JP2006248344A - Interior trimming member for vehicle and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an interior trimming member for a vehicle capable of reducing material cost and trouble in manufacturing it, especially a duct structure of the interior member for a vehicle. <P>SOLUTION: The duct 28 is constituted of a gutter type duct part 26 integrally molded on a base material 22, a part of a skin 24 to cover an opening part of the duct part 26 and a garnish 34 to reinforce the skin 24 between itself and the base material 22. The skin 24 is made of an outer skin 30 exposed to the inside of the vehicle and a foaming layer 32 backed on this outer skin 30, and this foaming layer 32 faces the duct part 26. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a vehicle interior member having an air conditioning duct on the inner side and having a part of the skin function as a heat insulating material for the duct, and a method of manufacturing the vehicle interior member.

  A vehicle interior member such as an instrument panel or a console is provided with a duct for air conditioning, and the duct communicates with an air circulation port opened at a proper position of the interior member. The duct is internally connected to a vehicle-mounted air conditioner and is used to supply temperature-controlled air from the air conditioner. However, the duct is also used for ventilation inside the vehicle by connecting to an external air intake port established in the vehicle body. .

For example, an instrument panel 10 shown in FIG. 8 is made of a base material 12 made of a hard resin such as polyethylene (PE) or polypropylene (PP) and a soft resin such as an olefin-based thermoplastic elastomer (TPO). The skin 14 is pasted. An air outlet 16 for defrost is formed along the window at a portion of the panel 10 on the front window side, and the base material 12 is exposed around the opening. FIG. 9 is a cross-sectional view taken along the line AA in FIG. 8. A separately formed duct portion 18 is formed on the back side of the base material 12 and corresponding to the air outlet 16 by vibration welding or the like. It is joined by means. The related art is disclosed in, for example, Patent Document 1.
JP 2003-326842 A

  Since cooling air passes through the duct portion 18, dew condensation tends to occur on the back side of the base material 12 exposed to the duct portion 18. Further, since noise and vibration from the air conditioner are transmitted to the duct portion 18, there is a great risk that the quietness in the vehicle is impaired. Therefore, for example, a foamed polypropylene sheet 19 is interposed on the back side of the base material 12 for the purpose of preventing condensation and reducing noise and other vibrations. As described above, in the conventional duct structure, it is necessary to separately provide the expanded polypropylene sheet 19 only for the purpose of preventing dew condensation, and therefore, there is a problem that the manufacturing cost increases. Further, in the step of attaching the duct portion 18 to the back side of the base material 12, a troublesome work of interposing the foamed polypropylene sheet 19 along the duct portion 18 is required.

  The present invention has been proposed to solve the problems inherent in the prior art described above, and it is not necessary to prepare a separate member such as a foamed polypropylene sheet in order to prevent dew condensation. It is an object of the present invention to provide a vehicle interior member that can reduce time and effort, in particular, a duct structure for a vehicle interior member.

  In order to solve the above-mentioned problem, the invention according to claim 1 is a vehicular interior member made of a base material molded into a required shape and a skin stuck to the base material, and is a bowl-shaped member integrally molded with the base material. A duct part, a part of the skin covering the opening of the duct part, and a garnish that is provided on the front side of a part of the skin and reinforces the skin with the base material And

  According to this invention, a part of the skin is located inside the air circulation duct defined between the bowl-shaped duct portion integrally formed on the base material and the garnish covering the opening portion, which is insulated. Functions as a material, sound absorbing material, and vibration isolator. For this reason, prevention of dew condensation inside the duct and reduction of noise and vibration are achieved.

  According to a second aspect of the present invention, in the first aspect of the invention, the outer skin is composed of an outer skin exposed inside the vehicle and a foam layer backed on the outer skin, and the foam layer faces the duct portion side. It is characterized by being. According to this invention, since the foam layer lined on the outer skin faces the duct portion side, a particularly high function as a heat insulating material can be obtained, and therefore the effect of preventing condensation within the duct can be further improved. .

The invention according to claim 3
Attaching the garnish to the required part of the first mold,
A step of setting a base material in which a bowl-shaped duct portion is integrally molded in a second molding die;
Interposing a skin softened by heating between the first mold and the second mold set with the base material;
By closing the first mold and the second mold, the skin is pasted on the base material while covering the opening of the duct portion, and the front side of the skin is pasted on the back surface of the garnish. Attaching process,
The first molding die and the second molding die are opened, and the vehicle interior member in which a part of the skin is positioned on the back side of the garnish is demolded.

  According to this invention, the pasting of the skin to the base material and the molding of the duct are simultaneously performed, and the molding process of the vehicle interior member can be shortened and simplified, and the molding cost can be reduced.

According to the vehicle interior member according to the present invention, a part of the skin is positioned inside the duct, so that dew condensation inside the duct is prevented and noise and vibration are reduced.
Moreover, according to the method for manufacturing an interior member for a vehicle according to another invention, the molding process can be shortened and simplified, and the molding cost can be reduced.

  Next, preferred embodiments of the vehicle interior member and the method for manufacturing the same according to the present invention will be described below with reference to the accompanying drawings. In addition, in the Example mentioned later, an instrument panel is illustrated as a vehicle interior member.

(About the instrument panel)
FIG. 1 is a cross-sectional view showing an instrument panel 20 according to an embodiment of a vehicle interior member. The instrument panel 20 is made of, for example, a hard resin such as PE or PP, and a base material 22 formed into a required shape by injection, and a soft material such as TPO attached to the surface of the base material 22 with a vacuum forming die. It is composed of a skin 24 made of resin.

  A duct portion 26 extending in a bowl shape is integrally formed at a required portion of the base material 22, and an outer skin 24 attached to the base material 22 is opened at an opening portion opened upward of the duct portion 26. A part of is located in the extended state and covers the opening. In other words, the opening of the bowl-shaped duct portion 26 is covered with the skin 24, thereby defining a duct 28 for air circulation inside. The duct 28 is connected to an air conditioner (not shown) mounted on the vehicle and supplied with temperature-controlled air, and a temperature-controlled air outlet opened at an appropriate position of the instrument panel 20 or a hot air outlet for defrosting. It comes to communicate with.

  The illustrated skin 24 is a composite sheet comprising an outer skin 30 that is exposed to the passenger compartment when the instrument panel 20 is assembled into a vehicle, and a foam layer 32 made of polypropylene (PP) or the like that is lined on the outer skin 30. . For this reason, at the part where the skin 24 covers the opening of the duct portion 26, the foamed layer 32 in the skin 24 is exposed facing the inside of the duct 28. The foamed layer 32 is intended to give a soft feeling when the occupant touches the skin 24 that is originally attached to the base material 22. Condensation due to the cooling air passing through 28 can be prevented. Moreover, since the foam layer 32 is also excellent in cushioning properties, the foam layer 32 also functions to absorb and suppress operating noise and vibrations generated from the air conditioner. However, it is not a requirement that the skin 24 is a composite sheet, and may be a single sheet according to cost and usage.

  As described above, the opening of the duct portion 26 is covered with a part of the skin 24 (the skin 24 not attached to the base material 22), but the portion covering the opening is covered with the skin 24. If it is alone, it may be dented or torn when any force is applied from the outside. For this reason, as shown in FIG. 1, a garnish 34 made of hard resin such as PP or wood is bonded to the outside of the skin 24 covering the opening of the duct portion 26 in a form along the duct portion 26. ing. Here, the garnish 34 is provided on the front side of a part of the skin 24, and serves as a decoration member that adjusts the appearance by being exposed in the passenger compartment, and the skin 24 that covers the opening of the duct portion 26 is connected to the base material 22. It also serves as a reinforcing member that reinforces the gap. That is, the outer surface 24 of the skin 24 (foamed layer 32) is bonded to the base material 22, and the front surface (outer skin 30) is bonded to the garnish 34.

  In the embodiment of FIG. 1, an air circulation port 36 that functions as an air outlet for a defrost of a required length is provided in the garnish 34 and the skin 24. In this case, the garnish 34 also functions as a grill that reinforces the opening periphery of the air circulation port 36 in a decorative manner. In addition to the defrost air flow port 36, a temperature-controlled air flow port may be provided on the surface of the instrument panel 20 facing the passenger compartment. At this time, the molding position of the duct portion 26 with respect to the base material 22 is close to the passenger compartment, and an air circulation port is opened correspondingly to the skin 24 and the garnish 34 covering the opening of the duct portion 26.

  As described above, the garnish 34 is adhered to the skin 24 covering the opening of the duct portion 26. However, the garnish 34 may be unstable due to vibration from the vehicle. Is preferably fixed to the base material 22. This fixing is easily achieved by techniques such as heat caulking and ultrasonic welding. Further, as shown in FIG. 2, a boss 38 is integrally projected in advance at a corresponding position on the back surface of the garnish 34, and a tapping screw (fastening member) 40 is screwed in from the back side of the base material 22, for example. 34 may be fastened to the base material 22 with the skin 24 sandwiched therebetween.

  The instrument panel 20 of the present embodiment configured as described above has the following effects. First, a part of the skin 24 is located in the duct 28 so as to be in an extended state, which functions as a heat insulating material, a sound absorbing material, and a vibration isolating material. Reduction is achieved. Secondly, since the foamed layer 32 lining the outer skin 30 in the outer skin 24 faces the opening side of the duct portion 26, a particularly high function as a heat insulating material can be obtained, and therefore the dew condensation preventing effect inside the duct 28 is obtained. Can be further improved. Third, the air circulation port 36 opened in the garnish 34 can function as, for example, a defrost outlet or a temperature-controlled air outlet toward the passenger, and surrounds the opening periphery of the air circulation port 36. There is no need to install a separate grill. Fourth, since a part of the skin 24 facing the opening of the duct portion 26 is attached to the garnish 34, a part of the skin 24 is suitably backed up. Fifth, the garnish 34 is stably attached to the base material 22 by using the tapping screw 40.

(About molding process)
Next, the molding process of the instrument panel 20 shown in FIG. 1 will be described with reference to FIGS. In this molding step, a first molding die 42 as an upper die and a second molding die 44 as a lower die are used. The first mold 42 holds the garnish 34 at a required position on the inner surface of the mold, and transfers vacuum patterns (fine irregularities resembling the leather surface) to the outer skin 30 of the skin 24 when the mold is closed. It is an electromold. The second mold 44 is set with the base material 22 molded in a separate process, and the mold surface has a recessed portion for tightly receiving the bowl-shaped duct portion 26 in the base material 22. It is recessed.

  As shown in FIG. 3, the 1st shaping | molding die 42 can set the garnish 34 shape | molded previously by another process to the required position of a type | mold inner surface. In this embodiment, the garnish 34 is provided with a defrost air flow port 36, so that the inner surface of the first mold 42 is set to a size that fits closely along the air flow port 36. A protruding ridge 46 is provided. The outer surface of the garnish 34 set in the first mold 42 is preliminarily coated with an adhesive so that the skin 24 and the garnish 34 are bonded together by closing the mold described later. As shown in FIG. 6, the set position of the garnish 34 in the first mold 42 is a part corresponding to the duct portion 26 of the base material 22 set in the second mold 44 and the mold closing.

  As shown in FIG. 4, for example, the base material 22 that has been injection-molded in a separate process is set in the second mold 44. Then, an adhesive is applied in advance on the outer surface of the base material 22 and at a place where the duct portion 26 is avoided. As a result, the base material 22 and the skin 24 are bonded at a site avoiding the duct portion when the mold is closed. Note that the setting of the garnish 34 on the first mold 42 and the setting of the base material 22 on the second mold 44 do not necessarily have a predetermined temporal relationship. May be.

  Next, as shown in FIG. 4, the skin 24 spread in a tensioned state is obliquely introduced and interposed between the first and second molds 42 and 44. The skin 24 is heated and softened by, for example, a heater (illustrated) immediately before it reaches between the molds 42 and 44.

  In this state, for example, the first mold 42 is lowered toward the second mold 44, and both the molds 42 and 44 are closed. Then, as shown in FIG. 5, the part (left side of the figure) close to the set part of the garnish 34 in the first mold 42 first comes into contact with the skin 24 that is obliquely positioned in the extended state. On the right side of 5, the epidermis 24 is stuck to the adhesive application site of the substrate 22. Since the first mold 42 is a vacuum mold, when the final mold shown in FIG. 6 is closed, the skin 24 is sucked by vacuum on the inner surface of the first mold 42, and the embossed pattern on the inner surface of the mold is formed on the outer surface of the skin 24. Transcribed.

  In the state after completion of mold closing in FIG. 6 and after demolding shown in FIG. 7, the epidermis 24 is pasted at a portion where the duct portion 26 of the base material 22 is avoided. Further, the upper opening of the duct portion 26 is covered with the spread skin 24, and the foam layer 32 is exposed inside the duct 28. Furthermore, the outer skin 30 of the portion of the skin 24 that extends in the upper opening of the duct portion 26 is stuck to the back surface of the garnish 34.

  When the application of the skin 24 is completed, the first mold 42 is raised from the second mold 44 to open the mold, and the instrument panel 20 shown in FIG. 7 is removed. At this stage, the air circulation port 36 provided in the garnish 34 is in a state of being blocked by the epidermis 24 positioned correspondingly. The skin 24 affixed to the instrument panel 20 trims the excess portion indicated by reference numerals 48 and 50 and the portion corresponding to the air circulation port 36 of the garnish 34 indicated by reference numeral 52, and further performs the winding process of the skin terminal. By doing so, the instrument panel 20 shown in FIG. 1 is obtained.

  As described above, the structural bond between the garnish 34 and the substrate 22 can be performed by using heat caulking, ultrasonic welding, other tapping screws, or the like.

  According to such a method for manufacturing an interior member for a vehicle, the following effects can be obtained. First, the skin 24 is stuck to the base material 22 and the duct 28 is molded at the same time, so that the molding process of the instrument panel 20 can be shortened and simplified, and the molding cost can be reduced. Second, since the first molding die 42 is a vacuum molding die, the surface pattern of the skin 24 can be molded, and at the same time, the molded skin 24 can be attached to the base material 22.

  In the above embodiment, the defrost air flow port 36 is provided in the instrument panel 20, but the air flow port is opened on the front side (side facing the passenger seat) of the instrument panel 20. The molding part of the duct part 26 in the base material 22 may be changed. Further, a floor console or the like may be used instead of the instrument panel 20.

  With respect to the vehicle interior member 20 such as an instrument panel or a floor console, it is not always necessary to open an air circulation port in the garnish 34. In this case, the garnish 34 supplements the structural strength of the skin 24 that covers the opening of the duct portion 26.

Sectional drawing which shows the instrument panel which concerns on one Embodiment of a vehicle interior member. Sectional drawing of the duct comprised by a duct part, a part of skin, and garnish. Process explanatory drawing which showed the state which sets a garnish to a 1st shaping | molding die. Process explanatory drawing which showed the state which clamps the 1st shaping | molding die which set the garnish, and the 2nd shaping | molding die which set the base material on both sides of the heat-softened skin. Process explanatory drawing which showed the state by which a skin is affixed on the surface of a base material, and the back surface of a garnish by mold closing of a 1st shaping | molding die and a 2nd shaping | molding die. Process explanatory drawing of the state which mold closing was completed. Sectional drawing which shows the instrument panel immediately after mold removal. The schematic perspective view which shows the instrument panel which is one Embodiment of the vehicle interior member. FIG. 9 is a cross-sectional view taken along line AA in FIG. 8.

Explanation of symbols

22 base material, 24 skin, 26 duct part, 30 outer skin, 32 foam layer, 34 garnish 42 first mold, 44 second mold

Claims (3)

In an interior member for a vehicle comprising a base material (22) molded into a required shape, and a skin (24) attached to the base material (22),
A bowl-shaped duct portion (26) integrally formed with the base material (22),
A portion of the skin (24) covering the opening of the duct portion (26);
A vehicle interior member comprising a garnish (34) provided on a part of a front side of the skin (24) and reinforcing the skin (24) with the base material (22).   The skin (24) is composed of an outer skin (30) exposed inside the vehicle and a foam layer (32) lined on the outer skin (30), and the foam layer (32) is located on the duct portion (26) side. The vehicle interior member according to claim 1, which faces the vehicle. Attaching the garnish (34) to the required part of the first mold (42);
Setting the base material (22) integrally formed with the bowl-shaped duct portion (26) in the second molding die (44);
Interposing a skin (24) softened by heating between the first mold (42) and the second mold (44) on which the substrate (22) is set;
By closing the first mold (42) and the second mold (44), the skin (24) is applied to the base material (22) in a state of covering the opening of the duct part (26). A step of attaching the front side of the skin (24) to the back side of the garnish (34),
Opening the first molding die (42) and the second molding die (44), and demolding the vehicle interior member in which a part of the skin (24) is located on the back side of the garnish (34). The manufacturing method of the interior member for vehicles characterized by these.

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