JP2008006620A - Automotive interior trim and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce the weight and cost of an automotive interior trim and to simply and inexpensively mold resin components such as a finisher, an escussion, and a grille. <P>SOLUTION: The interior trim (door trim) 10 is composed of a laminated structure (door trim upper) 20 and a door trim lower 30. The door trim upper 20 is composed of a foamed resin substrate 21 and resin ribs which are integrated with the back of the substrate 21 and is lightweight and inexpensive in constitution. Since an inside handle escusson 11 is integrated by using the element of the resin ribs 22 when the resin ribs 22 are molded, attaching man-days and facility costs are reduced. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage side trims, roof trims, rear side trims, and manufacturing methods thereof, and in particular, is lightweight and has a desired rigidity. The present invention relates to an automobile interior part that can be manufactured at low cost, and can be easily and inexpensively manufactured by integrating resin parts such as an inside handle escutcheon and a speaker grille, and a manufacturing method thereof.

  For example, the configuration of automobile interior parts will be described with reference to FIGS. The door trim 1 has shape retention and attachment rigidity to a vehicle body panel, and is configured by laminating and integrating a skin 3 excellent in surface appearance on the surface of a resin core material 2 extending over almost the entire product surface. . In the figure, reference numeral 1a denotes an inside handle escutcheon, and 1b denotes a power window switch finisher. The resin core material 2 is made of a polypropylene resin mixed with talc, and the skin 3 does not have shape retention itself, such as polyethylene foam on the back surface of a synthetic resin sheet such as a vinyl chloride sheet. In recent years, a cushioning material such as polyethylene foam is laminated on the back side of an elastomer sheet such as a TPO (thermoplastic olefin) sheet in consideration of environmental and recycling aspects. The laminated sheet material tends to be frequently used.

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

  Therefore, when the molding upper and lower molds 5 and 6 are in the mold open state, the skin 3 is set in the mold, and then the molding upper and lower molds 5 and 6 are clamped and then injected into the product cavity between both molds. By injecting and filling the molten resin M from the machine 7 through the manifold 6b and the gate 6c, the resin core material 2 is formed into a required curved shape, and the skin 3 is integrally formed on the surface of the resin core material 2 (for example, , See Patent Document 1). In FIG. 26, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6a in an open state. However, the molten resin M is injected and filled into the cavity after the mold upper and lower molds 5 and 6 are clamped. May be.

  By the way, accessory parts such as the inside handle escutcheon 1a and the power window switch finisher 1b are attached to the door trim 1, and in order to attach these accessory parts 1a and 1b to the door trim 1, the above-described steps are used to obtain the required shape. As shown in FIG. 27, an opening 9 for attaching these accessory parts 1 a and 1 b is formed in the molded door trim 1 by piercing with a cutting blade 8. Then, an inside handle escutcheon 1a or power is inserted into the door trim 1, as shown in FIG. The actual situation is that attached parts such as the window switch finisher 1b are attached. Recently, automotive interior parts such as automobile ceilings and doors are made of resin such as bosses, clips, and hooks, which are parts of reinforcement ribs on thermoplastic resin foam sheets and attachments to other parts. A molding method of fusing and integrating functional members is also known (for example, see Patent Document 2).

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

JP 2001-121561 A (Page 6, FIGS. 6 to 9)

  However, in the conventional door trim 1, since the projected area of the resin core material 2 is large, there are problems that the material cost is high and the product is heavy. Furthermore, since the projected area of the resin core material 2 is large, the injection pressure at the time of molding must be set high, a mold structure that can withstand the high injection pressure is required, and the production cost of the mold increases, 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 addition, in order to attach accessory parts such as finisher, escutcheon and grill to the door trim 1, the opening 9 must be punched in the hard resin core material 2, and the wear of the cutting blade 8 is significant. In addition, the cutting blade 8 has to be frequently replaced, which increases the equipment cost and necessitates reworking. Further, as shown in FIG. 27, the skin 3 is in a tent tension state (indicated by a symbol “a” in the figure) at the parting line between the peripheral edge of the inside handle escutcheon 1a and the skin 3, and the peripheral appearance of the inside handle escutcheon 1a is not preferable. The shortcoming is also pointed out at the same time.

  On the other hand, in interior parts of the type in which a resin functional member is fused and integrated with a foamed resin sheet, the rigidity around the opening in the foamed resin sheet is weak to attach an accessory such as a finisher, an escutcheon, or a grill, and the functional member is sufficient In addition to not being able to obtain a sufficient mounting strength, there is a problem in that skies and the like are likely to occur on the periphery, leading to a decrease in appearance.

  The present invention has been made in view of such circumstances, and is an automotive interior part that can promote weight reduction, has high rigidity, and can reduce costs, and a method for manufacturing the same, and includes accessory parts such as a finisher, an escutcheon, and a grill It is an object of the present invention to provide an automobile interior part and a method for manufacturing the same, which can enhance productivity by integrating the above easily and inexpensively.

  As a result of earnest research, the present inventors have given the function as a core material by imparting shape-retaining properties to the foamed resin sheet that has been used conventionally as the skin, and more. Compared to conventional resin cores with a large projected area, resin ribs with excellent rigidity are placed in places where rigidity is required, that is, peripheral parts of products, panels, parts mounting locations, and parts where loads are applied. The present invention has been completed by providing interior trim parts that are lightweight and inexpensive, and by integrating resin parts such as finishers, escutcheons, and grills with resin ribs.

  That is, the automotive interior component according to the present invention is a resin foam having a predetermined pattern shape that is molded into a required shape, is lightweight and has shape retention, and is integrated with the back surface of the foam resin base material. An automotive interior part that uses a laminated structure composed of ribs in whole or in part, and is formed by attaching resin parts such as finisher, escutcheon, and grill to the laminated structure. The resin parts are integrally formed with the resin ribs by forming the resin ribs into the product surface side through the holes of the foamed resin base material when the resin ribs are molded. Features.

  Here, the automobile interior parts can be applied to door trims, rear parcel shelves, floor trims, trunk trims, luggage side trims, roof trims, rear side trims, and the like. In addition, the laminated structure can be configured as an interior part of the entire laminated structure, but at least in an interior trim composed of a divided body such as a trim upper and a trim lower, such as a two-part upper and lower door trim. A laminated structure may be adopted on one side.

  Furthermore, as each constituent element of the laminated structure, a foamed resin base material having shape retention is obtained by heat-softening the foamed resin sheet and then molding it into a desired curved shape in a molding die. Even if there is no reinforcing material, it has a rigidity (shape retaining property) enough to retain the shape even after being removed from the mold after molding. Also, if the product shape includes a high expansion ratio part, after the foamed resin sheet is heat-softened, a vacuum suction mechanism is provided in the molding die and the foamed resin sheet is vacuumed along the inner surface of the molding die. A suction force may be applied. As the foamed resin sheet, a material obtained by adding a foaming agent to a thermoplastic resin is used. The thermoplastic resin may be one type of thermoplastic resin or two or more types of thermoplastic resins. Preferably, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / Styrene (ABS) resin or the like can be used. As the foaming agent, an organic foaming agent such as an azo compound, a sulfohydrazide compound, a nitroso compound or an azide compound, or an inorganic foaming agent such as sodium bicarbonate can be used.

  The foamed resin base material obtained by molding the foamed resin sheet into a required shape after heat softening treatment preferably has a foaming ratio of 2 to 10 times in consideration of the balance between the weight and strength of the product. The cell diameter of the foamed resin base material at that time is preferably in the range of 0.1 μm to 2.0 mm, and the thickness is 0.5 to 30 mm, preferably 1 to 10 mm. Moreover, in order to improve external appearance designability, you may laminate | stack a decorating material on the surface of a foamed resin base material. As the decorating material, a woven fabric, a non-woven fabric, a knitted fabric, a sheet, a film, a foam, a net-like material, or the like can be used. Although the material which comprises these decorating materials is not specifically limited, It is more preferable to use the raw material which has air permeability, such as a woven fabric, a nonwoven fabric, and a knitted fabric, in order to utilize the sound absorption performance of a foamed resin base material.

  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, Examples include acrylonitrile / butadiene / styrene (ABS) resin. 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.

  By the way, as resin parts integrated with resin ribs, when applied to a door trim upper in a door trim as a laminated structure, an inside handle escutcheon attached to the door trim upper corresponds to a resin part. Alternatively, a speaker grill when applied to a rear parcel shelf as a laminated structure corresponds to a resin part.

  According to the automotive interior part of the present invention, the entire laminated structure comprising the foamed resin base material having shape retention and the resin rib having a predetermined pattern shape laminated and integrated on the back surface of the foamed resin base material. Because it is a configuration that is adopted for some parts, it is possible to reduce the weight of the product by eliminating the conventional resin core material with a very large projected area, and to save the resin material. Reduction can also be achieved at the same time. In addition, the porous sound absorption function of the foamed resin base material provides interior parts with excellent sound absorption performance. When polyolefin resin is used as the material for the foamed resin base material and resin rib, it can be unified with all-olefin resin. During recycling, the separation process can be abolished and the recycling work can be simplified. Further, since the inside handle escutcheon, the speaker grill, and the like are integrated with the resin rib, the mounting strength does not become a problem, and it does not come off due to an impact or the like.

  And the manufacturing method of the said interior component WHEREIN: The resin rib of the predetermined pattern shape integrated in the back surface of this foamed resin base material which is shape | molded by required shape, and is lightweight and has shape retention property. Manufacturing interior parts for automobiles, in which the laminated structure consisting of the above is used in whole or in part, and the laminated structure is provided with resin parts such as finisher, escutcheon and grill In the method, the laminated structure is formed in a mold upper and lower mold in which a hole is formed in advance in the foamed resin sheet that is a material of the foamed resin base material, and the foamed resin sheet is heat-softened and then in a mold open state. The foaming resin sheet is set in the required shape along the cavity shape formed between the molding upper and lower molds by clamping the molded upper and lower molds and setting the foamed resin sheet to be set inside The resin rib is integrated with the back side of the foamed resin base material by injecting and filling molten resin from the injection machine into the groove of the molding lower mold during the resin base material molding process and the foamed resin base material molding process. At the same time, the molten resin is circulated to the product surface side from the groove portion to the concave portion of the molding upper mold through the hole of the foamed resin sheet, and the resin rib and the resin component are integrally formed with the resin rib. It is manufactured by the process which consists of a process.

  Here, the molding die used for the molding method of the interior parts for automobiles includes a molding upper mold that can move up and down, a molding lower mold that is a fixed side located below the molding upper mold, and a molding lower mold. The foamed resin sheet is press-molded into a foamed resin base material of the required shape by clamping the upper and lower molds, and the molten resin supplied from the injector is molded into the lower mold. The resin rib along the pattern shape of the groove is integrated with the back surface of the foamed resin base material through a resin passage such as a manifold and a gate provided in the groove formed in the mold surface of the lower mold. Furthermore, the hole formed in the foamed resin sheet is used to allow the molten resin supplied into the groove part to wrap around the product surface through the hole provided in the foamed resin sheet and to integrally mold the resin part with the resin rib. Corresponding to the part, a parting part is provided in the molding upper and lower molds, and a recess for shaping a resin part is formed in the periphery of the molding upper mold.

  And according to the manufacturing method of interior parts for automobiles according to the present invention, it is only necessary to mold resin ribs and resin parts as compared with the conventional resin core material having a large projected area. It can be set low, the load on the molding die is small, the amount of resin is small, the material cost can be saved, and the cooling time is shorter than that of the conventional resin core material, so that the molding cycle can be shortened.

  Further, according to the method for manufacturing an automotive interior part according to the present invention, the foamed resin base material is molded by drawing the foamed resin sheet into a required shape by clamping the upper and lower molds. The molten resin is supplied from the injection machine into the groove provided in the lower mold of the molding to mold a resin rib having a predetermined pattern shape on the back surface of the foamed resin base material, and the molten resin is provided on the foamed resin sheet. Since it is configured to integrate resin parts such as the inside handle escutcheon and speaker grille, the resin parts such as the inside handle escutcheon and the speaker grill are conventionally molded after molding the trim parts. However, the installation man-hour can be abolished and the molding equipment for separately molding the resin parts can be abolished.

  Next, in a preferred embodiment of the method of the present invention, a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a predetermined pattern shape that is integrated on the back surface of the foamed resin base material. An interior part for an automobile that uses a laminated structure composed of resin ribs in whole or in part, and the laminated interior is provided with resin parts such as a finisher, an escutcheon, and a grill. In the component manufacturing method, the laminated structure includes a foamed resin sheet setting step in which the foamed resin sheet, which is the material of the foamed resin base material, is heat-softened and then set in a mold upper and lower molds in a mold open state. The molded upper and lower molds are clamped to mold the foamed resin base material into the required shape along the cavity shape formed between the molded upper and lower molds, and the mold disposed on the upper mold is molded. By opening the opening in the foamed resin sheet by the blade mechanism, the foaming resin base material forming step for forming the foamed resin base material having a hole into a required shape, and at the time of molding the foamed resin base material, an injection machine The molten resin is injected and filled into the groove of the lower mold of the molding so that the resin rib is integrated with the back side of the foamed resin base material, and when the molten resin is supplied, the cutting blade of the cutting blade mechanism moves upward. The sealing block of the sealing mechanism installed in the lower mold of the molding moves into the opening of the foamed resin sheet, rises until it reaches the cutting blade, and the molten resin injected and filled in the groove is outside the sealing block. It is characterized by being manufactured in a process comprising a resin rib in which the resin rib and the resin part are integrated and a molding process of the resin part by going around the side of the product along the side surface.

  Here, as a mechanism for opening the hole during molding of the foamed resin sheet, a cutting blade mechanism is provided in the upper mold and a seal mechanism is provided in the lower mold. That is, a cutting blade that can be moved up and down by a hydraulic cylinder and an air cylinder is provided in the upper mold, and a sealing mechanism is provided in the lower mold so as to face this. Therefore, when forming a foamed resin base material using the foamed resin sheet as a raw material, the cut blade mechanism is driven to open the hole. Then, the cutting blade mechanism retracts upward after opening the hole, and then the sealing block provided in the molding lower die rises and comes into contact with the cutting blade, so that the outer surface of the sealing block A space for the molten resin to wrap around the product surface is formed. Therefore, according to this embodiment, it is possible to save time and labor for opening a hole in the foamed resin sheet in advance, to reduce the number of man-hours, and to eliminate the piercing equipment.

  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 same location, the conventional heavy resin core material can be abolished, making it a lightweight, low-cost, and porous material, so it has excellent sound absorption performance This has the effect of providing interior parts for automobiles.

  Furthermore, the automobile interior part according to the present invention employs a process of molding a foamed resin base material into a required shape along with the cavity shape of the molding die and simultaneously molding a resin rib on the back surface of the foamed resin base material. For example, 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, the cooling time can be shortened, and the yield can be increased. The efficiency can be increased and the cost can be greatly reduced.

  Furthermore, the interior parts for automobiles and the manufacturing method thereof according to the present invention are such that an inside handle escutcheon or a resin part such as a speaker grill is integrated with the resin rib when molding the resin rib integrated on the back surface of the foamed resin base material. The structure is molded so that even if an impact is applied, the resin part will not come off, and the mounting strength of the resin part can be maintained very firmly. After molding, the process of attaching resin parts to trim parts can be abolished, equipment can be simplified, and the cost can be greatly reduced by shortening the number of steps.

  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 by exemplifying the structure of a door trim and a rear parcel shelf for automobiles and a method for manufacturing them. 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 a first embodiment of the present invention. FIG. 1 is an explanatory view showing an automotive door trim to which the present invention is applied. FIG. 2 is a longitudinal sectional view showing the configuration of the automotive door trim. 3 is an explanatory view showing a pattern shape of a resin rib in the door trim upper of the door trim, FIG. 4 is a cross-sectional view showing a configuration of an inside handle escutcheon in the door trim upper, and FIG. 5 is a molding die used in the manufacturing method of the door trim. FIG. 6 is a cross-sectional view showing the structure corresponding to the inside handle escutcheon in the molding die, and FIGS. 7 to 11 are explanatory views showing each step in the method for manufacturing the door trim.

  1 and 2, a two-tone type automobile door trim 10 is composed of an upper and lower divided body of a door trim upper 20 made of a laminated structure and a door trim lower 30 made of a single resin product. As functional parts mounted on the door trim 10, an inside handle escutcheon 11 and a power window switch finisher 12 are attached to the door trim upper 20. A door pocket opening 13 is formed in the door trim lower 30, and a pocket back cover (made of a resin molded body) 14 is attached to the back side of the door trim lower 30, as shown in FIG. The speaker grill 15 is formed integrally with the door trim lower 30 or separately. Reference numeral 16 denotes a vehicle body panel.

  That is, the door trim upper 20 is formed into a desired curved surface shape and has a foamed resin base material 21 having shape retention, a resin rib 22 laminated and integrated on the back side of the foamed resin base material 21, and a foamed resin base material. It is generally composed of a decorating material 23 having a decorating function that is laminated and integrated on the surface side of the material 21. The foamed resin substrate 21 is heat-molded into a required shape after heat-softening 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 high expansion | deployment rate part, you may shape the foaming resin base material 21 by vacuum forming. 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. Moreover, the expansion ratio of the foamed resin base material 21 is set to 2 to 10 times, and the thickness is set to 0.5 to 30 mm, particularly preferably 1 to 10 mm.

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

  As described above, the door trim 10 shown in FIGS. 1 to 3 includes the door trim upper 20 made of a laminated structure and the door trim lower 30 made of a single synthetic resin, and has excellent appearance design due to the accent effect on the appearance. It has. Further, the door trim upper 20 includes a foamed resin base material 21 having shape retention, a resin rib 22 laminated and integrated on the back surface of the foamed resin base material 21, and a decorating material 23 having a decorating property. Therefore, the resin core material occupied over the entire surface of the product can be abolished as in the past, and the weight of the product is 40% or more compared to the conventional example because the lightweight foamed resin base material 21 is used. The weight of the resin can be reduced, and the resin material can be saved significantly, which can contribute to cost reduction.

  Furthermore, since the foamed resin base material 21 has a porous structure, the door trim upper 20 has excellent sound absorption performance and can reduce noise inside and outside the vehicle interior. Further, in order to enhance the sound absorption performance of the foamed resin base material 21 for vehicle interior noise, the decorative material 23 laminated and integrated on the surface of the foamed resin base material 21 is made of woven fabric, non-woven fabric, knitted fabric or the like. A sheet material having air permeability is preferable. In addition to the breathable sheet such as woven fabric, non-woven fabric, and knitted fabric, the decorative material 23 is a synthetic resin sheet such as a vinyl chloride sheet or a TPO (thermoplastic olefin) sheet (recyclable if a TPO sheet is used), Synthetic resin films, foams, nets and the like can be used. In addition, as a low-cost configuration, the decorating material 23 may be omitted, and the surface of the foamed resin base material 21 may be subjected to painting or printing processing.

  By the way, the door trim 10 to which the automotive interior part according to the present invention is applied can be manufactured particularly at a low cost as the door trim upper 20 is light as described above, and the inside handle escutcheon 11 has a foamed resin base as shown in FIG. It is integrated with the resin rib 22 located on the back surface of the material 21. Therefore, the inner handle escutcheon 11 molded in a separate process is superior in mounting strength to the structure in which the inside handle escutcheon 11 is attached to the door trim upper 20 via attachment means such as a claw, and the attachment work can be eliminated and the number of steps can be reduced. That is, after the door trim upper 20 is formed, the troublesome work of drilling and attaching a separately formed inside handle escutcheon can be eliminated, and the equipment cost can be reduced.

  Hereinafter, a method for manufacturing the door trim 10 will be described with reference to FIGS. 5 and 6. In the drawing, 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 fixed molding lower mold 42 that forms a pair with the molding upper mold 41, and a molding lower mold 42. It is mainly composed of two connected injection machines 43a and 43b. 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. Guide bushes 413 are provided at the four corners of the molding upper die 41.

  On the other hand, the molding lower die 42 is provided with a core portion 421 corresponding to the cavity portion 411 of the molding upper die 41. In addition, manifolds 422a and 422b and gates 423a and 423b are provided to supply molten resin to the mold surface of the core portion 421, and the injection machine passes through the resin passages of the manifolds 422a and 422b and gates 423a and 423b. Molten resins M1 and M2 supplied from 43a and 43b are supplied to the upper surface of the core portion 421. In order to form the resin rib 22, a groove portion 424 to which the molten resin M <b> 1 is supplied is formed on the upper surface of the core portion 421, and between the molded upper and lower molds 41 and 42 to form the door trim lower 30. A cavity 425 having a predetermined clearance is set. In addition, guide posts 426 serving as a guide mechanism protrude from the four corners of the molding lower die 42. The guide posts 426 guide the molding upper die 41 when the molding upper and lower dies 41, 42 are clamped. By being guided into the bush 413, the pressing posture of the molding upper die 41 can be properly maintained.

  Further, as shown in FIG. 6, in order to mold the inside handle escutcheon 11 integrally with the resin rib 22, the molded upper and lower molds 41 and 42 pass through the hole 21 a of the foamed resin base material 21 so that the molten resin is brought to the product surface side. A concave portion 414 that matches the product surface shape of the inside handle escutcheon 11 is formed in the molding upper die 41 so that the inside handle escutcheon 11 can be formed by wrapping around. When the mold 42 is clamped, a convex portion 427 that abuts the mold surface of the molding upper mold 41 is formed. In addition, if the movable block structure which can synchronize with the downward movement of the shaping | molding upper mold | type 41 is employ | adopted as the convex part 427, the dispersion | variation in product thickness etc. can be absorbed effectively and molding performance can be improved.

  Next, a method for manufacturing the door trim 10 will be described with reference to FIGS. First, as shown in FIG. 7, the heater device 50 laminates the decorative material 23 on one surface of the foamed resin sheet S and heat-softens it to a predetermined temperature. In this embodiment, 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. Before the heat treatment, a hole A is opened in the laminate of the foamed resin sheet S and the decorating material 23 in advance. And after heat-softening the foamed resin sheet S which opened the hole A, and the decorating material 23, as shown in FIG. 8, the cavity part 411 of the shaping | molding upper mold | type 41 in the location corresponding to the door trim upper 20, and the shaping | molding lower mold | type 42 Are set in the upper half of the cavity defined by the core portion 421. At this time, as shown in FIG. 9, the foamed resin sheet S and the decorating material 23 are set so that the convex part 427 of the molded lower mold 42 fits into the hole A of the foamed resin sheet S.

  After setting the foamed resin sheet S (laminated with the decorating material 23), 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, 42 are moved. As shown in FIG. 10, the foamed resin sheet S is shaped along a desired mold surface shape, and the foamed resin base material 21 is molded. Further, after the mold upper and lower molds 41 and 42 are clamped, the molten resin M1 is injected and filled from the first injection machine 43a into the groove portion 424 of the molded lower mold 42 through the manifold 422a and the gate 423a, and the resin ribs 22 have a predetermined pattern shape. And integrated with the back surface of the foamed resin base material 21. In addition, in order to mold the door trim lower 30, the molten resin M2 is injected and filled into the substantially lower half of the cavity from the second injector 43b through the manifold 422b and the gate 423b, and the door trim lower 30 is molded into a required shape. As the molten resins M1 and M2, a material in which talc is mixed at an appropriate ratio using Sumitomo Noblen BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 80 g / 10 min) is used. Accordingly, the resin ribs 22 and the door trim lower 30 in the door trim upper 20 are formed by filling and injecting the molten resins M1 and M2 into the groove 424 and the cavity 425 from the first injection machine 43a and the second injection machine 43b, respectively. The

  Furthermore, as shown in FIG. 11, at the same time as the molten resin M1 is injected and filled into the groove portion 424 of the molding lower die 42, in particular, in the present invention, the hole A is previously opened in the foamed resin sheet S. Therefore, a hole 21a corresponding to the foamed resin substrate 21 is formed, and the lower surface of the molded upper mold 41 and the upper surface of the convex portion 427 of the molded lower mold 42 are sealed in the hole 21a, as indicated by arrows in FIG. Further, the molten resin M1 passes from the groove portion 424 to the surface side of the foamed resin base material 21 through the hole portion 21a and is filled in the concave portion 414 of the molding upper die 41, and the inside handle escutcheon 11 is integrally molded with the resin rib 22. The Therefore, according to the first embodiment, as shown in FIG. 27, the inside handle escutcheon 1a is formed separately from the door trim 1 and pierced after the door trim 1 is formed. Compared to the conventional method of attaching the handle escutcheon 1a, the inside handle escutcheon 11 can be molded integrally with the molding of the door trim upper 20, so that the man-hours can be shortened and the mold equipment can be simplified. However, since the inside handle escutcheon 11 does not come off, it has various advantages that the mounting strength can be maintained firmly.

  FIGS. 12 to 17 show a second embodiment of the present invention. This second embodiment is also applied to the structure of the door trim upper 20 in the door trim 10 having the upper and lower split structures. The hole 21 a is pierced at the same time as the molding, and the inside handle escutcheon 11 is molded integrally with the resin rib 22. The configuration of the door trim 10 is the same as that of the first embodiment, and is omitted here.

  The molding die 40 used in the second embodiment is basically the same as the molding die 40 used in the first embodiment. However, as shown in FIG. 12, the cutting blade mechanism 44 is arranged on the molding upper die 41 in the portion corresponding to the inside handle escutcheon 11 and the molding lower die 42 is opposed to the cutting blade mechanism 44 as shown in FIG. 45 is arranged. Specifically, the cutting blade mechanism 44 has a cutting blade 441 supported by a cylinder 442 and moves up and down for a predetermined stroke, and the sealing mechanism 45 disposed in the molding lower die 42 has a sealing block 451 moved up and down by the cylinder 452. It is supported movably. That is, with respect to the action of the cutting blade mechanism 44 and the sealing mechanism 45, the molding upper die 41 is formed so that the process of making the hole A in the foamed resin sheet S can be performed when the molding upper and lower dies 41, 42 are clamped. A cutting blade mechanism 44 is provided, so that the inside handle escutcheon 11 can be molded integrally with the molding of the resin rib 22, and the molded lower die 42 is sealed so that the parting function can be performed even if the cutting blade 441 is retracted. A mechanism 45 is arranged. Therefore, when the molten resin M1 is supplied, the sealing block 451 in the sealing mechanism 45 rises and abuts against the lower surface of the cutting blade 441 of the upper molding die 41 to perform parting. A space is formed along which the molten resin wraps around the product surface.

  Next, each step of the manufacturing method using the molding die 40 shown in FIG. 12 will be described based on FIGS. 13 to 17. First, as shown in FIG. 13, when the molded upper and lower molds 41 and 42 are in the mold open state, the foamed resin sheet S (decorating material 23 is laminated) which is heat-softened by the heater device 50 as in the first embodiment. Is set at a position corresponding to the door trim upper 20. At this time, in the first embodiment, the hole A is previously formed in the foamed resin sheet S. However, in the second embodiment, the foamed resin sheet S does not need to be pierced as shown in FIG. That is, in the second embodiment, the piercing process can be omitted, and the setting operation can be performed relatively roughly.

  Next, as shown in FIG. 15, the molded upper and lower molds 41, 42 are clamped and the foamed resin sheet S is drawn into a required shape to form the foamed resin base material 21. At that time, as shown in FIG. 16. As described above, the cylinder 442 of the cutting blade mechanism 44 extends and the cutting blade 441 descends to open the hole 21a in the foamed resin base material 21, and the end material 21b generated by the cutting process is removed out of the mold. The After the foamed resin base material 21 is molded and the hole 21a is opened, the molten resin M1 is supplied from the injection machine 43a into the groove 424 of the molded lower mold 42, although not shown. Then, the resin rib 22 is molded, and the molten resin M2 is supplied from the injection machine 43b into the cavity 425, and the door trim lower 30 is molded. When the molten resin M1 is supplied into the groove portion 424, as shown in FIG. 17, in the cutting blade mechanism 44, the cylinder 442 contracts, the cutting blade 441 rises and moves away from the cavity, and the molding lower mold 42 When the cylinder 452 of the sealing mechanism 45 is driven, the sealing block 451 rises and the sealing block 451 having a smaller diameter rises from the hole 21a of the foamed resin base material 21 and comes into contact with the bottom surface (lower surface) of the cutting blade 441. Touch. Therefore, it is possible to form a space that allows the groove portion 424 of the molded lower mold 42 and the concave portion 414 of the molded upper mold 41 to communicate with each other along the inner periphery of the hole 21 a of the foamed resin base material 21. Therefore, when the molten resin M1 is filled in the groove portion 424, the molten resin M1 wraps around the product surface through this space, and the inside handle escutcheon 11 is integrally formed with the resin rib 22.

  Accordingly, in the second embodiment, since the resin rib 22 and the inside handle escutcheon 11 are integrated as in the first embodiment, it is possible to reduce the installation man-hours and simplify the molding tool, and the inside handle. In addition to the advantage that the mounting strength of the escutcheon 11 can be enhanced, a mold structure and a process for simultaneously opening the hole 21a when the foamed resin base material 21 is molded are adopted. Therefore, the hole A is pierced in the foamed resin sheet S. There is an advantage that the labor of processing can be saved and the positioning accuracy during the setting operation of the foamed resin sheet S can be relatively rough.

  FIGS. 18 to 23 show a third embodiment of the present invention. In the third embodiment, the present invention is applied to a rear parcel shelf 100 located behind a rear seat as an automobile interior part. That is, as shown in FIGS. 18 and 19, a resin-made speaker grill 110 is provided on a rear parcel shelf main body 20A having a shape retaining property attached to a parcel panel (not shown). More specifically, the rear parcel shelf main body 20A is basically substantially the same as the configuration of the door trim upper 20 of the door trim 10 in the first embodiment, and is vertically and horizontally oriented on the back surface of the lightweight and shape-retaining foamed resin base material 21. In this embodiment, a nonwoven fabric sheet is used as a decorating material 23 on the surface of the foamed resin base material 21. The speaker grill 110 includes a grid-like punching portion 111 and a dummy portion 112 around the punching portion 111. In addition, since the material of the foamed resin base material 21 and the resin rib 22 is the same as that of the first embodiment and the second embodiment, the description thereof is omitted here.

  The third embodiment is also characterized in that the speaker grill 110 is formed integrally with the resin rib 22. Therefore, as in the prior art, the speaker grill is manufactured in a separate process, and the rear parcel shelf 100 is formed. Installation work can be abolished. As the configuration of the molding die 40A, as shown in FIG. 20, the overall configuration is the same as the basic configuration of the molding die 40 in the first embodiment, and detailed description thereof will be omitted. However, in this third embodiment, since the rear parcel shelf 100 is constituted by the rear parcel shelf main body 20A and the speaker grill 110, which are laminated structures, only one injection machine 43 is provided in the molding die 40A. . Then, the difference from the first embodiment is that, as shown in FIG. 20, an uneven surface 415 is formed at the speaker grill 110 set location in the molding upper die 41 so as to form the product surface of the speaker grill 110. In addition, a frame-corresponding recess 416 is provided around the periphery. On the other hand, a punching block 461 is supported by a cylinder 462 as a punching mechanism 46 in the lower molding die 42. Then, the concavo-convex surface 463 formed on the upper surface of the punching block 461 is joined to the concavo-convex surface 415 formed on the mold surface of the molding upper die 41 to form the punching portion 111.

  Hereinafter, each step of the manufacturing method of the rear parcel shelf 100 will be described with reference to FIGS. First, as shown in FIG. 21, when the molded upper and lower molds 41 and 42 are in the mold open state, the foamed resin sheet S and the decorating material 23 are set separately, but the foamed resin sheet S is heated and softened to a predetermined temperature. The foamed resin sheet S is formed with a hole A that is processed and has a size that can accommodate the punching block 461 disposed in the lower mold 42. And as shown in FIG. 22, the foaming resin base material 21 is shape | molded by clamping the shaping | molding upper-lower molds 41 and 42. As shown in FIG. FIG. 22 shows an initial state of mold clamping, and when molten resin is injected and filled into the groove 424 through a gate 423 from an unillustrated injection machine, the molten resin M wraps around the space, and as shown in FIG. Thus, the speaker grill 110 is integrally formed integrally with the resin rib 22. Therefore, as in the first embodiment, in this third embodiment, although the applied part is the rear parcel shelf 100, the speaker grill 110, which is a resin part, can be integrally formed with the resin rib 22, and the speaker grill is separately provided. Compared to the conventional construction method and conventional structure of molding and mounting, the man-hours and equipment costs can be reduced, and the speaker grill 110 is integrated with the rear parcel shelf body 20A, so that the mounting strength can be maintained firmly. There is.

  In the first and second embodiments described above, the present invention is applied to the door trim 10 having the upper and lower split structures, and in the third embodiment, the present invention is applied to the rear parcel shelf 100 installed as a luggage shelf behind the rear seat. However, it can be applied to all interior parts such as integrated door trim, floor trim, trunk trim, luggage side trim, roof trim, and rear side trim. In the first and second embodiments, the present invention is applied to the inside handle escutcheon 11, and in the third embodiment, the present invention is applied to the speaker grille 110. The use is not limited as long as it is a resin part.

1 is a front view showing a door trim to which a first embodiment of an automobile interior part according to the present invention is applied. It is the II-II sectional view taken on the line in FIG. It is explanatory drawing which shows the pattern shape of the resin rib of the door trim upper in the door trim shown in FIG. It is sectional drawing which shows the inside handle escutcheon in the door trim upper shown in FIG. It is explanatory drawing which shows the whole structure of the molding die used when shape | molding the door trim shown in FIG. It is sectional drawing which shows the structure of the inside handle escutcheon installation location in the molding die shown in FIG. It is explanatory drawing which shows the preheating process of the foamed resin sheet in the manufacturing method of the door trim shown in FIG. It is explanatory drawing which shows the setting process of the foamed resin sheet in the manufacturing method of the door trim shown in FIG. It is explanatory drawing which shows the positioning state of the hole in the setting process of the foamed resin sheet shown in FIG. It is explanatory drawing which shows the clamping state of the shaping | molding upper / lower mold in the manufacturing method of the door trim shown in FIG. It is explanatory drawing which shows the process of integrally forming the resin rib and the inside handle escutcheon in the manufacturing method of the door trim shown in FIG. It is explanatory drawing which shows the principal part structure of the molding die used for 2nd Example of the manufacturing method of the interior component for motor vehicles which concerns on this invention. It is explanatory drawing which shows the setting process of the foamed resin sheet at the time of manufacturing a door trim using the shaping die shown in FIG. It is explanatory drawing which shows the structure of the cutting blade mechanism vicinity in the setting process of the foamed resin sheet shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material in the manufacturing method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the trim cut process of the hole part in the manufacturing method of the door trim which uses the shaping die shown in FIG. It is explanatory drawing which shows the shaping | molding process of the resin rib and the inside handle escutcheon in the manufacturing method of the door trim which uses the shaping die shown in FIG. It is a top view which shows the rear parcel shelf which is 3rd Example to which the interior component for motor vehicles based on this invention is applied. It is the XIX-XIX sectional view taken on the line in FIG. It is explanatory drawing which shows the shaping | molding die used when shape | molding the rear parcel shelf shown in FIG. It is explanatory drawing which shows the setting process of the foamed resin sheet in the manufacturing method of the rear parcel shelf shown in FIG. It is explanatory drawing which shows the state at the time of mold clamping of the shaping | molding upper / lower mold in the manufacturing method of the rear parcel shelf shown in FIG. It is explanatory drawing which shows the integral formation process of the resin rib and speaker grill in the manufacturing method of the rear parcel shelf shown in FIG. It is a front view which shows the conventional door trim. It is sectional drawing which shows the structure of the conventional door trim. It is explanatory drawing which shows the structure of the shaping die used when shape | molding the conventional door trim. It is explanatory drawing which shows the piercing cut process in the conventional door trim. It is explanatory drawing which shows the attachment structure of the inside handle escutcheon in the conventional door trim.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Two-tone type automobile door trim 11 Inside handle escutcheon 20 Door trim upper 21 Foamed resin base material 21a Hole 22 Resin rib 23 Decorating material 30 Door trim lower 40 Molding die 41 Molding upper mold 42 Molding lower mold 43a, 43b Injection machine 44 Cutting blade mechanism 441 Cutting blade 442 Cylinder 45 Sealing mechanism 451 Sealing block 452 Cylinder 46 Punching mechanism 50 Heater device 100 Rear parcel shelf 110 Speaker grill 111 Punching part 112 Dummy part S Foamed resin sheet A Hole part M, M1, M2 Molten resin

Claims (4)

From a foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21) An interior part (10, 100) for an automobile that employs the laminated structure (20, 20A) as a whole or a part of the laminated structure (20, 20A), such as a finisher, an escutcheon, and a grill. In automotive interior parts (10, 100) to which resin parts (11, 110) are attached,
When the resin rib (22) is molded, the resin part (11, 110) is a product through which the molten resin (M1), which is the material of the resin rib (22), passes through the hole (21a) of the foamed resin base material (21). An interior part for an automobile, which is integrally formed with the resin rib (22) by being wound around the surface side. From a foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21) An interior part (10, 100) for an automobile that employs the laminated structure (20, 20A) as a whole or a part of the laminated structure (20, 20A), such as a finisher, an escutcheon, and a grill. In the manufacturing method of the interior parts (10, 100) for automobiles formed by attaching the resin parts (11, 110),
In the laminated structure (20, 20A), the foamed resin sheet (S) which is the material of the foamed resin base material (21) is previously provided with a hole (A), and the foamed resin sheet (S) is used. A step of setting the foamed resin sheet (S) to be set in the upper and lower molds (41, 42) in the mold open state after the heat softening treatment;
A foamed resin base material that molds the foamed resin base material (21) into a required shape along the cavity shape formed between the molded upper and lower molds (41, 42) by clamping the molded upper and lower molds (41, 42). (21) the molding step;
When the foamed resin base material (21) is molded, the resin rib (22) is foamed by injecting and filling the molten resin (M1) into the groove (424) of the molded lower mold (42) from the injection machine (43a). While being integrated with the back surface side of the resin base material (21), molten resin (from the groove portion (424) to the concave portion (414, 416) of the molding upper die (41) through the hole portion (A) of the foamed resin sheet (S) ( M1) is wrapped around the product surface side, and the resin rib (22) and the resin part (11, 110) are molded integrally with the resin rib (22) and the resin part (11, 110). ,
A method for manufacturing an interior part for automobiles, characterized in that it is manufactured by a process comprising: From a foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21) An interior part (10, 100) for an automobile that employs the laminated structure (20, 20A) as a whole or a part of the laminated structure (20, 20A), such as a finisher, an escutcheon, and a grill. In the manufacturing method of the interior parts (10, 100) for automobiles formed by attaching the resin parts (11, 110),
The laminated structure (20, 20A) is formed in the molded upper and lower molds (41, 42) in a mold open state after heat-softening the foamed resin sheet (S) which is the material of the foamed resin base material (21). A step of setting the foamed resin sheet (S) to be set,
By clamping the upper and lower molds (41, 42), the foamed resin base material (21) is molded into a required shape along the cavity shape formed between the upper and lower molds (41, 42). By opening the opening in the foamed resin sheet (S) by the cutting blade mechanism (44) disposed in the mold (41), the foamed resin base material (21) having the hole (21a) is formed into a required shape. Molding step of the foamed resin substrate (21);
When the foamed resin base material (21) is molded, the resin rib (22) is foamed by injecting and filling the molten resin (M1) into the groove (424) of the molded lower mold (42) from the injection machine (43a). While being integrated with the back surface side of the resin base material (21), when supplying the molten resin (M1), the cutting blade (441) of the cutting blade mechanism (44) retreats upward to form a lower molding die (42). The sealing block (451) of the sealing mechanism (45) disposed on the inside enters the opening of the foamed resin sheet (S), rises until it reaches the cutting blade (441), and is injected and filled into the groove (424). The resin rib (22) and the resin parts (11, 110) are integrated by the molten resin (M1) wrapping around the outer surface of the sealing block (451) toward the product surface. (22) and resin parts (11, 10) and the molding process,
A method for manufacturing an interior part for automobiles, characterized in that it is manufactured by a process comprising: From a foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21) A laminated structure molding die (40) for use in molding a laminated structure (20) comprising:
The molding die (40) is connected to the molding upper die (41), the molding lower die (42), and the molding lower die (42) that can be clamped and opened with each other, and is a material for the resin rib (22). And an injection machine (43a) for supplying a molten resin (M1), and a cutting blade mechanism (a) for opening a hole (A) in the foamed resin sheet (S) in the molding upper die (41). 44) is arranged to be movable up and down, and the molding lower die (42) is provided with a seal mechanism (45) corresponding to the cut blade (441), and the resin rib (22) and When molding the resin parts (11, 110), the sealing block (451) of the sealing mechanism (45) rises until it comes into contact with the cutting blade (441), and this sealing mechanism (45) causes the molten resin (M1) to rise. A space is formed around the product surface. Molding die of the stacked structure to.

Images