edge part to the terminal part of the decorating material becomes an entrainment, but in the open terminal part, the cutting blade attached to the molding die or after molding, A winding white is formed by the cutting process. Therefore, when the forming process of the laminated structure is completed, the laminated structure is demolded from the molding die, and the decorative material wrapping white is wound around the back side of the foamed resin base material based on the trim cut line. The terminal treatment of the laminated structure can be performed by intrusion welding or intimate adhesion.

  And according to the interior part for automobiles according to the present invention, the decorative material having the decorating property is laminated on the front surface side of the foamed resin base material having the shape-retaining property, and the resin is meant to reinforce the rigidity on the back surface side. Since the ribs are laminated and integrated, the conventional resin core material can be eliminated. Therefore, since the conventional resin core material with a very large projected area can be eliminated, 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.

  Furthermore, at the end portion or the open end portion along the outer periphery of the product of the laminated structure, the end material of the foamed resin base material can be cut and removed simultaneously with the molding at the shear edge portion of the molding die. The structure is removed from the molding die, and the decorating material is wound on the back side of the foamed resin base material based on the cut line of the foamed resin base material, so the cut end is not exposed to the outside. , Appearance looks good. In addition, when the end portion (end material) of the foamed resin base material is cut and removed by the shear edge portion of the molding die, the foamed resin sheet is heated to a high temperature when the molding die is charged, and the decoration material is heated. Because the treatment is omitted or only low-temperature heat treatment is performed at a low temperature, the end material portion of the heat-softened foamed resin base material does not get entangled with the decorating material, and the decorating material and foam The end material of the resin base material can be separated smoothly, and the formation of the entrainment scissors can be performed reliably.

  In addition, the porous sound-absorbing function of the foamed resin base material provides interior parts with excellent sound-absorbing performance. When polyolefin resin is used as the material for the foamed resin base material and resin ribs, Since it is unified, the separation process can be abolished and the recycling work can be simplified. Furthermore, the rib thickness of the resin rib can be varied as appropriate, for example, by setting the rib thickness to be thicker at sites where a large external force is applied to the product, and by reducing the rib thickness at sites where external force is relatively difficult to apply. Can do. 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. Moreover, the clip seat or the attachment seat for attaching various escutcheon parts can also be integrally formed in the resin rib.

  Next, a method for manufacturing an automotive interior part according to the present invention includes a foamed resin base material that is molded into a required shape and is lightweight and has shape retaining properties, and a predetermined laminated body integrated on the back surface of the foamed resin base material. In the method of manufacturing an interior part for an automobile, in which a laminated structure including a pattern-shaped resin rib and a decorating material attached to the surface of the foamed resin base material is used in whole or in part, the foamed resin After heat-softening the foamed resin sheet that is the material of the base material and putting it into a molding die, the heat treatment is omitted, or a low-temperature heat-treated decorative material is placed on the upper surface of the foamed resin sheet. The molds are clamped together, press-molded at low pressure, the foamed resin base material is molded into the required shape, and a decorating material is pasted on the surface, and the foamed resin base material at the shear edge of the mold Perimeter terminal or open terminal The end material of the mold is cut and removed, and the molten resin is injected and filled into the groove portion of the molding lower mold at a timing just before or after the mold clamping of the molding die, and the resin rib is made of the foamed resin base material. Forming a laminated structure by laminating and integrating on the back surface side, and then winding and adhering a decorating material to the back surface of the foamed resin base material based on the trim cut line of the foamed resin base material to produce a laminated structure It is characterized by.

  Here, the molding die used in the method of the present invention includes a movable side die, a fixed side die, and an injection machine. For example, it is composed of a molding upper mold that can move up and down by a predetermined stroke, a molding lower mold positioned below the molding upper mold, and an injection machine connected to the molding lower mold. When the molding upper and lower molds are used, the molten resin supplied from the injection machine passes through the resin passages such as the manifold and gate provided in the molding lower mold, and more specifically the mold surface of the molding lower mold. The upper mold is lowered to the bottom dead center and the upper and lower molds are clamped, and then the molten resin is provided on the mold surface of the lower mold with a predetermined injection pressure. The groove portion may be injected and filled, but may be performed before mold clamping as the injection filling timing of the molten resin.

  Further, the mold surface shape of the molding die is set to be a curved surface shape that matches the product shape. In particular, at a terminal portion along the outer periphery of the product, a predetermined clearance (0 So as to form a so-called shear edge portion corresponding to the inner wall surface of the molding upper die. Similarly, in the opening portion, the molding upper and lower molds face each other with a narrow die clearance of 0 to 1 mm along the opening shape. A shear edge portion is formed.

  Therefore, according to the method of the present invention, since only the resin rib is molded as compared with the conventional resin core material having a large projected area, the injection pressure can be set lower than the conventional one, so that the load on the molding die can be reduced. In addition, the resin material can be saved and the cooling time can be shortened as compared with the conventional resin core material, so that the product molding cycle can be shortened.

  Further, for the end portion or the open end portion along the outer periphery of the product of the laminated structure, the cut processing along the trim cut line is performed at the shear edge portion where the mold clearance of the molded upper and lower molds is set narrow when molding the foamed resin base material. Therefore, the cutting process of the end material of the foam resin base material is completed at the same time as the molding, and after molding, the demolding operation is performed from the molding die, so that the decorative material is wound on the back surface of the foam resin base material. Therefore, the entrainment process can be performed simply and in a good manner.

  As described above, the automobile interior part according to the present invention is required to have rigidity such as a lightweight and shape-retaining foamed resin base material, a back surface of the foamed resin base material, and an outer peripheral edge of the product. Because it is composed of resin ribs that are laminated and integrated with the surface of the foamed resin base material, and a decorative material that is laminated on the surface of the foamed resin base material, the conventional heavy resin core material can be eliminated. And since it is a porous material, it has the effect that the interior component for motor vehicles excellent in the sound absorption performance can be provided.

  Furthermore, if the process of molding the resin foam on the back side of the foamed resin base material at the same time as molding the foamed resin base material into the required shape along the cavity shape of the molding die, the resin rib that is a resin molded body Compared to conventional resin core materials, the projected area is less, the load on the mold is less, the cooling time can be shortened, and the yield can be increased. This has the effect of reducing the cost.

  Moreover, according to the interior part for automobiles and the method for manufacturing the same according to the present invention, the foamed resin base material in the outer peripheral terminal part of the product or the open terminal part is trimmed by the shear edge part of the molding die when the foamed resin base material is molded. Since it is cut and removed along the cut line, after molding, the laminated structure is removed from the molding die, and the decorative material is rolled into the back side of the foamed resin substrate. If it does, it has the effect that a winding process can be performed simply and beautifully.

  BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of an automobile 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.

  FIG. 1 to FIG. 11 show a first embodiment of the present invention, FIG. 1 is a front view showing a two-tone type automobile door trim, FIG. 2 is a sectional view showing the configuration of the automobile door trim, and FIG. 4 is a front view showing a resin rib and a door trim lower of a door trim upper in the door trim, FIG. 4 is a cross-sectional view showing a configuration of a terminal portion of the door trim upper in the door trim for the automobile, and FIGS. 5 and 6 are used in the manufacturing method of the door trim for the automobile FIG. 5 is an overall view of the molding die, and FIG. 6 is a cross-sectional view showing a portion corresponding to a door trim upper edge portion of the molding die. 7 to 11 show a method for manufacturing the automobile door trim. FIG. 7 shows a preheating process for the foamed resin sheet, FIG. 8 shows a process for setting the foamed resin sheet in the mold, and FIG. FIG. 10 and FIG. 11 are explanatory views showing the terminal processing step of the door trim upper, respectively.

  First, a first embodiment of the present invention will be described with reference to FIGS. 1 and 2, a two-tone type automobile door trim 10 is composed of an upper and lower divided part of a door trim upper 20 made of a laminated structure and a door trim lower 30 made of a single resin product. As functional components to be mounted on the door trim 10, an inside handle escutcheon 11 and a power window switch escutcheon 12 are attached to the door trim upper 20. The door trim lower 30 is provided with a door pocket opening 13, and on the back side thereof, as shown in FIG. 2, a pocket back cover (made of a resin molded body) 14 is attached. The speaker grill 15 is formed integrally or separately on the side.

  By the way, the door trim 10 for automobiles according to the present invention is applied to the structure of the door trim upper 20 which is a laminated structure to reduce the weight of the product, improve the appearance of the outer peripheral terminal portion, and form the molding process, terminal It is characterized by a simplified processing process. That is, as shown in FIG. 2, the door trim upper 20 is molded into a desired curved surface shape and has a foamed resin base material 21 having shape retention, and a resin laminated and integrated on the back surface side of the foamed resin base material 21. The rib 22 and the decorating material 23 having a decorating function laminated and integrated on the surface side of the foamed resin base material 21 are roughly configured. In the figure, reference numeral 16 denotes a vehicle body panel. In addition, the foamed resin base material 21 is heat-softened to heat the foamed resin sheet so as to have shape retention, and then thermoformed into a required shape, for example, cold press-molded with a molding die having a desired mold surface. In addition, the foamed resin base material 21 may be shaped by vacuum forming for a portion with a higher development rate.

  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 resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. can be used. As the foaming agent, organic foaming agents such as azodicarbonamide and bicarbonate An inorganic foaming agent such as sodium 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. The expansion ratio of the foamed resin base material 21 is set to 2 to 10 times, and the thickness is set to a range of 0.5 to 30 mm, particularly 1 to 10 mm.

  Next, the resin ribs 22 are disposed on the back surface side of the foamed resin base material 21 and, in particular, are set in a predetermined pattern extending in an intersecting manner as shown in FIG. In addition, as for this pattern, arbitrary patterns may be selected as long as it is intersecting, such as a vertical and horizontal direction, an oblique direction, or a combination thereof. The resin rib 22 is made of a general-purpose synthetic resin molded body, and as a synthetic resin that can be preferably used normally, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin, A polyamide resin, a polyacetal resin, a polycarbonate resin, an ionomer resin, an acrylonitrile / butadiene / styrene (ABS) resin, or the like may be selected as appropriate. In this embodiment, a polypropylene resin is used in consideration of environmental and recycling aspects. Is used. The resin rib 22 is appropriately mixed with a filler such as inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica and calcium carbonate in the thermoplastic resin. May be.

  As described above, the door trim 10 shown in FIGS. 1 to 3 includes the door trim upper 20 formed of a laminated structure and the door trim lower 30 of a single resin, and has an excellent appearance design due to an accent effect on the appearance. I have. Further, the door trim upper 20 includes a foamed resin base material 21 having shape retention, a resin rib 22 laminated and integrated on the back surface of the foamed resin base material 21, and a decorating material 23 having a decorating property. Therefore, the resin core material that has been occupied over the entire circumference of the product as in the past can be abolished, and the resin rib 22 is skeleton-like in relation to the use of the lightweight foamed resin base material 21, and a load is applied. Parts, for example, parts excluding the clip seat, the waist upper surface, the arm rest upper surface, etc. have a thinning structure, so that the weight of the product can be reduced by 40% or more compared to the conventional example. In addition, the resin material can be saved significantly, which can contribute to cost reduction.

  Furthermore, since the foamed resin base material 21 has a porous structure, the door trim upper 20 is excellent in sound absorption performance and can reduce noise in the vehicle interior. Moreover, in order to maintain the sound absorption of the foamed resin base material 21, the decorative material 23 laminated in advance on the surface of the foamed resin base material 21 or integrated and laminated at the time of molding is a woven fabric. Sheet materials having air permeability such as nonwoven fabric and knitted fabric are preferred. The decorative material 23 may be a synthetic resin sheet such as a vinyl chloride sheet or a TPO sheet, a synthetic resin film, a foam, a net, or a fabric sheet, a synthetic sheet, in addition to a breathable sheet such as a woven fabric, a nonwoven fabric, or a knitted fabric. It is also possible to use a laminated sheet material in which a back surface of the resin sheet is lined with a cushion layer such as polyethylene foam or polyurethane foam. In addition, when a TPO sheet is used, it can be unified with an olefin resin material, which is advantageous in terms of recycling.

  And the outer periphery terminal structure of the door trim upper 20 in the door trim 10 is demonstrated based on FIG. That is, in the door trim upper 20, as described above, the resin ribs 22 having a predetermined pattern shape for reinforcing rigidity are integrated on the back surface of the lightweight foamed resin base material 21 having shape retention, and the foamed resin base material 21. A decorative material 23 having a decorative property is laminated and integrated on the surface. Further, a stepped flange 24 is formed downward along the product outer periphery of the door trim upper 20 so that the product has a three-dimensional effect. Since it is wound around the back surface side of the resin base material 21 and the cut end of the foamed resin base material 21 is not exposed, the appearance appearance is maintained well, and this product terminal portion is in contact with the vehicle body panel 16. In contact.

  Next, the outline | summary of the manufacturing method of the door trim 10 including the terminal processing process of the outer periphery terminal part of the door trim upper 20 is demonstrated below. First, the overall structure of the molding die 40 will be described with reference to FIG. 5, and the main part of the molding die 40 corresponding to the outer peripheral portion of the door trim upper 20 will be described with reference to FIG. In FIG. 5, 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. It consists of two injection machines 43a and 43b connected to each other.

  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. 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, manifolds 422a and 422b and gates 423a and 423b are provided to supply molten resin to the mold surface of the core portion 421, and the injection machine passes through the resin passages of the manifolds 422a and 422b and gates 423a and 423b. The molten resins M1 and M2 supplied from 43a and 43b are supplied into a groove 424 formed on the upper surface of the core 421 and into a cavity 425 for forming the door trim lower 30. In addition, guide posts 426 that serve as a guide mechanism protrude from the four corners of the molded lower mold 42, and the guide posts 426 guide into the guide bush 413 when the molded upper and lower molds 41 and 42 are clamped. As a result, the pressing posture of the molding upper die 41 can be properly maintained.

  FIG. 6 shows a portion corresponding to the outer peripheral end portion of the door trim upper 20 in the molding die 40. FIG. 6 shows a clamping state in which the molding upper die 41 is lowered to the bottom dead center. At the outer peripheral end portion of the cavity C, the mold clearance (indicated by the symbol d in the figure) between the corner portion 42a of the vertical wall portion of the molding lower die 42 and the wall surface 41a of the molding upper die 41 is 0 to 1 mm. An adjusted shear edge portion A is set.

  Subsequently, each process of the manufacturing method of the door trim 10 mentioned above is demonstrated based on FIG. 7 thru | or FIG. First, as shown in FIG. 7, the foamed resin sheet S is heated and softened at a high temperature of 160 to 220 ° C. by the heater device 50. 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. Subsequently, as shown in FIG. 8, the foamed resin sheet S that has been heat-softened is placed on the cavity defined by the cavity portion 411 of the upper molding die 41 and the core portion 421 of the lower molding die 42 at the location corresponding to the door trim upper 20. Set in half. Then, although the decorating material 23 is mounted on the upper surface of this foamed resin sheet S, this decorating material 23 has not performed the heat processing. If desired, the decoration material 23 can be subjected to a heat treatment at a low temperature of 120 ° C. or lower. However, whether the decoration material 23 is not subjected to the heat treatment or whether the heat treatment is performed is a decoration. It is determined according to the physical properties of the material 23 or the product shape.

  Then, after setting the foamed resin sheet S and the decorating material 23 in the molding die 40, the lifting cylinder 412 of the molding upper die 41 is operated, and the molding upper die 41 is lowered by a predetermined stroke, as shown in FIG. Thus, the molded upper and lower molds 41 and 42 are clamped, the foamed resin sheet S is shaped along a desired mold surface shape, the foamed resin base material 21 is molded, and the manifold from the first injection machine 43a is formed. In order to form the resin rib 22 in the door trim upper 20 through the gate 423a and the gate 423a, the molten resin M1 is injected and filled into the groove portion 424 of the core portion 421. Further, in order to mold the door trim lower 30, the molten resin M2 is injected and filled into the substantially lower half of the cavity from the second injector 43b through the manifold 422b and the gate 423b, and the door trim lower 30 is molded into a required shape.

  Therefore, the resin ribs 22 in the door trim upper 20 are molded into a required shape by injecting and filling the molten resins M1 and M2 into the cavities from the first injection machine 43a and the second injection machine 43b, respectively. A door trim lower 30 is formed. As the molten resins M1 and M2, talc is mixed in an appropriate proportion with Sumitomo Noblen BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min). The injection timing of the molten resins M1 and M2 may be set before the mold upper and lower molds 41 and 42 are clamped.

  Further, in the molding process of the foamed resin base material 21 and the resin rib 22 shown in FIG. 9, the part corresponding to the outer peripheral edge of the door trim upper 20 is defined by the molding upper and lower molds 41 and 42 as shown in FIG. 10. A stepped flange 24 is formed on the foamed resin base material 21 along the cavity shape to be formed, and is heated at the shear edge portion A having a narrow clearance formed by the upper and lower molds 41 and 42 at the end portion of the cavity C. Thus, the outer peripheral terminal portion of the foamed resin base material 21 in the softened state is cut and removed. At this time, the foamed resin base material 21 in the heat-softened state is easily cut because it is weak against the shearing force by the shear, and the decorating material 23 heated at a low temperature or at a low temperature is not cut by the shear because it is strong against the shearing force. And since the end material 21a of the foamed resin base material 21 is not integrated with respect to the decorating material 23 located in the outer periphery of the shear edge part A, both are easily separated. Next, as shown in FIG. 11, after the door trim upper 20 is taken out from the molding die 40, the winding 23 a of the decorating material 23 is wound on the back side of the foamed resin base material 21 along the arrow direction. Then, the winding process can be easily performed by adhesion fixing, welding fixing, or the like.

  As described above, in the method of the present invention, the mold clearance of the molding upper and lower molds 41 and 42 at the shear edge portion A is set narrow so that the shear stress at the time of clamping the molding upper and lower molds 41 and 42 can be used. After cutting and removing the end material 21a of the foamed resin base material 21 in a softened state by heating at the edge portion A, the winding white 23a of the decorating material 23 and the end material 21a of the foamed resin base material 21 are integrated. Since it is not easily separated, the winding operation can be performed with high accuracy. Therefore, unlike the prior art, the end material 21a of the foamed resin base material 21 can be cut and removed simultaneously with molding without requiring a separate cutting step, and the terminal processing operation can be performed efficiently. In order to manufacture the above-described two-tone type door trim 10, two injection machines 43 a and 43 b are connected to the molding lower mold 42, and the molten resin M <b> 1 passes through the resin passages of the door trim upper 20 and the door trim lower 30. , M2 can be injection-filled to produce a two-tone type door trim 10 with a single molding die 40 and a reduced number of processes.

  Therefore, after the molding of the door trim upper 20 and the door trim lower 30 is completed, after the molding upper die 41 is raised and the mold is opened, the molded product is taken out from the molding die 40, and as shown in FIG. In the outer peripheral terminal, the winding terminal 23a may be wound around the back surface side of the foamed resin base material 21, and the winding terminal processing operation may be performed by adhesion fixing or welding fixing. Therefore, the cut end is not exposed to the outside, and the terminal processing of the door trim upper 20 with a good appearance of the outer peripheral terminal can be easily performed.

  Further, the molten resins M1 and M2 branched and supplied by the door trim upper 20 and the door trim lower 30 can be supplied from the single injection machine 43 as the same material. In this case, a branch manifold serving as a passage for the molten resin M1 supplied to the door trim upper 20 side from a main manifold communicating with the injection machine 43 and a branch manifold serving as a resin passage for supplying the molten resin M2 to the door trim lower 30 are set. You can do it. Moreover, although the material used as the decorating material 23 is not specifically limited, Since it is strong to the shear stress at the time of a shearing process, it is preferable to use fabric sheets, such as a woven fabric.

  Next, FIGS. 12 to 17 show a second embodiment of the present invention, which is applied to a door trim 100 which is entirely composed of a laminated structure, and is used for the same parts as the first embodiment and its manufacturing method. About the same part of the shaping die 40, the same code | symbol is attached | subjected and the detailed description is abbreviate | omitted. As shown in FIGS. 12 and 13, the door trim 100 is obtained by applying the laminated structure of the door trim upper 20 shown in the first embodiment to the entire door trim 100, and the door trim 100 is molded into a desired curved surface shape. The foamed resin base material 21 is lightweight and has shape retention, the grid-shaped and hollow resin ribs 22 are laminated and integrated on the back side thereof, and the foamed resin base material 21 is laminated and integrated on the surface side of the foamed resin base material 21. It is comprised from the decorating material 23 to be.

  Then, along the outer peripheral edge portion of the door trim 100, as shown in the first embodiment, the outer peripheral terminal portion line is trim-cut at the shear edge portion A of the molding die, and the decorative material 23 is rolled up. 23a is wound around the back side of the foamed resin base material 21, and is bonded and wound and fixed. In the door trim 100, openings are opened at a plurality of locations such as an inside handle mounting opening 110, a pull handle mounting opening 120, a pocket opening 130, and the like, and the present invention is applied to the terminal processing structure. It is a feature. For example, with respect to the opening 110 for attaching the inside handle, the opening 110 can be opened simultaneously with the molding of the door trim 100. Further, in the next step, the winding white 23a of the decorating material 23 along the opening terminal line 110a is foamed resin. The terminal treatment of the opening 110 is performed by winding adhesion or winding welding on the back surface of the base material 21.

  Next, a method for manufacturing the door trim 100 described above will be briefly described. First, the molding die has substantially the same configuration as that of the first embodiment, and the molding die 40 is composed of a molding upper die 41 and a molding lower die 42. The molding lower die 42 has one injection machine. 43, and more specifically, the molding upper die 41 is provided with a cavity portion 411 and a lifting cylinder 412, and a guide bush 413 is opened. On the other hand, for the molding lower mold 42, the molten resin M is supplied from one injection machine 43 through the manifold 422 and the gate 423, and the mold surface of the core portion 421 of the molding lower mold 42 is formed on the resin rib 22 in the door trim 100. A corresponding groove portion 424 having a predetermined pattern shape is provided over the entire mold surface of the core portion 421. And in this 2nd Example, the convex part 414 protrudes in the cavity part 411 surface of the shaping | molding upper mold 41 so that opening 110 (120,130 is not shown) can be formed simultaneously with shaping | molding of the door trim 100. FIG. The formed lower mold 42 is provided with a hole 427 corresponding to the convex portion 414.

  Therefore, first, after the foamed resin sheet S, which is the material of the foamed resin base material 21, is heated and softened to a high temperature (160 to 220 ° C.) with a heater device (not shown), the molding metal in the mold open state as shown in FIG. It puts in the type | mold 40 and mounts the decorating material 23 on the upper surface of the foamed resin sheet S. FIG.

  Then, as shown in FIG. 15, the foamed resin sheet S is drawn by clamping the molded upper and lower molds 41 and 42, and the foamed resin is formed into a required shape along the mold surface shape of the molded upper and lower molds 41 and 42. While decorating the base material 21, the decorating material 23 is integrally stuck to the surface of the foamed resin base material 21 by residual heat. Then, the molten resin M is injected and filled into the groove portion 424 from the injection machine 43 through the manifold 422 and the gate 423 at any timing after the mold clamping or before the mold clamping. The door trim 100 is formed by integrating the ribs 22 along a predetermined pattern shape. At this time, as shown in FIG. 16, a shear edge having a mold clearance of about 0 to 1 mm between the corner portion of the convex portion 414 protruding from the molding upper die 41 and the corner portion of the hole portion 427 of the molding lower die 42. Since the portion A is formed, a portion corresponding to the opening 110 of the foamed resin base material 21 is cut and removed at the shear edge portion A, and an opening is formed by the foamed resin base material 21 simultaneously with the molding of the foamed resin base material 21 can do.

  After that, as shown in FIG. 17, a slit 23b is formed in the decorative material 23 corresponding to the opening 110, and the winding 23a of the decorative material 23 along the terminal line 110a of the opening 110 is formed as a foamed resin base material. The terminal treatment of the opening 110 shown in FIGS. 12 and 13 can be easily performed by winding adhesion or winding welding on the back surface side of 21.

  Therefore, there is an advantage that the terminal processing of the opening end portion of the inside handle attachment opening 110 or the pull handle attachment opening 120 and the pocket opening 130 which are opened in the door trim 100 can be performed easily and attractively.

  In the first embodiment described above, the present invention is applied to the door trim upper 20 in the two-tone type automobile door trim 10, and in the second embodiment, the present invention is applied to the integrated door trim 100. As interior parts other than the two-tone and integrated door trims 10, 100, the present invention can be applied to all interior parts such as a rear parcel shelf, a floor trim, a trunk trim, a luggage trim, a roof trim, and a rear side trim.

It is a front view which shows the door trim for motor vehicles which applied 1st Example of this invention. It is the II-II sectional view taken on the line in FIG. It is a front view which shows the resin rib and door trim lower of the door trim upper which abbreviate | omitted the foamed resin base material in the door trim for motor vehicles shown in FIG. It is the IV-IV sectional view taken on the line in FIG. FIG. 2 is an overall view of a molding die used in the method for manufacturing the automobile door trim shown in FIG. 1. It is sectional drawing which shows the location corresponded to the door trim upper edge part in the molding die shown in FIG. It is explanatory drawing which shows the preheating process of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process to the shaping die of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material and resin rib in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the terminal process process of the door trim upper in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the terminal process process of the door trim upper in the manufacturing method of the door trim for motor vehicles shown in FIG. It is a front view which shows the door trim for motor vehicles which applied 2nd Example of this invention. FIG. 13 is a sectional view taken along line XIII-XIII in FIG. 12. It is explanatory drawing which shows the setting process of the raw material in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the opening terminal part in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim for motor vehicles shown in FIG. It is a front view which shows the conventional door trim for motor vehicles. It is the XIX-XIX sectional view taken on the line in FIG. It is a schematic diagram which shows the shaping die which shape | molds the conventional door trim. It is explanatory drawing which shows the prior art example of the terminal part in the door trim for motor vehicles by press molding. It is explanatory drawing which shows the prior art example of the terminal part in the door trim for motor vehicle of a skin-wrapping type.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Two-tone type automobile door trim 20 Door trim upper 21 Foamed resin base material 22 Resin rib 23 Decorating material 23a Roll-in white 24 Stepped flange 30 Door trim lower 40 Molding die 41 Molding upper mold 42 Molding lower mold 43 (43a, 43b) ) Injection machine 414 Convex part 427 Hole part 50 Heater device 100 Door trim for automobile 110, 120, 130 Opening A Shear edge part S Foamed resin sheet M, M1, M2 Molten resin

Claims (2)

A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention; and a resin rib (22) having a predetermined pattern shape laminated and integrated on the back surface of the foamed resin base material (21); In the automotive interior part (10) formed by adopting the laminated structure (20) composed of the decorative material (23) attached to the surface of the foamed resin base material (21) as a whole or a part thereof,
In the laminated structure (20), the foamed resin sheet (S), which is the material of the foamed resin base material (21), is heat-softened to a high temperature and put into a molding die (41, 42). A decorative material (23) subjected to heat treatment being omitted or subjected to low-temperature heat treatment is placed thereon, and the low heat pressure due to the residual heat of the foamed resin sheet (S) and the clamping of the molding dies (41, 42) The foamed resin base material (21) is molded into a required shape, and the decorative material (23) is integrated on the surface thereof, and at the shear edge portion (A) of the molding die (41, 42). The end material (21a) at the outer peripheral end portion or the open end portion of the foamed resin base material (21) is cut and removed, and the decorative material (23) is wound on the basis of the cut line at the shear edge portion (A). White (23a) of the foamed resin base material (21) Automobile interior part, wherein the processed entrainment to the surface. A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention; and a resin rib (22) having a predetermined pattern shape laminated and integrated on the back surface of the foamed resin base material (21); Manufacturing method of automobile interior part (10) formed by adopting laminated structure (20) composed of decorating material (23) attached to the surface of foamed resin substrate (21) as a whole or a part thereof In
The foamed resin sheet (S), which is the material of the foamed resin base material (21), was subjected to heat softening treatment and charged into the molding dies (41, 42), and then the heat treatment was omitted or subjected to low temperature heat treatment. The decorating material (23) is placed on the top surface of the foamed resin sheet (S), the molding dies (41, 42) are clamped together, press-molded at a low pressure, and the foamed resin base material (21) is required. While shape | molding in a shape, a decorating material (23) is affixed on the surface, and the outer periphery terminal part of a foamed resin base material (21) in a shear edge part (A) of a shaping die (41, 42), or an opening terminal The end material (21a) is cut and removed, and melted into the groove (424) of the lower mold (42) either before or after the mold clamping (41, 42). Resin (M1) is injected and filled, and the resin rib (22) is foamed resin base material. 21) is laminated and integrated on the back side of 21) to form a laminated structure (20), and then the decorative material (23) is formed on the basis of the trim cut line of the foamed resin base material (21). A laminated structure (20) is produced by being wound around and secured to the back surface of the automobile interior parts.

Images