JP2008155574A - Trim part for vehicle and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent the appearance defectiveness caused by the shrinkage of a resin rib and to achieve weight reduction and cost reduction in a trim part for a vehicle which employs the whole or a part of a laminated structure composed of a foamed resin base material and the resin molded object integrated with the back side thereof, and its manufacturing method. <P>SOLUTION: A door trim 10 is constituted of a door trim upper (laminated structure) 20 and a door trim lower (resin single product) 30. The door trim upper 20 is constituted of a lightweight foamed resin base material 21 having shape retention and the resin molded object 22 integrated with the inner side thereof. The resin molded object 22 is constituted of the resin rib 24 and a resin flange 25, and by employing a hollow structure having a hollow part 26 formed in at least a part thereof, the shrinkage of the resin molded object 22 is absorbed by the hollow part 26 not only to eliminate appearance defectiveness but also to achieve weight reduction and cost reduction. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to automobile interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and manufacturing methods thereof, and is a light-weight automobile with improved appearance design and product rigidity. The present invention relates to interior parts for automobiles and methods for producing the same.

  For example, the configuration of automobile interior parts will be described with reference to FIGS. 16 and 17 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 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, considering the environmental and recycling aspects, a cushioning material such as polyethylene foam is provided on the back surface of an elastomer sheet such as a thermoplastic olefin (hereinafter referred to as TPO) sheet. 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 serving as a passage for the molten resin M 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.

  Accordingly, when the molding upper and lower molds 5 and 6 are in the mold open state, the skin 3 is set in the mold, the molding upper and lower molds 5 and 6 are clamped, and then the injection machine 7 is placed in the product cavity between both molds. The resin core material 2 is molded into a required curved shape by injection and filling the molten resin M through the manifold 6b and the gate 6c, and the skin 3 is integrally molded on the surface of the resin core material 2 (for example, patent Reference 1). In FIG. 18, 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, and the production cost of the mold is increased, In addition, since a large amount of molten resin is cooled and solidified, the molding cycle becomes longer, which is a major factor for reducing productivity.

  The present invention has been made in view of such circumstances, and relates to automotive interior parts such as door trims and a method for manufacturing the same. In particular, the present invention can promote weight reduction, reduce costs, and improve appearance quality and product rigidity. An object of the present invention is to provide an automotive interior part and a method for producing the same.

  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. A resin mold body such as a resin rib having excellent rigidity is arranged at a portion where rigidity is required, that is, a peripheral portion of a product, a panel, or a part mounting portion and a portion where a load is applied, so that a conventional projected area is wide. In addition to providing a laminated structure that is lighter and less expensive than a resin core material, and adopting a hollow structure for at least a part of this resin mold body, in addition to achieving a reduction in resin material, Focusing on the fact that the appearance performance can be satisfactorily maintained without appearance sink marks or rib traces, the present invention has been completed.

  That is, the present invention is an overall laminated structure composed of a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a resin mold body that is integrated on the back surface of the foamed resin base material. Alternatively, in an automotive interior part that is partially adopted, the foamed resin base material in the laminated structure is formed by drawing a heat-softened foamed resin sheet between the molding upper and lower molds, By injecting and filling molten resin into the groove of the lower mold, it is integrated with the back surface of the foamed resin base material, and a hollow portion is formed by injecting gas during injection and filling of the molten resin. Features.

  Here, the interior parts for automobiles can be applied to door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and the like. Further, the structure of the present invention can be applied to the entire interior parts for automobiles, and the structure of the present invention can also be applied to only a part of the interior parts for automobiles, for example, the door trim upper in the upper and lower divided door trims.

  Furthermore, the foamed resin base material having the shape retaining property can be obtained after the foamed resin sheet is heat-softened and then molded into a desired curved shape in a molding die, so that there is no reinforcing material such as a rib. , Has rigidity (shape retention) enough to retain the shape even when removed from the mold. 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.

  And in order to improve an external appearance design property, the decorating material may be laminated | stacked and integrated on the surface of the foamed resin base material. The decorating material is not limited, but is composed of a top layer that enhances the surface appearance and a laminated sheet material having a two-layer structure of cushioning layer that imparts cushioning performance. The top layer includes a TPO sheet and a thermostat. Synthetic resin sheets such as plastic urethane (TPU) sheets and PVC sheets, or fabric sheets such as woven fabrics, non-woven fabrics, and knitted fabrics can be used. As the cushion layer, polypropylene foam, polyethylene foam, polyurethane foam, etc. can be used. Can be used.

  On the other hand, the thermoplastic resin material used as the resin mold body can be appropriately selected from a wide range of thermoplastic resins. Usually preferred are 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.

  As the resin mold body, resin ribs having a predetermined pattern shape on the back surface of the foamed resin base material, for example, a grid-like pattern shape extending in the vertical and horizontal directions and oblique directions, and having a reduced projected area, A resin flange extending along the outer peripheral edge, a clip seat integrated with a part of the resin rib, a panel contact boss, and the like are applicable. And among these, the hollow part is provided in the resin rib or the resin flange. As this hollow part, when the resin mold body is injection-molded, the hollow part can be easily formed by adopting a gas injection method.

  And according to the interior parts for automobiles according to the present invention, since the resin mold body is integrated in the sense of reinforcing rigidity on the back side of the foamed resin base material having shape retention, the conventional resin The core material can be abolished. Therefore, by eliminating the conventional resin core material having a very large projected area, the weight of the product can be reduced and the resin material can be saved, so that the material cost can be reduced at the same time. In addition, the porous sound absorbing function of the foamed resin base material provides interior parts with excellent sound absorbing performance. When polyolefin resin is used as the material for the foamed resin base material and resin mold body, all-olefin resin is used. Since it is unified, the separation process can be abolished and the recycling work can be simplified.

  Furthermore, since the resin mold body has a hollow structure at least in part, the rigidity is enhanced, the amount of resin can be reduced, the weight can be reduced, and the material cost can be reduced. Particularly, since the influence of shrinkage strain of the resin mold body can be absorbed by the hollow portion, appearance defects such as appearance sink marks and rib traces do not occur.

  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 resin mold body that is integrated with the back surface of the foamed resin base material. In the manufacturing method of the interior part for automobiles, which employs the laminated structure consisting of the whole or a part thereof, the manufacturing method of the laminated structure is a molding in which the heat-softened foamed resin sheet is in a mold open state Foam resin that draws the foamed resin base material into the required shape along the cavity shape formed between the molded upper and lower molds by clamping the molded upper and lower molds by setting the foamed resin sheet to be set in the upper and lower molds The molding process of the base material and the upper and lower molds are clamped, and the molten resin is injected and filled into the groove of the lower mold from the injection machine, and then gas is injected from the spill-in mechanism into the groove. Characterized in that it consists of mechanism and the molding process of the resin molded body to integrate the resin molded body having a hollow portion by discharging the excess resin to the outside on the back a predetermined portion of the foamed resin base material.

  Here, the molding die used in the method for manufacturing automotive interior parts is 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 molten resin supplied from the injection machine is formed in the groove portion that is drilled in the mold surface of the molded lower mold through a resin passage such as a manifold and a gate provided in the molded lower mold. To be supplied.

  Furthermore, since the molding die according to the present invention employs a gas injection method, a spill-in mechanism is provided at one end of the groove and a spill-out mechanism is provided at the other end. As the spill-in mechanism part, a gas injection part connected to the air blow mechanism is provided, and as the spill-out mechanism part, a spill-out gate for discharging and storing surplus resin to the outside and a spill-out resin storage part are respectively provided in the mold. Is provided. If desired, a vacuum suction mechanism may be provided on the molding upper die, and the shape retention of the product shape is enhanced by applying a vacuum suction force from the molding upper die when drawing the foamed resin base material. At the same time, it is advantageous for transferring a drawn pattern or the like.

  Therefore, according to the method of the present invention, it is only necessary to mold a resin mold body such as a resin rib or a resin flange as compared with a conventional resin core material having a large projected area. Thus, the load on the upper mold can be reduced, 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.

  Furthermore, according to the method of the present invention, a hollow structure in which a hollow portion is formed is employed in at least a part of the resin mold body integrated on the back surface side of the foamed resin base material, thereby reducing weight and rigidity. In addition, the shrinkage distortion of the resin rib, resin flange, and the like can be absorbed by the hollow portion, so that the appearance performance can be remarkably improved without causing appearance sink or rib trace.

  As described above, according to the automotive interior part and the manufacturing method thereof according to the present invention, the laminated structure constituting the whole or a part of the automotive interior part is a foamed resin base that is lightweight and has shape retention. Because it is composed of a material and a resin molded body that is integrated with the back surface of the foamed resin base material, the conventional heavy resin core material can be eliminated, so it is lightweight, low-cost, and porous. Therefore, it is possible to provide interior parts for automobiles that are excellent in sound absorption performance. In addition, since a hollow structure is adopted for a part of the resin mold body, there is an effect that it is possible to further promote weight reduction and cost reduction.

  Furthermore, according to the interior parts for automobiles and the method for manufacturing the same according to the present invention, the foamed resin sheet is formed by drawing the foamed resin sheet by clamping the upper and lower molds, and the foamed resin base material is molded. After that, the molten resin is injected and filled into a predetermined pattern shape on the back side of the foamed resin base material, and at the same time, a hollow part is easily formed in the resin mold body. The shrinkage distortion at the time can be absorbed by the hollow part, the influence of the shrinkage distortion is not added to the foamed resin base material and the decorative material on the surface, and the appearance performance of the product surface can be maintained well. Has an effect.

  BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of an automobile interior part and a method for producing the same according to the present invention will be described in detail below by illustrating an automobile door trim and a method for producing the same. 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.

  FIGS. 1 to 15 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 same door trim for the automobile, and FIG. 4 is a front view showing a resin mold body of the door trim upper in FIG. 4, and FIG. 4 is a cross-sectional view showing the configuration of the main part of the door trim upper in the door trim for the automobile. 5 to 7 show a molding die used in the method of the present invention, which is a molding die for molding the door trim upper. FIG. 5 is a side view showing the entire configuration of the molding die, FIG. FIG. 7 is an explanatory view showing a spill-in mechanism and a spill-out mechanism in the same mold. Further, FIG. 8 to FIG. 12 are explanatory views showing each step of the method of the present invention, and FIG. 13 to FIG. 15 are respective explanatory views showing modifications of the automobile interior part according to the present invention.

  First, based on FIG. 1 thru | or FIG. 4, the structure of the two-tone type vehicle door trim 10 to which the structure of the interior component for motor vehicles which concerns on this invention is applied is demonstrated. The two-tone type automobile door trim 10 is composed of an upper and lower divided body including a door trim upper 20 made of a laminated structure and a door trim lower 30 made of a single resin. And as a functional component with which the door trim 10 is mounted | worn, the inside handle escutcheon 11 and the power window switch escutcheon 12 are attached to the door trim upper 20. FIG. Furthermore, the door trim lower 30 is provided with a door pocket opening 13, and on the back side thereof, as shown in FIG. 2, a pocket back cover (made of a resin molded body) 14 is attached. A speaker grill 15 is provided on the front side of the door trim lower 30 integrally with the door trim lower 30 or separately.

  By the way, the automotive door trim 10 according to the present invention is characterized by the structure of the door trim upper 20 formed of a laminated structure, and the weight of the product is reduced, and a good surface appearance and strong product rigidity are ensured. ing. 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 resin mold integrated with the back surface side of the foamed resin base material 21. The body 22 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. The decorative material 23 is made of a laminated sheet material in which a cushion layer 23b made of polypropylene foam is laminated on the back surface of the top layer 23a made of a TPO sheet.

  The foamed resin base material 21 has a shape after heat-softening treatment of the foamed resin sheet and heat molding into a required shape, for example, cold press molding with a molding die having a desired mold surface, so as to have shape retention. Is granted. 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 mold body 22 is a resin rib 24 that is thinned in a predetermined pattern shape over the entire back surface of the foamed resin base material 21, or a resin that is provided along the entire length or part of the peripheral edge of the foamed resin base material 21. A flange 25 and the like, which are not shown, include a panel abutting boss provided at the intersection of the resin ribs 24 and a clip mounting seat. The material of the resin mold body 22 is a general-purpose synthetic resin molded body to which reinforcing fibers such as glass fibers and natural fibers are added. As synthetic resins that can be preferably used, polyethylene resins, polypropylene resins, polystyrene resins , Polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. In the embodiment, a polypropylene resin is used in consideration of the environment and the recycling.

  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 which is a single synthetic resin, and has an excellent appearance design due to an accent effect on the appearance. It has sex. Further, the door trim upper 20 is composed of a foamed resin base material 21 having shape retention and a resin mold body 22 laminated and integrated on the back surface of the foamed resin base material 21, so that the entire surface of the product as in the prior art. The resin core material that has been occupied for a long time can be abolished and the lightweight foamed resin base material 21 is used, while the resin ribs 24 in the resin mold body 22 are bone-shaped, and a portion to which a load is applied, for example, a clip mounting seat The parts excluding the upper surface of the waist flange, armrest, etc. have a thinned structure, so that the weight of the product can be reduced by 40% or more compared to the conventional example, and the resin material is also used. It can save a lot and 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.

  Next, FIG. 4 is a cross-sectional view showing the configuration of the main part of the door trim upper 20. As described above, the door trim upper 20 is lightweight and has a shape retaining property, and is a foamed resin base material 21 molded into a required shape. A resin mold body 22 is integrated with the back surface of the foamed resin base material 21, and a decorative material 23 having cushioning properties is laminated on the surface of the foamed resin base material 21. And in the door trim upper 20 in this invention, the hollow part 26 is formed in the resin rib 24 which comprises a part of said resin mold body 22. As shown in FIG. Although a method for forming the hollow portion 26 will be described later, it can be easily formed by injecting a gas at the time of injection molding of the resin rib 24. Therefore, by forming the hollow portion 26, the resin rib 24 can be further reduced in weight, and the cost of the material can be saved. On the other hand, after the resin rib 24 is molded, even if shrinkage distortion occurs, Since these shrinkage strains can be absorbed by the hollow portion 26, defects such as appearance sink marks and rib traces do not occur on the surface of the decorating material 23, and the appearance performance can be maintained well. For joining the door trim upper 20 and the door trim lower 30 constituting the door trim 10, for example, a mounting boss is erected from the back side along the upper edge of the door trim lower 30, and a corresponding mounting hole of the door trim upper 20 is provided. After inserting the mounting boss into the interior, the two can be easily integrated by caulking.

  Next, the configuration of the molding die 40 used in the method for molding the door trim upper 20 in the door trim 10 will be described with reference to FIGS. In FIG. 5, a molding die 40 used for molding the door trim upper 20 includes a molding upper mold 41 that can move up and down by a predetermined stroke, a molding lower mold 42 that is paired with the molding upper mold 41, and a molding lower mold. And an injection machine 43 connected to 42. 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. Further, a manifold 422 and a gate 423 are provided to supply molten resin to the mold surface of the core portion 421. The molten resin M supplied from the injection machine 43 through the resin passages of the manifold 422 and gate 423 is provided. Is supplied to the upper surface of the core portion 421. In order to form the resin rib 24 or the resin flange 25, a groove portion 424 is formed on the upper surface of the core portion 421.

  In addition, guide posts 425 serving as a guide mechanism protrude from the four corners of the molding lower die 42. The guide posts 425 guide the molding upper die 41 when the molding upper and lower dies 41, 42 are clamped. Guided in the bush 413, the pressing posture of the molding upper die 41 can be properly maintained. Further, as shown in FIGS. 6 and 7, in order to form the hollow portion 26 in the resin rib 24 constituting a part of the resin mold body 22, one of the groove portions 424 of the molding lower mold 42 for forming the resin rib 24 is provided. A spill-in mechanism 44 is disposed on the end side, and a spill-out mechanism 45 is disposed on the other end side. In the spill-in mechanism 44, a supply pipe 442 connected to the blower 441 extends to the slit pin 443. The slit pin 443 functions as a gas injection unit, and gas is supplied into the molten resin M. On the other hand, the spillout mechanism 45 is provided with a spillout resin gate 451 and a spillout resin reservoir 452 for discharging and storing the spillout resin SA to the outside. Note that the spillout resin reservoir 452 is usually disposed outside the product cavity.

  Next, a method for forming the door trim upper 20 will be briefly described with reference to FIGS. First, as shown in FIG. 8, the heater device 50 heats and softens the laminate of the decorating material 23 on one surface of the foamed resin sheet S 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.

  Then, as shown in FIG. 9, the heat-softened foamed resin sheet S (with the decorative material 23 laminated) is defined by the cavity portion 411 of the molding upper die 41 and the core portion 421 of the molding lower die 42. Set in the cavity. If desired, the foamed resin sheet S and the decorating material 23 may be separately set in the molding die 40. Then, after setting the foamed resin sheet S, the lifting cylinder 412 of the molding upper die 41 is operated, the molding upper die 41 is lowered by a predetermined stroke, and the molding upper and lower dies 41 and 42 are clamped, and the foaming resin sheet S Is subjected to a primary pressure treatment that is shaped along a desired mold surface shape, and the foamed resin base material 21 is molded into a required shape (see FIG. 10). In the molding process of the foamed resin base material 21, although not shown, cooling air may be blown from the molding lower mold 42 side for forced cooling to speed up the cycle.

  Next, as shown in FIG. 11, the molten resin M is injected from the injection machine 43 into the groove portion 424 of the lower molding die 42 at the same time as or after the foaming resin base material 21 is drawn by the molding upper and lower molds 41 and 42. As the molten resin M, Sumitomo Nobrene BUE81E6 (manufactured by Sumitomo Chemical Co., Ltd., melt index = 80 g / 10 min) is used. In addition, although talc is mixed in the molten resin M in an appropriate proportion, other fillers can be used or no filler can be used.

  Then, as shown in FIG. 12, in the method of the present invention, molten resin M is injected and filled into the groove 424, and at the same time, gas is injected from the spill-in mechanism 44, and the spill-out resin SA is externally passed through the spill-out mechanism 45. It is possible to easily form the hollow portion 26 in the resin rib 24 by discharging the resin rib 24. Therefore, the hollow portion 26 can be easily formed in the resin rib 24 simply by disposing the spill-in mechanism portion 44 and the spill-out mechanism portion 45 in the molding die 40. By forming the hollow portion 26, the resin The shrinkage distortion at the time of forming the rib 24 is absorbed by the hollow portion 26, so that there is no sink or rib trace on the outer surface, and the smooth surface can be emphasized, and the rigidity can be increased and the weight can be reduced.

  FIG. 13 shows a modification in which the hollow portion 26 is formed in the resin flange 25 that forms a part of the resin mold body 22. In this case as well, although not shown at one end of the groove portion 424 of the molded lower mold 42. The spill-in mechanism 44 is provided with a spill-out mechanism 45 at the other end, and the molten resin M is injected and filled into the groove 424. At the same time, gas is injected into the interior by a gas injection method and hollowed into the resin flange 25. The portion 26 can be easily formed. As a result, the strength of the resin flange 25 that supports the door inner seal 16 can be increased, the cost can be reduced, and the appearance design of the surface of the waist portion can be enhanced.

  The embodiment described above is an embodiment applied to the upper and lower split type door trim 10 including the door trim upper 20 and the door trim lower 30, but as shown in FIGS. 14 and 15, an integrated automobile door trim 100. Can be applied to. This one-piece automobile door trim 100 is molded into a desired curved surface, is lightweight and has a shape retaining property, and a foamed resin base material 21 is molded into a predetermined pattern on the back surface of the foamed resin base material 21 and integrated. Resin mold body 22 and decorative material 23 laminated on the entire surface of foamed resin base material 21. As in the above-described embodiment, resin mold body 22 includes resin rib 24 and resin flange. In this modification, a hollow portion 26 is formed in the resin rib 24 along the periphery of the pocket opening 13. Thus, the setting location of the hollow portion 26 can be appropriately changed according to the function required for the product.

  In the embodiment described above, the structure of the present invention and the method of the present invention are applied to the door trim upper 20 in the two-tone type automobile door trim 10 or the integrated automobile door trim 100. However, the interior parts other than the door trims 10, 100, for example, The structure and method of the present invention can be applied to all interior trims such as rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, and rear side trims. Moreover, in the Example, although the laminated body which laminated the decorating material 23 on the surface of the foamed resin base material 21 was used, the interior component of the low-cost structure type which performs printing processing and coating processing on the surface of the foamed resin base material 21 The structure of the present invention can also be adopted.

It is a front view which shows the Example which applied the interior component for motor vehicles which concerns on this invention to the door trim for two-tone type vehicles. It is the II-II sectional view taken on the line in FIG. It is a front view which shows the resin mold body and door trim lower after removing the foamed resin base material of the door trim upper in the door trim for motor vehicles shown in FIG. It is sectional drawing which shows the principal part structure 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 shaping die used for shaping | molding the door trim upper in the door trim shown in FIG. It is explanatory drawing which shows the spill-in mechanism part and spill-out mechanism part in the shaping die shown in FIG. It is sectional drawing which shows the arrangement | positioning relationship of the spill-in mechanism part and spill-out mechanism part in the shaping die shown in FIG. It is explanatory drawing which shows the pre-heating process of the foamed resin sheet in the molding method of the door trim upper in the door trim shown in FIG. It is explanatory drawing which shows the setting process of the foamed resin sheet in the molding method of the door trim upper in the door trim shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material in the molding method of the door trim upper in the door trim shown in FIG. It is explanatory drawing which shows the injection filling process of the molten resin in the molding method of the door trim upper in the door trim shown in FIG. It is explanatory drawing which shows the gas injection | pouring process in the molding method of the door trim upper in the door trim shown in FIG. It is sectional drawing which shows the modification of the door trim shown in FIG. 1 is a front view showing an integrated automobile door trim to which an automotive interior part according to the present invention is applied. It is the XV-XV sectional view taken on the line in FIG. It is a front view which shows the conventional door trim for motor vehicles. It is the XVII-XVII sectional view taken on the line in FIG. It is explanatory drawing of the shaping die used when shape | molding the conventional door trim.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Two-tone type vehicle door trim 100 Integrated vehicle door trim 11 Inside handle escutcheon 12 Power window switch escutcheon 13 Pocket opening 14 Pocket back cover 15 Speaker grill 16 Door inner seal 20 Door trim upper (laminated structure)
DESCRIPTION OF SYMBOLS 21 Foamed resin base material 22 Resin mold body 23 Decorating material 24 Resin rib 25 Resin flange 26 Hollow part 30 Door trim lower 40 Molding die 41 Molding upper mold 42 Molding lower mold 424 Groove part 43 Injection machine 44 Spill-in mechanism part 45 Spill-out mechanism 50 Heater device S Foamed resin sheet M Molten resin

Claims (3)

A laminated structure comprising a foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin mold body (22) integrated with the back surface of the foamed resin base material (21). In automotive interior parts (10) formed by adopting (20) in whole or in part,
In the foamed resin base material (21) in the laminated structure (20), the heat-softened foamed resin sheet (S) is drawn between the upper and lower molds (41, 42), while the resin mold body (22). ) Is integrated with the back surface of the foamed resin substrate (21) by injection-filling the molten resin (M) into the groove (424) of the molded lower mold (42), and the molten resin (M) An interior part for an automobile, wherein a hollow portion (26) is formed by injecting gas during injection filling. A laminated structure comprising a foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin mold body (22) integrated with the back surface of the foamed resin base material (21). In the manufacturing method of the interior part (10) for automobiles, wherein (20) is employed in whole or in part,
The manufacturing method of the laminated structure (20) includes the step of setting the foamed resin sheet (S) in which the heat-softened foamed resin sheet (S) is set in the molded upper and lower molds (41, 42) in the mold open state. When,
A foamed resin base that draw-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 mold upper and lower molds (41, 42) are clamped, and the molten resin (M) is injected and filled into the groove (424) of the molded lower mold (42) from the injection machine (43), and then the spill-in mechanism section (44). ) Into the groove portion (424), and the excess resin (SA) is discharged from the spill-out mechanism portion (45) to the outside, so that the resin mold body (22) having the hollow portion (26) is foamed resin. A molding step of a resin mold body (22) integrated with a predetermined portion of the back surface of the substrate (21);
A method for producing an interior part for an automobile, comprising: A laminated structure comprising a foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin mold body (22) integrated with the back surface of the foamed resin base material (21). A molding die (40) for molding (20),
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 the resin mold body (22). And an injection machine (43) for supplying a molten resin (M), which is a raw material, and the mold surface of a molding lower mold (42) is filled with a molten resin (M) for a resin mold body (22). And a spill-out mechanism (44) at one end of the groove (424) and a spill-out mechanism (45) at the other end. Molding mold.

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