JP3303621B2 - Interior material and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an instrument panel for an automobile (hereinafter, simply referred to as "instrument panel").
The present invention relates to a manufacturing method for manufacturing an interior material such as a door trim in which a pad made of a skin material and a resin molding material is integrally fixed to a part of a base material. This manufacturing method is particularly characterized by the seal structure of the parting part of the interior material.

[0002]

2. Description of the Related Art As an interior material, for example, an instrument panel of an automobile, as shown in FIG. 6 , a pad 91 is integrally fixed to a part of a highly rigid base material 90 made of polypropylene (PP) or the like. Have been. Pad 91, X 6
As shown in FIG. 7 showing a cross section taken along the line VII-XVII, as shown in FIG. And a foam layer 91b made of polyurethane foam or the like. In this pad 91, a skin material 91a is arranged in a cavity of a mold, and a polyurethane foam stock solution is injected in this state,
It is formed by foaming and solidifying a polyurethane foam stock solution. At this time, a fastening member 92 having a necessary part to which a release material is applied is inserted in advance for assembling described later.

[0003] The pad 91 thus obtained is used as a base material 90.
After the burrs in the interference area with the base member 90 are removed, a fastening member 92 is attached to the base material 90 to form an instrument panel.

[0004]

However, when the interior material is manufactured by the above manufacturing method, for example, in the case of the instrument panel, for example, the skin material 91a is arranged in a mold, and the release material is applied to the fastening member 92. And a plurality of steps such as insertion of the fastening member 92 into the mold, injection of the urethane foam stock solution, deburring, and assembly. Therefore, such interior materials require a relatively long manufacturing cycle and a relatively high manufacturing cost.

[0005] Therefore, in order to shorten the manufacturing cycle and reduce the manufacturing cost, it is conceivable to adopt the manufacturing method shown in FIG. When the instrument panel is manufactured by this manufacturing method, first, a mold including the upper mold 80 and the lower mold 81 is prepared, and the base material 90 is arranged so as to face the lower end face 80a and the side face 80b forming the cavity of the upper mold 80. And an upper end surface 81 forming a cavity of the lower mold 81.
The central portion of the skin material 91a faces the surface material a, and the peripheral portion thereof is arranged to face the base material 90 covered by the side surface 80b. Thereby, the skin material 91a and the base material 90 are wrapped in the parting-off portion E. Hereinafter, the skin material 9 wrapped with the base material 90
The portion 1a is called a wrap portion 91c. Then, a urethane foam stock solution is injected from the center of the cavity, and the urethane foam stock solution is foamed.

At this time, the urethane foam stock solution presses the wrap portion 91c of the skin material 91a against the base material 90 as it foams in the direction indicated by the arrow A. Then, the urethane foam stock solution is further foamed to form a wrap portion 91c.
From between the wrap portion 91c and the base material 90 from the end portion. Thereafter, the urethane foam stock solution that has entered between the wrapping portion 91c and the base material 90 due to further foaming tends to leak to the parting portion E from between them, but the urethane foam stock solution inside the wrapping portion 91c moves from the A direction to the wrapping portion 91c. Base material 9
Since it is pressed to zero, its leakage is suppressed. When the foaming of the urethane foam stock solution is completed and solidified, the skin material 91 a is sealed to the base material 90 at the parting part E.

Thus, an instrument panel in which the base material 90 and the pad 91 made of the skin material 91a and the urethane foam 91b are integrated is obtained. However, in this method, the peripheral portion of the skin material 91a is not necessarily restricted when the urethane foam stock solution is injected. Therefore, in this method, as shown in FIG. 9 , there is a possibility that a gap may be formed in the parting-off portion E due to a slight shift in the installation position of the skin material 91a. Further, as shown in FIG. 10, the skin material 91
When the end of the peripheral portion of “a” is opened, there is a possibility that the parting-off portion E is greatly opened. In these cases, the urethane foam stock solution tends to excessively intrude between the wrap portion 91c of the skin material 91a and the base material 90. For this reason, the obtained instrument panel is likely to form burrs on the parting-off part E, and may have poor appearance. Further, in this method, the defective rate and the repair rate at the time of manufacturing are not sufficiently low, and the manufacturing efficiency is not always sufficient.

The present invention has been made in view of the above-mentioned conventional circumstances, and reliably realizes a reduction in a manufacturing cycle and a reduction in a manufacturing cost. An object of the present invention is to provide an interior material that is reliably sealed and has a good appearance, and a method for manufacturing the same.

[0009]

(1) The interior material according to claim 1 is a high-rigidity base material, a low-rigidity skin material fixed to a part of the base material at a wrap portion, and the base material. other pad composed has been a resin molding material filled between the back surface of the back surface and said surface skin material, a decorated member made of, the surface material is the La <br/>-up site Because it is formed thicker than the part
Wherein the Ri rigidity is enhanced.

In the interior material of the first aspect, since the shape retention of the wrap portion is increased when the resin molding material is injected, the resin molding material may excessively intrude between the wrap portion and the base material. Has been prevented.

[0011]

[0012]

[0013]

(2) The method for manufacturing an interior material according to claim 2 has a cavity in which a resin molding material is injected from a first direction to shape the interior material, and the cavity is substantially parallel to the first direction. The inner surface of the first mold and the second
A first step of preparing a mold formed having a second mold inner surface substantially parallel to the direction and continuous with the first mold inner surface, and a third mold inner surface facing the first mold inner surface; together arranged so as to face the substrate of the high rigidity and said type 1 inner surface and the second type inner surface, low rigidity to the portion facing the second type inner face of the third type inner and the substrate The second where the skin material is arranged facing each other
A step, by injecting the resin molding material from the first direction between the back of the portion facing the first type the inner surface of the back surface and the substrate of said surface skin material, in-mold the interior material Molded and formed of the skin material and the resin molding material.
To form a head and a manufacturing method of the interior material to be perforated and a third step of fixing the said surface skin material to the substrate, wherein the table
The skin material is formed so that the wrap part is thicker than other parts
Stiffness is enhanced by the presence of
The lap portion of the skin material which faces the substrate in step is in intimate contact with the substrate, wherein the are.

In the method of manufacturing an interior material according to a second aspect , in a first step, a resin molding material is injected from a first direction, and a mold having a cavity for shaping the interior material is prepared. The cavity has a first mold inner surface that is substantially parallel to the first direction, a second mold inner surface that is substantially parallel to a second direction that intersects the first direction, and is continuous with the first mold inner surface. It is formed to have an inner surface of the mold and an inner surface of the third mold facing the third mold.

Next, in a second step, a highly rigid base material is placed facing the inner surface of the first mold and the inner surface of the second mold. Further, a low-rigidity skin material is arranged to face the inner surface of the third mold and the portion of the base material facing the inner surface of the second mold.
At this time, the thick wrap portion of the skin material facing the base material is brought into close contact with the base material. In the third step, a molding material made of resin is injected between the back surface of the skin material and the back surface of a portion of the base material facing the inner surface of the first mold, and the molding is performed by in-mold molding. Composed of materials
A pad is formed and the skin material is fixed to the substrate .

At this time, the resin molding material presses the wrap portion of the skin material as it is filled, and presses the wrap portion against the base material. In addition, the resin molding material tends to penetrate between the wrap portion and the base material from the end of the wrap portion by filling. However, the wrap is thick
Since the rigidity is high, the wrap portion and the base material are in close contact with each other, so that the resin molding material is prevented from excessively entering between the wrap portion and the base material. Further, since the resin molding material inside presses the lap portion against the base material from the first direction, the resin molding material that has slightly entered does not leak from the parting-off portion. When the resin molding material is solidified, the skin material is sealed to the base material at a parting portion between the lap portion and the base material.

In the interior material thus obtained, burrs are less likely to be formed on the parting part, and the necessity of a deburring step is reduced, thereby reducing the defective rate and the rework rate at the time of manufacturing. In addition, since the interior material is formed by integrating the base material and the pad made of the skin material and the resin molding material, the conventional fastening member, mold release material and deburring are unnecessary, and the assembly is simple. Becomes

[0019]

[0020]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 in which the inventions of claims 1 and 2 are embodied in an instrument panel of an automobile and a method of manufacturing the same.
2 will be described with reference to the drawings. (Embodiment 1) Embodiment 1 embodies the first and second aspects of the present invention.

[First Step] First, as shown in FIG. 1, a polyurethane foam stock solution as a resin molding material is subjected to the first step.
Cavity C injected from direction A to shape instrument panel
A mold including a lower mold 3 and an upper mold 4 having the following is prepared. In the lower die 3, the upper end surface is a first die inner surface 3 a parallel to the first direction A, and a side surface continuous with the first die inner surface 3 a has an intersection angle of 90 ° or more with the first direction A. The second mold inner surface 3b is parallel to the second direction B having θ, and the mold surface 3c is formed parallel to the first mold inner surface 3a continuously with the second mold inner surface 3b.

In the upper mold 4, the lower end face is formed on the inner surface 3 of the first mold.
a third mold inner surface 4a opposed to the mold surface 4b.
Is formed in parallel with the third mold inner surface 4a continuously with the step. A cavity C is formed having the first mold inner surface 3a, the second mold inner surface 3b, and the third mold inner surface 4a. On the other hand, the skin material 2 is molded in advance by the two-layer slush molding method shown in FIG.

In this case, first, as shown in FIG.
Reservoir tank 5 with reservoir lower 5a standing upright
Is prepared, and an electroforming mold 6 having a predetermined shape is provided in the reservoir tank 5.
Is fixed. And, using a plastisol made of PVC,
After the steps of filling, heating, discharging, heating melting, and cooling, the first part of the skin material 2 is formed with the electroforming mold 6 inside the reservoir lower 5a.
The layer 2a is formed.

Thereafter, as shown in FIG. 2B, a jammer plate 5b is erected on the reservoir tank 5. This jam plate 5
In b, only the periphery of the first layer 2a of the skin material 2 is exposed, and the inside is shielded. Then, using the same plastisol again, through the same steps, the second layer 2b of the skin material 2 is formed with the electroforming mold 6 inside the reservoir lower 5a and outside the jammer plate 5b. In this way, the skin material 2 having a peripheral portion that is thickened by the first layer 2a and the second layer 2b and has increased rigidity is obtained.

[Second Step] As shown in FIG. 1, the PP base material 1 is disposed so as to face the first mold inner surface 3a, the second mold inner surface 3b, and the mold parting surface 3c. However, a primer or a paint is applied to the back surface of the substrate 1. Also, the third mold inner surface 4a
And the skin material 2 is disposed so as to face the portion of the base material 1 that faces the second mold inner surface 3b. At this time, in the parting-off part E, the periphery of the skin material 2 is wrapped around a portion of the base material 1 facing the second mold inner surface 3b. Then, the lower mold 3 and the upper mold 4 are clamped. At this time, the rigidity of the wrap portion 2c of the skin material 2 is increased by thickening, so that the wrap portion 2c comes into close contact with the portion of the base material 1 facing the second mold inner surface 3b.

"Third step" and the back surface of the skin material 2
The urethane foam stock solution is injected between the inner surface 3a of the first mold and the back surface of the portion facing the first mold in the base material 1 to perform in-mold molding. At this time, the urethane foam stock solution presses the wrap portion 2c of the skin material 2 as it foams in the first direction A, and presses the wrap portion 2c against the base material 1. Further, the urethane foam stock solution tends to enter between the wrap portion 2c and the base material 1 from the end 2d of the wrap portion 2c by foaming. However, since the wrap portion 2c is in close contact with the base material 1, excessive intrusion of the urethane foam stock solution between the wrap portion 2c and the base material 1 is prevented. Further, since the urethane foam stock solution inside presses the wrap portion 2c against the base material 1 from the first direction A, the urethane foam stock solution that has slightly entered does not leak from the parting-off portion E.

When the urethane foam stock solution completes foaming and solidifies, the parting portion E between the wrap portion 2c and the base material 1 is formed.
, The skin material 2 is sealed to the base material 1. FIG. 3 shows a perspective view of the obtained instrument panel and sectional views of various parts.
As shown in FIG. 3, this instrument panel had good appearance without burrs on the parting-off portion E at various sites. For this reason, this instrument panel does not require a deburring step, and reduces the defective rate and the repair rate at the time of manufacturing.

In addition, since the base material 1, the skin material 2 and the pad made of urethane foam are integrated with the instrument panel, the conventional fastening member, release material and deburring are not required, and the instrument panel is assembled. Was also simple. Therefore, by manufacturing such an instrument panel, it is possible to reliably realize a reduction in the manufacturing cycle and a reduction in the manufacturing cost.

As a slush molding method for increasing the thickness of the peripheral portion of the skin material 2, means shown in FIG. 4 or FIG. 5 can be employed. The means shown in FIG.
Guide 5 for guiding the plastisol to the periphery of electroforming mold 6
c is fixed, and a lid member 5d capable of sealing the periphery is provided on the guide 5c via a hinge. When the slush molding method of the skin material 2 is performed by this means, the peripheral portion is closed by the lid member 5d when the plastisol is collected, so that the plastisol is not collected from the peripheral portion.

In the means shown in FIG. 5, a pipe 7 extends around the periphery of the electroforming mold 6, and a balloon 7a is provided at the inner end of the pipe 7 so that the periphery can be closed when inflated. When the slush molding method of the skin material 2 is performed by this means, air or the like is injected from the pipe 7 when the plastisol is collected.
Thereby, the balloon 7a is inflated to close the peripheral portion,
Prevent recovery of plastisol from the periphery.

The same operation and effect as in the first embodiment can be obtained even if the skin material 2 whose peripheral portion is thickened by these means is adopted.

[0032]

[0033]

[0034]

[0035]

[0036]

[0037]

[0038]

[0039]

[0040]

[0041]

[0042]

[0043]

[0044]

[0045]

[0046]

[0047]

[0048]

[0049]

[0050]

[0051]

The present invention can be applied to the case where other interior materials such as door trims are manufactured in addition to the instrument panel of an automobile.

[0053]

As described above in detail, the interior material and the manufacturing method according to claims 1 and 2 employ the means described in each claim, so that the following excellent effects can be obtained. . That is, the obtained interior goods are
The skin material and the base material are securely sealed and have a good appearance.

Further, if such an interior material is manufactured, a reduction in the manufacturing cycle and a reduction in the manufacturing cost can be reliably realized.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a mold and the like after a mold is clamped and before a stock solution of a polyurethane foam is injected according to the manufacturing method of the first embodiment.

FIG. 2A is a cross-sectional view of an electroforming mold or the like showing a first-layer slush molding method, and FIG. 2B is a cross-sectional view of an electroforming mold or the like showing a second-layer slush molding method.

FIGS. 3A and 3B show the instrument panel of the automobile obtained according to the first embodiment, wherein FIG. 3A is a perspective view of the instrument panel, FIG. 3B is an enlarged sectional view of a portion B in FIG. (A) C
FIG. 4D is an enlarged sectional view of a portion D in FIG. 5A.

FIG. 4 is a sectional view of an electroforming mold or the like showing another slush molding method.

FIG. 5 is a sectional view of an electroforming mold or the like showing another slush molding method.

FIG. 6 is a perspective view showing an instrument panel of an automobile.

7 is a cross-sectional view taken along the line XV-XV of FIG. 6 according to the conventional instrument panel.

FIG. 8 is a cross-sectional view of a mold and the like during foaming of an undiluted polyurethane foam solution according to the proposed manufacturing method.

FIG. 9 is a cross-sectional view of a mold or the like during foaming of an undiluted polyurethane foam solution according to the proposed manufacturing method.

FIG. 10 is a cross-sectional view of a mold and the like during foaming of an undiluted polyurethane foam solution according to the proposed manufacturing method.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Base material 2 ... Skin material 2c
... Lap parts 1a, 2f ... convex parts 2e, 1b ... concave parts 8 ...
Adhesive member 9 ... Pressing pin 10 ... Magnetic tape 11
... permanent magnet 12 ... urethane slab 13 ... hooking needle 14
... soft material 15 ... urging member 16 ... locking plate 3 ...
Lower mold 3a: first mold inner surface (upper surface) 3b: second mold inner surface (side surface) 4: upper mold (4 ': first upper mold, 4 ": second upper mold) 4a: third mold inner surface (lower) A: First direction B: Second direction C: Cavity

──────────────────────────────────────────────────の Continued on front page (51) Int.Cl. ⁷ Identification code FI B29L 31:58 B29L 31:58 (72) Inventor Yoshimi Kitaoka 1 Toyota Town, Toyota City, Aichi Prefecture Inside Toyota Motor Corporation (72) Inventor Masato Nomura 1 Toyota Town, Toyota City, Aichi Prefecture Inside Toyota Motor Co., Ltd. (56) References JP-A-7-108545 (JP, A) JP-A-7-156163 (JP, A) JP-A 7-108 156164 (JP, A) JP-A-7-80859 (JP, A) JP-A-2-305611 (JP, A) JP-A-56-115233 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 39 / 10,33 / 14 B32B 3/02-3/06 B60R 13/02 B60K 37/00

Claims (2)

(57) [Claims] 1. A high-rigidity base material, a low-rigidity skin material fixed to a part of the base material at a wrap portion, and a filler filled between a back surface of the base material and a back surface of the skin material. a pad composed of a resin molding material, a decorated member made of, the skin material is formed thicker than the wrap sites other sites
Interior material, characterized in that the rigidity is enhanced by being. 2. A resin molding material is injected from a first direction, and has a cavity for shaping an interior material.
A first mold inner surface substantially parallel to the first direction; a second mold inner surface substantially parallel to a second direction intersecting the first direction and continuous with the first mold inner surface; and the first mold inner surface. A first step of preparing a mold having a third mold inner surface facing the first mold, and disposing a high-rigidity base material facing the first mold inner surface and the second mold inner surface. A second step of arranging a low-rigid skin material facing the third mold inner surface and a portion of the base material facing the second mold inner surface; and The first side is located between the inner surface of the mold 1 and the back surface of the facing portion .
By injecting the resin molding material from direction, and said surface skin material by in-mold molding the interior material and the resin molding material
And forming the pad with the skin material
In the production method of the interior material to be perforated and a third step of fixing the timber, the
The skin material has a thicker wrapped part than other parts
And rigidity is enhanced by being, and a feature in that the latch <br/> flop site of the skin material which faces the substrate in the second step is brought into close contact with the substrate Method of manufacturing interior materials.