JP2006327043A - Manufacturing method of trim element for car - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve weight reduction and cost reduction, to enhance the appearance of an outer peripheral terminal part and to simplify terminal treatment work in a manufacturing method of a trim element for a car. <P>SOLUTION: The door trim upper 20 in a two-tone type door trim 10 comprises a foamed resin base material 21 having lightweight properties and shape retention, the resin ribs 22 integrated with the inner surface side of the foamed resin base material 21 and the decorative material 23 laminated on the surface of the foamed resin base material 21. Accordingly, weight reduction and cost reduction are achieved by the use of the lightweight foamed resin base material 21 and the reduction of the projection areas of the resin ribs 22. Further, a polyfunctional block 50 is arranged to a molding upper mold 41 in order not only to facilitate the setting work of a decorative material 23 but also to certainly hold the decorative material 23 and a shear edge part A is formed between the polyfunctional block 50 and a molding lower mold 42 while the edge material 21a in the foamed resin base material 21 is cut off to efficiently perform terminal treatment. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and the like. The present invention relates to a method of manufacturing interior parts for automobiles that can be processed easily and inexpensively.

  For example, the configuration of automobile interior parts will be described with reference to FIGS. 15 and 16 exemplifying door trims. The door trim 1 has a shape retaining property and a mounting rigidity to a vehicle body panel, and is formed by laminating and integrating a skin 3 excellent in surface appearance on the surface of a resin core material 2 that extends over almost the entire product surface. Yes. The resin core material 2 is made of a polypropylene resin mixed with talc, and the skin 3 does not have shape retention itself, and the back surface of the synthetic resin sheet such as a vinyl chloride sheet is made of polyethylene foam or the like. A laminated sheet material in which a cushion material is laminated is used, and recently, an elastomer sheet such as a thermoplastic olefin (hereinafter referred to as TPO) sheet tends to be frequently used in consideration of environmental aspects and recycling aspects.

  Next, a conventional example of the method for forming the door trim 1 will be described with reference to FIG. First, a molding die 4 that molds the door trim 1 is connected to a molding upper die 5 that can move up and down by a predetermined stroke, a molding lower die 6 that forms a pair with the molding upper die 5, and a molding lower die 6. It is generally composed of the injection machine 7. When the upper and lower molds 5 and 6 are clamped, a cavity portion 5a is formed in the molded upper mold 5 and a core section 6a is provided in the molded lower mold 6 in order to shape the product shape of the door trim 1. Yes. In order to move the molding upper die 5 up and down by a predetermined stroke, an elevating cylinder 5b is connected, and the molding lower die 6 is provided with a manifold 6b and a gate 6c that serve as a passage of molten resin from the injection machine 7. Further, in order to maintain an appropriate posture, the upper molding die 5 that moves up and down is provided with guide posts 6d at the four corners of the lower molding die 6, and the molding upper die 5 has guides corresponding to the guide posts 6d. A bush 5c is provided.

  Therefore, when the molding upper and lower molds 5 and 6 are in the mold open state, either the skin 3 is set in the mold, and then either immediately before or after the molding upper and lower molds 5 and 6 are clamped The molten resin M is injected and filled from the injection machine 7 through the manifold 6b and the gate 6c into the product cavity between the molds at the timing, thereby forming the resin core material 2 into a required curved shape and the resin core material 2 The skin 3 is integrally formed on the surface (for example, see Patent Document 1). In FIG. 17, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state. Actually, however, the molten resin M is injected into the cavity after the 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. 18, after the outer skin 3 is simultaneously press-molded on the surface of the core material 2, piercing is performed in a separate process after the mold blade in the mold or molding. Cut processing is performed. Further, as shown in FIG. 19, after the core material 2 is press-molded, the skin 3 is integrated by vacuum pressing, press-bonding or the like in a separate process, and then the terminal 3 a of the skin 3 is wound around the back surface side of the core material 2. Processing is also conventionally performed.

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

  However, in the conventional door trim 1, since the projected area of the resin core material 2 is large, there are problems that the material cost is high and the product is heavy. In addition, since the projected area of the resin core material 2 is large, it is necessary to set the injection pressure at the time of molding high, and a mold structure that can withstand the high injection pressure is required, and the production cost of the mold is increased, In addition, since a large amount of molten resin is cooled and solidified, the molding cycle becomes longer, which is a major factor for reducing productivity.

  Furthermore, at the outer periphery of the door trim 1, as shown in FIG. 18, when the outer skin simultaneous press molding is performed, it is difficult to treat the outer periphery, and in the case of the outer edge of the outer skin 3 or the outer skin 3 of the laminated sheet material specification, In addition to the disadvantage that the foam layer's mouth is exposed to the outside and the appearance performance is deteriorated, as shown in FIG. 19, the method of enveloping the skin 3 in a separate process requires a lot of man-hours and costs. Up is inevitable.

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

  As a result of earnest research, the present inventors have given the function as a core material by imparting shape retention to the foamed resin sheet that has been used conventionally as the skin, and more. High rigidity is required at places where rigidity is required, i.e. it can be closely contacted with the peripheral part of the product, the panel, the mating part with the mating part, or a part where a certain clearance is secured, or where a part is attached and where a load is applied By placing resin ribs, the product weight is reduced compared to conventional resin cores with a large projected area, and the terminal processing is performed by driving the multi-functional block to the cylinder for processing the peripheral terminal of the product. It has been found that it can be done easily and quickly, and the present invention has been completed.

  That is, the method for manufacturing an automobile 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 shape that is 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 a resin rib and a decorative material affixed to the surface of the foamed resin base material is used in whole or in part, At the time of opening, the decorative material is set on the lower surface side of the upper mold, while the heat-softened foamed resin sheet is set on the lower mold surface and the upper and lower molds are clamped. The foamed resin sheet is press-molded into a desired curved shape along the cavity shape, and foamed by the shearing action between the multifunctional block placed in the upper mold and the vertical wall side of the lower mold Cut the end of the resin sheet The resin ribs are integrated on the back side of the foamed resin base material by injecting and filling molten resin into the groove of the molded lower mold at any timing immediately before or after clamping the molded upper and lower molds. Then, after the molding process of the laminated structure for forming the laminated structure, and then opening the upper and lower molds, the laminated structure is demolded, and then the decorative material is wound on the back side of the foamed resin substrate. The laminated structure was manufactured by each process consisting of the winding process process of the decorating material which winds up.

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

  As the foamed resin sheet, a material obtained by adding a foaming agent to a thermoplastic resin is used. The thermoplastic resin may be one type of thermoplastic resin or two or more types of thermoplastic resins. Preferably, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / Styrene (ABS) resin or the like can be used. As the foaming agent, an organic foaming agent such as an azo compound, a sulfohydrazide compound, a nitroso compound or an azide compound, or an inorganic foaming agent such as sodium bicarbonate can be used. The foamed resin base material obtained by heat-softening the foamed resin sheet and molded into a required shape preferably has a foaming ratio of 2 to 10 times in consideration of the balance between the weight and strength of the product. The cell diameter of the foamed resin base material at that time is preferably in the range of 0.1 μm to 2.0 mm, and the thickness is 0.5 to 30 mm, preferably 1 to 10 mm.

  On the other hand, the thermoplastic resin material used as the resin rib can be appropriately selected from a wide range of thermoplastic resins. Usually, those that can be preferably used include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, Acrylonitrile / butadiene / styrene (ABS) resin or the like can be used. Moreover, you may mix various fillers in these thermoplastic resins. Examples of the filler that can be used include inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica, and calcium carbonate. Moreover, various additives, such as antioxidant, a ultraviolet absorber, a coloring agent, a flame retardant, and a low shrinkage agent, may be mix | blended.

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

  The interior parts for automobiles manufactured by the method of the present invention are resin ribs in which a decorative material having a decorative property is laminated on the front surface side of a foamed resin base material having shape retention, and the rigidity is enhanced on the back surface side. Can be abolished, so that the conventional resin core material can be eliminated. Therefore, since the conventional resin core material with a very large projected area can be eliminated, the weight of the product can be reduced, and the resin material can be saved, so that the material cost can be reduced at the same time.

  Furthermore, at the end portion along the outer periphery of the product of the laminated structure, the end material of the foamed resin base material can be cut and removed at the same time as molding by the shearing action between the multifunctional block and the lower mold. After that, the laminated structure is removed from the molding die, and the decorating material may be wound on the back side of the foamed resin base material based on the cut line of the foamed resin base material, so that the cut end is exposed to the outside. Therefore, the appearance is good. In addition, when the end portion (end material) of the foamed resin base material is cut and removed by the multi-functional block and the molded lower die, the foamed resin sheet is heated to a high temperature when the molding die is inserted. If the heat treatment of the decorating material is omitted or only the low temperature heat treatment is performed at a low temperature, the end material portion of the heat-softened foamed resin base material is not entangled with the decorating material, and the decorating material And the end material of the foamed resin base material can be smoothly separated, and the wrapping white can be easily and reliably formed.

  In addition, the porous sound-absorbing function of the foamed resin base material provides interior parts with excellent sound-absorbing performance. For example, the rib thickness of the resin rib is set to be thick at parts where a large external force is applied to the product. The rib thickness can be varied as appropriate, for example, by reducing the rib thickness at a portion where external force is relatively difficult to apply. Therefore, it is sufficient to use the minimum necessary amount of resin material, which can contribute to weight reduction and cost reduction of the product. Moreover, the clip seat or the attachment seat for attaching various escutcheon parts can also be integrally formed in the resin rib.

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

  Further, the multifunctional block disposed in the molding upper die is driven by a cylinder. This cylinder is attached to the side surface of the molding upper die via a support member and a bracket, and the piston rod of this cylinder can slide in a direction parallel to the molding surface of the molding upper die. A multifunction block is attached to the tip. When the foamed resin sheet is press-molded, the end material of the foamed resin sheet is trim-cut by the shearing action between the multifunctional block and the outer surface of the molded lower mold. Furthermore, if desired, when setting the decorating material on the molding upper mold, the multifunctional block enters along the lower surface of the decorating material with the terminal held on the mold surface of the molding upper mold. Can also be held.

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

  Furthermore, for the end portion along the outer periphery of the product of the laminated structure, the cutting process along the trim cut line is performed by the shearing action between the molding lower mold and the multifunctional block at the time of molding the foamed resin base material. At the same time as molding, the cut processing of the end material of the foamed resin base material is completed, and after molding, it is necessary to remove the mold from the molding die and wind the decorating material wrap around the back surface of the foamed resin base material. Therefore, the wrapping process can be performed easily and in good appearance. Furthermore, depending on the thickness of the foamed resin sheet and the degree of softening, a zero clearance between the multifunction block and the outer surface of the molded lower mold can be easily achieved by adjusting the cylinder stroke. There is an effect that tuning work can be easily performed.

  In addition, when setting the decorative material, the multifunctional block is retracted outward by the cylinder, so it does not become an obstacle to the decorative material setting work. Can proceed.

  As described above, the automotive interior part obtained by the manufacturing method according to the present invention is a lightweight and shape-retaining foamed resin base material, the back surface of the foamed resin base material, and the outer periphery of the product. Because it is composed of resin ribs that are laminated and integrated at the part where rigidity is required, and a decorative material that is laminated on the surface of the foamed resin base material, the conventional heavy resin core material can be eliminated, Lightweight, low cost, and porous material has the effect of 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 into a required shape along the cavity shape of the molding die, and at the same time, the resin rib is formed on the back surface side of the foamed resin base material. Since the projected area of the resin rib, which is a resin molded body, is small, the load applied to the molding die is less than that of the conventional resin core material, and the cooling time can be shortened. Since the working efficiency can be increased, the working efficiency can be increased and the cost can be greatly reduced.

  Further, according to the method for manufacturing an automotive interior part according to the present invention, when the molded upper and lower molds are clamped, the end of the foamed resin sheet is caused by the shearing action between the outer wall surface of the molded lower mold and the multifunctional block. In order to trim the material, trimming of the foamed resin base material can be performed at the same time as molding. After molding, the laminated structure is removed from the molding die, so If the winding process is performed on the back side of the material, the winding process can be performed easily and beautifully, workability can be improved, and in particular, the stroke dimension of the multifunctional block can be finely adjusted. There is an effect that the clearance of the shear mechanism can be easily adjusted depending on the thickness of the sheet.

  DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments relating to a method for manufacturing an automobile interior part according to the present invention will be described below in detail with reference to the accompanying drawings. It should be noted that the gist of the present invention is as described in the scope of claims, and the contents of the embodiments described below are merely examples of the present invention.

  1 to 14 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 sectional view showing the configuration of the automobile door trim, and FIG. 4 is a front view showing a resin rib and a door trim lower of the door trim upper in FIG. 4, FIG. 4 is a sectional view showing a configuration of a terminal portion of the door trim upper in the door trim for the automobile, and FIGS. 5 and 6 are used in the method for manufacturing the door trim for the automobile. FIG. 5 is an overall view of the molding die, and FIG. 6 is a cross-sectional view showing a portion corresponding to a door trim upper edge portion of the molding die. FIGS. 7 to 14 show the manufacturing method of the automobile door trim, FIG. 7 is an explanatory view showing the preheating process of the foamed resin sheet, and FIGS. 8 and 9 are inside the mold of the decorating material and the foamed resin sheet. FIG. 10 is an explanatory view showing a state when the multifunctional block is entered, FIGS. 11 and 12 are explanatory views showing molding steps of the foamed resin base material and the resin rib, and FIG. FIG. 14 is an explanatory view showing the terminal processing step of the door trim upper.

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

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

  The foamed resin sheet has a structure in which a foaming agent is added to a general-purpose thermoplastic resin. The thermoplastic resin includes a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a chloride resin. Vinyl resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. can be used. As the foaming agent, organic foaming agents such as azodicarbonamide and bicarbonate An inorganic foaming agent such as sodium can be used. In this embodiment, a foamed resin sheet in which sodium bicarbonate is appropriately added as a foaming agent to a polypropylene resin is used. The expansion ratio of the foamed resin base material 21 is set to 2 to 10 times, and the thickness is set to a range of 0.5 to 30 mm, particularly 1 to 10 mm.

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

  As described above, the door trim 10 shown in FIGS. 1 to 3 includes the door trim upper 20 formed of a laminated structure and the door trim lower 30 of a single resin, and has an excellent appearance design due to an accent effect on the appearance. I have. Furthermore, the door trim upper 20 includes a foamed resin base material 21 having shape retention, a resin rib 22 integrated on the back surface of the foamed resin base material 21, and a decorating material 23 having a decorating property. Therefore, the resin core material that has been occupied over the entire circumference of the product as in the past can be abolished, and in addition to using the lightweight foamed resin base material 21, the resin rib 22 is skeleton-like and has a load. The part to be added, for example, the part excluding the clip seat, the upper surface of the waist part, the upper surface of the armrest part, etc. has a thinning structure, so the weight of the product should be reduced by 40% or more compared to the conventional example. As well as significant savings in resin materials, contributing to cost reductions.

  Furthermore, since the foamed resin base material 21 has a porous structure, the door trim upper 20 is excellent in sound absorbing performance and can reduce noise in the passenger compartment. Moreover, in order to maintain the sound absorption property of the foamed resin base material 21, the decorating material 23 laminated in advance on the surface of the foamed resin base material 21 or integrated and laminated at the time of molding is a woven fabric or a non-woven fabric. A sheet material having air permeability such as a knitted fabric is preferable. The decorative material 23 may be a synthetic resin sheet such as a PVC sheet or a TPO sheet, a synthetic resin film, a foam, a net, or a fabric sheet, a synthetic sheet, in addition to a breathable sheet such as a woven fabric, a nonwoven fabric, or a knitted fabric. A laminated sheet material in which a cushion layer such as polyethylene foam or polyurethane foam is lined on the back surface of the resin sheet can also be used. In addition, when a TPO sheet is used, it can be unified with an olefin resin material, which is advantageous in terms of recycling.

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

  Next, the outline | summary of the manufacturing method of the door trim 10 including the terminal processing process of the outer periphery terminal part of the door trim upper 20 is demonstrated below. First, the overall structure of the molding die 40 will be described with reference to FIG. 5, and the main part of the molding die 40 corresponding to the outer peripheral portion of the door trim upper 20 will be described with reference to FIG. In FIG. 5, a molding die 40 used for molding the door trim 10 includes a molding upper mold 41 that can move up and down by a predetermined stroke, a molding lower mold 42 that is paired with the molding upper mold 41, and a molding lower mold 42. It consists of two injection machines 43a and 43b connected to each other.

  More specifically, the molding upper die 41 has a cavity portion 411 that matches the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 412 connected to the upper surface of the molding upper die 41. In addition, guide bushes 413 serving as a guide mechanism are provided at the four corners of the molding upper die 41. On the other hand, the molding lower die 42 is provided with a core portion 421 corresponding to the cavity portion 411 of the molding upper die 41. In addition, manifolds 422a and 422b and gates 423a and 423b are provided to supply molten resin to the mold surface of the core portion 421, and the injection machine passes through the resin passages of the manifolds 422a and 422b and gates 423a and 423b. The molten resins M1 and M2 supplied from 43a and 43b are supplied into a groove 424 formed on the upper surface of the core 421 and into a cavity 425 for forming the door trim lower 30. In addition, guide posts 426 that serve as a guide mechanism protrude from the four corners of the molded lower mold 42, and the guide posts 426 guide into the guide bush 413 when the molded upper and lower molds 41 and 42 are clamped. As a result, the pressing posture of the molding upper die 41 can be properly maintained.

  Next, FIG. 6 shows a portion corresponding to the outer peripheral end portion of the door trim upper 20 in the molding die 40, and the peripheral end portion of the decorating material 23 is held on the lower peripheral portion of the molding upper die 41. A temporary fixing pin 414 is provided, and a multi-function block 50 is attached to a piston rod 51a of a drive cylinder 51 such as an air cylinder at a position arranged in parallel with this part. The drive cylinder 51 is attached to the side surface of the molding upper die 41 via a support bracket 52, and the multifunction block 50 repeats advancing and retracting a predetermined stroke by driving the drive cylinder 51, which will be described below. Thus, it has the function of holding the decorating material 23 and the function of trimming the surplus portion of the foamed resin sheet.

  Therefore, it is necessary to control the advance / retreat stroke of the multifunction block 50 with high accuracy. On the other hand, a set plate 427, which serves as a guide for setting the foamed resin sheet S, is supported by a shaft 428 at a position immediately below the entry position of the multifunction block 50, and this set plate 427 is not shown. It is supported so as to move up and down while being biased upward by a biasing spring. In order to avoid interference with the temporary fixing pin 414 of the molding upper die 41 when the multifunctional block 50 slides in the direction of the arrow in FIG. A groove for receiving the temporary fixing pin 414 is provided.

  Next, each step of the method for manufacturing the door trim 10 described above will be described with reference to FIGS. First, as shown in FIG. 7, the foamed resin sheet S is heated and softened at a high temperature of 160 to 220 ° C. by the heater device 60. As the foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumika Plustech, trade name: Sumiceller foam PP sheet, expansion ratio = 3 times, thickness 3 mm) is used. Subsequently, as shown in FIG. 8, the decorative material 23 and the heat-softened foamed resin sheet S are defined by the cavity portion 411 of the molding upper die 41 and the core portion 421 of the molding lower die 42 at the location corresponding to the door trim upper 20. Set in the upper half of the resulting cavity.

  The setting process of the decorating material 23 and the foamed resin sheet S described above will be described in more detail. As shown in FIG. 9, the decorating material 23 is formed with its peripheral terminal formed by an upward drive of a charging device (not shown). Temporarily held by a temporary fixing pin 414 provided on the lower surface of the mold 41. At this time, since the multifunctional block 50 is located outside the molding die 40, it does not interfere when the input device is raised. On the other hand, the foamed resin sheet S subjected to the heat softening treatment is set so that the peripheral end is placed on the set plate 427. Moreover, the multifunctional block 50 enters the molding die 40 in the direction of the arrow as shown in FIG. 10 by the extension operation of the drive cylinder 51, and the peripheral edge of the decorating material 23 is connected to the lower surface of the molding upper die 41. The decorative material 23 can be reliably held by being sandwiched between the multi-function block 50 and the upper surface 50a.

  Thereafter, the elevating cylinder 412 of the molding upper die 41 is operated to lower the molding upper die 41 by a predetermined stroke, and as shown in FIG. 11, the molding upper and lower dies 41 and 42 are clamped to obtain the foamed resin sheet S. In order to form the foamed resin base material 21 along the shape of the mold surface, and to form the resin ribs 22 in the door trim upper 20 from the first injection machine 43a through the manifold 422a and the gate 423a, M1 is injected and filled into the groove portion 424 of the core portion 421. Further, in order to form the door trim lower 30, the molten resin M2 is injected and filled into the cavity 425 from the second injection machine 43b through the manifold 422b and the gate 423b, and the door trim lower 30 is formed into a required shape. Further, in the molding step of the foamed resin base material 21 and the resin rib 22 shown in FIG. 11, the portion corresponding to the outer peripheral edge of the door trim upper 20 is particularly large with the outer wall surface 42 a of the molding lower mold 42 as shown in FIG. 12. At the shear edge portion A formed between the front end surface 50b of the functional block 50, the end material 21a of the foamed resin base material 21 in the softened state is trimmed.

  Therefore, in the present embodiment, the multi-function block 50 has two functions of a holding function of the decorating material 23 and a shear edge function of trim cutting the surplus portion of the foamed resin sheet S. Then, when the multifunction block 50 is lowered following the lowering operation of the molding upper die 41, the set plate 427 is lowered in synchronization with the pressing of the multifunction die block 50. Thereafter, when the molding is completed, as shown in FIG. 13, the multifunction cylinder block 50 is retracted in the direction of the arrow by driving the drive cylinder 51, and the molding upper mold 41 is raised and the mold is opened. The door trim 10 is taken out from the molding die 40, and in particular, the winding white 23 a of the decorating material 23 is wound along the inner surface of the vertical wall portion 24 of the foamed resin base material 21 at the outer peripheral edge portion of the door trim upper 20. The winding process can be easily performed by adhesion fixing, welding fixing, or the like (see FIG. 14).

  Thus, in the method of the present invention, the multi-function block 50 is arranged on the molding upper die 41, and the multi-function block 50 can hold the peripheral end portion of the decorating material 23 by the drive cylinder 51. And the standby position set to the outside of the molding upper die 41 can be moved back and forth, and by setting the multifunctional block 50 at the standby position, it becomes easier to set the decorating material 23, And by allowing the multifunctional block 50 to enter the cavity and holding the peripheral edge of the decorating material 23, the decorating material 23 can be securely held without falling off as in the prior art, During molding of the foamed resin base material 21 by clamping the upper and lower molds 41 and 42, the end material 21a of the foamed resin base material 21 is cut and removed by the shear edge portion A between the multi-functional mold block 50 and the lower mold 42. it can.

  Therefore, unlike the conventional method, the end material 21a of the foamed resin base material 21 can be cut and removed simultaneously with molding without requiring a separate cutting step, so that the terminal processing operation can be performed efficiently. In order to manufacture the above-described two-tone type door trim 10, two injection machines 43a and 43b are connected to the molding lower mold 42, and the molten resin M1, the door trim upper 20 and the door trim lower 30 are passed through the resin passages. By injection-filling M2, the two-tone door trim 10 can be manufactured with a single molding die 40 and with a reduced number of steps.

  Further, the molten resins M1 and M2 branched and supplied by the door trim upper 20 and the door trim lower 30 can be supplied from the single injection machine 43 as the same material. In this case, a manifold serving as a passage for the molten resin M supplied to the door trim upper 20 side from a main manifold communicating with the injection machine 43 and a branch manifold for the resin passage supplying the molten resin M to the door trim lower 30 are set. Just do it. In this embodiment, the molding step of the foamed resin base material 21 and the injection filling step of the resin rib 22 are performed using the molding die 40 described above. After the material 21 and the resin rib 22 are molded, both of them may be crimped and fixed with a crimping die. Further, the multi-function block 50 is used only for trimming the foamed resin base material 21 by a shearing action with the molding lower die 42, and the decoration material 23 may be held using another means. good.

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

It is a front view which shows the door trim for motor vehicles manufactured by applying the method of this invention. It is the II-II sectional view taken on the line in FIG. It is a front view which shows the resin rib and door trim lower of the door trim upper which abbreviate | omitted the foamed resin base material in the door trim for motor vehicles shown in FIG. It is the IV-IV sectional view taken on the line in FIG. FIG. 2 is an overall view showing a molding die used in the method for manufacturing the automobile door trim shown in FIG. 1. It is sectional drawing which shows the location corresponded to the door trim upper edge part in the molding die shown in FIG. It is explanatory drawing which shows the preheating process of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process to the shaping die of the decorating material and a foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process to the shaping die of the decorating material and a foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the state at the time of the approach of the multifunctional block in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material and resin rib in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material and resin rib in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the state at the time of reverse of the multifunctional block in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the terminal process process of the door trim upper in the manufacturing method of the door trim for motor vehicles shown in FIG. It is a front view which shows the conventional door trim for motor vehicles. It is XVI-XVI sectional view taken on the line in FIG. It is a schematic diagram which shows the shaping die which shape | molds the conventional door trim. It is explanatory drawing which shows the prior art example of the terminal part in the door trim for motor vehicles by press molding. It is explanatory drawing which shows the prior art example of the terminal part in the door trim for motor vehicle of a skin-wrapping type.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Two-tone type vehicle door trim 20 Door trim upper 21 Foamed resin base material 22 Resin rib 23 Decorating material 23a Roll-in white 24 Vertical wall part 30 Door trim lower 40 Molding die 41 Molding upper mold 42 Molding lower mold 43 (43a, 43b) ) Injection machine 414 Temporary fixing pin 427 Set plate 428 Support shaft 50 Multifunctional block 51 Drive cylinder 52 Support bracket 60 Heater A Shear edge part S Foamed resin sheet M1, M2 Molten resin

Claims (2)

A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21), In a method for manufacturing an interior part (10) for an automobile, in which a laminated structure (20) composed of a decorating material (23) attached to the surface of a foamed resin substrate (21) is employed in whole or in part. ,
When the mold upper and lower molds (41, 42) are opened, the decorating material (23) is set on the lower surface side of the mold upper mold (41) while the heat-softened foamed resin sheet (S) is molded into the mold lower mold (42). ) The setting process of each material to be set on the mold surface,
The upper and lower molds (41, 42) are clamped, and the foamed resin sheet (S) is press-molded into a desired curved shape along the cavity shape, and the multi-functional mold block disposed on the molding upper mold (41) (50) and a shearing action between the vertical wall side surfaces of the molded lower mold (42), the end material of the foamed resin sheet (S) is cut, and immediately before clamping the molded upper and lower molds (41, 42). Alternatively, the molten resin (M1) is injected and filled into the groove (424) of the molded lower mold (42) at any timing after the mold clamping, so that the resin rib (22 on the back surface side of the foamed resin base material (21). ) To form a laminated structure (20),
Next, after the mold upper and lower molds (41, 42) are opened, the laminated structure (20) is removed from the mold, and then the decorative material (23) is wrapped around the back surface (23a) of the foamed resin base material (21). ) Winding process of the decorative material (23) for winding process,
A method for manufacturing an interior part for an automobile, wherein a laminated structure (20) is manufactured by each step comprising the steps of: A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21), In the molding die (40) used when molding the laminated structure (20) composed of the decorative material (23) attached to the surface of the foamed resin substrate (21),
A mold upper mold (41), a mold lower mold (42) that can be clamped and opened with each other, and an injection machine (43) connected to the mold lower mold (42) as means for supplying the resin rib (22) The end material portion of the foamed resin sheet (S) is cut by a shearing action in cooperation with the molding lower mold (42) when the molding upper mold (41) is lowered. A molding die comprising a multi-functional block (50) that can be made and a cylinder (51) that drives the multi-functional block (50) to advance and retreat.

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