JP2014111403A - Method of manufacturing vehicular interior member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a vehicular interior member such that when the vehicular interior member is manufactured using a laminate sheet, an unnecessary part after thermal formation can be correctly and easily removed, the rigidity of a part provided with a fitting part is enhanced, and deformation is hardly caused after the vehicular interior member is fitted to a vehicle body etc.SOLUTION: A laminate sheet 11 comprising a foamed sheet layer 13 and a skin material layer 15 is thermally molded to have a recessed cross section and an intermediate molding 21 having an inner surface formed of the foamed sheet layer 13 is formed; and a reinforcing member 31 which includes fitting parts 40, 41 for a vehicular interior member to connect both opposed side walls 22, 23 of the intermediate molding 21 is bonded to an inner surface of the intermediate molding 21, and then an unnecessary part 26 of an edge of the intermediate molding 21 is removed.

Description

  The present invention relates to a method for manufacturing a vehicle interior member formed by thermoforming from a laminated sheet of a foam sheet layer and a skin material layer.

  In recent years, interior parts for vehicles have begun to use laminated sheets of foamed sheet layers and skin layers formed by thermoforming such as vacuum forming, pressure forming, or press forming for further weight reduction. It was. The laminated sheet is formed by thermally laminating a skin material layer controlled to a predetermined thickness on a foam sheet layer that has been extruded in advance. Thermoforming is a molding method in which a heat-softened resin sheet is brought into close contact with one surface of a mold and cooled in that state.

  In the method for manufacturing an interior member for a vehicle using the laminated sheet, an unnecessary portion existing on the edge is removed from the intermediate molded body obtained by thermoforming. The unnecessary portion of the edge of the intermediate molded body is a portion that is located outside the mold surface of the mold during the thermoforming of the laminated sheet and used for holding the laminated sheet. However, the intermediate molded body obtained by thermoforming from the laminated sheet is less rigid than the injection molded body, so it is easily deformed during the removal operation of unnecessary parts, and it cannot be cut at the correct position due to undulations. The part that is made may meander. In addition, the attachment part to the vehicle body etc. is retrofitted to the vehicle interior member by adhesion etc., but the rigidity of the part where the attachment part is adhered etc. is insufficient and it can not be attached to the vehicle reliably, or it can be attached after attachment Deformation may occur near the area.

JP 2012-126349 A Japanese Patent Laid-Open No. 2005-67529

  The present invention has been made in view of the above problems, and when manufacturing an interior member for a vehicle using a laminated sheet composed of a skin material layer and a foamed sheet layer, the removal of unnecessary portions after thermoforming is correctly performed. A vehicle that can be easily performed, can increase the rigidity of the portion provided with the mounting portion, can securely mount the vehicle interior member to the vehicle body, etc., and hardly deforms near the mounting portion after mounting. It aims at providing the manufacturing method of the interior member for a vehicle.

  The invention of claim 1 is to form a laminated sheet comprising a foam sheet layer and a skin material layer into a concave cross-sectional shape by thermoforming, and to form an intermediate molded body whose inner surface is composed of the foam sheet layer, Then, in the method for manufacturing an interior member for a vehicle that removes an unnecessary portion protruding outward at an edge of the intermediate molded body, both side walls opposed to the intermediate molded body are provided with attachment portions for the vehicle interior member. The reinforcing member to be connected is adhered to the inner surface of the intermediate molded body, and then the unnecessary portion of the edge of the intermediate molded body is removed.

  According to a second aspect of the present invention, in the first aspect, the reinforcing member has a plurality of protrusions on a bonding surface with the inner surface of the intermediate molded body, and the reinforcing member is bonded to the inner surface of the intermediate molded body. The tip of the protrusion is brought into contact with the inner surface of the intermediate molded body, and the thickness of the adhesive between the inner surface of the intermediate molded body and the adhesive surface of the reinforcing member is made equal to the height of the protrusion. It is characterized by.

  According to a third aspect of the present invention, in the first or second aspect, the reinforcing member includes a base that is bonded to an inner surface between both side walls of the intermediate molded body and a side wall of the intermediate molded body that extends from both ends of the base. And ribs projecting from the base between the side portions on both sides.

  According to the present invention, the intermediate molded body is bonded to the inner surface of the intermediate molded body obtained by thermoforming the laminated sheet and the reinforcing members that connect the opposite side walls of the intermediate molded body are reinforced by the reinforcing member. In order to remove the unnecessary portion of the edge, it is possible to easily perform correct removal work while suppressing deformation of both side walls, and it is difficult to cause meandering at the cut portion. Furthermore, since the reinforcing member is provided with an attachment portion for the vehicle interior member, the rigidity of the vehicle interior member can be increased in the vicinity of the attachment portion, and the attachment to the vehicle body or the like can be performed reliably and easily, and the attachment portion after the attachment. Deformation is less likely to occur in the vicinity.

It is a perspective view of a part of intermediate fabrication object and reinforcing member concerning one embodiment of the present invention. It is the perspective view and sectional drawing of a reinforcement member. It is a perspective view which shows the state which bonded the reinforcement member to the intermediate molded object. FIG. 4 is a sectional view taken along line 4-4 of FIG. 3. It is sectional drawing of the vehicle interior member after an unnecessary part removal.

  The method for manufacturing a vehicle interior member of the present invention includes a step of forming an intermediate molded body by thermoforming a laminated sheet, a step of bonding a reinforcing member, and a step of removing unnecessary portions.

  An intermediate molded body 21 shown in FIG. 1 is obtained by shaping the laminated sheet 11 into a concave cross-sectional shape by thermoforming, and finally becomes a pillar garnish for a vehicle. The laminated sheet 11 is formed by laminating and integrating a foam sheet layer 13 and a skin material layer 15. The intermediate molded body 21 has an unnecessary portion 26 at the edge. The unnecessary portion 26 is a portion that is located outside the mold surface of the mold and used for holding the laminated sheet 11 during thermoforming, and generally remains on the entire circumference of the intermediate molded body 21. For the thermoforming, known vacuum forming, pressure forming, press forming, or the like is used. In the state where the laminated sheet 11 is heated and softened, the foamed sheet layer 13 side is brought into close contact with the mold surface and cooled in that state. Is done. The heating temperature for softening by heating is a temperature at which the laminated sheet can be softened, and is generally in the range of 120 to 200 ° C.

The foam sheet layer 13 is a portion corresponding to the base material of the vehicle interior member, and is made of a polypropylene resin foam. The foam sheet layer 13 preferably has a thickness of 2.0 to 5.0 mm and a density of 0.15 to 0.5 g / cm ³ .
The polypropylene resin foam is not particularly limited, and a known polypropylene resin foam can be used. For example, a polypropylene resin produced by melt-kneading a polypropylene resin mixed raw material composed of a polypropylene resin, a thermal decomposable foaming agent, a crosslinking agent, a crosslinking aid, and appropriate additives below the decomposition temperature of the foaming agent, and extrusion molding. Examples of the resin foam sheet and a polypropylene resin foam sheet in which an inert gas such as nitrogen or carbon dioxide (carbon dioxide) is dissolved in a supercritical state and foamed.

Examples of the polypropylene resins include propylene homopolymers, ethylene-propylene block copolymers, ethylene-propylene random copolymers, and those containing polyethylene.
Examples of the pyrolytic foaming agent include azodicarbonamide, hydrazide carbonamide, dinitrosopentamethytetramine and the like.
Examples of the crosslinking agent include organic peroxides such as dicumyl peroxide, tertiary butyl perbenzoate and ditertiary butyl peroxide.
Examples of the crosslinking aid include divinylbenzene, diallylbenzene, divinylnaphthalene, divinylnaphthalene, and polyethylene dimethacrylate.
Appropriate additives include weathering stabilizers, heat stabilizers, anti-aging agents, pigments, fillers, and the like.

  The skin material layer 15 is preferably a thermoplastic resin sheet. Although it does not specifically limit as a thermoplastic resin, Olefin resin sheets, such as a polypropylene resin, are more preferable. The skin material layer 15 is manufactured by a known thermoplastic resin film or sheet manufacturing method, for example, a melt extrusion molding method, a melt casting method, a calendar method, or the like. The thickness of the skin material layer 15 is preferably in the range of 0.1 to 0.5 mm.

  The laminated sheet 11 is manufactured by thermally laminating the skin material layer 15 on one surface of a foam sheet layer 13 having a predetermined thickness that has been extruded. The heat laminating method can be performed by a known method. For example, it can be carried out by superposing the skin material layer 15 on the surface of the foam sheet layer 13 that is continuously supplied in one direction, and applying pressure and heating with a hot roll from the skin material layer 15 side. The temperature of the hot roll is set to a temperature equal to or higher than the softening point of the skin material layer 15.

  In the step of bonding the reinforcing members, the reinforcing members 31 that connect the opposite side walls 22 and 23 of the intermediate molded body 21 are bonded to the inner surfaces 24a, 24b, and 24c of the intermediate molded body 21. The reinforcing member 31 is made of a resin such as polypropylene or polyethylene, and as shown in FIGS. 1 and 2, the base 32 and the base that are bonded to the inner surface 24a between the side walls 22 and 23 of the intermediate molded body 21. 32 has side portions 33 and 34 (shown as 2-B in FIG. 2) that extend from both ends of the intermediate molded body 21 and are bonded to the inner surfaces 24b and 24c of the side walls 22 and 23 of the intermediate molded body 21. Ribs 35, 36 project from the base portion 32 between the side portions 33, 34 on both sides of the reinforcing member 31. Due to the presence of the ribs 35 and 36, the reinforcing effect on the side walls 22 and 23 of the intermediate molded body 21 is further enhanced.

  The reinforcing member 31 has a plurality of protrusions 38 on bonding surfaces 37a, 37b, and 37c that are bonded to the inner surfaces 24a, 24b, and 24c of the intermediate molded body 21. When the reinforcing member 31 is bonded to the inner surfaces 24 a, 24 b, 24 c of the intermediate molded body 21, the protrusion 38 abuts the tips of the protruding portions 38 on the inner surfaces 24 a, 24 b, 24 c of the intermediate molded body 21. By doing so, the thickness of the adhesive between the inner surfaces 24a, 24b, 24c of the intermediate molded body 21 and the adhesive surfaces 37a, 37b, 37c of the reinforcing member 31 is made equal to the height of the protrusion 38, thereby The amount of adhesive is ensured to strengthen the adhesion between the reinforcing member 31 and the intermediate molded body 21. The height (protrusion height) of the protruding portion 38 from the bonding surfaces 37a, 37b, and 37c is appropriately determined, and an example is about 0.5 to 2 mm. Moreover, it is preferable that the protrusions 38 have an appropriate shape such as a columnar shape or a hemisphere, and a plurality of the protrusions 38 are provided on the bonding surfaces 37a, 37b, and 37c of the base portion 32 and the side portions 33 and 34.

  The reinforcing member 31 has attachment portions 40 and 41 for attaching the vehicle interior member to the vehicle body or the like inside the ends of the side portions 33 and 34. The attachment portions 40 and 41 are formed of locking claws or the like. Further, positioning assisting pieces 42 and 43 are provided outward on the outer sides of the end portions of the side portions 33 and 34. The positioning assisting pieces 42, 43 overlap the unnecessary portion 26 at the edge of the intermediate molded body 21 when the reinforcing member 31 is disposed on the inner surface of the intermediate molded body 21 for bonding. 31 prevents tilting and helps positioning.

  The reinforcement member 31 is bonded to the inner surfaces 24a, 24b, and 24c of the intermediate molded body 21 by any one of the adhesion surfaces 37a, 37b, and 37c of the reinforcing member 31 and the inner surfaces 24a, 24b, and 24c of the intermediate molded body 21. A predetermined amount of adhesive is applied to one or both by application or the like, and the reinforcing member 31 is pushed between the side walls 22 and 23 of the intermediate molded body 21. The positioning assisting pieces 42 and 43 of the reinforcing member 31 are overlaid on the unnecessary portion 26 at the edge of the intermediate molded body 21 and the tip of the protrusion 38 is abutted against the inner surfaces 24a, 24b and 24c of the intermediate molded body 21. Make contact. Thereby, the adhesive is pressed by the inner surfaces 24a, 24b, 24c of the intermediate molded body 21 and the adhesive surfaces 37a, 37b, 37c of the reinforcing member 31, and the inner surfaces 24a, 24b, 24c of the intermediate molded body 21 are The space between the reinforcing surface 31 and the adhesive surface 37 is filled with an adhesive, and the thickness of the adhesive is made equal to the height of the protrusion 38, and the adhesive is cured in this state. The adhesive is not particularly limited, but a hot melt adhesive is preferable. 3 and 4 show a state in which the reinforcing member 31 is bonded to the intermediate molded body 21. FIG. Reference numeral 47 is an adhesive.

  In the step of removing the unnecessary portion, as shown in FIG. 4, the unnecessary portion 26 at the edge of the intermediate molded body 21 to which the reinforcing member 31 is bonded is cut and removed by the cutting tool 61, and the vehicle interior member shown in FIG. Get 50. The cutting method can be appropriately selected from punching (press or Thomson), laser, water jet and the like. Reference numeral 49 indicates a main body portion obtained by removing the unnecessary portion 26 from the intermediate molded body 21. When the unnecessary portion 26 is cut and removed, in the portion where the positioning assisting pieces 42, 43 of the reinforcing member 31 overlap the unnecessary portion 26, the positioning assisting pieces 42, 43 at the excision position of the unnecessary portion 26. Also cut off. Since the rigidity of the intermediate molded body 21 is improved by the reinforcing member 31 during the removal operation of the unnecessary portion 26, the removal operation of the unnecessary portion 26 can be performed correctly and easily. It is difficult to cause meandering. Further, the manufactured vehicle interior member 50 is attached to a vehicle body or the like using the attachment portions 40 and 41 provided in the reinforcing member 31. At this time, since the vehicle interior member 50 has a high rigidity in the vicinity of the attachment portions 40 and 41 by the reinforcing member 31, the vehicle interior member 50 can be easily attached to a vehicle body and the like after the attachment. It is difficult to cause deformation.

  The manufacturing method of the present invention is not limited to the manufacturing method of the pillar garnish, and is also applied to the manufacture of other vehicle interior members having a concave cross-sectional shape, such as door trims.

DESCRIPTION OF SYMBOLS 11 Laminated sheet 13 Foamed sheet layer 15 Skin material layer 21 Intermediate molded object 22, 23 Side wall of intermediate molded object 24a, 24b, 24c Inner surface of intermediate molded object 26 Unnecessary part 31 Reinforcement member 32 Base 33, 34 Side part 35, 36 Rib 37a, 37b, 37c Adhesion surface 38 Protrusion 40, 41 Mounting portion 47 Adhesive 50 Interior member for vehicle

Claims (3)

A laminated sheet composed of a foam sheet layer and a skin material layer is shaped into a concave cross-sectional shape by thermoforming to form an intermediate molded body having an inner surface composed of the foam sheet layer, and then the intermediate molded body In the method for manufacturing an interior member for a vehicle that removes unnecessary portions protruding outward at the edge,
A reinforcing member provided with an attachment portion for the vehicle interior member and connecting opposite side walls of the intermediate molded body is bonded to the inner surface of the intermediate molded body, and then unnecessary portions of the edges of the intermediate molded body are removed. A method for manufacturing an interior member for a vehicle.   The reinforcing member has a plurality of protrusions on an adhesive surface with the inner surface of the intermediate molded body, and when the reinforcing member is bonded to the inner surface of the intermediate molded body, the tip of the protrusion is attached to the intermediate molded body. 2. The vehicle according to claim 1, wherein the thickness of the adhesive between the inner surface of the intermediate molded body and the adhesive surface of the reinforcing member is made equal to the height of the protrusion. Manufacturing method of interior member.   The reinforcing member has a base bonded to the inner surface between both side walls of the intermediate molded body, and side portions extending from both ends of the base and bonded to the inner wall of the intermediate molded body. The method for manufacturing an interior member for a vehicle according to claim 1, wherein a rib protrudes from the base portion between the side portions.

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