JP3132387B2 - Manufacturing method of interior materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a method for manufacturing an interior material. This manufacturing method is suitable, for example, when manufacturing an interior material such as an instrument panel having a dual airbag.

[0002]

2. Description of the Related Art In recent years, a vehicle with a so-called dual airbag has been developed which has an airbag for a driver's seat provided on a steering wheel and an airbag for a passenger's seat provided on a passenger side of an interior material. When this passenger airbag is provided on the passenger side of the instrument panel, as shown in FIG. 6, an airbag (not shown) is provided inside a rectangular lid 2 on the passenger side of the lid-integrated instrument panel 1. However, the lid 2 can be opened and deployed by instantaneous inflation of the airbag.

[0003] Such a lid-integrated instrument panel 1 can be manufactured by the following manufacturing method. That is,
First, in the arrangement step, the core material 3 and the skin material 4 shown in FIG. 7 are prepared. Here, a stitch 3 a may be formed on the core material 3 in an annular shape with the size of the lid 2. In addition, a soft PVC cover material 4 obtained by vacuum forming, powder slush forming, or the like may be formed with a groove 4a having a U-shaped cross section with a lid 2 that is formed in a ring shape and has a thin bottom. Then, the skin material 4 is arranged in a molding die (not shown), and the core material 3 is arranged so as to face the skin material 4. At this time, the groove 4a of the skin material 4 is made to protrude inward. After this,
In the molding step, the urethane foam material injected between the skin material 4 and the core material 3 is foamed to form a semi-rigid foamed polyurethane foam 5.

In the thus obtained lid-integrated instrument panel, before the airbag is inflated, the grooves 4a of the skin material 4 show the design when viewed from the indoor side, and when the airbag is inflated, the stitches of the core material 3 are stitched. 3a and groove 4 of skin material 4
Since the stress concentration is achieved by the fact that the bottom of a is thin, a portion surrounded by the groove 4a of the skin material 4, a portion surrounded by the stitch 3a of the core material 3, and a The lid 2 constituted by a part of the sandwiched polyurethane foam 5 is opened and expanded.

[0005]

However, when the interior material is manufactured in the same manner as in the above manufacturing method, the interior design due to the groove of the skin material is impaired. For example, in the lid-integrated instrument panel, as shown in FIG. 7, the grooves 4a of the skin material 4 are likely to fall down at random due to the foaming pressure of the urethane foam material, and the interior design before the inflation of the airbag is impaired. Would. The same applies to interior materials having grooves in the skin material from other necessity.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and it is an object of the present invention to make it possible to manufacture an interior material without impairing the interior design by a groove of a skin material.

[0007]

[Means for Solving the Problems]

(1) The method for manufacturing an interior material according to claim 1 includes the steps of:
Preparing a skin material having a U-shaped groove portion, arranging the skin material in the mold so that the groove portion protrudes inward, and arranging the core material facing the skin material. When,
Forming an interior material by foaming a urethane foam material injected between the skin material and the core material while supporting the side surface of the groove.

According to the first aspect of the present invention, the urethane foam raw material is foamed while supporting the side surface of the groove of the skin material.
The grooves are prevented from falling down randomly due to the foaming pressure of the urethane foam raw material. Therefore, according to the first aspect of the present invention, the interior material can be manufactured without impairing the interior design due to the groove of the skin material.

(2) In the method for manufacturing an interior material according to claim 2, in the manufacturing method according to claim 1, the slide core of the molding die is projected inward, and at least one of the grooves of the skin material is formed on the side surface of the slide core. Performing an arrangement step by supporting the side surfaces, injecting and foaming the urethane foam material in this state, and then performing a molding step by injecting and foaming the urethane foam material with the slide core drawn in outside. Features.

A manufacturing method according to a second aspect embodies the means according to the first aspect. The operation and effect will be described in an embodiment. (3) In the method for manufacturing an interior material according to a third aspect, in the manufacturing method according to the first aspect, the core material has a leg portion capable of supporting one side surface of the groove portion of the skin material and capable of passing urethane foam. An arrangement process is performed by supporting the side surface of the groove portion of the skin material with the leg portion of the core material, and a molding process is performed in this state.

[0011] The manufacturing method of claim 3 also embodies the means of claim 1. The operation and effect will be described in an embodiment. In the case of manufacturing an instrument panel having an airbag inside the lid, it is preferable that the tip of the leg of the core material according to the third aspect be sharpened. This is because the stress concentration of the skin material can be adjusted by adjusting the sharpness at the tip of the leg portion of the core material, whereby the opening and deployment of the lid when the airbag is inflated can be adjusted.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments 1 and 2 in which the inventions of claims 1 to 3 are embodied in a method for manufacturing a lid-integrated instrument panel will be described below with reference to the drawings. (Embodiment 1) In Embodiment 1, claims 1 and 2 are embodied.

[Arrangement Step] First, as shown in FIG. 1, a core material 10 having an opening 10a which is opened in the size of the lid 2 (see FIG. 6) and an inlet 10b is prepared. In addition, a skin material 11 made of a soft PVC, which is annular with the size of the lid 2 and has a groove portion 11a having a U-shaped cross section with a thin bottom portion, is prepared.

On the other hand, the upper mold 12, the lower mold 13, and the upper mold 12
A mold having a slide core 14 that slides inside is prepared. The upper mold 12 is formed with an injection path 12a for urethane foam raw material. In addition, the slide core 14 is
And the outer surface of the leading end has a size that can abut the inner surface of the groove 11a. The slide core 14 also has an injection path 14a for urethane foam material.

Then, the skin material 11 is arranged in the mold, and the core material 10 is arranged so as to face the skin material 11. At this time, the groove 11a of the skin material 11 is made to protrude inward. Further, the slide core 14 is protruded inward, and the groove 11a of the skin material 11 is formed on the outer surface of the tip of the slide core 14.
Support the inner surface of the. "Molding process" In this state, a urethane foam material is injected between the skin material 11 and the core material 10 from the injection path 12a and the injection port 10b, and the urethane foam material is foamed to form a semi-rigid polyurethane foam 15 (see FIG. 2). At this time, since the urethane foam material is foamed while supporting the inner surface of the groove 11a of the skin material 11 on the outer surface of the tip of the slide core 14, regardless of the foaming pressure of the urethane foam material,
The groove 11a is kept protruding in an upright state.

Thereafter, as shown in FIG. 2, the slide core 14 is retracted outward, and in this state, a urethane foam material is injected between the skin material 11 and the slide core 14 from the injection path 14a, and the urethane foam is injected. The raw material is foamed to form a rigid foamed polyurethane foam 16 (see FIG. 3). At this time, the foamed polyurethane foam 15 previously foamed
In order to foam the urethane foam material while supporting substantially the outer surface of the groove portion 11a of the skin material 11, the groove portion 11a is still protruded in an upright state regardless of the foaming pressure of the urethane foam material. .

Thus, as shown in FIG.
A lid-integrated instrument panel is obtained in which the groove portion 11a protrudes in an upright state. For this reason,
In the lid-integrated instrument panel, before inflating an airbag (not shown), the skin material 1 is viewed from the indoor side.
One groove 11a represents an excellent design. When the airbag is inflated, the opening 10 a of the core 10 and the groove 1 of the skin 11 are inflated.
Since the stress concentration is achieved by the fact that the bottom of 1a is thin and the foamed polyurethane foam 16 is harder than the foamed polyurethane foam 15, a portion surrounded by the groove 11a of the skin material 11, Opening 1 of core material 10
The lid 2 composed of Oa and the foamed polyurethane foam 16 is opened and expanded.

A core material (not shown) may be provided on the distal end surface of the slide core 14. (Embodiment 2) In Embodiment 2, claims 1 and 3 are embodied. "Arrangement Step" First, as shown in FIG. 4, the same core material 10 and skin material 11 as in the first embodiment are prepared. Further, as a part of the core material, a bottom portion 17 for closing the opening 10a of the core material 10 is provided.
a, and a second core member 17 including a leg portion 17d rising from the bottom portion 17a is prepared. A plurality of communication ports 17b penetrate the leg 17d of the second core member 17, and a sharply formed projection 17c is formed at the tip thereof.

On the other hand, a molding die having an upper die 18 and a lower die 19 is prepared. The upper mold 18 is formed with an injection passage 18a for urethane foam material. Then, the skin material 1 is placed in the mold.
1 and the core material 10 facing the skin material 11. At this time, the groove 11a of the skin material 11 is made to protrude inward. And the leg 17 of the second core 17
The bottom part 17a is arranged in the opening 10a so that d projects inward and supports the inner surface of the groove part 11a of the skin material 11.

[Molding Step] In this state, the skin material 11, the core material 10, and the second core material 17 are supplied from the injection path 18a and the injection port 10b.
And a foamed urethane raw material is injected between the raw materials to form a semi-rigid polyurethane foam 2
0 (see FIG. 5). At this time, the urethane foam raw material to be injected and foamed also becomes the foamed polyurethane foam 20 inside the second core material 17 through the plurality of communication ports 17b penetrating through the leg 17d. The leg 17d of the second core member 17
In order to foam the urethane foam material while supporting the inner surface of the groove portion 11a of the skin material 11, the groove portion 11a remains in an upright state regardless of the foaming pressure of the urethane foam material.

Thus, as shown in FIG.
A lid-integrated instrument panel is obtained in which the groove portion 11a protrudes in an upright state. For this reason,
In this lid-integrated instrument panel,
Before inflation of an airbag (not shown), the groove 11a of the skin material 11 shows an excellent design when viewed from the indoor side. When the airbag is inflated, stress concentration is achieved by the opening 10a of the core material 10 and the thin bottom of the groove 11a of the skin material 11, so that the airbag is surrounded by the groove 11a of the skin material 11. The lid 2 composed of the part, the bottom part 17a of the second core member 17, and a part of the foamed polyurethane foam 20 sandwiched between these parts is opened and unfolded. At this time, since the projections 17c formed at the tips of the legs 17d of the second core member 17 increase the stress concentration of the skin material 11, the lid 2
Release and deployment are adjusted.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a molding die and the like according to a first embodiment.

FIG. 2 is a cross-sectional view of a molding die and the like according to the first embodiment.

FIG. 3 is an enlarged sectional view similar to FIG. 7, showing the lid-integrated instrument panel according to the first embodiment;

FIG. 4 is a cross-sectional view of a molding die and the like according to the second embodiment.

FIG. 5 is an enlarged sectional view similar to FIG. 7, showing the lid-integrated instrument panel according to the second embodiment.

FIG. 6 is a perspective view of a lid-integrated instrument panel.

FIG. 7 is an enlarged sectional view taken along the line IIV-IIV of FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Lid integrated instrument panel 10, 17 ... Core material (17 ... 2nd core material) 11 ... Skin material 11a ... Groove part 12, 13, 14, 18, 19 ... Mold (12, 18 ...)
Upper mold, 13, 19 ... Lower mold, 14: Slide core) 15, 16, 20 ... Foamed polyurethane foam 17d ... Leg 17b ... Communication port 17c ... Projection

Continuation of the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B29C 39/10 B29C 39/22-39/36 B29C 33/12-33/18

Claims (3)

(57) [Claims] 1. A core material and a skin material having a U-shaped groove are prepared, and the skin material is arranged in a mold so that the groove projects inward. An arranging step of arranging the core material facing each other, and a molding step of obtaining an interior material by foaming the urethane foam material injected between the skin material and the core material while supporting the side surface of the groove. A method for producing an interior material, comprising: 2. A slide core of a molding die is projected inward,
An arrangement step is performed by supporting at least one side surface of the groove of the skin material on the side surface of the slide core. In this state, the urethane foam material is injected and foamed, and then the urethane foam is drawn in a state where the slide core is drawn out. The method for manufacturing an interior material according to claim 1, wherein the molding step is performed by injecting and foaming the raw material. 3. The core material has a leg which can support one side surface of the groove of the skin material and can pass urethane foam, and the leg of the core material defines a side surface of the groove of the skin material. 2. The method according to claim 1, wherein the placing step is performed by supporting, and the forming step is performed in this state.
A method for producing the interior material described above.