JP2006347273A - Automobile interior component and manufacturing method thereof - Google Patents

Automobile interior component and manufacturing method thereof Download PDF

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JP2006347273A
JP2006347273A JP2005173820A JP2005173820A JP2006347273A JP 2006347273 A JP2006347273 A JP 2006347273A JP 2005173820 A JP2005173820 A JP 2005173820A JP 2005173820 A JP2005173820 A JP 2005173820A JP 2006347273 A JP2006347273 A JP 2006347273A
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base material
side base
panel
indoor
molding
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Kenichi Sudo
憲一 須藤
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Kasai Kogyo Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide an automobile interior component adopting a double-layer base material structure of a panel side base material and an interior side base material, and a manufacturing method thereof, capable of simply and certainly mounting an attachment such as a clip mounting seat or an electric equipment harness, and effectively corresponding to modularization. <P>SOLUTION: A molded ceiling (an interior component) 10 is composed of the panel side base material 11 molded in a required recessed/projecting shape, and the interior side base material 12 molded in a generally flat surface shape keeping a product surface shape. At least a part of the clip mounting seat 20 or the electric equipment harness 30 is put and supported between the panel side base material 11 and the interior side base material 12. Therefore, conventional bonding fixing by reactive hot-melt system adhesive is obsoleted, and secure mounting is carried out in a short time. Having the double-layer base material structure, the automobile interior component improves flexibility in shaping and effectively corresponds to modularization, regardless of a panes shape. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

本発明は、自動車用内装部品及びその製造方法に係り、特に、所望の凹凸形状に成形されるパネル側基材と、略フラットな製品面形状に成形される室内側基材との二層基材構造を採用した自動車用内装部品であって、クリップ取付座、ハーネスクリップ、電装用ハーネス、衝撃吸収パッド等の付属部品をパネル側基材と室内側基材との間でサンドイッチ状に強固に支持でき、付属部品を効率良くモジュール化できる自動車用内装部品及びその製造方法に関する。   The present invention relates to an automotive interior part and a method for manufacturing the same, and in particular, a two-layer base including a panel-side base material formed into a desired uneven shape and an indoor-side base material formed into a substantially flat product surface shape. Automobile interior parts that employ a material structure, with attachment parts such as clip mounting seats, harness clips, electrical harnesses, shock absorbing pads, etc., firmly sandwiched between the panel side substrate and the indoor side substrate The present invention relates to an automobile interior part that can be supported and can efficiently modularize accessory parts and a method for manufacturing the same.

例えば、図11に示すように、自動車のルーフパネル1の室内面側には、ほぼ湾曲状に成形された成形天井2が装着されており、この成形天井2は、適度の保形性とルーフパネル1への取付剛性を備えた基材2aと、その表面に積層一体化される表皮2bから構成されている。通常、基材2aの素材としては、ガラス繊維入り樹脂板や、ガラス繊維と樹脂繊維とをマット状に集積したものをプレス成形により板状に成形した繊維質成形体、PPO(ポリフェニレンオキシド)発泡樹脂基材、ウレタン樹脂基材、PET不織布成形体等が使用されており、表皮2bとしては、織布、不織布、合成樹脂シート等が適宜使用されている。   For example, as shown in FIG. 11, a molded ceiling 2 formed in a substantially curved shape is mounted on the indoor surface side of a roof panel 1 of an automobile, and this molded ceiling 2 has an appropriate shape retaining property and a roof. It is comprised from the base material 2a provided with the attachment rigidity to the panel 1, and the skin 2b laminated | stacked and integrated on the surface. Usually, the material of the substrate 2a is a resin sheet containing glass fibers, a fiber molded body in which glass fibers and resin fibers are accumulated in a mat shape, and formed into a plate shape by press molding, PPO (polyphenylene oxide) foaming A resin base material, a urethane resin base material, a PET non-woven fabric molded body, and the like are used, and as the skin 2b, a woven fabric, a non-woven fabric, a synthetic resin sheet, or the like is appropriately used.

更に、成形天井2をルーフパネル1に取り付けるには、図12に示すように、パネル取付用クリップ3を装着するためのクリップ取付座4が成形天井2の裏面所定位置に取り付けられるが、通常、反応性ホットメルト系接着剤5を基材2aに塗布して、その上にクリップ取付座4をセットして固定している。また、電装用ハーネス等を支持するクリップ6や衝撃吸収パッド(図示せず)についても、反応性ホットメルト系接着剤5を使用して取り付けているのが実情である。成形天井のルーフパネルへの取付構造の従来例については、特許文献1に詳細に記載されている。   Furthermore, in order to attach the molded ceiling 2 to the roof panel 1, as shown in FIG. 12, a clip mounting seat 4 for mounting the panel mounting clip 3 is attached at a predetermined position on the back surface of the molded ceiling 2, The reactive hot-melt adhesive 5 is applied to the substrate 2a, and the clip mounting seat 4 is set and fixed thereon. Further, the clip 6 and the shock absorbing pad (not shown) that support the electrical harness and the like are also attached by using the reactive hot melt adhesive 5. A conventional example of a structure for attaching a molded ceiling to a roof panel is described in detail in Patent Document 1.

特開平2000−85486号公報Japanese Unexamined Patent Publication No. 2000-85486

このように、従来の成形天井2は、例えば、クリップ取付座4やハーネスクリップ6等を成形天井2に取り付ける手段として、反応性ホットメルト系接着剤5を用いているが、この反応性ホットメルト系接着剤5は、養生時間が24時間程度必要であることから、在庫の管理やスペースの確保等、多くの問題点を有している。更に、成形天井における基材2aは、ルーフパネル1の形状にフィットするように成形されているため、電装用ハーネスや衝撃吸収パッド等を収容するスペース等を確保しづらく、モジュール化構造に不適であるという問題点が指摘されている。   As described above, the conventional molded ceiling 2 uses the reactive hot-melt adhesive 5 as means for attaching the clip mounting seat 4, the harness clip 6 and the like to the molded ceiling 2, for example. Since the system adhesive 5 requires a curing time of about 24 hours, it has many problems such as inventory management and space securing. Further, since the base material 2a in the molded ceiling is molded so as to fit the shape of the roof panel 1, it is difficult to secure a space for accommodating an electrical harness, shock absorbing pad, etc., and is not suitable for a modular structure. There are some problems.

この発明は、このような事情に鑑みてなされたもので、養生時間を長時間要する反応性ホットメルト系接着剤5を廃止するとともに、二層基材構造を採用し、二層の基材間にクリップ取付座やハーネスクリップ等、付属部品の少なくとも一部を挟み込んで支持することにより、短時間に作製できるとともに、在庫の管理がやり易く、スペースの確保も不要となる等、管理が容易で、かつモジュール化に有効に対応できる自動車用内装部品及びその製造方法を提供することを目的としている。   The present invention has been made in view of such circumstances, and eliminates the reactive hot-melt adhesive 5 that requires a long curing time, adopts a two-layer substrate structure, and provides a space between two layers of substrates. By attaching and supporting at least some of the accessory parts such as clip mounting seats and harness clips, it can be manufactured in a short time, and it is easy to manage, such as easy inventory management and no need for space. And it aims at providing the interior component for motor vehicles which can respond effectively to modularization, and its manufacturing method.

上記課題を解決するために、発明者は鋭意研究の結果、従来一層であった基材の構成として、裏面側に位置するパネル側基材と、表面側に位置する室内側基材の二層基材構造を採用し、クリップ取付座、ハーネスクリップ、電装用ハーネス、衝撃吸収パッド等の付属部品の少なくとも一部分を基材間で挟み込み固定することで、従来の養生時間を長時間要した反応性ホットメルト系接着剤を廃止できることを見出し、本発明を完成するに至った。   In order to solve the above-mentioned problems, the inventor has intensively studied, and as a conventional single-layer base material structure, the panel side base material located on the back side and the indoor side base material located on the front side have two layers. Reacts that require a long curing time by adopting a base material structure and sandwiching and fixing at least a part of accessory parts such as clip mounting seats, harness clips, electrical harnesses, and shock absorbing pads between the base materials The present inventors have found that a hot-melt adhesive can be eliminated and have completed the present invention.

すなわち、本発明は、所要形状に成形された基材からなり、車体パネルの室内面側に装着される自動車用内装部品であって、前記基材は、所望の凹凸形状に成形されるパネル側基材と、製品面形状を形成するように略フラット面形状に成形される室内側基材の二層基材構造が採用されているとともに、内装部品に付設される付属部品の少なくとも一部がパネル側基材と室内側基材との間に挟持されていることを特徴とする。   That is, the present invention is an automotive interior part that is composed of a base material molded into a required shape and is mounted on the interior surface side of a vehicle body panel, and the base material is a panel side that is molded into a desired uneven shape. A two-layer base material structure of a base material and an indoor base material formed into a substantially flat surface shape so as to form a product surface shape is adopted, and at least a part of the accessory parts attached to the interior part is It is sandwiched between the panel side base material and the indoor side base material.

更に、この自動車用内装部品の製造方法は、真空吸引機構をそれぞれ備えた成形金型が型開き状態にある時、パネル側基材の原反シートと、室内側基材の原反シートを加熱軟化処理した後、成形金型内に投入する原反シートのセット工程と、成形金型にそれぞれ真空吸引力を作用させ、一方側の原反シートを一方側の成形金型の型面形状に沿って真空成形し、所望の凹凸形状を備えたパネル側基材を成形するとともに、他方側の成形金型の型面形状に沿って他方側の原反シートを真空成形して、フラットな製品面形状を備えた室内側基材を成形する基材の真空成形工程と、成形金型を型開きした後、成形下型上に保持されている室内側基材上に付属部品をセットするとともに、上記付属部品の一部を基材の開口を通して裏面側に貫通させる場合には、成形上型に保持されているパネル側基材に開口を開設する付属部品のセット工程並びに基材のピアスカット工程と、成形上型に保持されているパネル側基材に再加熱処理を施し、成形金型を型締めし、パネル側基材と室内側基材とを圧着一体化するとともに、両基材間で付属部品の少なくとも一部を挟み込んで支持する基材の圧着一体化工程とからなることを特徴とする。   Furthermore, this method of manufacturing interior parts for automobiles heats the panel-side base material and the indoor-side base material sheet when the molding dies each having a vacuum suction mechanism are in an open state. After the softening treatment, the original sheet is put into the molding die, and the vacuum suction force is applied to the molding die, so that the one side of the original fabric sheet becomes the mold surface of the molding die. A flat product by forming a panel-side base material with a desired concavo-convex shape and vacuum-forming the other side of the original sheet along the mold surface shape of the other side mold A vacuum forming process of the base material for molding the indoor base material having the surface shape, and after opening the molding die, setting accessory parts on the indoor base material held on the lower mold , When part of the accessory is penetrated to the back side through the opening of the base material There is an accessory setting process for opening an opening in the panel-side base material held by the molding upper die, a piercing cut process for the base material, and a reheating treatment for the panel-side base material held by the molding upper die. The mold is clamped, and the panel side base material and the indoor side base material are pressure-bonded and integrated, and at least a part of the accessory is sandwiched and supported between the base materials. It consists of a process.

ここで、自動車用内装部品としては、ルーフトリム、ドアトリム、リヤパーセルシェルフ、フロアトリム、ラゲージトリム、トランクトリム、リヤサイドトリム等に適用できる。更に、二層基材構造をを構成する各基材(裏面側に位置するパネル側基材と表面側に位置する室内側基材)の素材としては、所要形状に真空成形することが必要であるため、非通気性で、かつ熱成形可能な素材であれば、熱可塑性樹脂シート、ガラス繊維等の補強材を混入した熱可塑性樹脂シート、あるいは独立気泡タイプの発泡樹脂シートが使用できるが、例えば、ガラス繊維と熱可塑性樹脂繊維とをマット状に集積した後、プレス成形した不織布マット材や、連続気泡タイプの発泡樹脂シート等、通気性を備えた素材であれば、非通気性フィルムを貼着することで非通気性を付加することで使用が可能となる。   Here, the interior parts for automobiles can be applied to roof trims, door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, and the like. Furthermore, as a material of each base material (panel side base material located on the back side and indoor side base material located on the front side) constituting the two-layer base material structure, it is necessary to vacuum form into a required shape. Therefore, if it is a non-breathable and thermoformable material, a thermoplastic resin sheet, a thermoplastic resin sheet mixed with a reinforcing material such as glass fiber, or a closed cell type foamed resin sheet can be used. For example, a non-breathable film can be used if the material is breathable, such as non-woven mat material that is pressed and molded after glass fibers and thermoplastic resin fibers are collected into a mat shape, or an open-cell foamed resin sheet. It can be used by adding non-breathability by sticking.

そして、パネル側基材及び室内側基材の素材である原反シートをまず加熱軟化処理した後、型開きされている成形金型内にセットし、パネル側基材の素材である原反シートを一方側の金型の型面形状に沿って真空吸引力を作用させ、所望の凹凸形状を備えるようにパネル側基材を真空成形する。一方、室内側基材の原反シートについても、他方側の金型の型面形状に沿ってほぼフラットな面形状を備えるように真空成形する。この時、室内側基材の表面に表皮を貼付する構成を採用するならば、室内側基材の原反シートと表皮の原反シートを重ね合わせてセットして、室内側基材の原反シートの余熱により両者を一体化することができる。   Then, the raw sheet that is the material of the panel side base material and the indoor side base material is first heat-softened and then set in a mold that is opened, and the raw sheet that is the material of the panel side base material A vacuum suction force is applied along the mold surface shape of the mold on one side, and the panel-side base material is vacuum-formed so as to have a desired uneven shape. On the other hand, the raw fabric sheet of the indoor side base material is also vacuum formed so as to have a substantially flat surface shape along the mold surface shape of the mold on the other side. At this time, if a structure in which the skin is applied to the surface of the indoor base material is adopted, the raw material sheet of the indoor base material and the raw material sheet of the skin are set so as to overlap each other. Both can be integrated by the residual heat of the sheet.

次いで、クリップ取付座、ハーネスクリップ、電装用ハーネス、衝撃吸収パッド等の付属部品をセットするには、成形下型上に保持されている室内側基材の表面所定位置にセットするが、この時、セット用治具を使用することで適正位置に付属部品を簡単にセットすることができる。また、付属部品のうち、例えば、クリップ取付座の取付座本体や、ハーネスクリップ本体等は、パネル側基材の開口を通してパネル側に向けて突出するが、そのために、パネル側基材の所定位置に開口を開設する必要がある。この開口の開設工程は、パネル側基材と室内側基材の一体化工程の前工程でパネル側基材の所定箇所にピアスカット処理を施して開口を開設する。その後、パネル側基材を再加熱処理を施し、成形上下型を型締めするためのパネル側基材と室内側基材とを接合一体化するとともに、パネル側基材と室内側基材との間に付属部品の少なくとも一部を挟み込んで支持することができる。   Next, to set accessory parts such as clip mounting seats, harness clips, electrical harnesses, shock absorbing pads, etc., set the surface of the indoor base material held on the lower mold at a predetermined position. By using a setting jig, it is possible to easily set accessory parts at appropriate positions. Among the accessory parts, for example, the mounting seat body of the clip mounting seat, the harness clip body, and the like protrude toward the panel side through the opening of the panel-side base material. It is necessary to open an opening. In the opening process, an opening is formed by performing a piercing cut process on a predetermined portion of the panel-side base material in the previous step of the process of integrating the panel-side base material and the indoor side base material. After that, the panel side base material is subjected to reheating treatment, and the panel side base material and the indoor side base material for clamping the upper and lower molds are joined and integrated, and the panel side base material and the indoor side base material At least a part of the accessory can be sandwiched between and supported.

従って、本発明に係る自動車用内装部品及びその製造方法は、内装部品の基材構造としてパネル側基材と室内側基材の二層構造を採用するとともに、クリップ取付座、ハーネスクリップ、電装用ハーネス、衝撃吸収パッド等の付属部品の少なくとも一部を双方の基材間で挟持固定するという構成であるため、従来、養生時間を長く必要とした反応性ホットメルト系接着剤を廃止でき、短時間で付属部品を固定することができる。また、二層基材構造としたため、付属部品をモジュール化するのに適切な形状にパネル側基材を成形することができることから、モジュール化に有効に対応することができる。   Therefore, the automotive interior part and the manufacturing method thereof according to the present invention adopt a two-layer structure of a panel side base material and an indoor side base material as a base material structure of the interior part, and also provide a clip mounting seat, a harness clip, and an electrical equipment Because it has a configuration in which at least a part of accessory parts such as harnesses and shock absorbing pads are sandwiched and fixed between both base materials, the conventional reactive hot-melt adhesive that requires a long curing time can be abolished. You can fix the accessories in time. In addition, since the two-layer base material structure is used, the panel-side base material can be formed into a shape suitable for modularizing the accessory parts, and therefore, it is possible to effectively cope with modularization.

以上説明した通り、本発明に係る自動車用内装部品及びその製造方法によれば、所望の凹凸形状に成形されるパネル側基材と、製品面形状を形成するようにほぼフラットな面形状に成形される室内側基材との二層基材構造が採用され、クリップ取付座、電装用ハーネス、ハーネスクリップ、衝撃吸収パッド等の付属部品は、少なくともその一部がパネル側基材と室内側基材との間でサンドイッチ状に挟持されることで、これら付属部品を堅固に固定することができ、従来の反応性ホットメルト系接着剤を使用した場合に比べ、付属部品の固定作業が短時間で完了するため、在庫管理が容易で、かつスペース的にも有利であるという効果を有する。   As described above, according to the automotive interior part and the manufacturing method thereof according to the present invention, the panel-side base material formed into a desired concavo-convex shape and molded into a substantially flat surface shape so as to form a product surface shape. A two-layer base material structure with the indoor base material to be used is adopted, and at least a part of the accessory parts such as clip mounting seats, electrical harnesses, harness clips, shock absorbing pads, etc. are panel side base material and indoor side base material. These sandwiched parts can be firmly fixed by sandwiching them with the material, and the attached parts can be fixed in a shorter time than when using a conventional reactive hot-melt adhesive. Therefore, the inventory management is easy and the space is advantageous.

更に、クリップ取付座、ハーネスクリップ、衝撃吸収パッド等については、フランジ状の取付プレートを二層の基材間で挟持するとともに、電装用ハーネスについては、二層の基材間に埋設すれば、付属部品の脱落を確実に防止でき、付属部品の確実な取付強度を確保できるという効果がある。また、パネル側基材を所望の凹凸形状に成形できることから、衝撃吸収パッドの収容スペースやハーネスクリップ等を収容するスペースを有効に確保でき、内装部品のモジュール化に好適であるという効果を有する。   Furthermore, for clip mounting seats, harness clips, shock absorbing pads, etc., the flange-shaped mounting plate is sandwiched between the two layers of the base material, and the electrical harness is embedded between the two layers of the base material, There is an effect that it is possible to surely prevent the accessory parts from falling off and to secure the attachment strength of the accessory parts. In addition, since the panel-side base material can be formed into a desired uneven shape, it is possible to effectively secure a space for storing the shock absorbing pad, a space for storing the harness clip, and the like, which is suitable for modularization of interior parts.

以下、本発明に係る自動車用内装部品及びその製造方法の実施例について、添付図面を参照しながら詳細に説明する。尚、念のため付言すれば、本発明の要旨は特許請求の範囲に記載した通りであり、以下に説明する実施例の内容は、本発明の一例を示すものに過ぎない。   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of an automobile interior part and a method for manufacturing the same 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.

図1乃至図10は本発明の一実施例を示すもので、図1は本発明を成形天井に適用した構成を示す断面図、図2は同成形天井の要部を示す拡大断面図、図3は同成形天井の製造方法の概要を示す説明図、図4乃至図10は同成形天井の製造方法における各工程を示す説明図である。   FIG. 1 to FIG. 10 show an embodiment of the present invention. FIG. 1 is a sectional view showing a configuration in which the present invention is applied to a molded ceiling. FIG. 2 is an enlarged sectional view showing a main part of the molded ceiling. 3 is an explanatory view showing an outline of a method for manufacturing the molded ceiling, and FIGS. 4 to 10 are explanatory views showing respective steps in the method for manufacturing the molded ceiling.

図1,図2において、車両のルーフパネル1の室内面側に装着される成形天井10に適用した実施例について説明する。この成形天井10は、所望の凹凸形状に成形されたパネル側基材11と、製品面形状を形造るほぼフラットな面形状をなす室内側基材12との二層の基材11,12と、室内側基材12の表面に貼付され、表面風合い及び手触り感を高める表皮13とから構成されている。   1 and 2, an embodiment applied to a molded ceiling 10 mounted on the interior side of a roof panel 1 of a vehicle will be described. The formed ceiling 10 includes two-layer base materials 11 and 12 including a panel-side base material 11 formed into a desired concavo-convex shape and an indoor-side base material 12 having a substantially flat surface shape that forms a product surface shape. The skin 13 is affixed to the surface of the indoor base 12 and enhances the surface texture and feel.

更に詳しくは、パネル側基材11及び室内側基材12は、それぞれ保形性、成形性、コスト等を考慮して、ガラス繊維を混入したPP(ポリプロピレン)樹脂が使用され、表皮13としては、ポリエステル不織布が使用されている。そして、上記パネル側基材11は、ルーフパネル1側に凹設される凹部11aと、室内側基材12側に突出する凸部11bを有する所望の凹凸形状に成形されており、凹部11a、凸部11bをいずれの箇所に設定するかは、ルーフパネル1の造形状、すなわち、レインフォース部1aとの干渉を避けるとともに、別部品取付用のスペース、あるいはハーネス収容スペース等の設定を考慮して決定される。また、パネル側基材11の凹部11aと室内側基材12との間には、図示するように中空部14が形成され、この中空部14は、ルーフパネル1の形状に左右されることなく、成形天井10の製品表面形状をほぼフラット形状に維持するために必要であり、また、この中空部14は、断熱性、遮音性についても効果がある。   More specifically, the panel side base material 11 and the indoor side base material 12 are made of PP (polypropylene) resin mixed with glass fiber in consideration of shape retention, moldability, cost, etc. Polyester nonwoven fabric is used. And the said panel side base material 11 is shape | molded by the desired uneven | corrugated shape which has the recessed part 11a recessedly provided by the roof panel 1 side, and the convex part 11b which protrudes in the indoor side base material 12 side, The recessed part 11a, The location where the convex portion 11b is set takes into consideration the shape of the roof panel 1, that is, avoiding interference with the reinforcement portion 1a, and setting of a space for mounting a separate part, a harness accommodating space, or the like. Determined. Further, a hollow portion 14 is formed between the recess 11 a of the panel side base material 11 and the indoor side base material 12 as shown in the figure, and this hollow portion 14 is not affected by the shape of the roof panel 1. It is necessary to maintain the product surface shape of the molded ceiling 10 in a substantially flat shape, and the hollow portion 14 is also effective in heat insulation and sound insulation.

そして、この成形天井10には、付属部品として、ルーフパネル1に取り付けるためのクリップ取付座20及びハーネス30が収容固定されている。更に、パネル側基材11の凹部11a裏面に接着剤15を塗布しておき、ルーフパネル1の室内面に成形天井10を接着固定する構造を併用しても良い。   The molded ceiling 10 accommodates and fixes a clip mounting seat 20 and a harness 30 for attachment to the roof panel 1 as accessory parts. Further, a structure in which the adhesive 15 is applied to the back surface of the recess 11 a of the panel-side substrate 11 and the molded ceiling 10 is bonded and fixed to the indoor surface of the roof panel 1 may be used in combination.

ところで、本発明に係る成形天井10は、モジュール化に有効に対応できるとともに、クリップ取付座20や電装用ハーネス30等の付属部品を短時間で取り付けることができ、しかも、これら付属部品が脱落する恐れがなく、強固に取り付けることを可能にするために、二層の基材11,12で付属部品20,30の少なくとも一部を挟持固定することが構成上の特徴である。   By the way, the molded ceiling 10 according to the present invention can effectively cope with modularization, and can attach accessory parts such as the clip mounting seat 20 and the electrical harness 30 in a short time, and these accessory parts fall off. In order to make it possible to attach firmly without fear, it is a structural feature that at least a part of the accessory parts 20 and 30 is sandwiched and fixed by the two-layer base materials 11 and 12.

すなわち、図2に示すように、クリップ取付座20及び電装用ハーネス30の保持構造を例示して説明すれば、クリップ21を保持するクリップ取付座本体22の基部に拡がる取付プレート23はその表裏面側からパネル側基材11と室内側基材12とにより挟持されているため、クリップ取付座20は脱落することがなく、堅固に固定されている。更に、従来の反応性ホットメルト系接着剤のように、長い養生時間(従来では約24時間)を必要とすることなく、短時間での固定が可能である。   That is, as shown in FIG. 2, if the holding structure of the clip mounting seat 20 and the electrical harness 30 is illustrated and described, the mounting plate 23 that extends to the base portion of the clip mounting seat body 22 that holds the clip 21 is the front and back surfaces thereof. Since it is clamped by the panel side base material 11 and the indoor side base material 12 from the side, the clip mounting seat 20 does not fall off and is firmly fixed. Furthermore, unlike conventional reactive hot melt adhesives, it can be fixed in a short time without requiring a long curing time (about 24 hours in the past).

また、電装用ハーネス30については、パネル側基材11と室内側基材12との間のスペースに埋設されており、この電装用ハーネス30についても脱落することがなく、堅固に支持固定されている。また、図示はしないが、電装用ハーネス30を成形天井10の裏面に保持する構造に使用するハーネスクリップや衝撃吸収パッド等の固定についても、上述した実施例同様、フランジ状の取付プレートをパネル側基材11と室内側基材12との間で挟持固定すれば、簡単かつ短時間に固定が完了する。更に、図2中拡大して示すように、クリップ取付座20における取付プレート23の下面23a(室内側基材12に対向する面)に係止爪24を一体に形成しておけば、アンカー効果により、クリップ取付座20の支持強度をより一層強固にできる。   In addition, the electrical harness 30 is embedded in the space between the panel-side base material 11 and the indoor-side base material 12, and the electrical harness 30 is also firmly supported and fixed without falling off. Yes. Although not shown, for fixing the harness clip or the shock absorbing pad used in the structure for holding the electrical harness 30 on the rear surface of the molded ceiling 10, the flange-like mounting plate is attached to the panel side as in the above-described embodiment. If it clamps and fixes between the base material 11 and the indoor side base material 12, fixation will be completed easily and in a short time. Further, as shown in an enlarged view in FIG. 2, if the locking claw 24 is integrally formed on the lower surface 23a of the mounting plate 23 of the clip mounting seat 20 (the surface facing the indoor base material 12), the anchor effect is obtained. Thus, the support strength of the clip mounting seat 20 can be further strengthened.

このように、成形天井10をパネル側基材11と室内側基材12の二層構造とすることにより、ルーフパネル1がどのような形状であっても、成形天井10の製品表面形状をほぼフラット状に成形でき、見栄え、手触り感を向上させることができるとともに、逆に、成形天井10により、ルーフパネル1の造形状が束縛されることなく、ルーフパネル1の自由度を高めることができる。更に、パネル側基材11と室内側基材12との間に形成される中空部14により、上述したように、断熱性、遮音性を高めることができるとともに、また、所望の凹凸形状を設定することで、衝撃吸収パッド等の付属部品を設置するスペースを設定することもでき、モジュール化にも最適である。   Thus, by forming the molded ceiling 10 into a two-layer structure of the panel-side base material 11 and the indoor-side base material 12, the product surface shape of the molded ceiling 10 is substantially the same regardless of the shape of the roof panel 1. It can be molded into a flat shape, can improve appearance and feel, and conversely, the molded ceiling 10 can increase the degree of freedom of the roof panel 1 without restricting the shape of the roof panel 1. . Further, as described above, the hollow portion 14 formed between the panel-side base material 11 and the indoor-side base material 12 can enhance heat insulation and sound insulation, and also sets a desired uneven shape. By doing so, it is possible to set a space for installing an accessory such as a shock absorbing pad, which is optimal for modularization.

上述した成形天井10の製造方法の概要について、図3を基に説明し、製造方法の各工程については、図4乃至図10を基に説明する。図3において、成形天井10を成形する際に使用する成形装置40は、それぞれ上下動可能な成形上型50、成形下型60と、成形金型50,60内に搬入及び搬出可能に設けられたヒーター70並びに基材投入装置71と、成形下型60と連結されるピアスカット型72と、クリップ取付座20や電装用ハーネス30をセットする際に使用するセット用治具73とから大略構成されている。   An outline of the method for manufacturing the molded ceiling 10 described above will be described with reference to FIG. 3, and each step of the manufacturing method will be described with reference to FIGS. 4 to 10. In FIG. 3, a molding apparatus 40 used when molding the molded ceiling 10 is provided so as to be able to be carried in and out of the molding upper mold 50, the molding lower mold 60, and the molding dies 50, 60 that can move up and down. The heater 70, the base material charging device 71, the piercing cut die 72 connected to the molding lower die 60, and the setting jig 73 used when setting the clip mounting seat 20 and the electrical harness 30 are roughly constituted. Has been.

まず、図4に示すように、成形上下型50,60が型開き状態にある時、基材投入装置71にパネル側基材11及び室内側基材12のそれぞれの原反シートS1,S2をセットして成形金型50,60内に投入するとともに、ヒーター70を成形金型50,60内に投入して、原反シートS1,S2を所定温度に加熱軟化させる。この時、原反シートS2の下面には、表皮13の原反シートS3が重ね合わされる。この時、成形上下型50,60は、昇降シリンダ51,61により所定ストローク上下動可能であるとともに、成形上下型50,60には、真空吸引機構52,62がそれぞれ配設されている。尚、基材投入装置71としては、具体的には各クランプ枠71a,71bである。   First, as shown in FIG. 4, when the upper and lower molds 50, 60 are in the mold open state, the raw sheets S 1, S 2 of the panel side base material 11 and the indoor side base material 12 are placed on the base material feeding device 71. While being set and put into the molding dies 50 and 60, the heater 70 is put into the molding dies 50 and 60, and the raw sheet S1, S2 is heated and softened to a predetermined temperature. At this time, the raw sheet S3 of the skin 13 is overlaid on the lower surface of the original sheet S2. At this time, the molding upper and lower molds 50 and 60 can be moved up and down by a predetermined stroke by the elevating cylinders 51 and 61, and the vacuum suction mechanisms 52 and 62 are disposed in the molding upper and lower molds 50 and 60, respectively. The base material feeding device 71 is specifically the clamp frames 71a and 71b.

この実施例では、パネル側基材11及び室内側基材12共、ガラス繊維を混入したPP樹脂材料を使用し、表皮13としてポリエステル不織布を使用しているため、それぞれクランプ枠71a,71bにより周縁を保持した状態でセットした後、図5に示すように、成形上下型50,60の各昇降シリンダ51,61を駆動させるか、あるいは原反シートS1,S2、表皮原反シートS3を保持するクランプ枠71a,71bをそれぞれ可動させることで、図示するように成形上型50の型面に沿って原反シートS1を真空成形して、パネル側基材11を所要形状に成形すると同時に、成形下型60の型面に沿って原反シートS2、表皮原反シートS3を真空成形して、室内側基材12、表皮13を一体成形する。尚、成形上下型50,60でそれぞれパネル側基材11と室内側基材12を予め真空成形することが必要であるため、使用する素材としては、上述したように、非通気性の原反シートS1,S2を使用することが必要であるが、例えば、連続気泡型の発泡樹脂シートや不織布マット等の通気性素材を使用する際には、非通気性を付与するためのフィルム等を片面に貼付しておけば良い。   In this embodiment, the panel side base material 11 and the indoor side base material 12 both use a PP resin material mixed with glass fiber, and use a polyester nonwoven fabric as the skin 13, so that the peripheral edges are formed by the clamp frames 71a and 71b, respectively. 5 is driven, the elevating cylinders 51 and 61 of the forming upper and lower molds 50 and 60 are driven, or the original fabric sheets S1 and S2 and the skin original fabric sheet S3 are held as shown in FIG. By moving the clamp frames 71a and 71b, respectively, the raw sheet S1 is vacuum-formed along the mold surface of the forming upper die 50 as shown in the figure, and the panel-side base material 11 is formed into a required shape and simultaneously formed. The raw fabric sheet S2 and the skin raw fabric sheet S3 are vacuum-formed along the mold surface of the lower mold 60, and the indoor base material 12 and the skin 13 are integrally molded. In addition, since it is necessary to preliminarily form the panel side base material 11 and the indoor side base material 12 with the molding upper and lower molds 50 and 60, respectively, as described above, the material to be used is a non-breathable raw fabric as described above. Although it is necessary to use the sheets S1 and S2, for example, when using a breathable material such as an open-cell foamed resin sheet or a non-woven mat, a film or the like for imparting non-breathability is used on one side. You can stick it on.

そして、成形上下型50,60による真空成形が完了すれば、成形下型60と連結しているトリムカット型72が図3中A1矢印方向にスライドして、成形上型50の直下位置にトリムカット型72が位置する。この時、室内側基材12を保持している成形下型60は、図3中B1矢印方向にスライドしている。すなわち、図6に示すように、ピアスカット型72にはカット刃72aが備わっているため、ピアスカット型72が昇降シリンダ61の駆動により、あるいは成形上型50の昇降シリンダ51の駆動により、成形上型50に保持されているパネル側基材11に開口16が開設される。   When the vacuum forming by the forming upper and lower molds 50 and 60 is completed, the trim cut mold 72 connected to the forming lower mold 60 slides in the direction of the arrow A1 in FIG. The cut mold 72 is located. At this time, the molded lower mold 60 holding the indoor side base material 12 slides in the direction of arrow B1 in FIG. That is, as shown in FIG. 6, since the piercing cut mold 72 is provided with a cutting blade 72a, the piercing cut mold 72 is molded by driving the lifting cylinder 61 or by driving the lifting cylinder 51 of the molding upper mold 50. An opening 16 is opened in the panel-side base material 11 held by the upper mold 50.

一方、図7に示すように、成形下型60上に保持されている室内側基材12に対してクリップ取付座20や電装用ハーネス30を所定位置にセットするが、この時、セット用治具73を所定位置に位置決めすることでクリップ取付座20及び電装用ハーネス30を適正位置に迅速にセットすることができる。その後、図3中A2矢印方向にピアスカット型72が移動するとともに、セット用治具73を使用して、クリップ取付座20及び電装用ハーネス30をセットした成形下型60が図3中B2矢印方向にスライドすることで、成形上型50の直下位置に成形下型60が位置する。   On the other hand, as shown in FIG. 7, the clip mounting seat 20 and the electrical harness 30 are set at predetermined positions with respect to the indoor base material 12 held on the molding lower mold 60. By positioning the tool 73 at a predetermined position, the clip mounting seat 20 and the electrical harness 30 can be quickly set at appropriate positions. Thereafter, the piercing cut mold 72 moves in the direction indicated by the arrow A2 in FIG. 3, and the molding lower mold 60 in which the clip mounting seat 20 and the electrical harness 30 are set using the setting jig 73 is indicated by the arrow B2 in FIG. By sliding in the direction, the molding lower mold 60 is positioned directly below the molding upper mold 50.

そして、図8に示すように、ヒーター70が再度成形金型50,60内に投入されて成形上型50で保持されているパネル側基材11を再軟化させた後、図9に示すように、成形上下型50,60が型係合することで、パネル側基材11と室内側基材12とが強固に圧着一体化される。この時、パネル側基材11と室内側基材12との間でクリップ取付座20における取付プレート23が挟持されるとともに、電装用ハーネス30は、双方の基材11,12内に埋設されるため、クリップ取付座20や電装用ハーネス30が脱落することがなく、これら付属部品を強固に取り付けることができる。そして、成形が完了すれば、成形上下型50,60が型開きした後、図10に示すように、成形下型60上に位置する成形天井10を脱型すれば良い。   Then, as shown in FIG. 8, the heater 70 is again put into the molding dies 50, 60 to re-soften the panel side substrate 11 held by the molding upper die 50, and then as shown in FIG. In addition, the panel-side base material 11 and the indoor-side base material 12 are firmly and pressure-integrated by the mold upper and lower molds 50 and 60 being mold-engaged. At this time, the mounting plate 23 in the clip mounting seat 20 is sandwiched between the panel side base material 11 and the indoor side base material 12, and the electrical harness 30 is embedded in both base materials 11 and 12. Therefore, the clip mounting seat 20 and the electrical harness 30 do not fall off, and these accessory parts can be firmly attached. And if shaping | molding is completed, after the shaping | molding upper and lower molds 50 and 60 open | release, what is necessary is just to demold the shaping | molding ceiling 10 located on the shaping | molding lower mold | type 60, as shown in FIG.

以上説明した実施例は、成形天井10及びその製造方法に本発明を適用したが、二層の基材11,12を備えた内装部品であれば、用途は限定されない。更に、実施例では非通気性を有する各素材を成形上下型50,60のそれぞれの型面形状に沿うように真空成形した後、成形上下型50,60の型締めにより一体化したが、真空成形を使用することなく、各基材11,12を別個に成形した後、圧着金型を使用して各基材11,12を圧着一体化することもできる。   In the embodiment described above, the present invention is applied to the molded ceiling 10 and the manufacturing method thereof. However, the use is not limited as long as it is an interior part including two layers of base materials 11 and 12. Further, in the embodiment, the non-breathable materials are vacuum-formed so as to conform to the respective mold surface shapes of the molded upper and lower molds 50, 60, and then integrated by clamping the molded upper and lower molds 50, 60. Without using molding, the base materials 11 and 12 can be separately molded, and then the base materials 11 and 12 can be integrated by pressure bonding using a crimping die.

本発明の一実施例である成形天井の構成を示す断面図である。It is sectional drawing which shows the structure of the shaping | molding ceiling which is one Example of this invention. 図1に示す成形天井におけるクリップ取付座及び電装用ハーネスのモジュール化構造を示す断面図である。It is sectional drawing which shows the modularization structure of the clip mounting seat and electrical harness in the shaping | molding ceiling shown in FIG. 本発明方法を適用した成形天井の製造方法に使用する成形装置の概略構成を示す全体図である。It is a general view which shows schematic structure of the shaping | molding apparatus used for the manufacturing method of the shaping | molding ceiling to which this invention method is applied. 本発明方法を適用した成形天井の製造方法における原反シートのセット工程を示す説明図である。It is explanatory drawing which shows the setting process of the raw fabric sheet in the manufacturing method of the shaping | molding ceiling to which this invention method is applied. 本発明方法を適用した成形天井の製造方法におけるパネル側基材と室内側基材の真空成形工程を示す説明図である。It is explanatory drawing which shows the vacuum forming process of the panel side base material and the indoor side base material in the manufacturing method of the shaping | molding ceiling to which this invention method is applied. 本発明方法を適用した成形天井の製造方法におけるパネル側基材のピアスカット工程を示す説明図である。It is explanatory drawing which shows the piercing cut process of the panel side base material in the manufacturing method of the shaping | molding ceiling to which this invention method is applied. 本発明方法を適用した成形天井の製造方法におけるクリップ取付座並びに電装用ハーネスのセット工程を示す説明図である。It is explanatory drawing which shows the setting process of the clip attachment seat and the electrical equipment harness in the manufacturing method of the shaping | molding ceiling to which this invention method is applied. 本発明方法を適用した成形天井の製造方法におけるパネル側基材の再加熱工程を示す説明図である。It is explanatory drawing which shows the reheating process of the panel side base material in the manufacturing method of the shaping | molding ceiling to which this invention method is applied. 本発明方法を適用した成形天井の製造方法におけるパネル側基材と室内側基材の一体化工程を示す説明図である。It is explanatory drawing which shows the integration process of the panel side base material and indoor side base material in the manufacturing method of the shaping | molding ceiling to which this invention method is applied. 本発明方法を適用した成形天井の製造方法における成形工程完了後の成形天井を示す説明図である。It is explanatory drawing which shows the shaping | molding ceiling after the shaping | molding process completion in the manufacturing method of the shaping | molding ceiling to which this invention method is applied. 従来の成形天井をルーフパネルに取り付ける状態を示す説明図である。It is explanatory drawing which shows the state which attaches the conventional shaping | molding ceiling to a roof panel. 従来の成形天井の取付構造を示す説明図である。It is explanatory drawing which shows the attachment structure of the conventional molded ceiling.

符号の説明Explanation of symbols

1 ルーフパネル
10 成形天井
11 パネル側基材
12 室内側基材
13 表皮
14 中空部
15 接着剤
16 開口
20 クリップ取付座
21 クリップ
22 クリップ取付座本体
23 取付プレート
24 係止爪
30 電装用ハーネス
40 成形装置
50 成形上型
51 昇降シリンダ
52 真空吸引機構
60 成形下型
61 昇降シリンダ
62 真空吸引機構
70 ヒーター
71 基材投入装置
71a,71b クランプ枠
72 ピアスカット型
72a カット刃
73 セット用治具
S1,S2 原反シート(基材用)
S3 原反シート(表皮用)
DESCRIPTION OF SYMBOLS 1 Roof panel 10 Molding ceiling 11 Panel side base material 12 Indoor side base material 13 Skin 14 Hollow part 15 Adhesive 16 Opening 20 Clip mounting seat 21 Clip 22 Clip mounting seat main body 23 Mounting plate 24 Locking claw 30 Electrical harness 40 Molding Device 50 Molding upper die 51 Lifting cylinder 52 Vacuum suction mechanism 60 Molding lower die 61 Lifting cylinder 62 Vacuum suction mechanism 70 Heater 71 Substrate loading device 71a, 71b Clamp frame 72 Pierce cut die 72a Cutting blade 73 Set jig S1, S2 Raw sheet (for base material)
S3 Original sheet (for skin)

Claims (5)

所要形状に成形された基材(11,12)からなり、車体パネル(1)の室内面側に装着される自動車用内装部品(10)であって、
前記基材(11,12)は、所望の凹凸形状に成形されるパネル側基材(11)と、製品面形状を形成するように略フラット面形状に成形される室内側基材(12)の二層基材構造が採用されているとともに、内装部品(10)に付設される付属部品(20,30)の少なくとも一部がパネル側基材(11)と室内側基材(12)との間に挟持されていることを特徴とする自動車用内装部品。
An automotive interior part (10) comprising a base material (11, 12) molded into a required shape and mounted on the interior side of the vehicle body panel (1),
The base material (11, 12) includes a panel-side base material (11) formed into a desired uneven shape, and an indoor side base material (12) formed into a substantially flat surface shape so as to form a product surface shape. The two-layer base material structure is adopted, and at least a part of the accessory parts (20, 30) attached to the interior part (10) includes a panel side base material (11) and an indoor side base material (12). Automotive interior parts characterized by being sandwiched between the two.
前記付属部品(20)における取付プレート(23)がパネル側基材(11)と室内側基材(12)との間で挟持され、パネル側基材(11)に開設した開口(16)を通して取付座本体(22)が車体パネル(1)側に向けて臨むように支持されていることを特徴とする請求項1に記載の自動車用内装部品。   The attachment plate (23) in the accessory part (20) is sandwiched between the panel-side base material (11) and the indoor-side base material (12), and through the opening (16) opened in the panel-side base material (11). The interior part for automobiles according to claim 1, wherein the mounting seat body (22) is supported so as to face the vehicle body panel (1) side. 前記取付プレート(23)の取付面には、室内側基材(12)に食い込む係止爪(24)が形成されていることにより、付属部品(20)がアンカー状に室内側基材(12)に接合固定されていることを特徴とする請求項2に記載の自動車用内装部品。   The attachment surface of the attachment plate (23) is formed with a locking claw (24) that bites into the indoor base material (12), so that the accessory (20) is anchored into the indoor base material (12). The interior part for automobiles according to claim 2, wherein the interior parts for automobiles are joined and fixed to each other. 請求項1乃至3のいずれかに記載の自動車用内装部品(10)を製造する自動車用内装部品の製造方法において、
真空吸引機構をそれぞれ備えた成形金型(50,60)が型開き状態にある時、パネル側基材(11)の原反シート(S1)と、室内側基材(12)の原反シート(S2)を加熱軟化処理した後、成形金型(50,60)内に投入する原反シート(S1,S2)のセット工程と、
成形金型(50,60)にそれぞれ真空吸引力を作用させ、一方側の原反シート(S1)を一方側の成形金型(50)の型面形状に沿って真空成形し、所望の凹凸形状を備えたパネル側基材(11)を成形するとともに、他方側の成形金型(60)の型面形状に沿って他方側の原反シート(S2)を真空成形して、フラットな製品面形状を備えた室内側基材(12)を成形する基材(11,12)の真空成形工程と、
成形金型(50,60)を型開きした後、成形下型(60)上に保持されている室内側基材(12)上に付属部品(20,30)をセットするとともに、上記付属部品(20,30)の一部を基材(11)の開口(16)を通して裏面側に貫通させる場合には、成形上型(50)に保持されているパネル側基材(11)に開口(16)を開設する付属部品(20,30)のセット工程並びに基材のピアスカット工程と、
成形上型(50)に保持されているパネル側基材(11)に再加熱処理を施し、成形金型(50,60)を型締めし、パネル側基材(11)と室内側基材(12)とを圧着一体化するとともに、両基材(11,12)間で付属部品(20,30)の少なくとも一部を挟み込んで支持する基材(11,12)の圧着一体化工程と、
からなることを特徴とする自動車用内装部品の製造方法。
In the manufacturing method of the interior component for motor vehicles which manufactures the interior component for motor vehicles (10) in any one of Claims 1 thru | or 3,
When the molding dies (50, 60) each having a vacuum suction mechanism are in the mold open state, the original fabric sheet (S1) of the panel side base material (11) and the original fabric sheet of the indoor side base material (12) After heating and softening (S2), a setting process of the raw sheet (S1, S2) to be put into the molding die (50, 60);
A vacuum suction force is applied to each of the molding dies (50, 60), and the original sheet (S1) on one side is vacuum-formed along the mold surface shape of the molding die (50) on one side to obtain desired irregularities. A flat product is formed by forming a panel-side base material (11) having a shape and vacuum-forming the other side of the original sheet (S2) along the mold surface shape of the other side mold (60). A vacuum forming step of the base material (11, 12) for forming the indoor base material (12) having a surface shape;
After opening the molding die (50, 60), the accessory parts (20, 30) are set on the indoor base material (12) held on the molding lower mold (60), and the accessory parts described above When a part of (20, 30) is penetrated to the back side through the opening (16) of the base material (11), the panel side base material (11) held by the molding upper die (50) is opened ( 16) setting process of accessory parts (20, 30) and piercing cut process of the base material,
The panel side base material (11) held by the molding upper die (50) is reheated, the molds (50, 60) are clamped, and the panel side base material (11) and the indoor side base material are clamped. (12) and pressure bonding integration step of the base material (11, 12) for supporting by sandwiching at least a part of the accessory parts (20, 30) between the base materials (11, 12). ,
A method for producing an interior part for an automobile, comprising:
前記室内側基材(12)の真空成形時、原反シート(S2)の一面側に表皮(13)の原反シート(S3)を重ね合わせ、原反シート(S2)の真空成形時に室内側基材(12)の表面側に表皮(13)を一体化したことを特徴とする請求項4に記載の自動車用内装部品の製造方法。
When vacuum forming the indoor base material (12), the raw sheet (S3) of the skin (13) is superposed on one surface side of the raw sheet (S2), and the indoor side is formed when the raw sheet (S2) is vacuum formed. The method for manufacturing an automotive interior part according to claim 4, wherein the skin (13) is integrated with the surface side of the substrate (12).
JP2005173820A 2005-06-14 2005-06-14 Automobile interior component and manufacturing method thereof Withdrawn JP2006347273A (en)

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