JP3329989B2 - Door trim integral foam molding method - 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 integrally molding a door trim for an automobile.

[0002]

2. Description of the Related Art A fabric is attached to a design surface of an automobile door trim. As shown in FIG. 6, a conventional molding method of the door trim is a step (A) of setting a skin 3 in a foaming mold including a lower mold 1a and an upper mold 1b.
Closing the upper mold 1b, injecting a urethane base material and foaming, and taking out the skin 3 integrally molded with the urethane foam 5 from the foaming mold as shown in FIG. 20 and a step (C) of applying an adhesive 21 to the surface of the portion of the skin 3 to which the fabric is to be adhered by a spray gun or the like, and as shown in FIG. Step (D) in which both ends are inserted with a wood grain blade 2 and the fabric 4 is bonded to the skin 3
It has been commercialized in four steps.

[0003]

In the above-mentioned conventional molding method, two steps of an adhesive application step and a grain setting step are added to the steps after the integral foam molding, and the number of steps is increased. A wood grain jig is required, and there is a problem in manufacturing efficiency and cost reduction.

[0004] In view of the above-mentioned conventional problems, an object of the present invention is to make it possible to integrally form a skin and a fabric in a foaming mold.

[0005]

To achieve the above object, the gist of the present invention is to provide a wood-grained blade in a lower mold of a foaming mold so as to be able to advance and retreat, and to a terminal in the foaming mold in advance. A step of setting the folded back portion of the skin and the fabric by setting the terminal thereof to overlap with the folded portion of the skin, and advancing the wood grain blade to partition the overlapped portion between the folded portion of the skin and the fabric end, and urethane. And foaming the substrate.

[0006]

According to the above-mentioned method, the skin and the fabric, which are different materials, are separated from each other in a foaming mold by a wood-grained blade so that urethane integral foaming can be performed.

[0007]

Embodiments of the present invention will be described below with reference to the drawings. In FIG. 1, 1a is a lower mold, 1b is an upper mold, and is a foaming mold. As shown in FIG. 3, in this foam molding die, a pair of right and left wood cut blades 2 (partition members) are provided in a lower die 1a so as to be able to move forward and backward (up and down) by an actuator 2a.

FIG. 1A shows a skin 3 in which a folded portion is previously formed in a terminal in the foaming mold, and a fabric 4.
1B is a first step in which the terminal is overlapped and set with the folded portion of the skin, and FIG. 1 (B) shows the second step in which the grained blade 2 is advanced to partition the folded portion of the skin 3 and the overlapped portion of the fabric terminal. FIG. 1 (C) shows a third step of injecting and foaming a urethane base material, and FIG. 1 (D) shows a skin terminal of a product taken out of a foaming mold after the third step. It is a trimming process to cut and finish, and this trimming process is adopted as necessary,
It is not a limiting requirement of the method of the invention.

The skin 3 having the folded portion formed on the terminal in advance is subjected to powder slush molding in a step before the first step of the present invention. As shown in FIG. 5, a protrusion 12 for forming a folded portion is provided on the bottom surface of an electroforming mold 10 provided with a powder box (not shown), and a seal 11 is provided near the protrusion 12. The electroforming mold 10 is rotated left and right to perform powdering to form a skin 3 having a stupid artist part 3a at a terminal, and the powder slush molding method itself has been conventionally used.

Therefore, a first step of setting the skin 3 and the fabric 4 in which the folded portion is formed on the terminal in advance in the foaming mold of FIG. 1A and setting the terminal so as to overlap the folded portion of the skin. 1 to 3C will be described in detail with reference to FIG.

FIG. 4A shows a state in which the skin 3 and the fabric 4 in which the folded portion is formed in advance in the terminal in the foaming mold of the first step are set such that the terminal is overlapped with the folded portion of the skin. At this point, the wood grain blade 2
Is receding. In the second step, the wood grain blade 2 is advanced (raised) so that the wood grain blade 2 pushes up the end 4 a of the fabric 4 and cuts into the folded portion 3 a of the skin 3 to perform a partitioning action.

In this state, the urethane base material in the third step is injected and foamed. In this third step, as shown in FIG. 4 (B), pressure is applied to the overlapping portion between the skin 3 and the fabric 4 by the foaming pressure, and the overlapping portion between the skin 3 and the fabric 4 is brought into close contact. The pressurization timing is controlled by a timer, and as shown in FIG. 4 (C), the grained blade 2 is retracted (downward) to perform partitioning.

Thereafter, as shown in FIG. 4D, the folded portion 3a of the skin 3 and the fabric 4
Terminal 4a surely adheres, and as shown in FIG.
Is formed integrally with the folded portion 3a and the terminal 4a of the fabric 4 in a unitary foam.

After the completion of the third step, the end of the skin 3 is cut and finished in the trimming step as necessary, as described above, for the product taken out of the foaming mold.

As described above, the skin 3 and the fabric 4 are separated by the wood cutting blade 2 in the foaming mold, and the folded portion 3a of the skin 3 and the fabric 4 are separated by urethane foaming pressure.
The terminal 4a can be integrally molded to form a door trim integrally foamed.

[0016]

As described above, according to the present invention, it is possible to reduce the number of steps for forming the door trim using different materials of the skin and the fabric, and to integrally fabricate the fabric and the urethane base material. The application jig, the bonding step, and the adhesive are not required, and the cost can be reduced. Further, since the skin portion serving as the back surface of the fabric can be omitted, there is an advantage that the yield of the skin is improved.

[Brief description of the drawings]

FIG. 1 is a process diagram of the method of the present invention.

FIG. 2 is an enlarged view of a part viewed from an arrow E in FIG. 1 (C).

FIG. 3 is an enlarged view of FIG.

FIG. 4 is a process explanatory view of each step of the method of the present invention in a portion viewed from an arrow F in FIG. 3;

FIG. 5 is a cross-sectional view of a main part showing powder slush molding of the skin.

FIG. 6 is a process diagram of a conventional door trim molding method.

FIG. 7 is an enlarged view of a part viewed from an arrow G in FIG. 6;

FIG. 8 is an enlarged view of a portion viewed from an arrow H in FIG. 6;

[Explanation of symbols]

 1a Lower die 1b Upper die 2 Grained blade 3 Skin 4 Fabric

────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁷ Identification symbol FI B29L 9:00 B29L 9:00 31:58 31:58 (56) References JP-A-6-344770 (JP, A) JP JP-A-2-103107 (JP, A) JP-A-5-16163 (JP, A) JP-A-63-46919 (JP, A) JP-A-64-85715 (JP, A) (58) Fields investigated (Int .Cl. ⁷ , DB name) B29C 39/00-39/44 B29C 43/00-43/58

Claims (1)

(57) [Claims] The present invention relates to a fabric and a fabric in which a folded portion is formed in a terminal in advance in a lower end of a foaming mold and a wood grain cutting blade is provided in a lower mold of the foaming mold. A door trim integral foam molding method, comprising the steps of: advancing the wood-grained blade, partitioning the overlapped portion between the folded portion of the skin and the fabric terminal, and injecting and foaming a urethane base material. .