JP2007160685A - Molded panel and mold - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded panel in which a cushioning body is molded/integrated between a structural member made of a foamed hard resin and a skin material, and which has enough strength to the attachment/detachment of a component and is provided with a fitting part with a wall thickness controlled accurately around the rim of a mounting hole. <P>SOLUTION: The molded panel has a panel body, the mounting hole which is formed at a prescribed position of the panel body and into which a component can be fitted, and a component mounting part having the fitting part which is formed around the rim of the mounting hole and has a wall thinner than the wall of the panel body. In the molded panel, the structural member made of the foamed hard resin, the cushioning body arranged on the surface excluding the component mounting part of the structural member, and the skin material covering the surface of a part corresponding to the component mounting part of the structural member and the surface of the cushioning body are formed/integrated. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a molded panel having a component mounting portion on which components can be mounted, and a mold used for manufacturing the panel, and in particular, various switches and air conditioner grills installed in a cab of a vehicle. The present invention relates to a molded panel that is applied to a dash panel or the like to which the above parts can be attached, and a mold that is used when manufacturing the molded panel.

  Various interior members are used in the interior of ordinary vehicles. Although the structure of the interior member varies, for example, an example of an interior member used as various trims is disclosed in Japanese Patent Laid-Open No. 2005-59632 (Patent Document 1). According to the literature 1, a lightweight and shape-retaining foamed resin base for the purpose of weight reduction and cost reduction, simplification of a molding die, and simplification of demolding after molding. An interior member is manufactured by inserting a hard resin layer only in a portion where rigidity is required. In this interior member, a decorative material (skin material) is integrally coated on the surface exposed to the outside of the foamed resin base material.

  In Patent Document 1, a thermoplastic resin foam is used as the foamed resin base material. In addition, this thermoplastic resin is a polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin. It is said that it consists of one kind of thermoplastic resin such as acrylonitrile / butadiene / styrene (ABS) resin or two or more kinds of thermoplastic resins.

  On the other hand, as the thermoplastic resin material used for the hard resin layer, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, polyamide resin, Conventional thermoplastic resins such as polyacetal resins, acrylonitrile / butadiene / styrene (ABS) resins, polycarbonate resins and the like are mentioned.

  Such an interior member is also used for a dash panel or the like incorporated in a driver's seat of a work vehicle such as a wheel loader. For example, as shown in FIG. 8, in the wheel loader cab 61, a glass 62 is disposed in a reverse concave shape in front view and the left and right side surfaces in order to ensure visibility. A front dash panel 67 is incorporated substantially horizontally along the inner bottom of the disposed glass 62. The front dash panel 67 is provided with various instruments 64, various switches 65, an air conditioner grill 66, and other monitors.

  Generally, the interior member used for such a dash panel or the like is manufactured by injection molding using a mold. For example, after setting a skin material in a molding cavity of the mold, By injecting a thermoplastic resin such as a polyethylene-based resin as described above, an interior member (molded panel) having a skin material coated and integrated on the surface is produced. At the time of injection molding, mounting holes for mounting various parts are formed at predetermined positions on the molded panel, and then the switches and the air conditioner grill are fitted into the mounting holes.

  On the other hand, in the cab 61 of the wheel loader as shown in FIG. 8, a steel column 63 is installed so as to overhang a corner portion in the cab 61 in order to protect the driver when the vehicle falls over. . For this reason, the front dash panel 67 must be assembled across the steel pillar 63 in the assembling area in front of the steel pillar 63, and the front end portions of the left and right wing parts of the front dash panel 67 are In order to fit to the pillar 63, it is necessary to form a so-called undercut portion 68 by cutting it into a triangular shape when viewed from above.

  The front dash panel 67 having such an undercut portion 68 is integrally coated with a skin material on an interior member as described in, for example, Patent Document 1, that is, a foamed resin base material made of a thermoplastic resin foam. In the case of using the interior member that has been changed, the following problems have occurred. That is, even if the undercut portion 68 is formed at the tip of the left and right wing portions of the front dash panel 67 as described above, the dimension between the corners on the depth side of each wing portion is the same as that of the left and right pillars 63. Since it is longer than the dimension between the side surfaces, the pillar 63 becomes an interference member and interferes with the corners on the depth side of the left and right wing parts, and the front dash panel 67 cannot be inserted further forward. . Moreover, once fitted by some means, for example, even if it is attempted to remove the front dash panel 67 for replacement or repair of instruments, it cannot be easily removed.

Therefore, conventionally, to remove the front dash panel from the installation position or to attach it to the installation position, for example, the front dash panel is simply a cover application, and the panel is formed by vacuum forming, and when it is detached from the installation position, Detach it by twisting to some extent, or divide the rigid front dash panel into two in the center, fit the left and right undercut parts to the left and right pillars and fix them, then assemble the center divided part, It was fixed by screwing.
JP 2005-59632 A

  By the way, the interior member as described in Patent Document 1 is manufactured by injection-molding a thermoplastic resin into a mold cavity as described above. In the case of producing an interior member to be used, although the cost required for the mold is high, there is a problem that a burden on the cost is large because the production amount of the molded panel formed from the mold is small.

  In order to solve such problems, instead of using a thermoplastic resin as exemplified in Patent Document 1 as a foamed resin base material (structural member) of a molded panel, a hard foamed polyurethane resin is used. Use is under consideration. For example, by using a rigid polyurethane polyurethane resin as the material of the structural member, the structural member can be molded by reaction injection molding (RIM molding) with a low molding pressure. Can be used. Thereby, the amortization burden of the mold can be reduced, and the manufacturing cost can be reduced.

  Also, in this case, for example, to improve the touch of the molded panel, to bring out the softness and luxury of the appearance, and to ensure heat insulation and soundproofing, etc., the polyurethane resin structural member and the skin material It is considered that a cushion body (for example, a semi-rigid foamed polyurethane resin) is provided over the entire panel.

  As one of the methods of molding a molded panel provided with such a cushion body with a resin mold, for example, it is considered to perform RIM molding in two stages using two types of resin molds. Are superimposed. Specifically, first, a structural member having a predetermined shape is produced by performing foam molding of a polyurethane resin material using one resin mold, and then the obtained structural member is used as an upper mold using another resin mold. In addition, the skin material prepared separately is placed in close contact with the cavity surface of the lower mold and clamped, and the cushion body is placed in the molding cavity formed between the structural member and the skin material. The resin material is injected to perform foam molding. This makes it possible to manufacture a three-layer molded panel in which the cushion body is molded and integrated between the structural member and the skin material.

  When it is considered to use a molded panel having a three-layer structure over the entire panel as an interior member such as the front dash panel, for example, in order to attach components such as various switches and an air conditioner grill, FIG. As shown in FIG. 2, the mounting hole 83 in which the component 82 can be mounted at a predetermined position of the molded panel 81, and the claw portion (hook portion) 84 of the component 82 are locked to the periphery of the mounting hole 83. It is necessary to form the locking portion 85. In the molded panel 81 shown in FIG. 9, reference numeral 86 denotes a skin material, and reference numeral 88 denotes a structural member made of a hard polyurethane foam resin, and a halfway between the skin material 86 and the structural member 88. A cushion body 87 made of a hard polyurethane foam resin is disposed.

  The inventors made a prototype of a molded panel in which a cushioning body of a semi-rigid foamed polyurethane resin was placed between a structural member made of a rigid foamed polyurethane resin and a skin material, and conducted various experiments and studies. As a result, it became clear that there were the following problems.

  That is, the locking portion 85 of the molded panel 81 is required to have sufficient strength to lock the claw portion 84 of the component 82, and in order to attach the component 82 having a predetermined shape appropriately, It is necessary to match the thickness with the shape and dimensions of the part 82. That is, if the thickness of the locking portion 85 becomes too thin, the attached component 82 is loosened and rattling occurs. On the other hand, if the thickness is too thick, the attachment of the component 82 becomes tight, The claw portion 84 of the component 82 cannot be fitted into the locking portion 85. For this reason, the locking portion 85 is required to have a strict dimensional accuracy with a tolerance of about ± 0.10 mm to ± 0.15 mm, for example.

  However, in the molded panel 81 shown in FIG. 9, since the cushion body 87 is arranged between the skin material 86 and the structural member 88 and has a three-layer structure, a semi-hard cushion body 87 is also formed in the locking portion 85. Therefore, the thickness of the hard structural member 88 is inevitably reduced. For this reason, the strength of the locking portion 85 is low, and there is a problem that the locking portion 85 is easily damaged when the component 82 is detached.

  Further, when the molded panel 81 is molded using the resin mold as described above, it is difficult to form the attachment hole 83 with high accuracy simultaneously with the molding, and in the process of molding the cushion body 87, the cushion It has been found that there is a problem that molding resin is liable to occur due to leakage of the resin material of the body into the mounting hole. Furthermore, since the thickness control in the molded product depends on the rigidity of the mold, when using a resin mold having a lower rigidity than the mold, the thickness of the locking portion can be controlled with high accuracy. There was also a problem of difficulty.

  Further, for example, in forming a molded panel using a resin mold, the mounting hole is not formed at the time of molding, but the mounting hole is formed by performing post-processing after the panel is formed, and the locking portion is also formed at the same time. It is possible. However, it has been found that even when the locking portion is formed by such post-processing, it is difficult to satisfy the dimensional accuracy of the locking portion as described above.

  The present invention has been made in view of the above problems, and an object of the present invention is used for a vehicle front dash panel or the like, and a cushion body is formed integrally between a structural member made of a hard foam resin and a skin material. Providing a molded panel provided with a locking portion at the periphery of the mounting hole, which has a sufficient strength with respect to detachment of parts, and whose thickness is dimensionally controlled with high accuracy, Furthermore, it is providing the shaping | molding die which can shape | mold the said molded panel stably, without producing the shaping | molding defect, such as leakage of a resin material.

In order to achieve the above object, a molded panel provided by the present invention has, as a basic structure, a panel body, a mounting hole formed at a predetermined position of the panel body, and capable of mounting components, and A molded panel provided with a component mounting part formed at the periphery of the mounting hole and having a thinner locking part than the panel main body, the molded panel having a structural member made of a hard foam resin and the same structure A cushion body disposed on the surface of the member excluding the component mounting portion, and a skin material covering the partial surface corresponding to the component mounting portion of the structural member and the surface of the cushion body are molded and integrated. Is the main feature.
In the molded panel of the present invention, the structural member includes a skin layer on a surface layer portion thereof.

  Moreover, it is preferable that the surface of the molded panel is flush or a step portion for fitting the flange of the component is formed on the surface of the component mounting portion.

  Furthermore, in the molded panel of the present invention, the rigid foamed resin is preferably a thermosetting foamed polyurethane resin, and the cushion body is preferably made of a semi-rigid foamed polyurethane resin.

  Next, according to the present invention, there is provided a structural member mold used for molding the structural member of the molded panel having the above-described configuration, and the structural member mold is made of a resin having a molding cavity for the structural member. A first core and a second mold for the structural member, and a metal core disposed in the structural member molding cavity between the first mold and the second mold for the structural member to form a molding cavity of the locking portion It is characterized by having.

  In the molding die of the present invention, the metal core is divided into a first divided member and a second divided member that are movable in the mold opening direction of the first and second molds for the structural member. The locking portion forming cavity is formed between the first divided member and the second divided member.

  In this case, it is preferable to further comprise pressing means for pressing the first divided member and / or the second divided member toward the other divided member along the mold opening direction. It is preferable to have a metal pressing jig that abuts against the first dividing member and / or the second dividing member, and a cylinder that applies a load to the pressing jig.

  On the other hand, in the molding die of the present invention, the metal core is arranged in parallel to the direction perpendicular to the mold opening direction in the structural member molding cavity along the periphery of the mounting hole to be formed, and It is comprised by the some parallel division member which can move to the same right angle direction, and each parallel division member forms the said latching | locking part shaping | molding cavity, respectively.

  In this case, it is preferable to further include a positioning member that is arranged in a gap formed between the parallel division members when the plurality of parallel division members are arranged and positions and fixes the parallel division members.

  According to the present invention, there is further provided a molding die for a molding panel used when molding and integrating the cushion body between the skin material and the structural member of the molding panel having the above configuration. A molding die for a panel is a resin-made first die for a molding panel in which the structural member and the skin material are arranged at the time of molding, and a molding cavity of the cushion body is formed between the structural member and the skin material. A metal first clamping member and a second clamping member are provided between the second mold and the molded panel first mold and the second mold and sandwich the locking portion and the skin material. It has the characteristics.

  In this case, it further includes pressing means for pressing the first clamping member and / or the second clamping member toward the other clamping member along the mold opening direction of the first mold and the second mold for the molded panel. Preferably, the pressing means further includes a metal pressing jig that abuts on the first clamping member and / or the second clamping member, and a cylinder that applies a load to the pressing jig. Preferably it is.

  The molded panel according to the present invention has component mounting holes and locking portions, a structural member made of hard foamed resin, and a cushion body disposed on the surface of the structural member excluding the component mounting portion; In addition, a part of the surface of the structural member corresponding to the component mounting portion and a skin material covering the surface of the cushion body are molded and integrated. That is, in the molded panel of the present invention, the panel main body has a three-layer structure in which the cushion body is disposed between the structural member and the skin material, and the engaging portion is not disposed on the cushion body on the surface. It is constituted by a structural member in which a skin material is integrally covered. Accordingly, the locking portion has a wall thickness that is dimensionally controlled with high accuracy, and can secure a sufficient strength against the detachment of components. For this reason, the mounting of the components is not cramped, and the mounted components are not loosened, so that the mounting of the components can be stabilized, and further, the locking portion can be prevented from being damaged. Installation and removal can be performed stably.

  Moreover, since the said structural member is equipped with the skin layer in the surface layer part, the intensity | strength of a latching | locking part can be improved further and damage to a latching | locking part can be prevented more reliably.

  The molded panel of the present invention can have a flush surface, and a beautiful appearance can be obtained. Alternatively, a stepped portion for fitting the flange of the component may be formed on the surface of the component mounting portion, and when the component is mounted on the molded panel, the surface of the molded panel and the surface of the component Can be arranged on the same plane, and appearance can be improved.

  Further, if the hard foamed resin forming the structural member is a thermosetting foamed polyurethane resin, and the cushion body is made of a semi-rigid foamed polyurethane resin, the weight of the molded panel can be reduced and the shape retaining property can be reduced. The shape of the molded panel can be stably maintained, and furthermore, the touch can be improved and the appearance can be soft and high-quality. Moreover, the adhesive force of each adhesive surface in a structural member, a cushion body, and a skin material improves, and it can ensure the outstanding adhesive strength. Furthermore, since a resin mold can be used as the mold, it is possible to reduce the depreciation burden of the mold and reduce the manufacturing cost.

  Next, the structural member molding die according to the present invention is arranged between a first mold and a second mold made of resin having a molding cavity of the structural member, and the first mold and the second mold, And a metal core that forms a molding cavity of the locking portion. Thus, by forming the molding cavity of the locking portion of the molded panel with a highly rigid metal core, the locking portion can be molded with excellent dimensional accuracy.

  In the present invention, the metal core can be divided into a first divided member and a second divided member that are movable in the mold opening direction of the first mold and the second mold for the structural member. As a result, the metal core can be easily set between the first mold and the second mold, and the locking portion forming cavity is stably formed between the first divided member and the second divided member. The shape and wall thickness can be easily and accurately controlled.

  Furthermore, if it has a pressing means for pressing the first divided member and / or the second divided member toward the other divided member along the mold opening direction of the first mold and the second mold, the first divided member is provided. A member and a 2nd division member can be stuck closely, and it can prevent that a burr | flash etc. are formed in a latching | locking part. In this case, if the pressing means has a metal pressing jig that abuts on the first divided member and / or the second divided member and a cylinder that applies a load to the pressing jig, The first divided member and / or the second divided member can be stably pressed by the means.

  On the other hand, in the present invention, the metal core is arranged in parallel with the direction perpendicular to the mold opening direction in the structural member molding cavity along the periphery of the mounting hole to be formed, and is movable in the same right angle direction. A plurality of parallel divided members may be used, and each parallel divided member has a locking portion forming cavity. Thereby, a latching | locking part can be formed with the very outstanding dimensional accuracy.

  In this case, if the positioning member for positioning and fixing the parallel dividing member is provided, the arrangement position of the parallel dividing member between the first mold and the second mold is stabilized, and the locking portion is more accurately and more accurately. It can be formed stably.

  Furthermore, the molding die for molded panels according to the present invention includes a first mold and a second die for resin molded panels in which a molding cavity of a cushion body is formed between the structural member and the skin material at the time of molding. The metal 1st clamping member and 2nd clamping member which clamp a part and a skin material are provided. Thus, when the molded panel is molded, the shape and size of the engaging portion formed in advance on a part of the structural member can be maintained as it is, and the cushion body is provided between the structural member constituting the component mounting portion and the skin material. It is possible to prevent the resin material from entering. As a result, it is possible to prevent the resin material from leaking from the mounting hole and cause molding defects, and to stably obtain the molded panel having a desired configuration.

  Furthermore, if it has a pressing means for pressing the first clamping member and / or the second clamping member toward the other clamping member along the mold opening direction of the first mold for the molded panel and the second mold, The first clamping member and the second clamping member can be more reliably brought into close contact with each other, and the resin material of the cushion body can be more reliably prevented from entering between the structural member and the skin material. In this case, if the pressing means has a metal pressing jig that abuts against the first clamping member and / or the second clamping member, and a cylinder that applies a load to the pressing jig, the pressing means Thus, the first clamping member and / or the second clamping member can be stably pressed.

Hereinafter, typical embodiments of the present invention will be described in detail with reference to the drawings.
First, a molded panel according to the first embodiment of the present invention will be described. The molded panel of the first embodiment is assumed to be used as a dashboard arranged in front of a driver's seat in a working vehicle such as a wheel loader as shown in FIG. However, the present invention is not limited to this, and can be applied to various molded panels to which parts are attached and used. Here, FIG. 1 is a partial cross-sectional view schematically showing a cross section of the molded panel according to the first embodiment. FIGS. 2A and 2B are enlarged views of a component mounting portion of the molded panel. These are front views, each showing a form of a locking portion.

  A molded panel 1 according to the first embodiment shown in FIG. 1 is formed on a panel body 2, a mounting hole 4 in which a component 9 indicated by a virtual line can be mounted, and a peripheral edge of the mounting hole 4. And a mounting part 4 having a locking part 5 thinner than the main body 2, and the mounting hole 4 is provided at a predetermined position where the mounting of the part 9 of the molded panel 1 is planned.

  The molded panel 1 includes a structural member 6, a cushion body 7 disposed on the surface of the structural member 6 excluding the component mounting portion 3, a partial surface corresponding to the component mounting portion 3 of the structural member 6, and the cushion body 7. The skin material 8 that covers the surface of the material is molded and integrated.

  That is, in the panel body 2, the structural member 6, the skin material 8 that forms the surface of the molded panel 1, and the cushion body 7 disposed between the structural member 6 and the skin material 8 are molded and integrated. It has a three-layer structure. The structural member 6 is made of a hard foamed resin, and the surface layer portion of the structural member 6 has a skin layer 14 formed by suppressing foaming when the structural member 6 is molded. In the first embodiment, a thermosetting foamed polyurethane resin is used as the foamed hard resin of the structural member 6. As a result, the structural member 6 can be molded by a reaction injection molding method with a low injection pressure, and an inexpensive resin mold can be used as the mold for the structural member 6. In addition, as the foamed hard resin of the structural member 6, it is also possible to use polyurea resin or the like.

  The cushion body 7 is made of a semi-rigid polyurethane resin, and is disposed between the structural member 6 and the skin material 8 over the entire panel body 2. Thereby, weight reduction of the shaping | molding panel 1 can be achieved. Moreover, since the adhesiveness is excellent if the cushion body 7 is a polyurethane resin, the adhesive strength with the structural member 6 and the skin material 8 can be raised. In the first embodiment, the cushion body 7 is configured to gradually decrease in thickness as it approaches the component mounting portion 3 in the region on the component mounting portion 3 side. The rigidity of the panel body 2 is ensured by increasing the thickness of the structural member 6 in the vicinity of the boundary region with the mounting portion 3.

  The skin material 8 is provided with a texture pattern, for example, on its surface, and is formed with a film thickness of 0.6 to 0.9 mm. As the material of the skin material 8, a general thermoplastic resin or thermoplastic elastomer can be applied if a material excellent in compatibility with the structural member 6 and the cushion body 7 and a certain degree of flexibility are obtained. In the first embodiment, since the structural member 6 and the cushion body 7 are made of polyurethane resin having excellent bonding properties with most synthetic resins, the skin material 8 is made of a soft material such as polyethylene or thermoplastic elastomer. Any resin can be used, but among them, polyvinyl chloride is used which is excellent in weather resistance and heat resistance and softens when a plasticizer is added.

  On the other hand, the component mounting portion 3 is formed by integrally forming a structural member 6 extending from the panel body 2 toward the mounting hole 4 and a skin material 8 covering the surface of the extended structural member 6. The cushion body 7 is not interposed between them. Accordingly, the locking portion 5 of the component mounting portion 3 is composed of the structural member 6 made of hard foamed resin, and the surface layer portion is provided with the skin layer 14. Strength can be secured.

  Further, since the locking portion 5 is formed using a metal core as will be described below, the shape and thickness of the component 9 are dimensionally controlled with high precision so that the hook portion 10 of the component 9 can be appropriately locked. have. For example, in the first embodiment, the thickness of the panel body 2, that is, the skin material 8 (thickness: 0.6 to 0.9 mm), the cushion body 7 (thickness: about 3.0 mm), and the structural member 6 The total thickness of (thickness: about 3.0 mm) is about 6 mm, while the locking portion 5 is formed with a thickness of 3.0 mm ± 0.1 mm, and its tolerance is very small. Moreover, the extension length to the attachment hole 4 of the latching | locking part 5 is set to 3.0 mm +/- 0.1mm. Furthermore, since the locking portion 5 is formed with high accuracy, the mounting hole 4 itself is also formed with a shape and size corresponding to the shape and size of the component 9 with high accuracy.

  Therefore, when the component 9 is attached, the molded panel 1 can be appropriately mounted without the hook portion 10 being caught tightly or being loosened. Further, when the component 9 is attached to and detached from the molded panel 1, it is possible to prevent the locking portion 5 from being damaged and to attach and remove the component 9 stably.

  In the first embodiment, the locking portion 5 is formed over the entire circumference of the peripheral edge of the mounting hole as shown in FIG. 2A, but the present invention is not limited to this. For example, as shown in FIG. 2B, the arc-shaped locking portions 5 formed in a partial region of the peripheral edge of the mounting hole can be formed at two or more locations.

  Moreover, in this 1st Embodiment, the intermediate part 11 which connects them is provided in the components attachment part 3 in the area | region between the latching | locking part 5 and the panel main body 2 which were formed by predetermined thickness. By providing such an intermediate portion 11, the rigidity of the panel body 2 in the boundary region between the panel body 2 and the component mounting portion 3 can be increased. In the present invention, the intermediate portion 11 can be arbitrarily formed and can be omitted.

  Moreover, since the surface of the molded panel 1 of the first embodiment is substantially flush, it is possible to obtain a beautiful appearance. However, actually, as described in the prior art, a slight step is formed in the surface material 8 corresponding to the boundary between the structural member 6 and the cushion body 7, and the texture depth of the texture pattern is also increased. It changes at the boundary. For this reason, in order to ensure the excellent appearance quality of the molded panel 1, for example, as shown in FIG. 1, the flange 12 of the component 9 is extended beyond the boundary between the structural member 6 and the cushion body 7. Alternatively, it is preferable that the formation region of the cushion body 7 be close to the attachment hole 4. As a result, the flange 12 of the component 9 can conceal changes in the level difference and the embossed depth from the outside and ensure excellent appearance quality.

Next, a molded panel according to the second embodiment of the present invention will be described. Here, FIG. 3 is a partial cross-sectional view schematically showing a cross section of the molded panel according to the second embodiment. In the second embodiment, parts having substantially the same configuration as those of the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted to avoid redundancy.
In the molded panel 1 ′ of the second embodiment shown in FIG. 3, when the component 9 is attached to the component attachment portion 3 ′, a step portion 13 for fitting the flange 12 of the component 9 to the component attachment portion 3 ′ is formed. Has been. The step portion 13 can be formed at the same time when the structural member 6 is molded, for example. By providing such a step portion 13, when the component 9 is attached, the surface of the molded panel 1 ′ and the surface of the component 9 can be formed on the same plane, and the molded panel 1 with the component 9 attached thereto. The appearance of ′ can be improved.

  Next, a method for manufacturing the molded panel 1 according to the first embodiment of the present invention will be described. Here, FIG. 4 is a partial cross-sectional view schematically showing a cross section of a first structural member mold used for forming the structural member 6 of the molded panel 1, and FIG. 7 is a skin material 8 of the molded panel 1. It is a fragmentary sectional view which shows typically the cross section of the shaping | molding die for shaping | molding panels used when the cushion body 7 is shape | molded and integrated between the structural member 6. FIG. 4 and 7, molding is performed with the upper and lower sides of the molding panel 1 opposite to those in FIG.

  First, the structural member 6 of the molded panel 1 is molded by a reaction injection molding method (RIM molding method) using the first structural member molding die 21 shown in FIG. The first structural member molding die 21 includes a first structural member mold (upper mold) 22 and a structural member second mold (lower mold) 23 having a molding cavity 30 of the structural member 6, and the upper mold 22. And a metal core 24 that is disposed in the structural member molding cavity 30 between the lower mold 23 and forms the molding cavity 31 of the locking portion 5, and a pressing means that presses the metal core 24 along the mold opening direction. 25.

  The upper mold 22 and the lower mold 23 are formed in a predetermined shape with an epoxy resin containing fine metal particles such as aluminum, the lower mold 23 is fixed, and the upper mold 22 is configured to be openable upward. Has been. Further, the upper mold 22 and the lower mold 23 are formed with notches in accordance with the shape of the metal core 24 so that the metal core 24 can be mounted at a predetermined position. Further, the lower mold 23 is provided with a magnet 28 for fixing the metal core 24.

  The metal core 24 is divided into a first divided member (upper divided member) 26 and a second divided member (lower divided member) 27 that can move in the mold opening direction of the upper die 22, and these upper sides A molding cavity 31 of the locking portion 5 is formed between the split member 26 and the lower split member 27.

  The pressing means 25 includes a metal pressing jig 29 that is brought into contact with the upper dividing member 26 and the lower dividing member 27 and a cylinder 32 that applies a load to the pressing jig 29 from above. The holding jig 29 is disposed in a through hole provided at the center of the upper mold 22, the upper divided member 26, and the lower divided member 27. In addition, two steps are provided on the peripheral surface of the holding jig 29, and the upper split member 26 and the lower split member 27 are pressed by each step surface. The holding jig 29 has a hollow structure in order to reduce the weight and reduce the cost.

  Using such a first structural member molding die 21, first, the lower split member 27 and the upper split member 26 are first set in order on the lower die 23, and then the upper die 22 is placed thereon. Clamp the mold. Further, the holding jig 29 is inserted into the through holes of the upper mold 22, the upper divided member 26, and the lower divided member 27, and a load is applied to the holding jig 29 from above by the cylinder 32. Thereby, a molding cavity 30 of the structural member 6 is formed between the upper mold 22 and the lower mold 23, and a molding cavity 31 of the locking portion 5 is formed between the upper split member 26 and the lower split member 27. It is formed.

  Then, a mixed material of polyol, diisocyanate, and water mixed, for example, by a mixing head (not shown) is introduced into the molding cavities 30 and 31 from a material introduction port (not shown), so RIM molding is performed. The amount of water mixed at this time is determined by the degree of foaming. Incidentally, the expansion ratio of the polyurethane foam resin in the present embodiment is set to 3 times. The mixture introduced into the molding cavities 30 and 31 starts to foam while generating heat, and eventually the hard polyurethane foam resin is filled into the molding cavities 30 and 31, and the structural member 6 having the locking portion 5 is molded. The The foaming temperature at this time is 50 to 60 ° C.

  The structural member 6 molded in this manner has a locking portion 5 formed integrally therewith, and a skin layer 14 is formed on the surface layer portion thereof. In particular, since the locking portion 5 is formed between the metal upper divided member 26 and the lower divided member 27, it is accurately formed with the designed shape and dimensions, and further on the surface layer portion. The skin layer 14 is thicker and more uniform than the part of the panel body.

  Next, in order to manufacture the molded panel 1 by molding and integrating the cushion body 7 and the skin material 8 into the structural member 6 molded by the first structural member molding die 21, the molded panel shown in FIG. RIM molding of the cushion body 7 is performed between the structural member 6 and the skin material 8 using the molding die 41.

  Here, the molding panel molding die 41 includes the structural member 6 and the skin material 8, and the molding panel first mold (upper mold) 42 and the molding panel having the molding cavity 50 of the cushion body 7 therebetween. A second metal mold (lower mold) 43, a metal first clamping member (upper clamping member) 44, which is disposed between the upper mold 42 and the lower mold 43 and sandwiches the locking portion 5 and the skin material 8, and A second clamping member (lower clamping member) 45, an upper clamping member 44 along the mold opening direction, and a pressing means 46 that presses the skin material 8 and the lower clamping member 45 are provided.

  The upper mold 42 and the lower mold 43 are formed in a predetermined shape with an epoxy resin containing metal fine particles such as aluminum, the lower mold 43 is fixed, and the upper mold 42 can be opened upward. Has been. The upper mold 42 is formed with a notch so that the upper clamping member 44 can be mounted at a predetermined position, and the lower mold 43 is cut so that the lower clamping member 45 can be mounted at a predetermined position. A notch is formed, and a magnet 49 for fixing the lower clamping member 45 is further provided.

  The pressing means 46 includes a metal pressing jig 47 that contacts the upper clamping member 44 and the skin material 8, and a cylinder 48 that applies a load to the pressing jig 47 from above. Is pressed toward the lower clamping member 45.

  In order to mold the molded panel 1 using such a molded panel mold 41, first, the skin material 8 is placed on the surface of the lower mold 43 to which the lower clamping member 45 is mounted, and further, The molded structural member 6 is placed. At this time, an adhesive or the like is applied to the surface of the part constituting the component mounting portion 3 of the structural member 6 to bond the structural member 6 and the skin material 8 together. In addition, it is preferable to prepare the skin material 8 separately beforehand and to give the surface the texture pattern.

  Subsequently, the upper clamping member 44 is set at a predetermined position, and the locking portion 5 and the skin material 8 are clamped between the upper and lower clamping members 44 and 45. Thereafter, the upper mold 42 is set on these and the mold is clamped. Further, the holding jig 47 is inserted into the through holes of the upper mold 42 and the upper holding member 44, and a load is applied to the holding jig 47 from above by the cylinder 48. Thereby, the molding cavity 50 of the cushion body 7 is formed between the structural member 6 and the skin material 8, and the structural member 6 and the skin material 8 can be brought into close contact with each other at the part constituting the component attachment portion 3. .

  Then, a mixed raw material of a semi-rigid polyurethane resin material and water is introduced into the molding cavity 50 of the cushion body 7 from a material introduction port (not shown), so that RIM molding of foamed polyurethane is performed. Also in this case, foaming is started upon introduction as in the case of RIM molding of the structural member 6, and eventually the semi-rigid foamed polyurethane resin fills the molding cavity 50, and between the structural member 6 and the skin material 8. The cushion body 7 is molded and integrated. Thereafter, the molded product is removed from the mold 41 for the molded panel, and the skin material 8 on the mounting hole 4 is cut, whereby the molded panel 1 of the first embodiment can be obtained.

  By manufacturing the molded panel 1 in this manner, the shape and size of the locking portion 5 formed with excellent dimensional accuracy by the first structural member molding die 21 can be maintained. At the same time, it is possible to prevent the resin material of the cushion body 7 from entering between the structural member 6 and the skin material 8 in the part constituting the component mounting portion 3. As a result, the cushion body 7 can be prevented from entering the component mounting portion 3 or leaking from the mounting hole 4, thereby preventing molding defects, so that the molded panel 1 of the first embodiment can be stabilized. Can be obtained.

  On the other hand, in the present invention, for example, as shown in FIG. 2B, two arc-shaped locking portions 5 formed in a partial region of the periphery of the mounting hole 4 (or a plurality of more). 4, the upper and lower divided members 26, 27 shown in FIG. 4 are connected to the other upper side that can form the molding cavity of the arcuate locking portion 5. By changing to the lower divided member, it can be manufactured easily and stably.

  In addition, for example, by using the second structural member molding die 51 shown in FIG. 5, a molded panel provided with two or more arcuate locking portions 5 can be manufactured. . Hereinafter, a method for manufacturing a molded panel using the second structural member molding die 51 will be described. Here, FIG. 5 is a partial cross-sectional view schematically showing a cross section of the second structural member mold, and FIG. 6 is a cross-sectional view of the structural member mold shown in FIG. It is.

  The second structural member molding die 51 shown in FIG. 5 includes a first structural member mold (upper mold) 52 and a structural member second mold (lower mold) 53 having a molding cavity 58 of the structural member 6; A metal core 54 that is disposed in the molding cavity 58 of the structural member 6 between the upper mold 52 and the lower mold 53 and forms the molding cavity 59 of the locking portion 5, and is fixed to the lower mold 53, A positioning member 55 for positioning and fixing the core 54 and an upper fixing member 56 for fixing the metal core 54 and the positioning member 55 from above are provided.

  The upper mold 52 and the lower mold 53 are formed of an epoxy resin containing metal fine particles such as aluminum, and the lower mold 53 is fixed and the upper mold 52 can be opened upward. Further, the lower mold 53 is formed with a notch in accordance with the shape of the metal core 54 so that the metal core 54 can be mounted at a predetermined position. On the other hand, the upper mold 52 is configured so that the upper fixing member 56 can be attached thereto.

  The metal core 54 is arranged in parallel to the direction perpendicular to the mold opening direction in the molding cavity 58 of the structural member 6 along the periphery of the mounting hole 4 to be formed, and is movable in the same right angle direction. It is composed of two parallel dividing members 57. Each of the parallel dividing members 57 has a molding cavity 59 of the locking portion 5 in which the arc-shaped locking portion 5 can be molded.

  Further, since a gap is formed between each parallel division member 57, the positioning member 55 is disposed in the gap, and each parallel division member 57 is fixed at a predetermined position by the positioning member 55. The positioning member 55 is preferably made of metal, whereby each parallel dividing member 57 can be positioned with higher accuracy.

  Further, the upper side outer peripheral portion of each parallel dividing member 57 is fixed by the upper side fixing member 56. As described above, since each parallel dividing member 57 is fixed to the positioning member 55 and the upper fixing member 56, each parallel dividing member 57 does not move even if a resin material is introduced into the molding cavities 58 and 59. Can be securely fixed at that position.

  When RIM molding of the structural member 6 is performed using the second structural member molding die 51 as described above, each parallel split member 57 is set on the lower mold 53 having the positioning member 55, and the positioning member 55 and parallel After placing the upper fixing member 56 from above the dividing member 57, the upper die 22 is placed on these and the mold is clamped. Thereby, a molding cavity 58 of the structural member 6 is formed between the upper mold 52 and the lower mold 53.

  The first structure is formed in the molding cavity 58 of the structural member 6 formed between the upper mold 52 and the lower mold 53 and in the molding cavity 59 of the locking portion 5 formed in each parallel split member 57. As in the case of the member molding die 21, a rigid foamed polyurethane RIM molding is performed by introducing a mixed material of polyol, diisocyanate and water from a material introduction port (not shown). The mixture introduced into the molding cavities 58 and 59 started to foam while generating heat, and eventually the hard foamed polyurethane resin was filled in the molding cavities 58 and 59, and the arc-shaped locking portions 5 were provided at two locations. The structural member 6 is molded.

  After the RIM molding is completed, the upper mold 52 and the upper fixing member 56 are removed in order, and then the molded product is removed from the lower mold 53 with the parallel dividing member 57 fitted to the engaging portion 5 of the structural member 6. Thereafter, the parallel dividing member 57 is moved in the diameter-reducing direction of the mounting hole 4 and removed, whereby the structural member 6 in which the arc-shaped locking portions 5 are integrally formed can be obtained.

  In the second structural member molding die 51, as described above, each molding cavity 59 of the locking portion 5 is formed by a single parallel dividing member 57. For example, the first structural member molding die Compared with the structural member molded using the 21, the locking portion 5 can be formed with higher dimensional accuracy. The second structural member molding die 51 can be molded with the upper and lower structures reversed with the structural member 6 to be molded interposed therebetween.

  The structural member 6 thus molded by the second structural member molding die 51 is then used between the structural member 6 and the skin material 8 in the same manner as described above using the molding panel molding die 41. By performing RIM molding of the cushion body 7, these can be molded and integrated to stably manufacture the molded panel 1.

  In addition, the typical embodiment of the present invention has been described above, and various modifications are possible as long as they have the basic features and configuration of the present invention. For example, the first structural member molding die 21 shown in FIG. 4 and the molding panel molding die 41 shown in FIG. 7 are provided with pressing means 25 and 46, respectively. Sufficient force for pressing the first divided member 26 toward the second divided member 27 by the mold clamping force and the magnetic force of the magnet, or sufficient force for pressing the first holding member 44 toward the second holding member 45 Is obtained, the arrangement of the pressing means 25 and 46 can be omitted.

It is a fragmentary sectional view showing typically a section of a forming panel concerning a 1st embodiment. (A) And (b) is the front view which expanded and showed the component attachment part which has a latching part from which a form differs. It is a fragmentary sectional view showing typically a section of a forming panel concerning a 2nd embodiment. It is a fragmentary sectional view which shows typically the cross section of the 1st shaping | molding die for structural members. It is a fragmentary sectional view which shows typically the cross section of the 2nd shaping | molding die for structural members. It is sectional drawing in the VI-VI line of the shaping | molding die for structural members shown in FIG. It is a fragmentary sectional view which shows typically the cross section of the shaping | molding die for molded panels. FIG. 3 is a partial perspective view of a vehicle interior when a driver's seat of the wheel loader is viewed from obliquely above in front. It is a fragmentary sectional view which shows typically the cross section of the components attachment part of the conventional front dash panel, and its vicinity.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1,1 'Molding panel 2 Panel main body 3,3' Component attachment part 4 Attachment hole 5 Locking part 6 Structural member 7 Cushion body 8 Skin material 9 Part 10 Hook part 11 Intermediate part 12 Flange 13 Step part 14 Skin layer 21 1st 1 Structural member molding die 22 Structural member first die (upper die)
23 Second type for structural members (lower type)
24 metal core 25 pressing means 26 first divided member (upper divided member)
27 Second divided member (lower divided member)
28 Magnet 29 Pressing jig 30 Molding cavity of structural member 31 Molding cavity of locking part 32 Cylinder 41 Molding die for molding panel 42 First die for molding panel (upper die)
43 Molded panel second mold (lower mold)
44 1st clamping member (upper clamping member)
45 Second clamping member (lower clamping member)
46 Pressing means 47 Holding jig 48 Cylinder 49 Magnet 50 Cushion body molding cavity 51 Second structural member molding mold 52 Structural member first mold (upper mold)
53 2nd mold for structural members (lower mold)
54 Metal Core 55 Positioning Member 56 Upper Fixing Member 57 Parallel Split Member 58 Structural Member Molding Cavity 59 Locking Portion Molding Cavity 61 Driver's Room 62 Glass 63 Steel Column 64 Instrument 65 Various Switches 66 Air Conditioner Grill 67 Front Dash panel 68 Undercut part 81 Molded panel 82 Parts 83 Mounting hole 84 Claw part (hook part)
85 Locking part 86 Skin material 87 Cushion body 88 Structural member

Claims (15)

The panel body,
A mounting hole formed at a predetermined position of the panel main body and capable of mounting a component; and a component mounting portion formed at a peripheral edge of the mounting hole and having a thinner locking portion than the panel main body;
A molded panel comprising:
The molded panel includes a structural member made of rigid foam resin, a cushion body disposed on a surface of the structural member excluding the component mounting portion, a partial surface corresponding to the component mounting portion of the structural member, and the cushion A molded panel comprising a skin material covering a body surface and molded and integrated.   The molded panel according to claim 1, wherein the structural member includes a skin layer on a surface layer portion thereof.   The molded panel according to claim 1 or 2, wherein the surface of the molded panel is flush.   The molded panel according to claim 1, wherein a step portion for fitting a flange of the component is formed on a surface of the component mounting portion.   The molded panel according to claim 1, wherein the hard foamed resin is a thermosetting foamed polyurethane resin.   The molded panel according to claim 1, wherein the cushion body is made of a semi-rigid foamed polyurethane resin. In the molding die for a structural member used for molding the structural member of the molded panel according to any one of claims 1 to 6,
A first mold and a second mold made of resin having a molding cavity of the structural member;
A metal core disposed in the structural member molding cavity between the first mold for the structural member and the second mold, and forming a molding cavity of the locking portion;
A mold characterized by comprising.   The metal core is divided into a first divided member and a second divided member that are movable in the mold opening direction of the first and second molds for the structural member, and the first divided member and the second divided member. The mold according to claim 7, wherein the locking portion molding cavity is formed between the two.   The mold according to claim 8, further comprising pressing means for pressing the first divided member and / or the second divided member toward the other divided member along the mold opening direction.   The pressing means includes a metal pressing jig that abuts against the first divided member and / or the second divided member, and a cylinder that applies a load to the pressing jig. Item 10. The mold according to Item 9.   The metal cores are arranged in parallel in the direction perpendicular to the mold opening direction in the structural member forming cavity along the peripheral edge of the mounting hole to be formed, and a plurality of parallel arrangements are movable in the right angle direction. 8. The mold according to claim 7, wherein the mold is composed of divided members, and each of the parallel divided members forms the locking portion forming cavity.   12. The apparatus according to claim 11, further comprising a positioning member that is disposed in a gap formed between the parallel division members when the plurality of parallel division members are arranged, and that positions and fixes the parallel division members. Mold. A molding panel molding die used when molding and integrating the cushion body between the skin material and the structural member of the molding panel according to any one of claims 1 to 6,
The first and second molds for resin-molded panels in which the structural member and the skin material are arranged at the time of molding, and a molding cavity of the cushion body is formed between the structural member and the skin material, and the molding A first clamping member and a second clamping member made of metal that are arranged between the first and second molds for the panel and sandwich the locking portion and the skin material;
A mold characterized by comprising.   The apparatus further comprises pressing means for pressing the first clamping member and / or the second clamping member toward the other clamping member along the mold opening direction of the first mold for the molded panel and the second mold. The mold according to claim 13, wherein   The pressing means includes a metal pressing jig that abuts on the first clamping member and / or the second clamping member, and a cylinder that applies a load to the pressing jig. Item 15. A mold according to Item 14.

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