JP2006346945A - Manufacturing method of trim part for car - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve weight reduction and cost reduction while simply and inexpensively performing terminal treatment in a manufacturing method of a trim part for a car. <P>SOLUTION: The trim part (door trim upper) 20 is equipped with a lightweight foamed resin base material 21 having shape retention property and the resin ribs 22 integrated with the inner surface side of the foamed resin base material 21. After a foamed resin sheet S is heated and softened, it is charged in a mold 40 and press-molded into a desired curved surface shape by clamping the mold 40. Then, at the time of molding of a foamed resin base material 21, an involving flange 25 is integrally formed by the collapsing blocks 44, 45 and 46 provided to the outer periphery of a product cavity C and, after molding, the molded foamed resin base material 21 is demolded from the mold 40 and the involving flange 25 is subjected to involving treatment to increase the appearance and strength of the outer peripheral part of the trim part. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing interior parts for automobiles 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 for manufacturing an automotive interior part that is excellent and 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 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 TPO (thermoplastic olefin) 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. 21, 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. Cut processing is performed. Further, as shown in FIG. 23, after the core material 2 is press-molded, the skin 3 is integrated in a separate process by vacuum pressure bonding, press pressure bonding, or the like, and then the terminal 3a 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, as shown in FIG. 22, the outer peripheral edge of the door trim 1 has the disadvantages that 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 can promote weight reduction, can reduce cost with high rigidity, can reduce molding cost, can shorten the molding cycle, It aims at providing the manufacturing method of the interior component for motor vehicles which improved the external appearance performance by improving the appearance and rigidity of a terminal part.

  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 By arranging ribs, it can be made lighter than conventional resin cores with a large projected area, and it is possible to achieve end processing easily and beautifully by simply attaching a crushing block for processing the peripheral end of the product. As a result, the present invention has been completed.

  That is, the present invention relates to a laminated structure comprising a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and resin ribs having a predetermined pattern shape integrated with the back surface of the foamed resin base material. In the manufacturing method of interior parts for automobiles, wherein the laminated structure is put into a molding die after heat-softening the foamed resin sheet, which is the material of the foamed resin base material. The mold is clamped and press-molded at a low pressure to form the foamed resin base material into the required shape, and the lower mold is molded either before or after the mold is clamped. The molten resin is injected and filled into the groove portion of the foamed resin base material, and a resin rib having a predetermined pattern shape is integrally formed on the back side of the foamed resin base material. At the time of clamping the molding die, at least a part of the outer periphery of the product cavity Squeeze the bottom mold By setting the hook, the outer periphery of the foamed resin base material is formed into a flat shape on the outer periphery based on the hinge portion, and after the molding, the laminated structure is demolded. After that, it is characterized in that it is manufactured by winding a winding white on the back side of the foamed resin base material.

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

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

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

  And in order to improve an external appearance design property, you may laminate | stack and integrate a decorating material on the surface of a foamed resin base material. As the decorating material, a woven fabric, a non-woven fabric, a knitted fabric, a sheet, a film, a foam, a net-like material, or the like can be used. 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, when a TPO sheet is used as a decorating material, the material can be unified with an olefin resin, so that the recycling work can be performed smoothly. Furthermore, the outer peripheral edge of the interior part is formed with a thin hinge part that forms a fold line on the foamed resin base material, and the winding wrap around the outer periphery of the hinge part is compressed into a flat shape, which is a terminal treatment. As a structure, the outer winding white is wound on the back side of the foamed resin base material based on the hinge portion.

  And according to the interior parts for automobiles manufactured by the method of the present invention, the decorative material having the decorating property is laminated on the front surface side of the foamed resin base material having the shape retaining property, and the rigidity is enhanced on the back surface side. In the sense, since the resin rib is 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 part of the interior part, since the outer part is wound around the hinge part as a folding base point, the cut end is not conspicuous on the outside, the appearance design is excellent, and the terminal part is The foamed resin base material has a double structure, and the rigidity can be enhanced. 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.

  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. However, 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. Although it is good, it may be performed before mold clamping as the injection filling timing of the molten resin.

  Further, a crushing block is provided on at least a part of the outer periphery of the product cavity in the upper and lower molds. This crushing block is provided in the molding lower mold at a position facing the lower surface of the molding upper mold when the peripheral part of the molding upper and lower molds has a horizontal parting structure. Then, a winding white is formed between the lower surface of the upper mold and the upper surface of the crushing block by clamping the upper and lower molds. In addition, when the product outer peripheral part has a vertical parting structure, a crushing block is embedded in the molding lower mold at a position facing the inner wall surface of the molding upper mold. By moving forwards and backwards, the rolled-up whitening is made flat and thin.

  Therefore, according to the method of the present invention, since only the resin rib is molded compared to the conventional resin core material having a large projected area, the injection pressure can be set lower than the conventional one, so that the load on the molding die can be reduced. In addition, the amount of resin is small, material costs can be saved, and since the cooling time is shorter than that of the conventional resin core material, the molding cycle of the product can be shortened. Furthermore, as the terminal treatment process of the laminated structure, it is possible to flatten and thin the winding roll between the crushing block and the molding die simultaneously with the molding of the foamed resin base material. The body is removed from the mold, and the entrainment scissors need only be folded back and secured to the back side of the foamed resin base material based on the hinge part. A sharp outer peripheral line can be secured, and the terminal part has a double structure. It is possible to smoothly process the terminal processing portion that is excellent in and has no fear of deformation.

  Furthermore, in a preferred embodiment of the method of the present invention, the crushing block is provided with a shearing function for cutting and removing the end material of the foamed resin base material from the inner surface of the molding upper die. . And according to this embodiment, since the end material of the foamed resin base material can be cut and removed between the crushing block and the molding upper mold, the trim cutting process that has been conventionally required can be dispensed with and produced. The sex can be increased.

  As described above, the method for manufacturing an automotive interior part according to the present invention forms a foamed resin base material into a required shape along the cavity shape of a molding die, and at the same time, a resin rib on the back side of the foamed resin base material. Because it is a process of integration, the projected area of the resin rib is small, the load applied to the molding die is less than conventional resin core materials, the cooling time can be shortened, and the yield can be increased. It has the effect of increasing efficiency and incurring significant cost reductions.

  Furthermore, in the method for manufacturing an automotive interior part according to the present invention, a crushing block is arranged in a lower mold, and the foamed resin base material is disposed along the outer periphery of the foamed resin base material by molding the mold. By compressing and flattening, forming a winding scissors at the same time, forming a laminated structure, then removing from the mold, turning the winding scissors back and performing a winding process, forming a sharp outer peripheral line It is possible to provide an effect that the terminal processing with excellent appearance design can be performed smoothly. In addition, since the folded portion has a double structure in the terminal portion, the rigidity can be strengthened, the waviness defect does not occur, the moldability can be improved, and the alignment accuracy with respect to the panel or the adjacent counterpart component Have various effects such as Furthermore, by adopting a configuration in which the trim material is trimmed between the block for crushing and the molding upper die, the piercing process required conventionally can be omitted, and the productivity can be further increased. Has an effect.

  Hereinafter, a method for manufacturing an automotive interior trim according to the present invention will be described by exemplifying a method for manufacturing a vehicle door trim. 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 a first embodiment of the present invention. FIG. 1 is a front view showing a two-tone type automobile door trim, FIG. 2 is a cross-sectional view showing the configuration of the automobile door trim, and FIG. 4 is a front view showing a resin rib and a door trim lower of a door trim upper in an automobile door trim, FIG. 4 is a cross-sectional view showing a configuration of an outer peripheral edge portion of the door trim upper in the automobile door trim, and FIGS. FIG. 5 is an overall view of the molding die, and FIG. 6 is a cross-sectional view showing a portion corresponding to the outer peripheral edge portion of the door trim upper in the molding die. Further, FIGS. 7 to 11 show each process of the manufacturing method of the door trim for the automobile, FIG. 7 is a preheating process of the foamed resin sheet, FIG. 8 is a process of setting the foamed resin sheet to the molding die, and FIG. FIG. 10 is an explanatory view showing the forming step of the winding white, FIG. 11 is an explanatory view showing the terminal processing step of the winding white, and FIGS. 12 to 14 are explanatory views showing modifications.

  First, a first embodiment of the present invention will be described with reference to FIGS. 1 and 2, a two-tone type automobile door trim 10 is composed of an upper and lower divided part of a door trim upper 20 made of a laminated structure and a door trim lower 30 made of a single resin product. As functional parts 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 manufactured by the method of the present invention for the door trim upper 20 which is a laminated structure, and the weight of the product is reduced, the appearance of the outer peripheral terminal portion is improved, and the molding process and terminal processing are performed. It is characterized by simplifying the process. That is, as shown in FIG. 2, the door trim upper 20 is molded into a desired curved surface shape and has a foamed resin base material 21 having shape retention, and a resin laminated and integrated on the back surface side of the foamed resin base material 21. The rib 22 and the decorating material 23 having a decorating function laminated and integrated on the surface side of the foamed resin base material 21 are roughly configured. In the figure, reference numeral 16 denotes a vehicle body panel.

  In addition, the foamed resin base material 21 is heat-softened to heat the foamed resin sheet so as to have shape retention, and then thermoformed into a required shape, for example, cold press-molded with a molding die having a desired mold surface. In addition, the foamed resin base material 21 may be shaped by vacuum forming for a portion with a higher development rate. In addition, in flat parts like lid parts, such as a jack lid, it can shape | mold into a flat shape, without performing a heat softening process to a foamed resin sheet. The foamed resin sheet has a structure in which a foaming agent is added to a general-purpose thermoplastic resin. The thermoplastic resin includes a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a chloride resin. Vinyl resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. can be used. As the foaming agent, organic foaming agents such as azodicarbonamide and bicarbonate An inorganic foaming agent such as sodium can be used. In this embodiment, a foamed resin sheet in which sodium bicarbonate is appropriately added as a foaming agent to a polypropylene resin is used. The expansion ratio of the foamed resin base material 21 is set to 2 to 10 times, and the thickness is set to a range of 0.5 to 30 mm, particularly 1 to 10 mm.

  Next, the resin ribs 22 are disposed on the back surface side of the foamed resin base material 21 and, in particular, are set in a predetermined pattern extending in an intersecting manner as shown in FIG. In addition, as for this pattern, arbitrary patterns may be selected as long as it is intersecting, such as a vertical and horizontal direction, an oblique direction, or a combination thereof. The resin rib 22 is made of a general-purpose synthetic resin molded body, and as a synthetic resin that can be preferably used normally, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin, A polyamide resin, a polyacetal resin, a polycarbonate resin, an ionomer resin, an acrylonitrile / butadiene / styrene (ABS) resin, or the like may be selected as appropriate. 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 made of a single synthetic resin, and has an excellent appearance design due to an accent effect on the appearance. ing. Further, the door trim upper 20 includes a foamed resin base material 21 having shape retention, a resin rib 22 laminated and integrated on the back surface of the foamed resin base material 21, and a decorating material 23 having a decorating property. Therefore, the resin core material occupied over the entire circumference of the product can be abolished as in the past, and the weight of the product is 40% compared to the conventional example because the lightweight foamed resin base material 21 is used. The weight can be reduced as described above, and the resin material can be greatly saved, thereby contributing to cost reduction.

  Furthermore, since the foamed resin base material 21 has a porous structure, the door trim upper 20 is excellent in sound absorption performance and can reduce noise in the vehicle interior. In order to maintain the sound absorption of the foamed resin base material 21, the decorative material 23 laminated in advance on the surface of the foamed resin base material 21 or integrated and laminated at the time of molding is a woven fabric. Sheet materials having air permeability such as nonwoven fabric and knitted fabric are preferred. In addition to the breathable sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric, the decorative material 23 may be a synthetic resin sheet such as a vinyl chloride sheet or a TPO sheet, a synthetic resin film, a foam, or a net-like body. 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 structure along the outer peripheral terminal of the door trim upper 20 in the door trim 10 will be described based on 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 flange 211 is formed downward along the product outer periphery of the door trim upper 20 so that the product has a three-dimensional effect, and the front side edge is further extended from the flange 211 with an extension 212 in a horizontal shape. A thin-walled hinge portion 24 is set at the tip, and a winding white 25 is set along the outer peripheral edge of the hinge portion 24. Then, the winding scissors 25 are wound around the back surface of the extension portion 212 based on the hinge portion 24, and are fixed by ultrasonic welding, heat welding, adhesive bonding, or the like. Abutting in contact.

  Accordingly, since the thin-walled hinge portion 24 corresponds to the outer peripheral edge portion of the door trim upper 20, a sharp outer peripheral line can be secured, the appearance is excellent, and the winding 25 is folded back on the back surface of the extension portion 212. Since it has a heavy structure, there is an advantage that the rigidity of the outer peripheral portion can be strengthened, there is no fear of undulation deformation, etc., it can be tightly adhered to the vehicle body 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, the overall structure of the molding die 40 will be described with reference to FIG. 5, and the main configuration of the molding die 40 corresponding to the outer peripheral edge portion of the door trim upper 20 will be described with reference to FIG. In FIG. 5, a molding die 40 used for molding the door trim 10 includes a molding upper mold 41 that can move up and down by a predetermined stroke, a molding lower mold 42 that is paired with the molding upper mold 41, and a molding lower mold 42. It consists of two injection machines 43a and 43b connected to each other. More specifically, the molding upper die 41 has a cavity portion 411 that matches the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 412 connected to the upper surface of the molding upper die 41. In addition, guide bushes 413 serving as a guide mechanism are provided at the four corners of the molding upper die 41.

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

  FIG. 6 shows the configuration of the main part of the molding die 40 corresponding to the terminal processing part of the door trim upper 20. The cavity part 411 of the molding upper mold 41 constituting the product cavity C and the core part 421 of the molding lower mold 42 are shown. In the outer periphery of the product cavity C between them, a crushing block 44 is disposed in the molding lower die 42 particularly at a place where a winding process is necessary. That is, the crushing block 44 has a function of simultaneously forming the winding scissors 25 simultaneously with the molding of the foamed resin base material 21, as will be described in detail in the molding process of the door trim upper 20 described later.

  Next, a method for manufacturing the door trim 10 will be described in order. First, as shown in FIG. 7, the heater device 50 heats and softens the laminate of the decorating material 23 on one surface of the foamed resin sheet S to a predetermined temperature. 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 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 locations corresponding to the door trim upper 20. Set in the upper half of the cavity defined by the core part 421.

  Then, after the foamed resin sheet S is set, the lifting cylinder 412 of the molding upper die 41 operates to lower the molding upper die 41 by a predetermined stroke, so that the molding upper and lower dies 41 and 42 are molds as shown in FIG. The foamed resin sheet S is shaped along the desired mold surface shape to form the foamed resin base material 21 and the resin ribs in the door trim upper 20 from the first injection machine 43a through the manifold 422a and the gate 423a. In order to form 22, molten resin M <b> 1 is injected and filled into the groove portion 424 of the core portion 421. At the same time, in order to mold the door trim lower 30, the molten resin M2 is injected and filled into the substantially lower half of the cavity from the second injector 43b through the manifold 422b and the gate 423b, and the door trim lower 30 is molded into a required shape.

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

  Thus, in order to manufacture the two-tone type door trim 10, two injection machines 43 a and 43 b are connected to the molding lower mold 42, and the molten resin M <b> 1 passes through each resin passage for the door trim upper 20 and the door trim lower 30. , M2 can be injection-filled to produce a two-tone door trim 10 with a single molding die 40 and a reduced number of processes. When the foamed resin base material 21 is press-molded in the door trim upper 20, as shown in FIG. 10, the outer periphery of the product cavity C formed by the cavity portion 411 of the molding upper die 41 and the core portion 421 of the molding lower die 42. A crushing block 44 is disposed on a part of the crushing block 44. Since the crushing block 44 and the molding upper die 41 have a horizontal parting structure, the crushing blocks 44 and 42 are crushed at the same time as the molds are clamped. By means of the block 44, the winding scissors 25 are integrally molded simultaneously with the molding.

  Therefore, after the molding of the door trim upper 20 and the door trim lower 30 is completed, the molding upper die 41 is raised and the molding die 40 is opened, and then the molded product is taken out from the molding die 40, as shown in FIG. In addition, at the outer peripheral terminal of the door trim upper 20, the winding scissors 25 positioned on the outer periphery of the thin-walled hinge portion 24 as the folding base point are ultrasonically welded, thermally welded, or adhered to the back surface of the foamed resin base material 21. As shown in FIG. 4, the outer peripheral edge portion of the door trim upper 20 corresponds to the thin-walled hinge portion 24, the outer peripheral terminal portion looks good, has a double structure, and has rigidity as shown in FIG. The terminal processing of the reinforced door trim upper 20 is easily completed. In this method, the material of the resin rib 22 in the door trim upper 20 and the material of the door trim lower 30 can be made different, and the material can be appropriately changed according to each required item.

  Further, the molten resins M1 and M2 branched and supplied to the door trim upper 20 and the door trim lower 30 can be supplied from one injection machine 43 as the same material. In this case, a branch manifold serving as a passage for the molten resin M1 supplied to the door trim upper 20 side from a main manifold communicating with the injection machine 43 and a branch manifold serving as a resin passage for supplying the molten resin M2 to the door trim lower 30 are set. You can do it.

  12 to 14 show a modification of the first embodiment of the present invention. FIG. 12 shows a mold configuration of a molding die 40A used in the modification, and FIGS. It is process explanatory drawing which each shows the press molding process which uses the metal mold | die 40A, and the terminal processing process of rolling-in white. In this modified example, the first embodiment has a horizontal parting structure, whereas, as shown in FIG. 12, the product terminal portion adopts a vertical parting structure. Is a movable structure, and is provided so as to be able to advance and retreat in the direction of the arrow in FIG. 12 by a cylinder 45a, and a vertical parting block 414 is attached to the molding upper die 41 in correspondence with the crushing block 45. .

  Therefore, after the foamed resin sheet S is heat-softened, it is put into the molding die 40 and the molded upper and lower molds 41 and 42 are clamped, so that the foamed resin base material 21 and the decoration are decorated as shown in FIG. The material 23 is press-formed into a required shape. In this press molding process, the end portion of the foamed resin sheet S is compressed and flattened between the crushing block 45 and the vertical parting block 414 by the extension operation of the cylinder 45a, and downward from the hinge portion 24. The extending part is formed as a thin flattened winding 25. Next, as shown in FIG. 14, after the mold 40 is opened, if the winding scissors 25 are wound based on the hinge portion 24 at the outer peripheral terminal portion of the door trim upper 20, the terminal in the door trim upper 20 is processed. Processing is completed easily.

  15 to 18 show a second embodiment of the present invention. FIG. 15 is an explanatory view showing the configuration of the main part of the molding die 40B. FIGS. 16 to 18 show a method for molding the door trim upper 20 as in the first embodiment. It is each process explanatory drawing which shows the example applied to. That is, FIG. 16 is an explanatory diagram showing a material charging process to the molding die 40B, FIG. 17 is a molding process of the foamed resin base material 21 and the winding white, and FIG. . As shown in FIG. 15, the molding die 40B used in the second embodiment is arranged in a state where the crushing block 46 is heated to a predetermined temperature at a predetermined location on the outer peripheral portion of the molding lower mold 42. In particular, both of the shearing functions can be obtained so that the end material 21a of the foamed resin base material 21 can be trim-cut between the outer side surface 46a of the heated crushing block 46 and the inner side surface 415 of the molding upper die 41. It is necessary to set an appropriate clearance between them.

  Next, the process of molding the door trim 10 using this molding die 40B will be briefly described. As shown in FIG. 16, when the molding die 40B is in the mold open state, the foamed resin heat-softened. The sheet S (decorating material 23 is laminated if desired) is put in, and as shown in FIG. 17, the upper mold 41 and the lower mold 42 are clamped to form the foamed resin sheet S in the required shape. The foamed resin base material 21 is press-molded. At this time, the end material 21a of the foamed resin base material 21 can be trimmed by the shearing action between the inner side surface 415 of the molding upper die 41 and the outer side surface 46a of the crushing block 46. Piercing cut processing is performed. Furthermore, between the upper surface 46b of the crushing block 46 and the mold surface of the molding upper die 41, the foaming base 25 can be integrally formed by processing the foamed resin base material 21 into a compression flat shape. Next, as shown in FIG. 18, the end treatment of the trim upper 20 can be easily performed by winding the winding scissors 25 on the back side of the foamed resin base material 21 based on the hinge portion 24.

  In the first and second embodiments described above, the present invention is applied to the manufacture of the door trim upper 20 in the two-tone type automobile door trim 10. However, the present invention can also be applied to an integrated door trim. In addition, it can be applied to all interior parts such as rear parcel shelf, floor trim, trunk trim, luggage trim, roof trim, and rear side trim.

It is a front view which shows the 1st Example of the door trim for motor vehicles manufactured by 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 in the door trim for motor vehicles shown in FIG. FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. 1 and is a cross-sectional view illustrating a configuration of an outer peripheral terminal portion of the door trim upper. FIG. 2 is an overall view showing a configuration of a molding die used when molding the automobile door trim shown in FIG. 1. It is sectional drawing which shows the site | part corresponding to the outer peripheral part of the door trim upper 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 of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material and resin rib in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the winding white in the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process of the winding white in the door trim upper shown in FIG. It is explanatory drawing which shows the principal part of the molding die used for the modification in 1st Example of this invention method. It is explanatory drawing which shows the process of shape | molding a door trim upper using the shaping die shown in FIG. It is explanatory drawing which shows the terminal process process in the door trim upper shape | molded using the shaping die shown in FIG. It is explanatory drawing which shows the principal part of the shaping die used for 2nd Example of this invention method. It is explanatory drawing which shows the process of setting a foamed resin sheet to the shaping die shown in FIG. It is explanatory drawing which shows the process of shape | molding a door trim upper using the shaping die shown in FIG. It is explanatory drawing which shows the terminal process process in the door trim upper shape | molded using the shaping die shown in FIG. It is a front view which shows the conventional door trim for motor vehicles. FIG. 20 is a sectional view taken along line XX-XX in FIG. 19. It is explanatory drawing which shows the shaping | molding die of the conventional door trim for motor vehicles. It is explanatory drawing which shows the prior art example of the terminal part of the door trim for motor vehicles by press molding. It is explanatory drawing which shows the prior art example of the terminal part in the door trim for motor vehicle of a skin-wrapping type.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Two-tone type automobile door trim 11 Inside handle escutcheon 12 Power window switch escutcheon 13 Pocket opening 14 Pocket back cover 15 Speaker grill 20 Door trim upper 21 Foamed resin base material 211 Flange 212 Extension part 22 Resin rib 23 Decorating material 24 Hinge part 25 Rolling Shiro 30 Door Trim Lower 40, 40A, 40B Molding Die 41 Molding Upper Mold 414 Vertical Parting Block 415 Inner Side 42 Molding Lower Mold 43a, 43b Injection Machine 44 Crushing Block (Fixed)
45 Crushing block (cylinder drive type)
46 Crushing block (heating type)
50 Heater device S Foamed resin sheet M1, M2 Molten resin

Claims (3)

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 integrated with the back surface of the foamed resin base material (21). In the manufacturing method of the automotive interior part (10) formed by employing the laminated structure (20) in whole or in part,
The laminated structure (20) is obtained by heat-softening the foamed resin sheet (S), which is the material of the foamed resin base material (21), and then charging it into the molding dies (41, 42). 41, 42) are clamped and press-molded at a low pressure to form the foamed resin base material (21) into a required shape, and either immediately before or after the molding of the molding die (41, 42). At this timing, the molten resin (M) is injected and filled into the groove (424) of the molded lower mold (42), and the resin rib (22) having a predetermined pattern shape is integrally formed on the back side of the foamed resin base material (21). When the molds (41, 42) are clamped, the crushing blocks (44, 46) are set on at least a part of the molding lower mold (42) on the outer peripheral edge of the product cavity (C). The foamed resin base material (21) has a hinge on the outer peripheral edge. On the basis of (24), the winding white (25) is formed in a flat shape, and after molding, the laminated structure (20) is removed from the mold, and then the winding white (25) is used as a foamed resin base material. (21) A method of manufacturing an interior part for an automobile, which is manufactured by being wound on the back side.   The crushing block (46) is provided with a shear function for cutting and removing the end material (21a) of the foamed resin base material (21) between the molding upper die (41) and the inner surface (415). The manufacturing method of the interior component for motor vehicles of Claim 1 characterized by these. 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 integrated with the back surface of the foamed resin base material (21). In the manufacturing method of the automotive interior part (10) formed by employing the laminated structure (20) in whole or in part,
The laminated structure (20) is obtained by heat-softening the foamed resin sheet (S), which is the material of the foamed resin base material (21), and then charging it into the molding dies (41, 42). 41, 42) is clamped and press-molded at a low pressure to form the foamed resin base material (21) into a required shape, and either immediately before or after the molding of the molding die (41, 42). At this timing, the molten resin (M) is injected and filled into the groove (424) of the molded lower mold (42), and a resin rib (22) having a predetermined pattern shape is integrally formed on the back side of the foamed resin base material (21). Formed,
A vertical parting structure is adopted between the upper and lower molds (41, 42) along the outer peripheral edge of the product cavity (C), and a crushing block (45) is advanced and retracted inside the lower mold (42) by driving the cylinder. The wrapping block (45) is compressed into a thin flat shape between the crushing block (45) and the vertical parting block (414) of the molding upper die (41), and then laminated. The structure (20) is removed from the molding die (40A), and the winding sheet (25) is wound on the back surface of the foamed resin substrate (21) based on the hinge portion (24). The manufacturing method of the interior component for motor vehicles characterized by the above-mentioned.

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