JP2008080559A - Automotive interior trim and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To realize weight reduction of a product, to reinforce rigidity and to keep appearance performance well in an automotive interior trim at least partly containing a laminated structural body and its manufacturing method. <P>SOLUTION: A door trim 10 is composed of a laminated structural body (door trim upper) 20 in which a resin rib 22 is integrally laminated on the back face of a foamed resin substrate 21 being lightweight and having shape holding properties, and a resin single article (door trim lower) 30. By arranging a resin plate 24 on the back face of the foamed resin substrate 21 at a rigidity reinforcing site A of the laminated structural body 20, a rigidity required for the product is ensured, and by simplifying a pattern shape of the resin rib 22, the degree of flexibility for shaping of the resin rib 22 is improved and a mold structure is simplified. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to automotive interior parts such as door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, pillar garnishes, roof trims, and the like. The present invention relates to an automotive interior part excellent in appearance design and moldability and a method for producing the same.

  For example, the configuration of automobile interior parts will be described with reference to FIGS. 17 and 18 exemplifying door trims. 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. . The resin core material 2 is made of polypropylene resin mixed with talc, and the skin 3 itself does not have shape retention, such as a vinyl chloride sheet, a thermoplastic olefin (hereinafter referred to as TPO) sheet, or the like. The synthetic resin sheet is usually 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 upper and lower molds 5 and 6 are in the mold open state, the skin 3 is set in the mold, and then the 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. 19, 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 upper and lower molds 5 and 6 are clamped. May be.

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

  However, in the conventional door trim 1, since the projected area of the resin core material 2 is large, there are problems that the material cost is high and the product is heavy. In addition, since the projected area of the resin core material 2 is large, it is necessary to set the injection pressure at the time of molding high, and a mold structure that can withstand the high injection pressure is required. 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.

  The present invention has been made in view of such circumstances, and can be used to manufacture automobile interior parts that can promote weight reduction and contribute to cost reduction. In particular, desired rigidity can be easily ensured, and the product surface can be obtained. It is an object of the present invention to provide an automotive interior part and a method for manufacturing the same that can enhance the appearance of the vehicle.

  As a result of diligent research, the present inventors have performed compression processing on a foamed resin sheet that has been conventionally used as an outer skin and imparted shape retention, thereby serving as a core material. The resin ribs with excellent rigidity are placed on the parts that require more rigidity, that is, the peripheral part of the product, the panel, or the part mounting part and the part where the load is applied, and the other parts are hollow. This makes it possible to reduce the projected area of the resin ribs compared to the conventional resin core material with a large projected area, and to provide a lightweight and inexpensive interior trim part. The resin rib structure can be simplified by insert molding of the resin plate at the position, the desired rigidity can be obtained with a simple configuration, and the appearance performance can be improved by simplifying the resin rib shape. Noting that the mold manufacturing costs can be reduced, thereby completing the present invention.

  That is, the present invention is a laminated structure comprising a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a resin rib having a predetermined pattern shape that is laminated and integrated on the back surface of the foamed resin base material. In automotive interior parts that employ the body as a whole or a part thereof, a resin plate whose both edges are supported by resin ribs is disposed on the back surface of the foamed resin substrate at the rigidity-enhanced portion of the laminated structure. It is characterized by being.

  Here, as an interior part for an automobile, as long as it has a structure including at least a part of a laminated structure, for example, a door trim, a rear parcel shelf, a floor trim, a luggage trim, a trunk trim, a rear side trim, Applicable to pillar garnish, roof trim, etc.

  Furthermore, the laminated structure is molded into a desired curved shape, is lightweight and has a shape-retaining foamed resin base material, and a resin rib having a predetermined pattern shape laminated and integrated on the back surface of the foamed resin base material. The foamed resin base material is formed into a required curved shape in the molding die after heat-softening the foamed resin sheet. The shape is retained by molding. The term “shape retention” as used herein refers to having sufficient rigidity to retain the shape at least when the mold is removed after molding, even without a reinforcing material such as a rib.

  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 azo compound such as azodicarbonamide, an organic foaming agent such as a sulfohydrazide compound, a nitroso compound or an azide compound, or an inorganic foaming agent such as sodium bicarbonate can be used. The foamed resin base material obtained by molding the foamed resin sheet into a required shape after heat softening treatment preferably has a foaming ratio of 2 to 10 times in consideration of the balance between the weight and strength of the product. The cell diameter of the foamed resin base material at that time is preferably in the range of 0.1 μm to 2.0 mm, and the thickness is 0.5 to 30 mm, preferably 1 to 10 mm.

  On the other hand, the thermoplastic resin material used as the resin rib can be appropriately selected from a wide range of thermoplastic resins. Usually, those that can be preferably used include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, Acrylonitrile / butadiene / styrene (ABS) resin 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.

  Here, when it applies to a door trim upper as a laminated structure, the site | part which wants to strengthen rigidity corresponds to the places where a passenger | crew's body is easy to touch, such as an armrest and a waist part. Moreover, as a resin plate, resin materials, such as a rubber-type material, PP resin, ABS resin, are not limited.

  In order to enhance the appearance design, a decorative material may be laminated and integrated on the surface of the foamed resin base material. As a decorating material to be used, thermoplastic resin sheets such as TPO, thermoplastic urethane (hereinafter referred to as TPU), PVC, or fabric sheets such as woven fabric, non-woven fabric, and knitted fabric can be used. Moreover, the laminated sheet material which integrated the foam sheets, such as a polyurethane foam, a polyethylene foam, a polypropylene foam, on the back surface of these thermoplastic resin sheets and fabric sheets as a cushion layer can also be used.

  Therefore, according to the interior parts for automobiles according to the present invention, as the structure of the laminated structure, it is composed of a lightweight foamed resin base material and a hollow-shaped resin rib disposed on the back side thereof. Weight reduction can be achieved by eliminating the conventional heavy resin core material.

  Next, a method for manufacturing an automotive interior part according to the present invention includes 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. In a method for manufacturing an interior part for an automobile that employs a laminated structure composed of resin ribs and resin plates in whole or in part, the method for producing the laminated structure includes: The resin plate is housed in the cavity of the molded lower mold, and the foamed resin sheet, which is the material of the foamed resin base material, is preheated and softened. By clamping the mold, the foamed resin base material is pressed into the required shape along the cavity shape formed between the molded upper and lower molds, and the molded upper and lower molds are clamped. Resin rib that injects and fills molten resin from the injection machine into the groove of the molded lower mold, integrates resin ribs of a predetermined pattern shape on the back surface of the foamed resin base material, and supports both ends of the resin plate by the resin ribs It is characterized by comprising a process consisting of:

  The molding die for molding the laminated structure includes a pair of split molds and an injection machine attached to one mold. For example, it is comprised from the shaping | molding upper die which can be moved up and down, the shaping | molding lower die which is a fixed side located in the downward side of a shaping | molding upper die, and the injection machine connected with a shaping | molding lower die. When the molding upper and lower molds are used, the molten resin supplied from the injection machine passes through resin passages such as a manifold and a gate provided in the molding lower mold, that is, on the mold surface of the molding lower mold, that is, the mold of the molding lower mold. Molten resin is injection-filled into grooves (corresponding to the resin rib shape) formed on the surface, and the resin rib is formed into a predetermined pattern shape.

  Therefore, according to the interior part for automobiles and the manufacturing method thereof according to the present invention, after the resin plate is accommodated in the cavity of the molded lower mold, the foamed resin sheet is introduced, and the molded upper and lower molds are clamped, The foamed resin base material is press-molded into the required shape, and then a resin rib with a predetermined pattern shape is integrated on the back surface of the foamed resin base material. Therefore, the resin rib and the resin plate can easily secure the desired rigidity, the resin rib does not become excessive quality, and the occurrence of sink marks on the surface can be prevented in advance. The die structure can be simplified, such as reduction of the number of gates.

  Next, in a preferred embodiment of the present invention, the edge of the resin plate facing the foamed resin base is provided with recesses at appropriate pitch intervals, and injection filling of molten resin that is a material of the resin rib At this time, the molten resin flows into the recess to form a resin molded portion, whereby the resin plate is firmly integrated with the back surface of the foamed resin base material. Then, according to this embodiment, the resin resin plate is formed with recesses at appropriate pitch intervals on the foam resin substrate facing edge, and when the molten resin flows into the recesses, the molten resin solidifies. Since the foamed resin base material and the resin plate can be firmly integrated, the structure of the rigidity-enhanced portion can be further stabilized.

  As described above, according to the interior part for automobiles and the manufacturing method thereof according to the present invention, the foamed resin base material that is lightweight and has shape retention, and the predetermined pattern laminated and integrated on the back surface of the foamed resin base material Because the laminated structure is composed of the resin ribs in the shape and the resin plates arranged at the rigidity-enhanced parts, the conventional heavy resin core material can be eliminated, and it is possible to provide interior parts for automobiles that are lightweight and low in cost. Has an effect.

  Furthermore, according to the interior part for automobiles and the method for manufacturing the same according to the present invention, as a structure for ensuring product rigidity, a resin rib having a predetermined pattern shape is disposed on the back surface of the foamed resin base material, and a resin plate is disposed on the rigidity reinforcing portion. Therefore, the basic shape of the resin rib does not need to be set so wide, and since it can be installed with the minimum amount, there is no sink on the product surface, and the mold structure can be simplified. It has the effect of contributing to weight reduction.

  Hereinafter, preferred embodiments of an automobile interior part and a manufacturing method thereof according to the present invention will be described by exemplifying an automobile door trim and a manufacturing method thereof. 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.

  1 to 16 show an embodiment of the present invention, FIG. 1 is a front view showing a two-tone type automobile door trim, FIG. 2 is a sectional view showing the configuration of the automobile door trim, and FIG. FIG. 4 is a sectional view showing the structure of the door trim upper, FIG. 5 is an overall view showing a molding die used for the door trim for the automobile, and FIG. 6 is the same molding. FIG. 7 to FIG. 13 are explanatory views showing respective steps of the automobile door trim manufacturing method, and FIG. 14 to FIG. 16 are modifications of the automobile door trim and the manufacturing method thereof. It is each explanatory drawing which shows an example.

  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. An inside handle escutcheon 11 is attached to the door trim upper 20 of the door trim 10, and an armrest 12 bulging indoors is provided on the lower side of the door trim upper 20. A power window switch escutcheon is provided on the armrest 12. 13. A pull handle 14 is attached. On the other hand, a door pocket opening 15 is formed in the door trim lower 30, and a pocket back cover (made of a resin molded body) 16 is attached to the back side thereof as shown in FIG. A speaker grille 17 is formed integrally with or separately from the door trim lower 30 on the front side of the opening 15.

  By the way, the door trim 10 for automobiles according to the present invention is characterized in that the door trim upper 20 which is a laminated structure is reduced in weight, and the appearance performance and touch feeling of the door trim upper 20 are improved. That is, as shown in FIG. 2, the door trim upper 20 is molded into a desired curved surface shape and has a foamed resin base material 21 having shape retention, and a reinforcement integrated and laminated on the back surface side of the foamed resin base material 21. The resin rib 22 having a function and a decorating material 23 having a decorating function laminated and integrated on the surface side of the foamed resin base material 21 are roughly constituted. Furthermore, in the present invention, a reinforcing resin plate 24 is disposed in the rigidity-enhancing portion A such as the armrest 12. In the figure, reference numeral 18 denotes a vehicle body panel. In addition, the foamed resin base material 21 is heat-softened to heat the foamed resin sheet so as to have shape retention, and then thermoformed into a required shape, for example, cold press-molded with a molding die having a desired mold surface. In addition, the foamed resin base material 21 may be shaped by vacuum forming for a portion with a higher development rate.

  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 resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, acrylonitrile / butadiene / styrene (ABS) resins, etc. can be used. As blowing agents, azo compounds such as azodicarbonamide, sulfohydrazide compounds Organic foaming agents such as nitroso compounds and azide compounds and inorganic foaming agents such as sodium bicarbonate 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 21 is set to 2 to 10 times, and the thickness is set to 0.5 to 30 mm, particularly 1 to 10 mm.

  Next, the resin ribs 22 are disposed on the back surface side of the foamed resin base material 21 and, in particular, as shown in FIG. 3, are set in a predetermined pattern extending in an intersecting manner, and a portion to which a load is applied (for example, a clip seat). The portion excluding the upper surface of the waist portion, the upper surface of the armrest portion, etc.) has a thinned shape. In addition, as for this pattern, arbitrary patterns may be selected as long as it is intersecting, such as a vertical and horizontal direction, an oblique direction, or a combination thereof. The resin rib 22 is made of a general-purpose synthetic resin molded body, and as a synthetic resin that can be preferably used normally, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin, A polyamide resin, a polyacetal resin, a polycarbonate resin, an ionomer resin, an acrylonitrile / butadiene / styrene (ABS) resin, or the like may be selected as appropriate. In this embodiment, a polypropylene resin is used 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. The resin plate 24 is made of a general-purpose synthetic resin material such as a rubber-based material, PP resin, or ABS resin.

  As described above, the door trim 10 shown in FIGS. 1 to 3 includes the door trim upper 20 formed of a laminated structure and the door trim lower 30 of a single resin, and has an excellent appearance design due to an accent effect on the appearance. I have. Furthermore, the door trim upper 20 reinforces the foamed resin base material 21 having shape retention, the resin rib 22 laminated and integrated on the back surface of the foamed resin base material 21, the decorating material 23 having a decorating property, and the rigidity. Therefore, the resin core material occupied over the entire circumference of the product can be abolished, and the weight of the product is used because the lightweight foamed resin base material 21 is used. As compared with the conventional example, the weight can be reduced, the resin material can be saved, and the cost can be reduced. Furthermore, since the foamed resin base material 21 has a porous structure, the door trim upper 20 is excellent in sound absorption performance and can reduce noise in the vehicle interior.

  Moreover, the decorating material 23 affixed on the surface of the foamed resin base material 21 is comprised in the present Example from the two-layer laminated structure of the top layer 23a and the cushion layer 23b laminated | stacked and integrated on the back surface. Specifically, a TPO sheet is used as the top layer 23a and polyethylene foam is used as the cushion layer 23b, but a TPU sheet, woven fabric, non-woven fabric, knitted fabric, etc. can be used as the top layer 23a. As the cushion layer 23b, a foam sheet such as polyurethane foam or polypropylene foam can be used. Further, an olefin resin is used as the material of the foamed resin base material 21 and the resin rib 22, and in addition to this, the top layer 23a of the decorating material 23 is a TPO sheet, and the cushion layer 23b is an olefin type such as polyethylene foam. When all the resin is unified, it is advantageous in terms of recycling.

  Further, the structural feature of the present invention is that a resin rib 22 having a predetermined pattern shape is formed on the back surface of the foamed resin base material 21 in the door trim upper 20 and is supported by the resin rib 22 in order to reinforce the rigidity of the resin rib 22. The resin plate 24 is arranged in the rigidity-enhancing portion A such as the armrest 12 and the waist portion. The resin plate 24 is made of a rubber material, PP resin, ABS resin, or the like as a material. The vertical dimension of 24 is slightly shorter than the dimension of the resin rib 22, and the width is preferably 1 to 3 mm. The both end edges 24 a of the resin rib 22 are held by the resin ribs 22, and the opposite surface of the foamed resin base material 21 is laminated with the hot melt film a on the opposite edge of the resin plate 24. However, the hot melt film a may be omitted.

  Accordingly, the rigidity of the door trim upper 20 is ensured by the resin rib 22 and the resin plate 24. In particular, the resin plate 24 is easily reinforced by being disposed in the rigidity reinforcement portion A such as the armrest 12 or the waist portion. Since the resin rib 22 only needs to have the minimum groove width and rib length as well as being able to take a structure, there is no sink or the like on the product surface, and the number of gate points can be reduced. The mold structure can also be simplified.

  Next, the molding die 40 used in the method for manufacturing the door trim 10 will be described with reference to FIG. A molding die 40 used for molding the door trim 10 is connected to a molding upper mold 41 that can move up and down by a predetermined stroke, a molding lower mold 42 that is paired with the molding upper mold 41, and a molding lower mold 42. It is mainly composed of two 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. 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. Further, in order to supply molten resin to the mold surface of the core portion 421, manifolds 422a and 422b and gates 423a and 423b are provided in the molding lower mold 42. Resins of the manifolds 422a and 422b and gates 423a and 423b are provided. The molten resins M1 and M2 supplied from the injection machines 43a and 43b through the passages are supplied into the groove 424 formed on the upper surface of the core 421 and into the cavity 425 for forming the door trim lower 30. In addition, guide posts 426 that serve as a guide mechanism protrude from the four corners of the molded lower mold 42, and the guide posts 426 guide into the guide bush 413 when the molded upper and lower molds 41 and 42 are clamped. As a result, the pressing posture of the molding upper die 41 can be properly maintained.

  When the molding upper mold 41 and the molding lower mold 42 are in the mold open state, the foamed resin sheet S that is the material of the foamed resin base material 21 and the resin plate 24 are set in the mold. As shown, a narrow groove-shaped space 427 is formed in the molded lower mold 42 corresponding to the rigidity-enhanced portion A, such as the armrest 12 and the waist, and this space 427 is formed with the resin rib 22 formed therein. Is inserted into the groove portion 424.

  Next, each step in which the method of the present invention is applied to a method for manufacturing a two-tone type automobile door trim 10 will be described with reference to FIGS. First, as shown in FIG. 7, the foamed resin sheet S is heated and softened by a heater device 50 such as an infrared heater and put into a molding die 40 in a mold open state. As described above, the decorating material 23 is laminated on one surface of the foamed resin sheet S. 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. Further, the foamed resin sheet S is set at the upper half of the cavity defined by the cavity portion 411 of the molding upper die 41 and the core portion 421 of the molding lower die 42 at the location corresponding to the door trim upper 20 (FIG. 8). reference). Further, as shown in FIG. 9, the resin plate 24 is set in the void 427 of the molded lower mold 42 before the foamed resin sheet S is introduced.

Then, after setting the resin plate 24 and the foamed resin sheet S, the elevating cylinder 412 of the molding upper die 41 is operated, and the molding upper die 41 is lowered by a predetermined stroke, as shown in FIGS. The upper and lower molds 41 and 42 are clamped, the foamed resin sheet S is shaped along a desired mold surface shape, the foamed resin base material 21 is molded into a required shape, and the top surface of the foamed resin base material 21 The decorative material 23 is integrated. At this time, the molding upper and lower molds 41 and 42, is carried out molding at a low pressure press 0~40kgf / cm ^2, it is possible to halve the pressing pressure compared to the pressing pressure 80 ± 20kgf / cm ² conventional press molding , The load required for molding can be reduced.

  Then, after the foamed resin base material 21 and the decorating material 23 are integrally press-molded by clamping the molding upper and lower molds 41, 42, as shown in FIGS. 12 and 13, the manifold 422a, In order to form the resin rib 22 in the door trim upper 20 through the gate 423a, the molten resin M1 is injected and filled into the groove portion 424. At this time, compared to the conventional resin core material having a large projected area, the resin injection is sufficient to form the hollow resin ribs 22, so that the injection pressure of the resin can be lowered and the injection pressure can be overcome. It is not necessary to apply a high press pressure to the molding upper die 41, and it is only necessary to apply a press pressure sufficient to form the foamed resin base material 21 and the decorating material 23. It is possible to effectively solve the problem of falling over. In addition, the molten resin M1 flows into both end edges 24a of the resin plate 24, and the resin plate 24 is firmly supported and fixed by the resin ribs 22.

  Thus, in the present invention, since the rigidity of the foamed resin base material 21 can be strengthened by the resin plate 24, the pattern shape of the resin rib 22 can be simplified, and the mold flexibility of the molding die 40 can be increased. It has the advantage that the number of gates can be improved and the mold cost can be reduced. The injection timing of the molten resin M1 can be set before the mold upper and lower molds 41 and 42 are clamped. Further, as the molten resin M1, a resin in which talc is mixed at an appropriate ratio using Sumitomo Noblen BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min) is used. Then, as described above, after the integral press molding of the foamed resin base material 21 and the decorating material 23, the molding of the door trim upper 20 is completed by integrally molding the resin rib 22 on the back surface side of the foamed resin base material 21.

  Simultaneously with the molding of the door trim upper 20, in order to mold the door trim lower 30, the molten resin M2 is injected and filled into the cavity 425 for molding the door trim lower 30 through the manifold 422 b and the gate 423 b from the second injection machine 43 b. Lower 30 is formed into a required shape. In this embodiment, the molten resin M2 used as the material of the door trim lower 30 is Sumitomo Nobrene BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min). In comparison, since the door trim lower 30 appears on the surface of the product, the appearance performance may be improved by mixing the pigment or the like to give a desired color, or by engraving the surface on the surface.

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

  Next, FIGS. 14 to 16 show a modification of the present invention. As shown in FIG. 14, in this modification, in the structure of the joint between the foamed resin base material 21 and the resin plate 24, the resin Resin molding portions 25 are provided at appropriate pitch intervals on the edge of the foam resin base material 21 side of the plate 24, and the resin plate 24 is firmly fixed to the back surface of the foam resin base material 21 by the resin molding portion 25. Has been. In order to achieve the structure shown in FIG. 14, the resin plate 24 is provided with recesses 26 at appropriate pitch intervals on the upper edge as shown in FIG. The resin plate 24 is set in And as shown in FIG. 15, the laminated sheet material which laminated the decorating material 23 on the upper surface of the foamed resin sheet S from the upper side of the resin plate 24 is heat-softened with the heater apparatus which is not shown in figure, and is set from the upper side. Thereafter, as shown in FIG. 16, the molded upper and lower molds 41 and 42 are clamped to press-mold the foamed resin base material 21 into a required shape, and the molten resin M1 is supplied into the groove 424 of the molded lower mold 42. At that time, the molten resin M1 also flows into the concave portion 26 of the resin plate 24 installed at the boundary portion between the resin plate 24 and the foamed resin base material 21, and is cooled and solidified as the resin molding portion 25, whereby the resin The plate 24 is firmly integrated with the back side of the foamed resin base material 21. And in this modification, the resin plate 24 for reinforcing rigidity can be more firmly integrated on the back surface of the foamed resin base material 21, and the quality performance can be improved.

  In the embodiment described above, the structure of the laminated structure according to the present invention is applied to the door trim upper 20 in the door trim 10 having the upper and lower divided structure. However, the entire door trim 10 may be formed of the laminated structure, and foaming is performed. If it is a laminated structure of resin base material 21, resin rib 22, and decorating material 23, it applies to all interior parts such as rear parcel shelf, floor trim, luggage trim, trunk trim, rear side trim, pillar garnish, roof trim, etc. be able to. Furthermore, the material and thickness of the resin plate 24 are not particularly limited.

It is a front view showing an example in which the present invention is applied to a two-tone type automobile door trim. It is the II-II sectional view taken on the line in FIG. It is a front view which shows the resin rib and door trim lower of the door trim upper in the door trim for motor vehicles shown in FIG. It is sectional drawing which shows the structure of the door trim upper in the door trim shown in FIG. It is a general view which shows the shaping | molding die used for shaping | molding of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the set part of the resin plate 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 for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process of the decorating material in the manufacturing method of the door trim for motor vehicles shown in FIG. 1, and a foamed resin sheet. It is explanatory drawing which shows the setting process of the resin plate in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the resin plate in the formation process of the foamed resin base material shown in FIG. It is explanatory drawing which shows the formation process of the resin rib of a door trim upper and the door trim lower in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the connection relation with the resin plate in the formation process of the resin rib shown in FIG. It is sectional drawing which shows the modification of the door trim to which this invention is applied. It is explanatory drawing which shows the setting process of the resin plate in the manufacturing method of the door trim shown in FIG. It is explanatory drawing which shows the integration process of the resin plate and the resin rib in the manufacturing method of the door trim shown in FIG. It is a front view which shows the conventional door trim. It is the XVIII-XVIII sectional view taken on the line in FIG. It is explanatory drawing which shows the shaping | molding method of the conventional door trim.

Explanation of symbols

10 Automotive Door Trim 20 Door Trim Upper (Laminated Structure)
DESCRIPTION OF SYMBOLS 21 Foamed resin base material 22 Resin rib 23 Decorating material 23a Top layer 23b Cushion layer 24 Resin plate 24a Both-ends edge 25 Resin molding part 26 Concave part 30 Door trim lower (single resin product)
40 Molding mold 41 Molding upper mold 42 Molding lower mold 424 Groove (for resin rib molding)
425 Cavity (for door trim lower molding)
427 Empty space 43a, 43b Injection machine 50 Heater device A Stiffening part S Foamed resin sheet M1, M2 Molten resin

Claims (3)

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 laminated and integrated on the back surface of the foamed resin base material (21) In the interior part (10) for an automobile formed by adopting the laminated structure (20) as a whole or a part thereof,
A resin plate (24) having both end edges (24a) supported by resin ribs (22) is disposed on the back surface of the foamed resin base material (21) in the rigidity-enhanced portion (A) of the laminated structure (20). Automotive interior parts characterized by being made.   On the edge of the resin plate (24) facing the foamed resin substrate (21), recesses (26) are provided at appropriate pitch intervals, and the molten resin (M1) that is the material of the resin rib (22) When the resin is injected and filled, the molten resin (M1) flows into the recess (26) to form the resin molded portion (25), whereby the resin plate (24) is formed on the back surface of the foamed resin substrate (21). The interior part for automobiles according to claim 1, which is firmly integrated. A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21), and a resin plate (24) In the manufacturing method of the interior part (10) for automobiles formed by using the laminated structure (20) consisting of
In the manufacturing method of the laminated structure (20), when the molded upper and lower molds (41, 42) are opened, the resin plate (24) is accommodated in the space (427) of the molded lower mold (42), and A step of setting the material to be set in the molded upper and lower molds (41, 42) after preliminarily heat-softening the foamed resin sheet (S) which is the material of the foamed resin base material (21);
A foamed resin base that press-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). Forming the material (21);
The molded upper and lower molds (41, 42) are clamped, and the molten resin (M1) is injected and filled into the groove (424) of the molded lower mold (42) from the injection machine (43a), and the foamed resin base material (21). A resin rib (22) having a predetermined pattern shape on the back surface of the resin plate (24), and molding the resin rib (22) to support both end edges (24a) of the resin plate (24) by the resin rib (22);
The manufacturing method of the interior component for motor vehicles characterized by including the process which consists of these.

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