JP2991363B2 - Manufacturing method and molding die for automotive interior parts - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing interior parts for automobiles such as door trims for automobiles, and a mold for mold press molding used in the production method.

[0002]

2. Description of the Related Art FIG. 9 is a cross-sectional view showing an automobile door trim, which is one of interior parts for automobiles. The automobile door trim 1 is formed into a desired curved shape, and has a shape retaining property and a shape to be applied to a body panel. A skin material 3 for imparting decorativeness and cushioning property is integrally attached to a surface of a resin core material 2 having mounting rigidity.

[0003] Normally, the door trim 1 is provided with an opening 4a for attaching a speaker grill 4 and an opening (not shown) for attaching an inside handle.

Incidentally, recently, as a molding method of the resin core material 2, a mold press molding method tends to be frequently used.

In this mold press molding method, a molten resin material is distributed and supplied into an upper mold and a lower mold for mold press molding, and an upper and lower mold is clamped to obtain an interior part with less material loss and excellent moldability. Is possible.

The manufacturing process of the door trim 1 shown in FIG. 9 will be briefly described with reference to FIGS. 10 and 11. First, as shown in FIG.
In 5b, at the same time as the resin core material 2 is subjected to mold press molding, the skin material 3 is integrally attached to the surface side of the resin core material 2.

[0007] The supply mechanism of the resin core material 2 is performed through an injection molding machine 6 connected to the lower mold 5a.

Next, as shown in FIG. 11, the upper piercing die 7b is lowered with respect to the door trim 1 set on the lower piercing die 7a, and opened by the cutting blade 8 attached to the upper piercing die 7b. 4a is stamped.

Then, the speaker grill 4 is inserted into the opening 4a.
By attaching other components such as the above, the automobile door trim 1 shown in FIG. 9 is obtained.

[0010]

As described above, in the conventional mold press molding method, the resin core 2 and the skin 3
When molding is integrally formed, the opening 4a is formed at the time of mold press molding.
Cannot be formed at the same time, and the resin core material 2 and the skin material 3 are simultaneously punched out separately in a piercing process.

[0011] Therefore, it is pointed out that the number of steps is increased and a die facility for piercing is required, thereby significantly increasing the production cost.

Further, in the case of the conventional method, for example, an opening 4a for attaching the speaker grill 4 will be described. Since the opening 4a is formed by the piercing dies 7a and 7b, the resin core material 2 and the skin material 3 are formed. But at the same time cutting blade 8
As a result, the cutting edge of the periphery of the opening 4a is visible to the outside. Therefore, it is necessary to cover the cutting edge with the peripheral flange of the speaker grill 4.
If the peripheral material 3 at the peripheral edge of the opening 4a is not held with an appropriate pressing force by the peripheral flange, there may be a problem that the peripheral material 3 at the peripheral portion of the opening 4a may be turned up or peeled off.

The present invention has been made in view of such circumstances, and is directed to a method of manufacturing an automobile interior component having an opening for mounting another component such as a speaker grill, and a molding die used in the method. In order to provide a method for manufacturing interior parts for automobiles and a mold for press molding, which can shorten the manufacturing process and simplify the equipment and make it possible to keep the appearance of the opening periphery good. I have.

[0014]

In order to achieve the above object, according to the present invention, a skin material is integrally adhered to the surface of a resin core material, and another component is attached to an opening formed at a predetermined site. In the method for manufacturing interior parts for automobiles, the upper mold for press molding with the skin material set down is lowered to engage with the lower mold for press molding formed by attaching a spacer block at a predetermined position, Mold press molding of molten resin distributed and supplied on the mold surface to form a resin core material with an opening at a position equivalent to the spacer block, and a skin material is adhered to the surface of this resin core material to integrate it. Forming process, a skin material that forms a slit or an opening slightly smaller than the opening in the skin material located at the opening of the resin core material, and wraps the periphery of the opening in the skin material on the back side of the resin core material and fixes it And the opening end treatment step, characterized the separate parts of the mounting step of fitting the separate parts fixed in an opening device of the skin material has been processed, in that it consists of.

Further, the mold press molding die used in the method of the present invention comprises a mold press molding upper and lower mold, and the lower mold press molding die is provided with a vertically movable spacer block. The block is always urged upward by a spring or a cylinder, and the lower die moves to contact the upper die.
After the molten resin is supplied, the spacer block is
It is characterized in that it descends following the descending operation, and an opening equal to the cross-sectional area of the spacer block is opened in the resin core material.

[0016]

As is apparent from the above configuration, the upper mold for mold press molding in which the skin material has been set in advance is moved down by a predetermined stroke to supply the molten resin to the upper mold for mold press molding. The skin material is sealed between the installed spacer block and the upper die.

Then, as the upper die further descends to the bottom dead center, the spacer block correspondingly retreats into the lower die against the spring force of the spring or by the lowering operation of the cylinder, and the spacer block is cut off. A cavity shape with an opening equal to the area formed is formed, and the resin core material is molded and pressed into a required shape, and the resin core material and the skin material are bonded together, and the resin core material is fixed at a predetermined position. Only the opening is formed.

Next, in the laminated molded product removed from the mold, a slit or a smaller opening is cut in a skin material portion corresponding to the opening of the resin core material, and the resultant is wound around and fixed to the back surface of the resin core material at the edge of the opening. In addition, the cut edge of the opening is not exposed to the outside, and there are no problems such as peeling or curling of the periphery of the opening of the skin material.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a method for manufacturing an automobile interior part according to the present invention will be described below in detail with reference to the accompanying drawings.

FIG. 1 is a front view showing an automobile door trim manufactured using the method of the present invention, FIG. 2 is a cross-sectional view showing the structure of the automobile door trim, and FIG. 3 is a mold press molding used in the method of the present invention. FIG. 4 to FIG. 7 are cross-sectional views showing respective steps of the method of the present invention, and FIG. 8 is a cross-sectional view showing another embodiment of a mold for mold press molding used in the method of the present invention. is there.

First, the structure of a door trim 10 for an automobile manufactured by the method of the present invention will be briefly described with reference to FIGS.

The door trim 10 for an automobile is composed of a resin core material 11 formed into a desired curved surface shape and a skin material 12 pressed and integrated on the surface thereof.
As No. 1, a polypropylene composite resin material obtained by mixing talc as a filler with a polypropylene resin is used, and as the skin material 12, a material having a good cushioning property with a polyethylene foam lined on the back surface of a PVC sheet is used.

Further, openings 15 and 16 for mounting a speaker grill 13 and an inside handle 14 attached to the door trim 10 for an automobile are opened.

The edges of the openings 15 and 16 are fixed by winding the ends of the skin material 12 around the back surface of the resin core material 11, and the edges of the openings 15 and 16 are subjected to beautiful edge treatment of the skin material 12. .

Therefore, the speaker grill 13 and the inside handle 14 attached to the openings 15 and 16 are provided.
In the case of the conventional method, it is possible to abolish an attempt of shaping to conceal the cut edge of the opening edge as in the related art.

Next, before describing the method of manufacturing the above-described automotive door trim 10, the configuration of the molding die 20 used in the method of the present invention will be described with reference to FIG.

The molding die 20 includes a lower mold press molding 30 having a desired mold surface shape, and an upper and lower mold press molding capable of engaging and clamping with the lower mold press molding 30. A mold 40, an injection molding machine 50 for supplying a molten resin as a material of the resin core material 11 onto the mold surface of the lower mold 30 for mold press molding, and an opening 13 provided in the lower mold 30 and opening the resin core material 11. Spacer block 60 to be opened
It is roughly composed of

More specifically, the lower mold 30 is supplied with the molten resin M supplied from the nozzle 51 of the injection molding machine 50.
A hot runner 31 and a plurality of gates 32 branching from the hot runner 31 are provided as a supply passage for supplying a predetermined position on the mold surface of the zero.

Further, the spacer block 60 is provided with the lower mold 30.
In the present embodiment, the spacer block 60 is always urged upward by the spring 61, and the upper die 40 is slidably accommodated in the accommodation space 33 formed in the upper die 40.
During the lowering operation, the mold surface of the upper mold 40 and the upper end face 60a of the spacer block 60 come into contact with each other and are pressed by the lower mold 40,
The spacer block 60 moves backward into the accommodation space 33, and when the upper die 40 is raised, the spacer block 60 is raised by the spring force of the spring 61.

Further, set pins 41 for holding the skin material 12 are provided at predetermined intervals on the outer periphery of the upper mold 40 for mold press molding.

Next, the manufacturing process of the door trim 10 for an automobile will be described step by step with reference to FIGS.

First, as shown in FIG. 4, the skin material 12 is set on the upper mold 40. At this time, the upper mold 40 is located at the uppermost position.

Similarly, the spacer block 60 is also raised to the uppermost position by the spring force of the spring 61.

When the setting of the skin material 12 is completed, the lifting device (not shown) is driven, and the upper die 40 for mold press molding is moved down by a predetermined stroke, so that the upper and lower dies 3 are moved.
Stop at the stage where the clearance of 0, 40 is 10 to 20 mm.

At this time, due to the lowering operation of the upper mold 40, the mold surface of the upper mold 40 (actually, the skin material 12 is interposed in the middle) and the upper end face 60a of the spacer block 60 come into contact with each other. The block 60 is pushed downward against the spring force of the spring 61.

At this stage, the nozzle 51 of the injection molding machine 50
Through the hot runner 31 and the gate 32, the molten resin M is distributed and supplied to a predetermined portion of the lower mold 30.

Thereafter, as shown in FIG. 6, the upper mold 40 starts lowering again, and the molten resin M is shaped by engaging and pressing the upper and lower molds 30 and 40 to form the resin core material 11 having a desired curved surface shape. While molding, the skin material 12 is integrated with the surface side of the resin core material 11.

At this time, the molten resin M is supplied to the upper and lower dies 30, 40.
An opening 15 equal to the cross-sectional area of the spacer block 60 is formed in the resin core material 11 in order to avoid the spacer block 60, while passing through the cavity formed therebetween.

Although not shown, a similar spacer block 60 is provided at a position corresponding to the opening 16 for attaching the inside handle 14.

As described above, only the opening 15 is formed on the resin core material 11 side with respect to the resin core material 11 and the skin material 12 formed by the mold press molding, and as shown in FIG. A slit 17 is opened in the skin material 12 corresponding to the opening 15 of the skin material 11, and the skin material 1 is formed based on the slit 17.
When the speaker grill 13 is attached to the opening 15 after being wound and fixed along the periphery of the opening 15 of the second 2, the manufacture of the automobile door trim 10 shown in FIGS. 1 and 2 is completed.

As described above, according to the method of the present invention, by attaching the vertically movable spacer block 60 to the lower mold 30 for mold press molding, the resin core material 11 and the skin material 1 are provided.
Since the opening 15 is formed only in the resin core material 11 at the time of the mold press molding with No. 2,
After the mold press molding, there is no need to separately perform piercing with a piercing die, so that the manufacturing process can be shortened and the mold equipment can be simplified.

Further, an opening 15 is formed only in the resin core material 11 by the method of the present invention, and a slit 17 or an opening slightly smaller than the opening 15 is formed in the skin material 12 so that the peripheral edge of the opening of the skin material 12 is If it is wrapped around and adhered to the side of the material 11, the cutting edge of the opening 15 will not be exposed as in the prior art, so that the degree of freedom in shaping the speaker grill 13 can be greatly eased, and the skin material 12 is formed around the opening edge. Conventional problems such as peeling off from the surface can be effectively solved.

FIG. 8 shows another embodiment of the molding die 20 used in the method of the present invention. In this embodiment, a hydraulic cylinder 62 or an air cylinder is used instead of the spring 61 of the above embodiment. This is an embodiment using a cylinder such as the above.

According to the present embodiment, the spacer block 60
Since the ascending operation and the descending operation are performed by driving the cylinder 62, there is no problem of deterioration of the spring 61, and there is an advantage that the smooth lifting and lowering operation of the spacer block 60 can be obtained even after long-term use.

Further, in the present invention, since the raising operation of the spacer block 60 can be used for the eject function, there is an additional effect that the number of eject pins can be reduced.

[0046]

As described above, according to the present invention, the following special effects can be obtained.

(1) According to the method of the present invention, a predetermined opening is formed in the resin core material during the mold press molding of the resin core material by installing a vertically movable spacer block in the lower mold for mold press molding. Therefore, unlike the conventional method, the piercing process is not performed by the piercing mold device after the mold press molding, so that the process can be shortened and the number of mold facilities can be reduced, which has an effect of causing a significant cost reduction. .

(2) According to the method of the present invention, at the time of mold press molding of a resin core material, an opening is opened only in the resin core material, and an opening is simultaneously formed in the resin core material and the skin material as in the conventional case. Since the edge of the skin material can be wound around the resin core material back side along the opening edge of the resin core material and fixed, and the cut edge is not exposed at the opening edge, it is not possible to form a separate part such as a speaker grill. Without the restrictions of
This has the effect that the degree of freedom in forming a separate part can be greatly improved.

(3) According to the method of the present invention, since the spacer block forming the opening in the resin core material is constantly urged upward, when the mold is opened after the mold press molding, the molded product is removed from the spacer block. As a result, there is an effect that the number of eject pins can be reduced by the eject effect.

[Brief description of the drawings]

FIG. 1 is a front view showing an automobile door trim manufactured using the method of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a sectional view showing a configuration of a mold press molding apparatus used in the method of the present invention.

FIG. 4 is a cross-sectional view showing one step of the method of the present invention and showing a step of setting a skin material.

FIG. 5 is a cross-sectional view showing one step of the method of the present invention and showing a supply step of a molten resin.

FIG. 6 is a cross-sectional view showing one step of the method of the present invention and showing a mold press molding step.

FIG. 7 is an explanatory view showing one step of the method of the present invention and showing a step of processing a peripheral edge of an opening of a skin material.

FIG. 8 is a sectional view showing a modified example of the mold press molding apparatus used in the method of the present invention.

FIG. 9 is a cross-sectional view showing a schematic configuration of a conventional automobile door trim.

FIG. 10 is a cross-sectional view showing a mold press molding step of a conventional automobile door trim.

FIG. 11 is a sectional view showing a piercing process of a conventional automobile door trim.

[Explanation of symbols]

 REFERENCE SIGNS LIST 10 Door trim for automobile 11 Resin core material 12 Skin material 13 Speaker grille 15, 16 opening 20 Mold press molding die 30 Mold press molding lower die 32 Gate 33 Housing space 40 Mold press molding upper die 41 Set pin 50 Injection molding Machine 60 Spacer block 61 Spring 62 Cylinder

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁶ , DB name) B29C 33/00-33/76 B29C 43/00-43/58

Claims (2)

(57) [Claims] 1. A skin material (12) on the surface of a resin core material (11).
And a separate part (13) is attached to an opening (15) opened at a predetermined location, and a method for manufacturing a mold press molding, wherein a skin material (12) is set. The upper die (40) is lowered, and a lower die (3) for mold press molding, in which a spacer block (60) is attached at a predetermined position.
0), the molten resin (M) distributed and supplied onto the mold surface of the lower mold (30) is subjected to mold press molding, and a resin core having an opening (15) at a position corresponding to the spacer block (60). The material (11) is formed and the resin core material (1) is formed.
1) A mold press molding step of attaching and integrating a skin material (12) on the surface, and a skin material (1) located at an opening (15) of the resin core material (11).
2) Forming a slit (17) or an opening slightly smaller than the opening (15) in the opening (15), and winding the periphery of the opening in the skin (12) to the back side of the resin core (11) and fixing the opening. And another part (1) in the opening (15) where the skin material ends are treated.
3) a process of mounting another component in which the component is fitted and fixed; 2. A molten resin (M) supplied onto a mold surface of a lower mold (30) for mold press molding is subjected to mold press molding by upper and lower molds (30, 40) for mold press molding to form a resin core material (11). ) Into a required shape, and a mold press molding die for molding an interior part for an automobile by integrally attaching a skin material (12) to the surface side of the resin core material (11). The lower mold (30) is provided with a vertically movable spacer block (60). The spacer block (60) is constantly urged upward by a spring (61) or a cylinder (62). The upper mold (40) is moved downward by the lowering motion of the upper mold (40).
After contact with the molten resin (M), the spacer block
(60) descends following the downward movement of the upper mold (40),
An opening (1) equal to the cross-sectional area of the spacer block (60)
5) A mold for mold press molding, wherein the mold is formed on a resin core material (11).