JP2008080885A - Automotive interior part - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To attain light weight of a product, to strengthen rigidity and to maintain a good appearance performance in an automotive interior part including a laminated layer structure body in at least one part. <P>SOLUTION: A door trim 10 is constituted by the laminated layer structure body (door trim upper) 20 in which a resin rib 22 is superposed/integrated on a back surface of a light weight foam resin base material 21 having shape-retaining property; and a resin single substance article (door trim lower) 30. By integrating a fiber-reinforced sheet on at least one surface of a front surface or a back surface of the foam resin base material 21, rigidity required for the product is ensured and it is prevented that thermal damage in molding of the resin rib 22 affects the foam resin base material 21 and a decoration material 23. Further, by reducing a burden on the resin rib 22, molding freedom of the resin rib 22 is enhanced 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. Related to automotive interior parts.

  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. . 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 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. 14, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state, but 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.

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 interior parts for automobiles that can promote weight reduction and contribute to cost reduction, and in particular, enhance the appearance and feel of the product surface. An object of the present invention is to provide automobile interior parts that can be used.

  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. As a result, compared to conventional resin cores with a large projected area, the projected area of the resin rib can be reduced, and it is possible to provide interior trim parts that are lightweight and inexpensive. Focusing on the fact that by increasing the rigidity of the material, deformation and surface sinks can be eliminated, and various effects can be expected, such as a wider range of choices for resin rib modeling patterns, and the present invention has been completed. This has led to the.

  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. An interior part for an automobile in which the body is employed in whole or in part is characterized in that a fiber reinforced sheet is integrated on at least one surface side of the foamed resin base material in the laminated structure.

  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.

Furthermore, the fiber reinforced sheet laminated on at least one side of the front and back surfaces of the foamed resin base material is a non-woven sheet made of natural fibers such as bamboo, basalt, kenaf, and fibers such as glass fibers and carbon fibers. Is done. The nonwoven fabric sheet preferably has a basis weight of 10 to 200 g / m ² and a thickness of 0.1 to 1.0 mm. And as this nonwoven fabric sheet, it should just have the property which can strengthen rigidity first, but it considers recyclability and heat insulation, and is selected. The fiber reinforced sheet may be laminated on the entire surface of at least one side of the front and back surfaces of the foamed resin base material, or may be partially laminated on a portion where the rigidity is desired to be reinforced.

  And in order to improve an external appearance design property, you may laminate | stack and integrate a decorating material on the surface of a 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. It is also possible to use a laminated sheet material in which a foam sheet such as polyurethane foam, polyethylene foam, polypropylene foam or the like is integrated as a cushion layer on the back surface of these thermoplastic resin sheets and fabric sheets.

  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. The material supplied to the molding die may be a laminate of a foamed resin sheet, which is a material of the foamed resin base material, and a decorative material, and the decorative material and the foamed resin sheet are molded into a mold. They may be stacked and set in the mold and integrated during molding. Further, the fiber reinforced sheet laminated on at least the front and back sides of the foamed resin sheet can be laminated at the same time when the foamed resin sheet is extruded, but the foamed resin sheet and the fiber reinforced sheet are formed after molding by a hot melt film. Lamination may be performed.

  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.

  Furthermore, since the fiber reinforced sheet is integrated on at least one of the front and back surfaces of the foamed resin base material, the rigidity can be strengthened, and in particular, the fiber reinforced sheet is provided between the foamed resin base material and the resin rib. If placed, the fiber-reinforced sheet can ease the adverse effects of heat during resin rib molding and excessive stress associated with shrinkage distortion during molding, so the surface appearance of the product can be maintained well, Since the rigidity can be enhanced, the amount of resin ribs can be reduced, the degree of freedom in design can be increased, and the number of gates can be reduced.

  As described above, according to the automotive interior part of the present invention, the foamed resin base material that is lightweight and has shape retention, and the resin rib having a predetermined pattern shape laminated and integrated on the back surface of the foamed resin base material A laminated structure is constructed from the above, and a fiber reinforced sheet is laminated on at least one of the front and back surfaces of the foamed resin base material. And low-cost interior parts for automobiles can be provided.

  Furthermore, since the interior parts for automobiles according to the present invention are integrated with a fiber reinforced sheet that reinforces rigidity on at least one of the front surface or the back surface of the foamed resin base material, even when external stress is applied, There are no defects such as breakage, and when molding resin ribs molded by injection filling with molten resin, adverse effects such as heat and shrinkage distortion can be eliminated with fiber reinforced sheets, eliminating surface defects such as sink marks, and appearance quality Since the performance can be enhanced and the rigidity can be strengthened, the thickness and pattern shape of the resin rib can be simplified, the degree of design freedom can be increased, the number of gates can be reduced, and the mold structure can also be simplified. Have.

  Hereinafter, a preferred embodiment of an automobile interior part according to the present invention will be described by illustrating an automobile door trim. 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 11 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 door trim for the automobile, and FIG. 3 is a door trim for the automobile. 4 is a front view showing a resin rib and a door trim lower of the door trim upper in FIG. 4, FIG. 4 is an overall view showing a molding die used for the door trim for the automobile, and FIG. 5 is a foamed resin sheet used for the door trim upper in the automobile door trim. FIG. 6 to FIG. 9 are explanatory views showing respective steps of the manufacturing method of the automobile door trim, and FIG. 10 and FIG. 11 are explanatory views showing modified examples of the door trim. It is.

  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 components to be mounted on the door trim 10, an inside handle escutcheon 11 and a power window switch escutcheon 12 are attached to the door trim upper 20. On the other hand, the door trim lower 30 is provided with a door pocket opening 13, and a pocket back cover (made of a resin molded body) 14 is attached to the rear side of the door trim lower 30, as shown in FIG. The speaker grill 15 is formed integrally with or separately from the door trim lower 30 on the front side.

  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. Further, in this embodiment, a fiber reinforced sheet 24 for reinforcing rigidity is laminated on the back surface of the foamed resin base material 21. In the figure, reference numeral 16 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 portions excluding the upper surface of the armrest, the upper surface of the waist portion, etc.) are thinned. 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.

  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. The fiber reinforced sheet 24 is made up of the resin core material that has been occupied over the entire circumference of the product as in the past, and the lightweight foamed resin base material 21 is used. The weight can be reduced as compared with the conventional example, 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, a structural feature of the present invention is that a fiber reinforced sheet 24 is laminated on the back surface of the foamed resin base material 21 in the door trim upper 20. The material of the fiber reinforced sheet 24 is bamboo. Natural fibers such as basalt and kenaf, or reinforcing fibers such as glass fibers and carbon fibers can be used, but natural fibers are preferred because of excellent recyclability and heat insulation. The basis weight of the fiber reinforced sheet 24 is preferably set in the range of 10 to ²⁰⁰ g / m ² and the thickness in the range of 0.1 to 1.0 mm. And since the foamed resin base material 21 is reinforced by the fiber reinforced sheet 24, it is possible to prevent the bending deformation of a portion to which a load is easily applied, such as an armrest or a waist part. Since the heat damage to the resin base material 21 and the decorating material 23 is blocked by the barrier function of the fiber reinforced sheet 24, there is no sink on the product surface, and conversely the pattern shape of the resin rib 22 By setting it freely, there is an advantage that it is excellent in modeling freedom.

  Next, an outline of a 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 and the decorating material 23 are put into the mold. In this embodiment, the foamed resin sheet S and the decorating material are used. 23, a raw material A in which a fiber reinforced sheet 24 is laminated in advance is used. The raw material A is heated and softened to 160 to 220 ° C. by the heater device 50 and then put into the molding die 40.

  The manufacturing process of the raw material A will be briefly described with reference to FIG. 5. When the foamed resin sheet S is extruded from the extruder 60, the decorating material 23 is supplied from the raw roll 62 to the surface side of the foamed resin sheet S. Furthermore, the fiber reinforced sheet 24 is supplied from the raw fabric roll 62 to the back surface side of the foamed resin sheet S, and the decorative material is applied to the front surface side of the foamed resin sheet S using the residual heat of the foamed resin sheet S by the pair of pressure rolls 63. 23, the raw material A is formed by integrating the fiber reinforced sheet 24 on the back side.

  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. 6, after the raw material A is heated and softened by a heater device 50 such as an infrared heater, it is put into a mold 40 in an open state as shown in FIG. As described above, in the raw material A, the decorating material 23 is laminated on one surface of the foamed resin sheet S, and the fiber reinforced sheet 24 is laminated on the other surface. 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. The raw material A is set in 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.

After the raw material A is set, the elevating cylinder 412 of the molding upper die 41 is operated, the molding upper die 41 is lowered by a predetermined stroke, and the molding upper and lower dies 41 and 42 are molded as shown in FIG. 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 decorating material 23 is integrated on the upper surface of the foamed resin base material 21. Is done. At this time, a pressing pressure of molding upper and lower dies 41, 42 is carried out molding at low pressure press 0~40kgf / cm ^2, half the press pressure than the pressing pressure 80 ± 20kgf / cm ² conventional press molding And the load on molding can be reduced.

  Furthermore, since the pressure is low at the time of press molding, when a squeezed resin sheet is used as the top layer 23a of the decorative material 23, thermal deformation such as squeezing flow on the product surface can be prevented as much as possible. In addition, even when a fabric sheet such as woven fabric, non-woven fabric, or knitted fabric is used as the top layer 23a, it is possible to effectively solve the problem of hair fall caused by excessive heating and high-pressure press, and feel and appearance Thus, the door trim upper 20 can be molded well.

  Then, as shown in FIG. 9, the foamed resin base material 21 and the decorative material 23 are integrally press-molded by clamping the molding upper and lower molds 41 and 42, and then from the first injection machine 43 a through the manifold 422 a and the gate 423 a. In order to form the resin rib 22 in the door trim upper 20, the molten resin M <b> 1 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.

  Furthermore, heat transfer from the molten resin M1 in a high temperature state is blocked by the fiber reinforced sheet 24, and the decorative material 23 is not damaged by heat, which is a major factor in maintaining good product appearance performance. ing. Further, the heat insulating action of the fiber reinforced sheet 24 allows the pattern shape of the resin rib 22 to be arbitrarily set, improves the mold freedom of the molding die 40 and reduces the number of gates, thereby reducing the die cost. It also has the advantage that it 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. 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.

  Thus, in the present invention, since the fiber reinforced sheet 24 is laminated on the back surface of the foamed resin base material 21, the rigidity of the door trim upper 20 can be strengthened, and there is a possibility that deformation defects may occur even after long-term use. In addition, since the quality performance can be improved and the heat insulation function is provided, the adverse effect of the heat from the molten resin M1 can be eliminated, the sink of the product surface does not occur, and the fiber reinforced sheet 24 Since the rigidity is reinforced by the above, there is an advantage that the arrangement of the resin ribs 22 can be minimized and the number of gates can be reduced.

  Although the Example mentioned above employ | adopted the structure which integrated the fiber reinforcement sheet | seat 24 in the back surface of the foamed resin base material 21, as shown in FIG. Although not shown, the fiber reinforced sheet 24 can be laminated on both the front and back surfaces of the foamed resin base material 21 if desired. Further, as shown in FIG. 11, the fiber reinforced sheet 24 laminated on at least one of the front surface and the back surface of the foamed resin base material 21 is partially only at a portion where the rigidity is to be reinforced, such as an armrest or a waist portion. It may be provided. And if the structure which integrates the fiber reinforced sheet 24A only in a rigidity reinforcement | strengthening part is employ | adopted, the cost reduction by reduction of material cost can be aimed at.

  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 structures. However, the entire door trim 10 may be formed of the laminated structure. In addition, in the case of a laminated structure composed of the foamed resin base material 21, the resin rib 22, and the decorating material 23, interior parts such as a rear parcel shelf, floor trim, luggage trim, trunk trim, rear side trim, pillar garnish, roof trim, etc. It can be applied in general.

  Further, in the example, the decorating material 23 and the fiber reinforced sheet 24 were integrated by the pressure-bonding roll by the residual heat of the foamed resin sheet S at the time of extrusion of the foamed resin sheet S, but after the foamed resin sheet S was extruded, You may make it integrate with the decorating material 23 and the fiber reinforced sheet | seat 24 by the lamination construction method.

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 a general view which shows the structure of the molding die used for the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the manufacturing process of the raw material which is a raw material of the door trim upper in the door trim for motor vehicles 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 formation process of the door trim upper 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 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 sectional drawing which shows the structure of the modification of the door trim for motor vehicles to which this invention is applied. It is a front view which shows the further modification of the door trim for motor vehicles to which this invention is applied. It is a front view which shows the conventional door trim. FIG. 13 is a sectional view taken along line XIII-XIII in FIG. 12. It is 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)
21 Foamed resin base material 22 Resin rib 23 Decorating material 23a Top layer 23b Cushion layer 24, 24A Fiber reinforced sheet 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)
43a, 43b Injection machine 50 Heater device 60 Extruder 61, 62 Raw roll 63 Press roll A Raw material 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,
An automobile interior part, wherein a fiber reinforced sheet (24) is integrated with at least one surface side of a foamed resin base material (21) in the laminated structure (20).   The said fiber reinforced sheet | seat (24) is excellent in heat insulation, and is comprised by the nonwoven fabric sheet | seat made from the natural fiber selected from the recyclable bamboo, basalt, and kenaf, The feature of Claim 1 characterized by the above-mentioned. Automotive interior parts.   The fiber reinforced sheet (24A) is integrated with at least one side of the front and back of the rigid reinforcement part of the foamed resin base material (21) in the laminated structure (20). The automotive interior part described.

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