JP2006231535A - Manufacturing method of trim component for car - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve weight reduction and cost reduction while simplifying a terminal treatment process in a manufacturing method of a trim component for a car. <P>SOLUTION: A trim component (door trim) 10 is constituted of a laminated structure (door trim upper) 20 and a resin single product (door trim lower) 30. The door trim upper 20 is composed of a foamable resin base material 21 and a resin rib 22 and, if desired, a decorative material 23 is laminated to the surface of a product. Accordingly, the weight reduction and cost reduction of the trim component are achieved by abolishing the resin core material increasing in volume. Further, when the foamable resin base material 21 is heated and softened by a heating fixture 70 in the outer peripheral terminal part of the door trim upper 20, the heating fixture 70 is composed of two stages of a low temperature heater 71 and a high temperature heater 72 and a folding fulcrum part 213 is sufficiently heat-treated using the high temperature heater 72 while a folding allowance 24 is heat-treated by the low temperature heater 71 not only to eliminate the unevenness of a molten surface but also to enable smooth folding work. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing interior parts for automobiles such as door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, roof trims, etc., and in particular, the appearance and strength of the outer peripheral terminal portions are excellent, The present invention relates to a method for manufacturing automobile interior parts that can be easily and inexpensively manufactured.

  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 attachment rigidity to the door panel, and is configured by laminating and integrating a skin 3 excellent in surface appearance on the surface of the resin core material 2 that extends over almost the entire product surface. . The resin core material 2 is made of polypropylene resin mixed with talc, and the skin 3 does not have a shape-retaining property itself and is a single sheet material of a synthetic resin sheet such as a vinyl chloride sheet. Or, a laminated sheet material in which a cushioning material such as polyethylene foam is laminated on the back side of a synthetic resin sheet is used, and recently, an elastomer such as a thermoplastic olefin (hereinafter referred to as TPO) sheet in consideration of environmental aspects and recycling aspects. Sheets tend to be used frequently.

  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. 15, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state, but actually, 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.

  Further, regarding the processing of the outer peripheral terminal of the door trim 1 product, as shown in FIG. 16, after the outer skin 3 is simultaneously press-molded on the surface of the core material 2, the core material 2 and the outer skin 3 are formed by the mold blade in the mold. The piercing cut process is performed in a separate process after the piercing cut process or molding. In addition, as shown in FIG. 17, after the core material 2 is press-molded, the skin 3 is integrated by vacuum pressing, press-bonding, etc. 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.

  Further, at the outer periphery of the door trim 1, as shown in FIG. 16, when the outer skin simultaneous press molding is performed, the outer peripheral terminal processing is difficult, the appearance is not good, and the appearance performance is deteriorated. As shown in FIG. 3, the method of winding the skin 3 in a separate process requires a large number of man-hours and inevitably increases costs.

  The present invention has been made in view of such circumstances, and is a method for manufacturing an interior part for automobiles that can promote weight reduction, can achieve high rigidity, and can reduce costs. In particular, an object of the present invention is to provide a method for manufacturing an interior part for an automobile having improved appearance performance by enhancing the appearance and rigidity of the outer peripheral terminal portion of the product.

  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. Resin with excellent rigidity at locations where high rigidity is required, i.e. it can be intimately contacted with 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 The ribs are arranged and the other parts are hollowed out to reduce the weight compared to the conventional resin core material with a large projected area. It is found that the terminal treatment can be achieved easily and beautifully by softening and melting the winding polymerization part along the heating jig with a heating jig and simplifying the operation of the heating jig and the winding mechanism part, Which resulted in the completion of the invention.

  That is, the 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 retention, and a predetermined pattern that is laminated and integrated on the back surface of the foamed resin base material. In a manufacturing method of an interior part for an automobile, in which a laminated structure composed of resin ribs having a shape is adopted in whole or in part, the manufacturing method of the laminated structure is a foamed resin sheet that is a material of a foamed resin base material After heat softening treatment, after setting in the mold, the molds are clamped together to form the foamed resin base material into the required shape along the cavity shape of the mold, A laminated structure in which molten resin is injected and filled from the injection machine into the groove of the molding die either before or after mold clamping, and the resin rib is laminated and integrated on the back side of the foamed resin base material. Molding process and the molding The laminated structure formed in the above step is removed from the molding die, and the laminated structure is set on the receiving jig, and then the heating jig in which the low-temperature heater is arranged on the top and the high-temperature heater is arranged on the outside Is brought close to or in contact with the back surface side of the foamed resin base material at the edge of the laminated structure, and the winding fulcrum part of the foamed resin base material is sufficiently softened and melted by a high-temperature heater, and the heating jig After raising the winding piece located outside and elevating the winding wire from the corner of the heating jig along the outer surface, heat softening with a low-temperature heater, and then retracting the heating jig , A sliding operation of the winding piece along the winding direction, the winding piece is wound on the back side of the foamed resin base material by the winding piece, and then the terminal processing step of the laminated structure is fixed by welding. It is characterized by.

  Here, the automobile interior parts can be applied to door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, roof trims, and the like. In addition, when the foamed resin base material constituting a part of the laminated structure is close to a flat shape, the heat softening step is omitted and a desired shape is formed by a mold, but this 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 sufficient 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, you may laminate | stack and integrate a decorating material on the surface of a foamed resin base material. As this decorating material, a synthetic resin sheet such as a TPO sheet, a thermoplastic plastic urethane (hereinafter referred to as TPU) sheet or a vinyl chloride sheet, or a fabric sheet such as a woven fabric, a nonwoven fabric or a knitted fabric, or a synthetic resin film, a foam or a net-like material It can also be used in the form of a single sheet such as an article, or in the form of a laminated sheet material in which a back surface of a synthetic resin sheet or a fabric sheet is lined with a cushion layer such as polyethylene foam, polypropylene foam or polyurethane foam. 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.

  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.

  And according to the manufacturing method of the interior component for automobiles according to the present invention, the laminated structure employed for the whole interior component or a part thereof is strengthened on the back side of the foamed resin base material having shape retention. In this sense, since the resin ribs are laminated and integrated, the conventional resin core material 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. Furthermore, for the outer peripheral edge of the laminated structure, the winding point of the outer portion of the laminated structure is wound around the rising point, so that the cut end is not conspicuous on the outside, the appearance design is excellent, and the terminal In the portion, the foamed resin base material has a double structure, and the rigidity can be enhanced.

  Here, the molding die used in the method of the present invention is connected to a molding upper mold that can move up and down by a predetermined stroke, a molding lower mold that is a fixed side located below the molding upper mold, and a molding lower mold. It consists of an injection machine. The molten resin supplied from the injection machine is supplied to the mold surface of the molded lower mold through a resin passage such as a manifold and a gate provided in the molded lower mold, and more specifically, into a groove formed on the mold surface of the molded lower mold. Is done. In addition, after the upper mold is lowered to the bottom dead center and the upper and lower molds are clamped, the molten resin may be injected and filled into the groove provided on the mold surface of the lower mold with a predetermined injection pressure. The injection timing of the molten resin may be performed before mold clamping.

  By clamping the upper and lower molds, the foamed resin sheet is molded into a desired curved surface shape along the mold surface shape of the molding die, and the resin is injected on the back surface of the foamed resin base material by injection filling with molten resin. Ribs are laminated and integrated. At this time, after performing the heat softening process with a heater or the like in the previous step, the foamed resin sheet is set in a molding die. And simultaneously with shaping | molding of a foamed resin base material, what is necessary is just to laminate | stack and integrate a resin rib on the back surface of a foamed resin base material. In the case where the final product shape has a high development rate portion, it is preferable to perform mold clamping of the molding die a plurality of times and perform injection filling of the molten resin in the final mold clamping process. In addition, if the product shape includes a portion with a higher development ratio, a vacuum suction mechanism is provided in the molding upper mold, and the foamed resin base material is molded into the required shape by the vacuum suction force along the mold surface of the molding upper mold. Good to do.

  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. At the same time, the amount of resin is small, material costs can be saved, and the cooling time is shorter than that of conventional resin cores, so that the product molding cycle can be shortened.

  Next, as a terminal processing apparatus used for terminal processing of a laminated structure, a foamed resin base material that is molded into a required shape and is lightweight and has shape retention properties, and laminated on the back surface of the foamed resin base material are integrated. A terminal processing apparatus for performing a terminal treatment of a foamed resin base material along an edge of the laminated structure after forming a laminated structure composed of resin ribs having a predetermined pattern shape with a molding die. The apparatus includes: a receiving jig for setting the laminated structure; a heating jig for heating and softening the foamed resin base material in the laminated structure set on the receiving jig; and a foamed resin base material subjected to heat softening treatment. A winding mechanism having a winding piece that winds the winding sheet on the back surface of the main body, and the heating jig includes a low-temperature heater that heats the winding sheet to a relatively low temperature, and a winding fulcrum High temperature heater to heat the part Characterized by comprising the two upper and lower stages of the heater.

  Here, the receiving jig is composed of a set base for setting the laminated structure, a spacer for fixing the laminated structure set on the set base, and a receiving jig holder. In addition, as a heating jig, a heater support provided with upper and lower two-stage heaters is supported so that it can move up and down, and as upper and lower two-stage heaters, a low temperature heater is provided in the upper stage and a high temperature heater is provided in the lower stage, respectively. Has been placed. Further, as the winding mechanism, a rectangular parallelepiped winding piece is driven forward and backward by the forward / backward cylinder in the winding direction of the winding white, and the table supporting the forward / backward cylinder is moved vertically by the table driving cylinder. It is a configuration to be driven. Accordingly, the winding piece moves in the winding direction and the up and down direction of the winding roller by driving the advance / retreat cylinder and the table.

  Next, as a terminal processing method of the laminated structure, the laminated structure is removed from the molding die, the laminated structure is set on the set stand and fixed by the holding jig holder, and then the heating jig is moved up and down the cylinder. In this case, the lower side high-temperature heater is brought close to or in contact with the vicinity of the winding fulcrum of the foamed resin substrate. Is done. After that, the winding piece in the winding mechanism part rises to raise the winding base of the foamed resin base material, and the part near the winding fulcrum part is heated by contact with the high temperature heater, and the upper part thereof Is not heated excessively by the low-temperature heater, and is moderately heated. After that, after the heating jig is retracted upward, the winding piece in the winding mechanism unit is slid to return the winding white to the main body side and weld and integrate.

  Therefore, since the terminal processing part of the laminated structure is a double structure in which a winding scissor is wound, the rigidity can be enhanced, there is no deformation, the cut end is not exposed, and the appearance is also preferable. In addition, there is no need for a separate adhesive application process, drying process, etc., and after the heat softening treatment of the foamed resin base material, when the heat softened part is cooled and solidified, the wrapping white is integrated, so an adhesive-less structure Therefore, the terminal processing man-hour can be simplified.

  Furthermore, the heating jig has two upper and lower heaters with different temperature differences, and the winding fulcrum is heated easily with a high-temperature heater so that the folding operation can be easily performed. However, the entrainment with a good appearance is achieved. In addition, the parts other than the winding fulcrum are prevented from being overheated by a low-temperature heater and softened at an appropriate temperature, so that it is less likely to follow a heating jig in which the molten resin advances and retracts. It is possible to suppress the occurrence of unevenness on the melt surface. Therefore, the appearance performance of the terminal processing unit can be enhanced, for example, the position of the winding fulcrum portion is constant and a uniform thickness can be secured.

  As described above, according to the method for manufacturing an automotive interior part according to the present invention, the laminated structure constituting the whole or a part of the automotive interior part is lightweight and has a shape retaining property. And the resin rib that is laminated and integrated on the back side of this foamed resin base material and the parts that require rigidity, such as the outer periphery of the product. Therefore, since it is lightweight, low-cost, and is a porous material, it has an effect of providing an automotive interior part having excellent sound absorption performance.

  Furthermore, according to the method for manufacturing an automotive interior part according to the present invention, the foamed resin base material is molded along the cavity shape of the molding die, and at the same time, the resin rib is integrated on the back surface side of the foamed resin base material. Because of the configuration, the projected area of the resin rib is less than that of the conventional resin core material, so the load on the molding die is small, the cooling time can be shortened, and the yield can be increased, thus increasing the work efficiency. , It has the effect of bringing about a significant cost reduction.

  Further, according to the method for manufacturing an automotive interior part according to the present invention, after forming the laminated structure, the laminated structure is taken out from the molding die, and the heating jig is provided on the back side of the outer peripheral edge of the laminated structure. Heating and softening treatment is performed by approaching or abutting. Particularly, the winding fulcrum is sufficiently heated by a high-temperature heater so that the bending operation can be performed smoothly and the position of the winding fulcrum is stable. In addition to being obtained, the other parts are suppressed by excessive heating by a low-temperature heater, and moderate heating is performed. Therefore, it is possible to prevent unevenness on the molten surface when the heating jig is retracted, and the accuracy is improved. A good winding process can be performed, and the thickness dimension of the winding roller can be kept constant. For example, a sharp and accurate outer peripheral line can be formed, and the appearance design is excellent. Furthermore, since the terminal portion has a double structure in which the winding wrap is folded back, the rigidity is enhanced, and there is no undulation failure, etc., and the alignment accuracy with respect to the panel or adjacent mating parts can be increased, and the processing time can be increased. Can be shortened and productivity can be increased.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a preferred embodiment of a method for manufacturing an automotive interior part according to the present invention will be described with reference to an automotive door trim and a method for manufacturing the same.

  1 to 12 show an embodiment of the present invention, FIG. 1 is a front view showing a two-tone type automobile door trim, FIG. 2 is a cross-sectional view showing the configuration of the automobile door trim, and FIG. FIG. 4 is a cross-sectional view showing the structure of a terminal processing portion of the door trim upper in the door trim for the automobile, and FIGS. 5 and 6 show the molding process of the door trim for the automobile. FIG. 7 is an explanatory diagram showing a configuration of a terminal processing apparatus used for terminal processing of the door trim upper, and FIGS. 8 to 12 are explanatory diagrams showing terminal processing steps in the door trim upper.

  1 and 2, a two-tone type automobile door trim 10 is composed of an upper and lower divided body 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. On the side, the speaker grill 15 is formed integrally with or separately from the door trim lower 30.

  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 door panel.

  The foamed resin substrate 21 is heat-molded into a required shape after heat-softening the foamed resin sheet so as to have shape retention, for example, cold press-molded with a molding die having a desired mold surface. About the high expansion | deployment rate part, you may shape the foaming resin base material 21 by vacuum forming. 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, etc. can be used. As foaming agents, azo compounds, sulfohydrazide compounds, nitroso compounds, azides Organic foaming agents such as compounds 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. 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 side of the foamed resin base material 21, and in particular, as shown in FIG. 3, are set in a predetermined pattern extending in an intersecting manner, and are terminals along the outer peripheral edge of the door trim upper 20. In the (winding portion), there is a portion where the resin rib 22 is not provided. 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 made of a laminated structure and the door trim lower 30 made of a single synthetic resin, and has excellent appearance design due to the accent effect on the appearance. It has. 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 weight of the resin core material occupied over the entire circumference of the product as in the past can be eliminated and the lightweight foamed resin base material 21 is used. In addition, the weight can be reduced by 40% or more, the resin material can be saved significantly, and the cost can be reduced.

  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 property of the foamed resin base material 21, the decorating material 23 previously laminated on the surface of the foamed resin base material 21 or integrated at the time of molding is a woven fabric, a nonwoven fabric, a knitted fabric. A fabric sheet having air permeability such as the above is preferable. The decorative material 23 is not only a fabric sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric, but also a single sheet such as a synthetic resin sheet such as a TPO sheet, a TPU sheet, and a vinyl chloride sheet, a synthetic resin film, a foam, and a net-like body. Can be used. Moreover, the laminated sheet material which backed cushion layers, such as a polyethylene foam, a polypropylene foam, a polyurethane foam, can be used for the back surface of a synthetic resin sheet or a fabric sheet. In addition, when a TPO sheet is used, since it can unify with an olefin resin material, it is advantageous in terms of recycling.

  Next, the terminal processing structure along the outer periphery of the door trim upper 20 in the door trim 10 will be described with reference to FIG. That is, as described above, the door trim upper 20 is integrated with the resin ribs 22 that reinforce the rigidity on the back surface of the lightweight foamed resin base material 21 having shape retention, and on the surface of the foamed resin base material 21. The decorative material 23 having a decorative property is laminated and integrated. Further, a vertical wall flange portion 211 extends downward (door panel 16) along the product outer periphery of the door trim upper 20, and the distal end portion of the vertical wall flange portion 211 is connected to the door panel 16. An extension part 212 is horizontally extended in parallel, and the extension part 212 is wound and fixed to the foamed resin base material 21 side of the extension part 212 based on the winding fulcrum part 213. The terminal processing unit A is in contact with the door panel 16 in an abutting state.

  Therefore, the terminal processing part A of the door trim upper 20 does not expose the cut end, and the wrapping white 24 is folded and fixed to the back surface side of the extension part 212. In particular, the winding fulcrum part 213 corresponds to the outer peripheral line of the door trim upper 20, so that a sharp outer peripheral line can be secured, the appearance is excellent, and the winding white 24 is fixed to the back surface of the extension part 212. Due to the double structure, there is an advantage that the rigidity of the terminal portion can be enhanced, there is no fear of undulation deformation and the like, it can be tightly adhered to the door panel 16 and the alignment accuracy can be increased. Further, even when the mating shape is provided with a certain clearance with the counterpart part, the mating accuracy can be increased.

  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, a molding die 40 used for molding the door trim 10 will be described with reference to FIGS. As shown in FIG. 5, a molding die 40 used for molding the door trim 10 includes a molding upper die 41 that can move up and down by a predetermined stroke, a fixed molding lower die 42 that forms a pair with the molding upper die 41, and molding. This is mainly composed of two injection machines 43 a and 43 b connected to the lower mold 42. 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.

  Subsequently, each process of the manufacturing method of the door trim 10 mentioned above is demonstrated. First, what laminated the decorating material 23 on the one side of the foamed resin sheet S with a heater apparatus (not shown) is heat-softened to predetermined temperature. As this foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumika Plustech, trade name: Sumiceller foam PP sheet, foaming magnification = 3 times, thickness 3 mm) is used in this embodiment. Subsequently, as shown in FIG. 5, the heat-softened foamed resin sheet S (with the decorative material 23 laminated) is formed between the cavity portion 411 of the molding upper mold 41 and the molding lower mold 42 at the location corresponding to the door trim upper 20. Set in the upper half of the cavity defined by the core part 421.

  Then, after setting the foamed resin sheet S, the molding upper die 41 is lowered by a predetermined stroke by driving the elevating cylinder 412 in the molding upper die 41, and the molding upper and lower dies 41, 42 are clamped as shown in FIG. Then, the foamed resin sheet S is shaped along a desired mold surface shape, and the foamed resin base material 21 is molded. Further, in order to form the resin rib 22 in the door trim upper 20 from the first injector 43a through the manifold 422a and the gate 423a, the molten resin M1 is injected and filled into the groove portion 424 of the core portion 421. Subsequently, in order to mold the door trim lower 30, the molten resin M2 is injected and filled into the door trim lower molding cavity 425 from the second injection machine 43b through the manifold 422b and the gate 423b, and the door trim lower 30 is molded into a required shape. Is done.

  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. As described above, in order to manufacture the two-tone type automobile door trim 10, the two injection machines 43 a and 43 b are connected to the molding lower mold 42, and the door trim upper 20 and the door trim lower 30 are melted through the resin passages. By injection-filling the resins M1 and M2, the two-tone type automobile door trim 10 can be molded with a single molding die 40 and with a reduced number of processes.

  And in the manufacturing method of the door trim 10 mentioned above, especially the door trim upper 20 requires the terminal processing process mentioned later. In order to perform this terminal processing step, a terminal processing device 50 shown in FIG. 7 is used. The overall configuration of the terminal processing device 50 will be described with reference to the drawings. The terminal processing device 50 includes a receiving jig 60 for setting the door trim upper 20, a heating jig 70 for heating and softening the foamed resin base material 21 at the part to be wrapped in the door trim upper 20, and the winding white 24 as an extension. A winding mechanism unit 80 that performs a winding process on the back surface side of 212 is roughly configured.

  More specifically, the receiving jig 60 includes a set base 61 for setting the door trim upper 20, a spacer 62 for positioning and fixing the door trim upper 20 at a predetermined position, and a receiving jig presser 63. Yes. Further, as the heating jig 70, heaters 71 and 72 having a temperature difference in two upper and lower stages are attached to the outer surface of the heater support 73. The heater support 73 can be moved up and down by a cylinder 74. It is supported. The upper and lower two-stage heaters 71, 72 have a low-temperature heater 71 (set to a heating temperature of 150 to 180 ° C.) in the upper stage and a high-temperature heater 72 (a heating temperature of 200 to 230 ° C.) in the lower stage. Is provided). In addition, the winding mechanism unit 80 is driven forward and backward along the winding direction by the forward / backward cylinder 82 by the winding piece 81 that performs the winding process of the winding white 24. The table 83 to which the advance / retreat cylinder 82 is attached is configured to be driven up and down by a predetermined stroke by the table drive cylinder 84.

  Next, based on FIG. 8 thru | or FIG. 12, the terminal process process of the door trim upper 20 using the terminal processing apparatus 50 mentioned above is demonstrated. First, as shown in FIG. 8, the door trim upper 20 is set on the set base 61 of the receiving jig 60, and fixed at a predetermined position by the spacer 62 and the receiving jig presser 63. Thereafter, the heater jig 73 is lowered by the drive of the cylinder 74, and the heating jig 70 is heated sufficiently in proximity to or in contact with the foamed resin base material 21 in the door trim upper 20 particularly in the vicinity of the winding fulcrum 213. To do. At this time, the winding white of the foamed resin base material 21 is positioned on the upper surface of the winding piece 81 in the winding mechanism portion 80.

  Thereafter, as shown in FIG. 9, the table driving cylinder 84 in the winding mechanism unit 80 is driven to raise the winding piece 81, and the side surfaces of the low temperature heater 71 and the high temperature heater 72 of the heating jig 70. In addition, the winding scissor 24 is caused to stand up along the side surface, and at the same time, the portion near the winding fulcrum part 213 is sufficiently heated and melted by the high-temperature heater 72 and is used for low temperature. The portion in contact with the heater 71 is prevented from overheating and is maintained in an appropriate heat-softened state.

  Next, as shown in FIG. 10, the heating jig 70 avoids upward by the operation of the cylinder 74, but at this time, the winding white 24 in contact with the low-temperature heater 71 is excessively excessive. Since it is not melted, it does not follow the heating jig 70, so that there is no significant unevenness on the melted surface. Then, as shown in FIG. 11 with the heating jig 70 retracted upward, the winding piece 81 is slid by the extension operation of the advancing / retreating cylinder 82 in the winding mechanism 80, and the winding slab 24 is moved. The winding fulcrum portion 213 is sufficiently heated by the high-temperature heater 72 at this time, so that the winding operation of the winding sill 24 can be smoothly performed, and the winding fulcrum portion 213 is wound. The position of is stable. Thereafter, as shown in FIG. 12, the cable driving cylinder 84 in the winding mechanism portion 80 contracts in order to press-fit the winding roller 24 to the main body side, so that the winding piece 81 is pushed in the direction indicated by the arrow in FIG. Pressure is applied, and the winding scissors 24 are crimped and fixed.

  Thus, in the terminal processing method of the door trim upper 20 in the present embodiment, the low temperature heater 71 and the high temperature heater 72 are installed in the upper and lower stages as the heating jig 70 so that the winding white 24 is wound. The vicinity of the fulcrum part 213 is sufficiently heated by the high-temperature heater 72 to facilitate the winding operation, and the winding fulcrum part 213 can be accurately positioned. Therefore, the thickness of the terminal processing unit A can be set to be uniform and the appearance can be maintained well.

  Although the embodiment described above is applied to the method of manufacturing the door trim upper 20 in the two-tone type automobile door trim 10, it can also be applied to an integrated door trim. Further, the present invention can be applied to all interior parts other than the door trim 10, such as a rear parcel shelf, a floor trim, a luggage trim, a trunk trim, a rear side trim, and a roof trim.

It is a front view which shows one Example of the door trim for motor vehicles manufactured by applying the manufacturing method of the interior component for motor vehicles which concerns on 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 in the door trim for motor vehicles shown in FIG. It is sectional drawing which shows the structure of the terminal process part of the door trim upper in the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process of the raw material in the shaping die in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the formation process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the whole structure of the terminal processing apparatus used for the terminal processing process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim upper shown in FIG. It is a front view which shows the conventional door trim. FIG. 14 is a sectional view taken along line XIV-XIV in FIG. 13. It is a schematic diagram which shows the shaping | molding method of the conventional door trim. It is explanatory drawing which shows the prior art example of the terminal part of the door trim by press molding. It is explanatory drawing which shows the prior art example of the terminal part in a skin-wrapping type door trim.

Explanation of symbols

10 Two-tone type automotive door trim 20 Door trim upper (laminated structure)
21 Foamed resin base material 212 Extension part 213 Winding fulcrum part 22 Resin rib 23 Decorating material 24 Winding white 30 Door trim lower (single resin product)
40 Molding mold 41 Molding upper mold 42 Molding lower mold 43a, 43b Injection machine 50 Terminal processing device 60 Receiving jig 61 Set stand 62 Spacer 63 Receiving jig holder 70 Heating jig 71 Low temperature heater 72 High temperature heater 73 Heater support Body 74 Vertical movement cylinder 80 Winding mechanism section 81 Winding piece 82 Advancing / retreating cylinder 83 Table 84 Table driving cylinder S Foamed resin sheet M1, M2 Molten resin A Terminal processing section

Claims (2)

From 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 manufacturing method of the interior part (10) for automobiles formed by employing the laminated structure (20) as a whole or a part thereof,
The manufacturing method of the laminated structure (20) is that the foamed resin sheet (S), which is the material of the foamed resin base material (21), is heat-softened, set in the molding die (41, 42), and then molded. The molds (41, 42) are clamped together to mold the foamed resin base material (21) into a required shape along the cavity shape of the molds (41, 42), and the molds (41, 42). The molten resin (M1) is injected and filled from the injection machine (43) into the groove (424) of the molding die (41, 42) at any timing immediately before or after the mold clamping. (22) forming step of the laminated structure (20) in which the foamed resin base material (21) is laminated and integrated on the back side;
The laminated structure (20) molded in the molding step is removed from the molding dies (41, 42), the laminated structure (20) is set on the receiving jig (60), and then the upper structure is used for low temperature. A heater (71), a heating jig (70) having a high-temperature heater (72) disposed on the lower side thereof in proximity to the back side of the foamed resin substrate (21) at the edge of the laminated structure (20), Alternatively, the winding fulcrum portion (213) of the foamed resin base material (21) is sufficiently softened and melted by the high-temperature heater (72) and is wound outside the heating jig (70). The piece (81) is lifted, and is heated and softened by the low-temperature heater (71) while the winding (24) is erected from the corner of the heating jig (70) along the outer surface, and further, the heating jig After retracting (70), wind the winding piece (81) The end treatment of the laminated structure (20) that is slid along the direction, the winding piece (81) is wound around the back surface (24) of the foamed resin base material (21), and is welded and fixed. Process,
A method for producing an interior part for an automobile, comprising: From 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) After forming the laminated structure (20) to be formed by the molding dies (41, 42), a terminal processing device (50) that performs terminal treatment of the foamed resin base material (21) along the edge of the laminated structure (20). ) And
The terminal processing device (50) includes a receiving jig (60) for setting the laminated structure (20), and a foamed resin base material (20) in the laminated structure (20) set on the receiving jig (60). 21) a heating jig (70) for heating and softening, and a winding piece (81) for winding a winding sheet (24) of the heat-softened foamed resin base material (21) on the back surface of the main body side. The heating jig (70) includes a low temperature heater (71) for heating the winding scissors (24) to a relatively low temperature, and a winding fulcrum (213). A terminal processing apparatus provided with two upper and lower heaters (71, 72) and a high temperature heater (72) for heating.

Images