JP2007301889A - Interior part for automobile and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve, regarding an interior part for an automobile and its manufacturing method, the weight reduction and cost reduction and dissolve the resin leakage at the time of molding of a clip seat to eliminate the deburring work and prevent the defective molding such as a short shot. <P>SOLUTION: The door trim main body 30 in the door trim 20 is composed of the foamed resin base material 31 lightweight and having shape retainability, the resin rib 32 integrated with its inner surface side, and the resin-made functional part (clip seat) 34 integrated with the resin rib 32. As to the resin-made functional part (clip seat) 34A that contacts the inner face of the peripheral flange 311 of the foamed resin base material 31, the inner face of the arm rest 22 or the inner face of the stepped part, by forming the thickness-cut part 344 in the vertical wall part 343, the contact area between it and the foamed resin base material 31 is decreased and the resin leakage is prevented, and also the degree of freedom of the shaping can be improved since the tilt angle of the peripheral flange 311 of the foamed resin base material 31 can be set to be an acute angle. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to automobile interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and manufacturing methods thereof, and in particular, to lightweight and inexpensive automotive interior parts. The present invention relates to an automotive interior part that can be provided, has no resin leakage during resin rib molding, and has improved moldability, and a method for manufacturing the same.

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

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

  Therefore, when the molding upper and lower molds 5 and 6 are in the mold open state, either the skin 3 is set in the mold, and then either immediately before or after the molding upper and lower molds 5 and 6 are clamped The molten resin M is injected and filled from the injection machine 7 through the manifold 6b and the gate 6c into the product cavity between the molds at the timing, thereby forming the resin core material 2 into a required curved shape and the resin core material 2 The skin 3 is integrally formed on the surface (for example, see Patent Document 1). In FIG. 14, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state, but actually, the molten resin M is injected into the cavity after the mold upper and lower molds 5 and 6 are clamped. It may be filled.

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

  In order to solve these problems, the applicant previously provided a function as a core material by imparting shape retention to the foamed resin sheet that was conventionally used as the skin, and more rigid. By placing resin ribs at necessary locations, i.e. peripheral parts of products, panels, mating parts with mating parts, etc., interior parts designed to reduce product weight compared to conventional resin cores with a large projected area is suggesting. 15 and 16 show an outline thereof. That is, the door trim 10 is formed by integrating resin ribs 12 having a predetermined pattern shape that are formed in a desired curved surface shape and run in a vertical and horizontal cross shape on the back surface of the foamed resin base material 11 having shape retention. On the surface side of the resin base material 11, a decorating material 13 is affixed in order to improve the surface feel and the surface texture. FIG. 16 shows the pattern shape of the resin rib 12. The resin rib 12 is integrated with a resin seat such as a clip seat 14, a component mounting bracket (not shown), or an impact absorbing pad. It has become. The interior part based on the foamed resin base material 11 is described in detail in Patent Document 2.

JP 10-138268 A

Japanese Patent No. 3431915

  As described above, the door trim 10 based on the foamed resin base material 11 can be manufactured at a low cost with a light weight, and the resin rib 12 can be integrated with resin functional parts such as the clip seat 14 and the bracket. However, there is a problem when a resin functional part is set on the product terminal side. That is, normally, the foamed resin base material 11 has a peripheral flange 11a formed along the peripheral edge portion to give the door trim 10 a three-dimensional effect, and the clip seat 14 is particularly set on the inner surface side of the peripheral flange 11a. As shown in FIG. 17, the laminated body of the foamed resin base material 11 and the decorating material 13 is press-molded by clamping the molding upper and lower molds 15, 16, and in the groove portion 17 of the molded lower mold 16 after press molding. The resin rib 12 and the clip seat 14 are integrated by pouring molten resin. When the resin rib 12 and the clip seat 14 are molded, the general part of the foamed resin base material 11 has a surface orthogonal to the press direction, that is, a so-called press surface, which is a product surface. In this case, when the molten resin is injected and filled into the portion that is in contact with the peripheral flange 11a, the mold clamping pressure of the upper and lower molds 15 and 16 is different from the sealing direction. Is likely to occur, and resin burrs are easily formed. Accordingly, a trimming process for trimming resin burrs in post-processing is required, and a resin leak occurs, so that there is a problem that molding defects such as short shots are likely to occur. In addition, when the clip seat 14 is set on the inner surface side of the peripheral flange 11a of the foamed resin base material 11 in terms of modeling, the inclination angle (indicated by α in the figure) of the peripheral flange 11a is 10 ° or more. It has been pointed out at the same time that it has to be set to an inclination, cannot be set to a steep inclination angle of less than 10 °, and is restricted by the degree of freedom in forming the door trim 10. In addition to the peripheral flange 11a, the clip seat 14 set at the stepped portion of the inner surface of the armrest portion or the inner surface of the trim has the same problem.

  The present invention has been made in view of such circumstances, and is a lightweight, foamed resin base material molded into a desired curved shape, a resin rib having a predetermined pattern shape integrated with the back surface thereof, and a resin product. In particular, at least one of the resin functional parts is set on the peripheral flange inner surface, armrest inner surface, or stepped inner surface of the foamed resin base material, and resin leakage occurs when resin functional components are molded. Providing an interior part for automobiles and a method for manufacturing the same with improved formability, such as by reliably preventing occurrence and improving formability and freely setting the inclination angle of the peripheral flange. It is aimed.

  In order to solve the above problems, the present inventors have devised the shape of the slide piece used when integrating resin functional parts such as clip seats as a result of earnest research, and the inner surface of the foam resin base material and The present invention has been completed by reducing the contact area of the resin and avoiding resin leakage.

  That is, the present invention relates to a foamed resin base material that is molded into a required shape, is lightweight and has shape retention, a resin rib having a predetermined pattern shape integrated with the back surface of the foamed resin base material, and a resin functional component In the interior part for automobiles that adopts the laminated structure composed of the whole or a part thereof, the foamed resin base material is subjected to heat softening treatment of the foamed resin sheet, and then put into a molding die, While being molded into the required shape by clamping the molding die, among the functional parts made of resin integrated on the back surface of the foamed resin base material, against the press surface orthogonal to the pressing direction of the molding die The vertical wall portion of the resin functional part integrated with the inner surface of the foamed resin base material at the inclined portion is provided with a lightening portion for avoiding resin leakage.

  Furthermore, the manufacturing method of the present invention includes a foamed resin base material that is molded into a required shape, is lightweight and has shape retention, and a resin rib and a resin having a predetermined pattern shape integrated with the back surface of the foamed resin base material. In a method for manufacturing an interior part for an automobile, in which a laminated structure composed of functional parts is used in whole or in part, the laminated structure is foam that has been heat-softened when the molded upper and lower molds are opened. The process of setting the material for setting the resin sheet in the molding upper and lower molds, and the foamed resin base material that press-molds the foamed resin sheet into a desired curved shape along the cavity shape of the molding die by clamping the molding upper and lower molds When the molten resin is injected and filled into the grooves and recesses of the lower mold at any time immediately before or after the upper and lower molds are clamped, the resin function is achieved by sliding the slide core. parts In addition to molding, by setting a spacer protrusion between the inner surface of the foamed resin base material and the slide core at a portion inclined with respect to the press surface orthogonal to the press direction of the molding die, The resin rib and the resin functional part are formed by forming each of the steps while forming the resin rib and the resin functional part while avoiding the resin leakage of the molten resin. .

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

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

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

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

  Further, the resin functional parts integrated with the resin rib include a clip seat for attaching a clip, a mounting bracket for attaching other parts such as lamps and lock parts, a shock absorbing pad formed in a lattice shape, etc. Can be considered. Of these functional parts made of resin, the contact area with the foamed resin base material is reduced in parts provided on the inner surface of the peripheral flange flange, the inner surface of the armrest, or the inner surface of the stepped portion of the foamed resin base material. For this purpose, a thinned portion is formed on the component side. Accordingly, the interior part for automobiles according to the present invention has a low contact pressure with the inner surface of the foamed resin base material during injection molding of the resin functional part, so the seal pressure at this part is low. Even resin leakage can be minimized.

  Next, the molding die used in the method of the present invention is composed of a movable side die, a fixed side die, an injection machine, and a slide core provided in the fixed side die. For example, a molding upper mold capable of moving up and down by a predetermined stroke, a molding lower mold positioned below the molding upper mold, an injection machine connected to the molding lower mold, and a resin functional component provided in the molding lower mold And a slide core for molding. When the molding upper and lower molds are used, the molten resin supplied from the injection machine passes through the resin passages such as the manifold and gate provided in the molding lower mold, and more specifically the mold surface of the molding lower mold. Supplied to the grooves, recesses, etc. formed on the top, but after the molding upper mold is lowered to the bottom dead center and the molding upper and lower molds are clamped, the mold surface of the molding lower mold is molded with a predetermined injection pressure. The groove portion and the recess portion provided in the container may be injected and filled, but may be performed before mold clamping as the injection filling timing of the molten resin.

  Therefore, according to the method of the present invention, only the resin rib and the functional part made of resin need to be molded as compared with the conventional resin core material having a large projected area. The load on the mold can be reduced, the resin material can be saved, and the cooling time can be shortened compared to the conventional resin core material, so that the product molding cycle can be shortened.

  Furthermore, when molding a resin functional part that is integrated with the inner surface of the peripheral flange, the inner surface of the armrest, or the inner surface of the stepped portion of the foamed resin base material, the convex portion for the spacer of the slide core contacts the foamed resin base material. In addition, since the molten resin that is the material of the resin functional component is kept small in contact with the foamed resin base material due to the presence of the convex portions for spacers, even if the sealing pressure at the joint surface with the foamed resin base material is low Resin leakage can be suppressed. In addition, it is possible to abolish molding processing such as short shots and trim processing that is necessary after the occurrence of burrs. Furthermore, since resin leakage is suppressed to a minimum, the inclination angle of the peripheral flange of the foamed resin base material can be set to a steep angle, and the degree of freedom of modeling can be improved.

  As described above, the automobile interior part according to the present invention is required to have rigidity such as a lightweight and shape-retaining foamed resin base material, a back surface of the foamed resin base material, and an outer peripheral edge of the product. Because it is made up of resin ribs that are laminated and integrated at the part to be integrated, and resin functional parts that are integrated with the resin ribs, the conventional heavy resin core material can be abolished. Since it is a porous material, it has an effect of excellent sound absorption performance.

  Furthermore, according to the method for manufacturing an automotive interior part according to the present invention, the foamed resin base material is molded into a required shape along the cavity shape of the molding die, and at the same time, the resin rib is formed on the back surface side of the foamed resin base material. Since the projected area of the resin rib, which is a resin molded body, is small, the load applied to the molding die is less than that of the conventional resin core material, and the cooling time can be shortened. Since it can be increased, the working efficiency can be increased, and in addition, there is an effect that a significant cost reduction can be brought about.

  In addition, the resin functional parts set on the inner surface of the peripheral flange, the inner surface of the armrest, or the inner surface of the stepped portion of the foamed resin base material are formed with a thinned portion at the opposite part of the foamed resin base material, Since the contact area is reduced, resin leakage can be minimized even when the sealing pressure with the foamed resin base material is low during injection molding of resin functional parts. In addition to preventing molding defects, it is possible to abolish deburring work due to the occurrence of burrs and to improve work efficiency.

  Furthermore, since the resin leakage can be suppressed even if the inclination angle of the peripheral flange of the peripheral portion of the foamed resin base material is set to a steep angle, the inclination angle of the peripheral flange can be arbitrarily set, and the product can be shaped. The effect is that the degree of freedom can be increased.

  Hereinafter, preferred embodiments of an automobile interior part and a method for manufacturing the same according to the present invention will be described in detail with reference to the accompanying drawings. Note 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.

  FIG. 1 to FIG. 11 show an embodiment of the present invention, FIG. 1 is a front view showing a door trim as an example of an automobile interior part according to the present invention, and FIG. 2 is a cross-sectional view showing the configuration of the door trim. 3 is an explanatory view showing the pattern shape of the resin rib when the door trim is viewed from the back side, FIG. 4 is an explanatory view showing a clip seat set at the peripheral edge of the door trim, and FIG. 5 shows a configuration of the clip seat. Cross-sectional views, FIG. 6 and FIG. 7 are an overall view of a molding die used in the method of the present invention and a cross-sectional view of the main part, and FIG. 8 to FIG.

  1 and 2, an automotive door trim 20 is configured by attaching various functional parts to a door trim main body 30 formed in a desired curved surface shape. Specifically, an inside handle escutcheon 21 is attached to the inscribed portion of the door trim main body 30, and an armrest 22 that bulges indoors and rests on an elbow is swelled almost in the center of the door trim main body 30. A pull handle unit 23 and a power window switch escutcheon 24 are attached to the upper surface of the armrest 22, and a door pocket 25 that can accommodate equipment is provided below the armrest 22. The speaker grille 26 is attached to the door trim main body 30 or separately.

  As shown in FIG. 2, the door trim main body 30 is molded into a desired curved surface shape, and has a foamed resin base material 31 having shape retention, and a resin rib integrated with the back surface side of the foamed resin base material 31. 32 and a decorating material 33 having a decorating function that is molded on the surface side of the foamed resin base material 31. The foamed resin base material 31 is heat-molded into a required shape after heat-softening treatment of the foamed resin sheet so as to have shape retention, for example, cold press-molded with a molding die having a desired mold surface. About the expansion | deployment rate part, you may shape the foamed resin base material 31 using vacuum forming together.

  The foamed resin sheet has a structure in which a foaming agent is added to a general-purpose thermoplastic resin. The thermoplastic resin includes a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a chloride resin. Vinyl resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. can be used. As the foaming agent, organic foaming agents such as azodicarbonamide and bicarbonate An inorganic foaming agent such as sodium can be used. In this embodiment, a foamed resin sheet in which sodium bicarbonate is appropriately added as a foaming agent to a polypropylene resin is used. The expansion ratio of the foamed resin substrate 31 is set to 2 to 10 times, and the thickness is set to a range of 0.5 to 30 mm, particularly 1 to 10 mm.

  Next, the resin ribs 32 are disposed on the back side of the foamed resin base material 31 and, in particular, are set in a predetermined pattern extending in an intersecting manner as shown in FIG. In addition, as for this pattern, arbitrary pattern shapes may be selected if it is cross shape, such as a vertical and horizontal direction, an oblique direction, or a combination thereof. The resin rib 32 is made of a general-purpose synthetic resin molding, and as a synthetic resin that can be preferably used usually, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin, A polyamide resin, a polyacetal resin, a polycarbonate resin, an ionomer resin, an acrylonitrile / butadiene / styrene (ABS) resin, or the like may be selected as appropriate. In this embodiment, a polypropylene resin is used in consideration of environmental and recycling aspects. Is used. The resin rib 32 is appropriately mixed with a filler such as inorganic fibers such as glass fibers and carbon fibers, and inorganic particles such as talc, clay, silica, and calcium carbonate in the thermoplastic resin. May be.

  As described above, the door trim main body 30 in the door trim 20 shown in FIGS. 1 to 3 includes a foamed resin base material 31 having shape retention, a resin rib 32 integrated on the back surface of the foamed resin base material 31, and a decoration. In addition to using the lightweight foamed resin base material 31, the resin core material occupied over the entire surface of the product can be abolished. The resin rib 32 has a bone shape, and the weight of the product can be reduced by 40% or more compared to the conventional example, and the resin material can be saved significantly, which can contribute to cost reduction.

  Moreover, since the foamed resin base material 31 has a porous structure, the door trim main body 30 is excellent in sound absorption performance and can reduce noise in the vehicle interior. Moreover, in order to maintain the sound absorption of the foamed resin base material 31, the decorating material 33 laminated in advance on the surface of the foamed resin base material 31 or integrated and laminated at the time of molding is a woven fabric or a non-woven fabric. A sheet material having air permeability such as a knitted fabric is preferable. In addition, the decorating material 33 is a synthetic resin sheet such as a PVC sheet or a TPO sheet, a synthetic resin film, a foam, a net, or a fabric sheet, a synthetic sheet, in addition to a breathable sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric. It is also possible to use a laminated sheet material in which a back surface of the resin sheet is lined with a cushion layer such as polyethylene foam or polyurethane foam. Moreover, if the raw material of the decorating material 33 is unified with an olefin resin material, it is advantageous in terms of recycling.

  Furthermore, as described above, the automobile door trim 20 according to the present invention greatly contributes to the weight reduction by using the foamed resin base material 31. Since it cannot be said that it is ensured, a peripheral flange 311 that is bent toward the panel side is formed along the outer periphery of the product, and the rigidity of the peripheral portion is strengthened so that the warped deformation of the foamed resin base material 31 is poor. The peripheral edge 311 gives a texture to the door trim 20 and gives a three-dimensional appearance rather than a two-dimensional appearance to enhance appearance performance.

  As shown in FIGS. 3 to 5, the clip seat 34 is integrated with the resin rib 32 integrated with the back surface of the foamed resin base material 31 along a predetermined pattern shape. As will be described later, the clip seat 34 is formed using a slide core, and an attachment seat for mounting a clip (not shown) is provided in an undercut shape. In particular, the present invention is characterized in that the formability of the clip seat 34A that contacts the inner surface side of the peripheral flange 311 is improved. For this purpose, the clip seat 34A provided on the inner surface of the peripheral flange 311 is provided with a clip locking hole 342 in the mounting seat 341 to which the clip is attached, and the dimension height from the reference surface of the foamed resin base material 31 to the mounting seat 341 is high. A vertical wall portion 343 that secures the thickness is formed. In the vertical wall portion 343, a thinned portion 344 is formed at a portion that contacts the inner surface of the peripheral flange 311 of the foamed resin base material 31. Due to the presence of the thinned portion 344, as will be described later, the contact area with the foamed resin base material 31 can be regulated small, and resin leakage can be prevented as much as possible. Furthermore, the inclination angle of the peripheral flange 311 (indicated by α in FIG. 5) can also be set to a steep inclination angle of less than 10 °, and the degree of freedom of modeling in the automobile door trim 20 compared to the conventional one is possible. It has improved. In addition to the inner surface of the peripheral flange 311, for example, the clip seat 34 </ b> A configured as described above may be applied to the inner surface of the armrest 22 or the inner surface of the stepped portion.

  Next, each process of the manufacturing method of the door trim 20 mentioned above is demonstrated. First, the overall configuration and the main configuration of the molding die 40 will be described with reference to FIGS. In FIG. 6, a molding die 40 used for molding the door trim 10 includes a molding upper mold 41 that can move up and down by a predetermined stroke, a molding lower mold 42 that is paired with the molding upper mold 41, and a molding lower mold 42. And an injection machine 43 connected to the main body.

  More specifically, the molding upper die 41 has a cavity portion 411 that matches the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 412 connected to the upper surface of the molding upper die 41. In addition, guide bushes 413 serving as a guide mechanism are provided at the four corners of the molding upper die 41. On the other hand, the molding lower die 42 is provided with a core portion 421 corresponding to the cavity portion 411 of the molding upper die 41. In addition, a manifold 422 and a gate 423 are provided to supply the molten resin to the mold surface of the core portion 421. The molten resin M supplied from the injection machine 43 via the manifold 422 and the gate 423 is the core portion. It is supplied into a groove portion (for forming the resin rib 32) 424 and a recess portion (for forming the clip seat 34) 425 formed on the upper surface of 421. In addition, guide posts 426 that serve as a guide mechanism protrude from the four corners of the molded lower mold 42, and the guide posts 426 guide into the guide bush 413 when the molded upper and lower molds 41 and 42 are clamped. As a result, the pressing posture of the molding upper die 41 can be properly maintained.

  By the way, molten resin M is supplied into the groove portion 424 of the lower molding die 42 to form a resin rib 32 having a predetermined pattern shape. The slide core 44 enters the recess 425 provided in the molding lower mold 42 by driving the cylinder 441, and the clip seats 34, 34A are molded in an undercut shape. In particular, with respect to the clip seat 34A set on the inner surface side of the peripheral flange 311 of the foamed resin base material 31, in consideration of the fact that the conventional one is likely to cause resin leakage, it is for a spacer for forming the thinned portion 344. The feature on the mold structure is that the convex portion 442 is provided.

  Next, each step in the method for manufacturing the door trim 20 will be described with reference to FIGS. First, as shown in FIG. 8, the foamed resin sheet S is heated and softened to a high temperature state of 160 to 220 ° C. by the heater device 50. As the foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumika Plustech, trade name: Sumiceller foam PP sheet, expansion ratio = 3 times, thickness 3 mm) is used. Subsequently, as shown in FIG. 9, the decorative material 33 and the above-described heat-softened foamed resin sheet S are put into the mold when the molded upper and lower molds 41 and 42 are in the mold open state. Specifically, the decorating material 33 is preferably held by a set pin (not shown) in the lower stage of the molding upper die 41 or by a vacuum suction force by a vacuum suction mechanism attached to the molding upper die 41. It may be placed on the upper surface of the resin sheet S. Thereafter, the elevating cylinder 412 of the molding upper die 41 is operated, the molding upper die 41 is lowered by a predetermined stroke, and the molding upper and lower dies 41 and 42 are clamped as shown in FIG. The foamed resin base material 31 is molded into a required shape.

  After molding the foamed resin base material 31, the molten resin M is injected and filled into the groove portion 424 from the injection machine 43 through the manifold 422 and the gate 423, and the resin rib 32 has a predetermined pattern shape at a predetermined position on the back surface of the foamed resin base material 31. It is integrated along. Further, the molding lower mold 42 is formed with a recess 425 so as to communicate with the groove 424. When the slide core 44 enters the recess 425 by the operation of the cylinder 441 in the slide core 44, the resin rib 32 and The clip seat 34 is formed integrally. In particular, as for the clip seat 34A formed so as to abut on the inner surface side of the peripheral flange 311 of the foamed resin base material 31, since the spacer convex portion 442 is formed on the slide core 44, as shown in FIG. In addition, since the spacer convex portion 442 of the slide core 44 functions as a spacer on the back surface of the foamed resin base material 31, the molten resin M does not leak resin and reliably prevents molding defects such as burrs and short shots. be able to. Further, FIG. 11 shows a state at the time of injection filling of the molten resin M after the mold upper and lower molds 41 and 42 are clamped. With respect to the direction F1 in FIG. Since it is the same as the pressing direction, a strong pressing pressure acts and the sealing property of the molten resin M can be maintained well.

  In the present invention, a peripheral flange 311 is formed in order to give poor rigidity of the foamed resin base material 31 and a three-dimensional feeling of the product, and the molten resin M for forming the peripheral flange 311 and the clip seat 34A is formed. Ensuring the sealing property is related to the pressing direction of the molding upper and lower molds 41 and 42, and it is very difficult to ensure the sealing property satisfactorily. 11 is formed on the slide core 44, the contact area of the molten resin M for forming the clip seat 34A with the foamed resin base material 31 can be reduced. Even if the sealing pressure in the F2 direction is slightly insufficient, resin leakage does not occur. Therefore, after molding the door trim main body 30, deburring work is not required, so that productivity can be improved and molding defects such as short shots can be prevented. In addition, it is possible to set the inclination angle of the peripheral flange 311 to a steep angle by forming the thinned portion 344 in the clip seat 34A installed on the inner surface of the peripheral flange 311 of the foamed resin base material 31. There is also an effect that the degree can be improved.

  In the embodiment described above, the present invention is applied to the door trim main body 30 in the automobile door trim 20 and the manufacturing method thereof. However, the method of the present invention can be applied to the door trim upper in the upper and lower split type door trim. Other interior parts can be applied to all automotive interior parts such as rear parcel shelf, floor trim, trunk trim, luggage trim, roof trim, and rear side trim.

  In addition to the clip seat 34A shown in the embodiment of the present invention, as long as it is a resin functional part provided to contact the inner surface of the peripheral flange 311 or the inner surface of the armrest 22 or the inner surface of the stepped portion of the foamed resin base material 31, The present invention can be applied to a shock absorber made up of a bracket for attaching another part, a grid-like rib, or the like.

It is a front view which shows the door trim for motor vehicles which applied the interior component for motor vehicles based on this invention. It is the II-II sectional view taken on the line in FIG. It is a front view which shows the back surface side of the door trim for motor vehicles shown in FIG. It is a perspective view which shows the clip seat in the door trim shown in FIG. It is sectional drawing which shows the clip seat in the door trim shown in FIG. It is explanatory drawing which shows the whole structure of the shaping die used for the manufacturing method of the door trim shown in FIG. It is principal part sectional drawing which shows the clip seat formation site | part in the shaping die shown in FIG. It is explanatory drawing which shows the preheating process of the foamed resin sheet in the manufacturing method of the door trim shown in FIG. It is explanatory drawing which shows the setting process of the raw material in the manufacturing method of the door trim shown in FIG. It is explanatory drawing which shows the formation process of the door trim main body in the manufacturing method of the door trim shown in FIG. It is explanatory drawing which shows the shaping | molding process of the clip seat in the manufacturing method of the door trim shown in FIG. It is a front view which shows the conventional door trim. FIG. 13 is a sectional view taken along line XIII-XIII in FIG. 12. It is a schematic diagram which shows the shaping die which shape | molds the conventional door trim. It is sectional drawing which shows the structure of the conventional lightweight door trim. It is explanatory drawing which shows the relationship between the resin rib and clip seat in the conventional lightweight door trim. It is sectional drawing which shows the clip seat in the conventional lightweight door trim. It is explanatory drawing which shows the installation location of the clip seat in the conventional lightweight door trim.

Explanation of symbols

20 Automotive door trim 30 Door trim body (laminated structure)
DESCRIPTION OF SYMBOLS 31 Foamed resin base material 311 Peripheral flange 32 Resin rib 33 Decorating material 34 Clip seat 34A Clip seat 341 Mounting seat 342 Clip latching hole 343 Vertical wall part 344 Meat part 40 Molding die 41 Molding upper mold 42 Molding lower mold 424 Groove part 425 Concave part 426 Guide post 43 Injection machine 44 Slide core 441 Cylinder 442 Spacer convex part 50 Heater device S Foamed resin sheet M Molten resin

Claims (2)

A foamed resin base material (31) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (32) and a resin having a predetermined pattern shape integrated with the back surface of the foamed resin base material (31) In an automotive interior part (20) formed by adopting a laminated structure (30) composed of a functional part (34) as a whole or a part thereof,
The foamed resin base material (31) is subjected to heat softening treatment for the foamed resin sheet (S), and then charged into the molding die (40), and the molding die (41, 42) is clamped to obtain the required shape. Of the resin functional component (34) integrated with the back surface of the foamed resin base material (31), which is inclined with respect to the press surface orthogonal to the pressing direction of the molding die (40). The vertical wall portion (343) of the resin functional part (34A) integrated with the inner surface of the foamed resin base material (31) at the site is provided with a lightening portion (344) for avoiding resin leakage. Automotive interior parts characterized by A foamed resin base material (31) that is molded into a required shape and is lightweight and has shape retention, and a resin rib (32) and a resin having a predetermined pattern shape integrated with the back surface of the foamed resin base material (31) In the manufacturing method of the automotive interior part (20) formed by employing the laminated structure (30) composed of the functional part (34) as a whole or a part thereof,
The laminated structure (30) includes a material setting step for setting the heat-softened foamed resin sheet (S) in the molded upper and lower molds (41, 42) when the molded upper and lower molds (41, 42) are opened. ,
A step of molding a foamed resin substrate by clamping the upper and lower molds (41, 42) and press-molding the foamed resin sheet (S) into a desired curved shape along the cavity shape of the molding die (40);
The molten resin (M) is injected and filled into the grooves (424) and the recesses (425) of the molded lower mold (42) either before or after the mold clamping of the molded upper and lower molds (41, 42). At this time, the resin functional part (34) is molded by the sliding operation of the slide core (44), and the foamed resin base material (in the portion inclined with respect to the press surface orthogonal to the press direction of the molding die (40)) ( 31) By forming a spacer convex portion (442) between the inner surface and the slide core (44), a resin-made functional part (34A) is formed with a thinned portion (344), and the molten resin (M) A resin rib and a resin functional component molding step for molding the resin rib (32) and the resin functional component (34) while avoiding resin leakage of the resin,
A method for manufacturing an interior part for an automobile, which is manufactured by each process comprising:

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