JP2006205477A - Method for producing car interior component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a car interior component which can prevent the floating and peeling of a reinforcement sheet. <P>SOLUTION: The method for producing the car interior article in which the reinforcement sheet is arranged between a skin and a substrate includes a process in which the skin 1 is held in molds 10t and 10b having a part corresponding to a corner part 13, and a molten resin constituting the substrate is made to flow from a gate 12 to the internal space 11 of the molds. In this process, the internal space 11 has a thin-wall part (flow rate adjustment part) 15 the thickness of which is different from that of the surroundings. Because of the existence of the thin-wall part 15, the internal space 11 gives relatively strong resistance to the flow (arrow F) of the molten resin from the gate 12 supplying the molten resin to the internal space 11 toward the end part of the reinforcement sheet 14 in the corner part 13. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing automotive interior parts such as instrument panels.

Patent Document 1 discloses that a skin material (skin) is formed by powder slush molding and a mold press molding is performed to manufacture this type of automobile interior part. Disclosed is a manufacturing method for integrating the components. Further, it is disclosed that it is preferable to set a sheet-like material between the skin material and the resin core material when the adhesiveness between the resin core material and the skin material is insufficient at the time of mold press molding.
Japanese Patent No. 3298657 (paragraph numbers 0004, 0012, 0033)

  In the above-mentioned Patent Document 1, the “sheet-like material” is simply described as being attached when the adhesiveness is insufficient, and there is no specific description of where the sheet-like material is set. However, for example, an instrument panel or the like is often designed to have a three-dimensional shape that frequently uses a curved portion, a corner portion, or the like, and thus the sheet-like object may be arranged to cover the corner portion. Conceivable. Moreover, not only at the time of the mold press molding as in Patent Document 1, it is also conceivable to integrate the skin and the substrate by, for example, injection molding.

  However, if a sheet is placed at the corner of the skin and molten resin is supplied from the gate, the sheet is likely to peel off from the skin at the corner, and the appearance of the corner of the interior part will be damaged. There was a fear that there was room for improvement in this regard.

Means and effects for solving the problems

  The problems to be solved by the present invention are as described above. Next, means for solving the problems and the effects thereof will be described.

  ◆ According to the first aspect of the present invention, the skin and the substrate are integrated into a shape having a corner portion, and at least part of the corner portion is between the skin and the substrate. A method for manufacturing an interior product for an automobile with a reinforcing material interposed therebetween, and the following manufacturing method is provided. The method includes a step of holding the outer skin inside a molding die having a portion corresponding to the corner portion and flowing a molten resin constituting the base material into an inner space of the die. In the step, the inner space of the mold has a thick part or a thin part whose thickness is different from the surroundings. The “molten resin” includes semi-molten resin.

  According to this configuration, the thick-walled portion or the thin-walled portion can cause a deviation in the flow of the molten resin in the internal space. As a result, the reinforcing material at the corner portion can be lifted off the skin. Peeling can be prevented. Therefore, it is possible to obtain an automobile interior product having an excellent surface appearance at the corner portion.

  ◆ According to the second aspect of the present invention, the skin and the base material are integrated into a shape having a corner portion, and at least part of the corner portion is between the skin and the base material. A method for manufacturing an interior product for an automobile with a reinforcing material interposed therebetween, and the following manufacturing method is provided. The method includes a step of holding the outer skin inside a molding die having a portion corresponding to the corner portion and flowing a molten resin constituting the base material into an inner space of the die. In the above step, the internal space of the mold has a flow rate adjusting unit whose flow path resistance is different from that of the surrounding area.

  According to this configuration, the flow rate adjusting unit can cause the flow of the molten resin in the internal space to be biased, and as a result, prevent the reinforcing material from floating or peeling off from the skin at the corner portion. it can. Therefore, it is possible to obtain an automobile interior product having an excellent surface appearance at the corner portion.

  In the method for manufacturing an automotive interior product, the inner space of the mold is against the flow of molten resin from the gate supplying the molten resin to the inner space toward the end of the reinforcing material in the corner portion. It is preferably configured in a shape that imparts a relatively large resistance.

  Thereby, the flow which goes into the area | region of the said reinforcing material from the edge part side of the said reinforcing material so that a corner part may be followed can be made small. As a result, it is possible to reliably prevent the reinforcing material from floating or peeling off from the skin at the corner portion.

  In the method for manufacturing an automobile interior product, the thick part, the thin part, or the flow rate adjusting part is preferably provided in the vicinity of a gate that supplies the molten resin to the internal space of the mold.

  As a result, the action of the thick part or thin part or the flow rate adjusting part (flow rate adjusting action) works more directly on the flow of the molten resin injected from the gate. Can be produced.

  In the method for manufacturing an automobile interior product, in the step, after the molten resin is filled into the internal space corresponding to the corner portion, the thickness of the thick or thin portion or the flow rate adjusting portion in the internal space Is preferably equal to the thickness of other portions.

  Thereby, the thickness of the interior product for automobiles finally completed can be made uniform.

  In the method for manufacturing an automotive interior product, it is preferable that the thickness of the thick portion, the thin portion, or the flow rate adjusting portion in the internal space is made equal to the thickness of the other portion by sliding the slide core. .

  Thereby, the operation for making the thickness of the automobile interior part uniform is easy, and the configuration of the mold can be simplified.

  First, a middle pad part as an example of an automotive interior manufactured by the manufacturing method of the present invention will be described in detail. FIG. 1 is an overall perspective view showing an instrument panel having a middle pad portion together with a console box and the like, and FIG. 2 is a perspective view showing a passenger seat side middle pad portion. 3A is a cross-sectional view taken along the line XX in FIG. 2, and FIG. 3B is a cross-sectional view showing a state when the airbag is inflated.

  FIG. 1 is an overall perspective view of the instrument panel 50 in a state where the console box 51, the lower panel 52, and the glove box 53 are assembled. The manufacturing method of the present invention is suitable, for example, when manufacturing a part (reference numeral 54) of the passenger seat side middle pad portion of the instrument panel 50 among the automobile interior parts shown in FIG.

  FIG. 2 is an enlarged perspective view of the passenger seat side middle pad portion 54, and FIG. 3 (a) is a sectional view taken along line XX of FIG. As shown to Fig.3 (a), the middle pad part 54 is equipped with the base material 2 and the skin 1 which covers the whole surface (surface at the side of a passenger | crew). An airbag (not shown) can be disposed on the back side of the middle pad portion 54.

  As shown in FIG. 2, an air conditioner outlet 19 is formed in the passenger seat side middle pad portion 54 in a penetrating manner. Further, as shown in FIG. 2 and FIG. 3A, an angular corner portion 13 is formed on the middle pad portion 54.

  The passenger seat side middle pad portion 54 is formed with breakable easy lines 16a to 16e with weakened strength so that the airbag can be easily broken when the airbag is inflated to form an opening in a predetermined region A. . These easy-to-break lines 16a to 16e can be formed, for example, by arranging fine through holes that are normally impossible to see from the passenger at appropriate intervals.

  As shown in FIG. 2, the easy break lines 16 a to 16 e are two split vertical lines 16 a and 16 b extending in the vertical direction, a split horizontal line 16 c extending in the horizontal direction at the center in the vertical direction, and the cleavage line 16 c arranged above and below the split vertical line 16 a It comprises two hinge lines 16d and 16e extending substantially parallel to the horizontal line 16c.

  As a result, when the airbag is inflated, the inflating airbag presses the back surface of the region A. As a result, the split vertical lines 16a and 16b and the split horizontal line 16c are broken, and the hinges as shown in FIG. Upper and lower double doors 17 and 18 that rotate around the lines 16d and 16e are formed in the region A of the middle pad portion 54.

  Further, as shown in FIG. 2 and the like, two flexible thin reinforcing sheets 14 and 14 are provided on the back side (between the outer skin 1 and the base material 2) of the outer skin 1 of the passenger seat side middle pad portion 54. Buried. As shown in FIG. 2 and FIG. 3A, the reinforcing sheet 14 is installed so as to straddle the two hinge wires 16d and 16e, and not to straddle the cleavage horizontal line 16c. Yes. With this configuration, the hinge wires 16d and 16e are prevented from being completely broken when the airbag is inflated (see FIG. 3B), and the door portions 17 and 18 are cut off and separated from the middle pad portion 54. To prevent that.

  As shown in FIG. 3A, the upper reinforcing sheet 14 is interposed between the skin 1 and the base material 2 so as to straddle the corner portion 13. As shown in FIG. 2, the upper reinforcing sheet 14 is installed so as to cover a part of the corner portion 13.

  Next, with reference to FIG. 4A and FIG. 4B, an injection molding process for manufacturing the middle pad portion 54 by integrating the skin 1 and the substrate 2 will be described. FIG. 4A is a schematic view seen from the bottom side at the time of injection molding, and FIG. 4B is a cross-sectional view taken along the line PP in FIG. FIG. 5 is a cross-sectional view taken along the line Q-Q in FIG. FIG. 6 is a partial cross-sectional view showing the vicinity of the corner portion of the middle pad portion after injection molding.

  In addition, the said skin 1 shall be manufactured previously in the step before this injection molding process. This skin 1 is composed of a skin layer formed by powder slush molding and a foam layer formed by laminating foamed plastic around the back side, and is manufactured by, for example, a known method as shown in Patent Document 1 above. can do.

  In the injection molding step, the skin 1 is held in close contact with the mold surface of the injection molding upper mold 10t by vacuum suction. On the other hand, the lower mold 10b is provided with a gate 12 for introducing molten resin (which constitutes the base material 2) extruded by a plunger or the like into the internal space 11 of the mold.

  The internal space 11 is configured to have a corner portion 13 ′. As a result, the middle pad portion 54 as a finished product has a shape having the corner portion 13 corresponding to the corner portion 13 ′. A flexible reinforcing sheet 14 is previously installed on the back surface of the skin 1 held in the internal space 11 so as to straddle the inside of the corner portion 13 ′.

  In the injection molding step shown in FIG. 4, the molten resin supplied from the gate 12 is directed to the end of the reinforcing sheet 14 in the internal space 11 formed by the upper mold 10t and the lower mold 10b. A thin portion (flow rate adjusting portion) 15 is provided in the vicinity of the gate 12 so as to restrict the flow. In other words, the contours of the mold surfaces of the upper mold 10t and the lower mold 10b are determined so that the thin portion 15 having a smaller thickness than the periphery is formed in the vicinity of the gate 12.

  As shown in FIG. 5, a slide core 20 is installed in the lower mold 10 b at a position corresponding to the thin portion 15, and the slide core 20 is connected to a movable portion of the hydraulic cylinder 21. In the state shown in FIG. 5, the end portion of the slide core 20 protrudes from the internal space 11, thereby forming the thin portion 15. From this state, the hydraulic cylinder 21 is driven to move the slide core 20. By sliding in the retracting direction (arrow), the thickness of the thin portion 15 can be changed to be equal to the surrounding thickness.

  When the molten resin is supplied from the gate 12 with the above configuration, a flow of the molten resin is formed in the internal space 11 as shown by a white arrow in FIG. 4A (the flow rate increases as the arrow is thicker). Indicates big). As shown in FIG. 4A, the flow F of the molten resin directly from the gate 12 to the end of the reinforcing sheet 14 in the corner portion 13 is limited by the thin portion 15. Accordingly, it is possible to suppress the flow G of the molten resin that enters the region of the reinforcing sheet 14 from the end of the reinforcing sheet 14 at the corner portion 13 (13 '). In other words, the flow H entering the region of the reinforcing sheet 14 toward the corner 13 (13 ′) rather than the flow G entering the region of the reinforcing sheet 14 along the corner 13 (13 ′), It can be relatively strong.

  As a result, as shown in FIG. 6, peeling of the reinforcing sheet 14 at the corner portion 13 and floating (in other words, lifting of the skin 1 from the reinforcing sheet 14 at the corner portion 13) is prevented. The surface appearance of the corner portion 13 of the portion 54 can be kept good.

  FIG. 7 shows a case where the thin portion (flow rate adjusting portion) 15 is not provided as a comparative example. In the case of this comparative example, as shown in FIG. 7A, to the end portion of the reinforcing sheet 14 in the corner portion 13. The molten resin flow F directed directly from the gate 12 is strong. Therefore, the molten resin flow G entering the region of the reinforcing sheet 14 from the end of the reinforcing sheet 14 along the corner portion 13 becomes too strong. G peels off or floats from the skin 1 of the reinforcing sheet 14 due to the influence of G (part indicated by reference numeral s in FIG. 8). In this regard, in the embodiment (FIG. 4), by providing the thin portion 15, the flow G along the corner portion 13 is suppressed, while the flow H of the molten resin toward the corner portion 13 is increased. As a result, the reinforcing sheet 14 can be prevented from peeling off or floating (FIG. 6).

  After filling the corner portion 13 with a sufficient amount of resin while controlling the flow of molten resin to be biased in this way, the hydraulic cylinder 21 is driven and the slide core 20 is moved as shown by the arrow in FIG. By retracting, the thickness of the thin portion 15 of the internal space 11 is made equal to the thickness of the surrounding portion (in other words, the thin portion 15 is lost). Thereby, the thickness of the middle pad part 54 after shaping | molding can be made uniform. After this, after removing the resin from the mold and performing a predetermined finishing process such as deburring, the middle pad part 54 as a finished product can be obtained.

  As described above, the method for manufacturing the middle pad portion 54 of the present embodiment is such that the molding die 10t · 10b has a portion (corner portion 13 ′) corresponding to the corner portion 13 of the middle pad portion 54. The process includes a step of flowing molten resin constituting the base material 2 into the internal space 11 in a state where the skin 1 is held in the internal space 11 of this type. As shown in FIG. 4A, in this step, the inner space 11 of the mold has a thin portion (in other words, a flow rate adjusting portion whose flow resistance is different from the surroundings) 15 whose thickness is different from the surroundings. ing.

  As a result, the flow of the molten resin in the internal space 11 can be biased, and as a result, the reinforcing sheet 14 can be prevented from being lifted or peeled off from the skin 1 at the corner 13.

  In addition, by changing the shape of the thin wall portion (flow rate adjusting portion) 15 in various ways, it is possible to finely control the deviation of the flow of the molten resin and reduce the number of gates 12. That is, as a method of causing a deviation in the flow of the molten resin, a method in which a plurality of gates 12 are provided and the flow rates from the respective gates 12 are different from each other can be considered. In addition, the number of man-hours increases and the manufacturing cost increases. Although a method of changing the flow rate with a gate controller can be considered, this method can change the flow rate of the molten resin as a whole, but it is difficult to change the flow rate partially (locally). is there. In this respect, this embodiment does not have such a problem.

  Further, as shown in FIG. 4A, the inner space 11 of the mold is provided with the thin portion (flow rate adjusting portion) 15, so that the reinforcement from the gate 12 to the corner portion 13 (13 ′) is performed. It is configured in a shape that gives a relatively large resistance to the flow F of the molten resin toward the end of the sheet 14. As a result, the flow G entering the region of the reinforcing sheet 14 along the corner 13 (13 ′) can be reduced. As a result, the reinforcing sheet 14 can be lifted or peeled off from the skin 1 at the corner 13. Can be prevented.

  Further, as shown in FIG. 4A, the thin portion 15 is provided in the vicinity of the gate 12. Accordingly, the flow rate adjusting action of the thin wall portion (flow rate adjusting portion) 15 works more directly on the flow of the molten resin injected from the gate 12, and the deviation of the flow of the molten resin can be effectively created.

  Moreover, in the said embodiment, after filling the interior space (corner part 13 ') equivalent to the said corner part 13 with molten resin, the thickness of the said thin part 15 in the said internal space 11 is set to the thickness (periphery) of the other part. The thickness). Thereby, the middle pad part 54 with uniform thickness can be obtained. Further, since the thickness of the thin portion 15 is made equal to the surrounding thickness by sliding the slide core 20 by the hydraulic cylinder 21, an operation for making the thickness of the middle pad portion 54 uniform is easy and the configuration can be simplified.

  Although the manufacturing method of this embodiment was demonstrated above, said embodiment can be changed further as follows.

  (1) Although the manufacturing method of the middle pad part 54 was demonstrated above, if it is components which have reinforcements, such as a reinforcement sheet, in a corner part, other interior parts for motor vehicles, for example, the console box 51 shown in FIG. 1, lower panel, etc. 52 and glove box 53 can also be applied to the manufacturing method.

  (2) The corner portion may have an angular shape to some extent, and may be not only a substantially perpendicular corner portion 13 as shown in FIG.

  (3) The reinforcing sheet 14 may be installed not only when covering a part of the corner portion 13 as shown in FIG. 2 but also covering the entire corner portion. Further, the present invention is not limited to the purpose of reinforcing the hinge portion of the door portions 17 and 18 that rotate when the airbag is inflated, and is installed to reinforce other portions or the middle pad portion 54 itself. May be.

  (4) The position, number, and shape of the thin wall portions 15 provided in the internal space 11 are not limited to the case shown in FIG. 4A, and can be changed as desired.

  (5) Instead of providing the thin portion 15 in the internal space 11, the portion may have a normal thickness, and the other portion may be a thick portion having a larger thickness than usual to facilitate the flow of the molten resin. Even in this configuration, it is possible to give a relatively large resistance to the molten resin flow F from the gate 12 toward the end of the reinforcing sheet 14 at the corner portion 13 (13 '). In this case, the thick part corresponds to the flow rate adjusting part. Furthermore, the structure which provides both a thin part and a thick part may be sufficient.

  (6) The configuration for making the thin wall portion and the thick wall portion (flow rate adjusting portion) equal to the surrounding thickness is not limited to the slide core 20, and other configurations may be used. Further, the slide core 20 is not limited to a system driven by the hydraulic cylinder 21, but may be driven by an air cylinder, or a cam guide type or a spring type may be used. Further, the slide core 20 may be provided only for changing the thickness of the thin portion 15, and is also used as a slide core for extracting the undercut portions of the upper mold 10t and the lower mold 10b for injection molding. May be.

  (7) Not only when the middle pad portion 54 is molded by injection molding, any molding method may be used as long as it is molded by pouring a molten resin into the mold.

The whole perspective view which shows an instrument panel provided with a middle pad part with a console box etc. FIG. The perspective view which shows a passenger seat side middle pad part. 3A is a cross-sectional view taken along line XX in FIG. 2, and FIG. 3B is a cross-sectional view showing a state when the airbag is inflated. 4A is a schematic diagram showing the shape of the internal space and the flow of the molten resin during injection molding, and FIG. 4B is a cross-sectional view taken along the line PP in FIG. 4A. The QQ sectional view taken on the line in FIG. The partial cross section figure which shows the corner part vicinity of the middle pad part after injection molding. Fig.7 (a) is a schematic diagram which shows the shape of the internal space at the time of injection molding of a comparative example, and the flow of molten resin, FIG.7 (b) is the RR sectional view taken on the line of the RR line of Fig.7 (a). The partial cross section figure which shows the corner part vicinity of the middle pad part after injection molding in the said comparative example.

Explanation of symbols

1 skin 2 base material 10t upper mold for injection molding (molding mold)
10b Lower mold for injection molding (molding mold)
11 Internal space 13 Corner 13 'Corner of internal space 14 Reinforcement sheet (reinforcing material)
15 Thin part (flow rate adjustment part)
20 Slide core 54 Passenger side middle pad part of the instrument panel (car interior parts)

Claims (6)

Manufacture of automobile interior parts in which a skin and a base material are integrated to form a shape having a corner portion, and a reinforcing material is interposed between the skin and the base material in at least a part of the corner portion. A method,
Holding the skin inside a molding die having a portion corresponding to the corner portion, and including flowing a molten resin constituting the base material into the inner space of the die,
In the above process, the interior space of the mold has a thick or thin part whose thickness is different from the surrounding area. Manufacture of automobile interior parts in which a skin and a base material are integrated to form a shape having a corner portion, and a reinforcing material is interposed between the skin and the base material in at least a part of the corner portion. A method,
Holding the skin inside a molding die having a portion corresponding to the corner portion, and including flowing a molten resin constituting the base material into the inner space of the die,
In the above process, the interior space of the mold has a flow rate adjusting portion whose flow path resistance is different from that of the surrounding space. It is a manufacturing method of the interior product for automobiles according to claim 1 or 2,
The internal space of the mold is shaped to give a relatively large resistance to the flow of molten resin from the gate supplying the molten resin to the internal space toward the end of the reinforcing material in the corner portion. The manufacturing method of the interior goods for motor vehicles characterized by being comprised. It is a manufacturing method of the interior goods for vehicles according to any one of claims 1 to 3,
The method for manufacturing an interior product for an automobile, wherein the thick part, the thin part, or the flow rate adjusting part is provided in the vicinity of a gate that supplies the molten resin to the internal space of the mold. It is a manufacturing method of the interior item for cars according to any one of claims 1 to 4,
In the step, after the molten resin is filled in the internal space corresponding to the corner portion, the thickness of the thick or thin portion or the flow rate adjusting portion in the internal space is made equal to the thickness of the other portions. A method for producing an interior product for an automobile. It is a manufacturing method of the interior goods for cars according to claim 5,
A method for manufacturing an interior product for an automobile, wherein the thickness of the thick or thin portion or the flow rate adjusting portion in the internal space is made equal to the thickness of the other portion by sliding the slide core.

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