JP3358344B2 - Vehicle door trim and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle door trim and a method of manufacturing the same.

[0002]

BACKGROUND OF THE INVENTION Conventional vehicle dual door trim, there is a type which is manufactured through the process chart shown in FIG. 8 (a) ~ (d). In this vehicle door trim, a skin material 51 is formed on a surface of a base material 50 obtained by molding a wooden board into a predetermined shape.
It is adhered (see FIGS. 8A and 8B), and its skin material 51
8b (FIG. 8 (b) and FIG. 8 (c))
) To manufacture the door trim body. Then
By bonding a cushioning material 52 made of a foam material separately manufactured to a predetermined portion of the base material 50 (see FIGS. 8C and 8D), the shock applied to the door from the outside of the vehicle is absorbed, and the occupant is absorbed. Is trying to protect.

[0003]

In the door trim for the above vehicle INVENTION SUMMARY it is], since the door trim main body and the buffer material 52 is configured separately, the step of separately preparing slow衝材52,
The及beauty gentle衝材52 is necessary work to be fixed to the door trim body. In addition, a step of forming the skin material 51 in a sheet shape in advance and a step of bonding the skin material 51 to the base material 50 are also necessary,
A series of steps of the door trim manufacturing vehicle there problem Ru that it is complicated.

[0004]

SUMMARY OF THE INVENTION Accordingly, the present invention has been made to solve the above-mentioned problems, and it is an object of the present invention to form a skin material into a sheet shape, to manufacture a cushioning material separately, and to attach the cushioning material to an adhesive. It is an object of the present invention to simplify the manufacturing process of the vehicle door trim and to reduce the material used (for example, an adhesive) by integrating the material into the skin material without using a fixing material such as the above.

[0005]

The present invention SUMMARY OF THE INVENTION may, the above object
Since Accomplish the front is integrally formed by laminating a skin material made of a resin material on the front surface of the substrate molded into a predetermined shape
A skin portion which entirely covers the surface, the pressure in the hollow formed surface of the skin portion by injecting gas into a portion of the resin material forming the skin material at a predetermined portion of the back side of the substrate But
Gas flow that, when added, releases the gas present inside it
And a buffer provided with a through-hole.
The door trim is provided.

[0006] The present invention also provides a vehicle door trim having the above-described configuration, in order to provide a vehicle door trim having a predetermined shape.
Set the material in the mold on the substrate side and use it as a skin material on the top surface
After feeding the resin material in the molten state, the skin material molding die
Molten resin supplied to the upper surface of the base material by lowering
While spreading the base material,
Inside the slide mold provided in the substrate side molding die through the substrate
Gas outlet inside the molten resin-based material
Injecting high pressure gas by inserting the gas supply pipe located
A skin portion that entirely covers the front surface of the base material
And a hollow buffer portion is formed on the back side of the base material.
Then , the resin-based material supplied in a molten state is cooled and cured.
After that, the gas supply pipe is withdrawn and gas is supplied to the buffer section.
Manufacturing method of vehicle door trim with flow holes
It proposes a law.

In carrying out the present invention , a predetermined shape is formed.
Skin material with the shaped base material set in the base-side mold
Lowering the side mold, the molding surface of the skin material side mold and the
Melts resin-based material used as skin material in gaps between base material surfaces
Inject in the state and the same base material at a predetermined site of the base material
Into the slide mold provided on the substrate side molding die.
Gas outlet located inside filled molten resin-based material
By inserting a gas supply pipe to
Forming a skin portion that covers the entire front surface of the base material.
And forming a hollow buffer portion on the back side of the base material ,
Cooling and curing the resin-based material supplied in a molten state
After that, pull out the gas supply pipe and gas flow to the buffer
A method of manufacturing a vehicle door trim having a hole formed therein.
May be adopted.

[0008]

[0009]

Operation and effect of the invention The vehicle door constructed as described above
In trims, the buffer is formed integrally with the skin of the base material.
Because it is made, the buffer material is separately prepared as in the prior art
Therefore, there is no need to adhere or assemble the cushioning material to the substrate,
The manufacturing process can be simplified. Also, as described above,
The cushioning part formed integrally with the skin part of the material
Exists inside from the gas flow hole when impact is applied to the part
Shock is absorbed by releasing buckling gas
Perform the function of

[0010] Thus, since the conventional cushioning material is not formed separately from the skin material but is integrally formed with the skin portion as a cushioning portion of the skin material, the use of an adhesive can be omitted and the material used can be reduced. it can. In addition, there is no need to perform a step of separately manufacturing a cushioning material and a step of bonding or assembling the cushioning material, which are essential in the conventional manufacturing method, so that the manufacturing process can be simplified.

Further, in a door trim in which a gas flow hole is formed in the buffer portion, when pressure is applied to the buffer portion, the gas sealed through the gas flow hole is released, so that the impact rebound in the buffer portion is released. The force is weakened, that is, the shock absorbing effect of the buffer part is increased. And this gas flow hole, the molten resin-based material is cured while the gas supply pipe is inserted,
Thereafter, if the gas supply pipe is formed by removing the gas supply pipe, the gas flow hole can be formed by a simple method.

[0012]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view of a door trim according to an embodiment of the present invention as viewed from obliquely above the rear side, and FIG.
Is a cross-sectional view taken along line 2-2 shown in FIG. This vehicle door trim is made of wood chips and fibers,
Wood-based substrate 1 formed by maintaining the porosity of an aggregate obtained by adding and mixing a phenolic resin as a binder to a main material such as powder.
1 and a skin material 12 made of polypropylene resin, which covers the surface of the wood-based base material 11. The skin material 12 includes a skin portion 12a and a buffer portion 12b . Slow衝部1
2b is formed of a part of the polypropylene resin constituting the skin material 12, and is formed into a hollow shape by injecting a gas into the inside.
It has been, gas distributing holes 12b1 which communicates the interior and exterior settings
Have been killed.

[0013] Incidentally, the junction of the wood-based substrate 11 and the skin portion 12a is made in the form cured in a state in which the polypropylene resin constituting the skin material 12 is impregnated, filled in the inner part of the wood-based substrate 11 and, woody base material 11 and the skin material 12 is bonded by the anchor effect.

In the vehicle door trim configured as described above ,
In this case , since the buffer portion 12b is formed integrally with the skin portion 12a of the base material 11 , a buffer material is separately manufactured as in the related art.
It is not necessary to adhere or assemble the cushioning material to the substrate.
No. In addition, as described above, it is integrated with the skin portion 12a of the base material 11.
The shock-absorbing portion 12b is provided with an impact on the vehicle door.
When the skin portion 12a is pressed by the
2b1 to release the internal gas and buckle
Performs the function of absorbing shock.

Next, as one embodiment of a method for manufacturing a vehicle door trim according to the present invention, a method for manufacturing a vehicle door trim having the above-described configuration will be described with reference to FIGS. 3 (a) to 3 (c).
In this manufacturing method, the rear molding surface 20 of the door trim is used.
a from the lower die 20 (corresponding to the substrate-side molding die of the present invention) and the upper die 21 (corresponding to the skin material-side molding die of the present invention) having the front molding surface 21a. A pair of upper and lower molding dies 20 and 21 and a resin supply for discharging and supplying the molten polypropylene resin constituting the skin material onto the wooden base material 11.
A feeding device 22 is used. As described in detail below, a slide die 20b for forming the buffer 12b is incorporated in the lower die 20 so as to be able to advance and retreat toward the back surface forming surface 20a by a hydraulic cylinder (not shown). I have . The slide 20b of this, the back surface of the molten resin pool of woody substrate 11 a high-pressure gas (see FIG. 3 (b))
A gas supply pipe 23 for supplying the gas is provided through the gas supply pipe 23.

[0016] In the production, it was shown in Figure 3 (a)
Thus , the mold 2 previously heated to a temperature of 40 ° C. to 80 ° C.
After setting the wooden base material 11 formed into the shape of the door trim on the forming surface 20a of the lower mold 20, the molten state (18) serving as a skin material is set on the upper surface of the wooden base material 11.
0 ° C. to 200 DEG ° C.) resin polypropylene resin 12melt in
Supply is performed using the supply device 22. At this time, the slide mold 20b of the lower mold 20 is approximately 5
It is arranged at a position keeping a distance of mm, and a space is formed for filling the molten resin in a subsequent step. Then, in the middle of this space, the tip end nozzle portion (23) of the gas supply pipe 23 provided through the slide die 20b.
a: Corresponds to the gas ejection port of the present invention. ) Is positioned.

[0017] Then, by lowering the upper mold 21, push the molten resin 12melt into a gap between the woody base material 11 and both molds 20 and 21. In this step, the molten resin 12melt
As shown in FIG. 3 (b), together with the spread so as to cover the surface of the wood-based substrate 11 to a thickness of about 0.5 mm, the wood-based substrate from the hole 11a provided in the wood-based substrate 11 wraparound to the rear surface 11, the charge in the space formed between the rear surface of the slide 20b and the woody base material 11 of the lower mold 20
Fully to form a molten resin pool 12melt1 in this portion. In this step, the molten resin 12melt spread so as to cover the surface of the wooden base material 11 is impregnated into at least the front side holes inside the wooden base material 11 and immediately cooled and hardened,
The skin portion 12a is formed. And contrast, thicker than the thickness of the molten resin pool 12Melt1 (about 5mm) is the skin portion 12a thickness (about 0.5 mm), the molten resin Pool 1
Although the outer periphery of 2melt1 cools and hardens as quickly as the skin portion 12a, the cooling inside is slow and the molten resin 12
The melt remains fluid.

[0018] Thus, before the molten resin pool 12melt1 interior of the molten resin is completely cured, shows the <br/> so on in FIG. 3 (c), the gas pressure (30 atm) from the gas supply pipe 23 At the same time as the injection, the slide mold 20b is lowered. This ensures <br/>, inside is expanded gas space of the molten resin pool 12melt1 by the pressure of Note input to the high-pressure gas is formed, hollow cushioning portion 12b is formed. Na us, slow衝部12b are molten resin 12melt is due to be cured impregnated in the rear surface of the internal pores of the wood-based substrate 11 woody base materials 1
1 are integrated. Vehicle door trim thus produced, the gas supply pipe 23 to the buffer portion 12b is formed as a hole gaga scan flow holes 12b1 which has been penetrated.

[0019] Therefore, according to the manufacturing method of the vehicle door trim in this embodiment, as in the conventional door trim for vehicles
The cushioning material is manufactured separately, and the cushioning material is adhered to the base material or assembled.
There is no need to find them , and the manufacturing process can be simplified.
Further, the molten resin is hardened while the gas supply pipe 23 is inserted.
And then withdrawing the gas supply pipe 23
The gas flow hole 12b1 can be easily provided in the buffer 12b.
Can be.

[0020] The contact in the vehicle door trim above Symbol embodiment, one of the space therein as a buffer portion 12b is formed
It is provided a hollow cushioning portion, as when the door trim and the door inner spacing position where the buffer portion between the panels, such as different by site were shown in FIGS. 4-6, a plurality
The buffer portion may be provided to <br/> configured by changing the thickness of the buffer section depending on the site. Your name, as shown in FIG. 7 (a) ~ (c) ( Fig. 3
(A) to (c). ) Contains such multiple
As an example of a method for manufacturing a vehicle door trim with a gentle衝部of, the manufacturing process of the type of door trim for a vehicle shown in FIG. 4 is shown. The manufacturing process shown in FIG. 7 and the manufacturing process shown in FIG. 3 correspond to the lower mold 2 used in each manufacturing process.
The number of slide dies assembled in FIG. 3 is one in FIG. 3 and three in FIG. 7, and both slide dies shown in FIG. 7 are provided with gas supply pipes penetrating therethrough. Although there is a difference between the processes, the manufacturing process shown in FIG.
Is the same as the manufacturing process shown in FIG.

[0021] Also, the supply means of molten resin forming the skin material 12 which adopts carrying out the method of manufacturing the above SL embodiment
A resin supply device 22 for discharging and supplying the molten resin, but using a lower mold having a built-in resin supply passage that is opened at positions dispersed over the entire rear surface molding surface, and injecting the molten resin into the resin supply passage. Supply means for supplying the molten resin to the front side surface of the wood-based base material 11 may be employed.

Further, in the manufacturing method of the above embodiment , the upper die 21 is polymerized after the wooden base material is placed on the lower die 20 and the molten resin to be the skin material 12 is supplied. Instead, the same pair of upper and lower molds 20 and 21 are used, the wooden base 11 is set between the two molds 20 and 21, and then the wooden base 11 and the molding surfaces 20a and 21 of the two molds 20 and 21 are set.
A molten resin serving as the skin material 12 may be injected into a gap between the cover 21a. The buffer 12 after the injection of the molten resin.
The method of manufacturing b may be the same as that of the above-described embodiment described with reference to FIGS.

In the above embodiment, a wood-based base material is used as the base material, but a porous resin-based molded body made of hard foamed urethane or the like may be used. In addition, a porous resin mainly composed of a thermosetting material such as a phenolic resin, an epoxy resin, or a polyester resin, or a thermoplastic resin such as a polypropylene resin or an ABS resin, to which a reinforcing agent or a conductive agent for antistatic is appropriately added. use system moldings and metal fibers pressurized molded porous molded body, the molded body made of a carbon material, a metal lath or nonwoven fabric molded body and the porous resin supported or laminated to a support made of such like as the substrate <br/> When wettability such as bad and the resin constituting the base material and a skin material made of these materials, coating the surface modifier, such as modified olefin in the substrate surface or impregnated to the porous base By improving the permeability of the molten resin into the holes of the material, the bonding strength between the two can be increased. For example, the skin material substrate is a polypropylene resin when such that vinyl chloride based primer salt iodination polyolefin as a surface modifier is used.

[0024] In the manufacturing method of the examples above mentioned, the base material 11 and the skin material 12 due to the use of wood-base material 11 as the substrate is bonded by the anchor effect, the substrate side or the skin material side Although it is not necessary to apply the adhesive, for example, as in the case of using a phenolic resin of the thermosetting resin in non-porous base material, to facilities in advance adhesive to a substrate was set on the substrate side mold Engineering as is necessary. And contrast, the use of the polypropylene resin is a thermoplastic resin having no pores as a substrate, it is possible to join by polypropylene and welding constituting the surface material. In this case , a surface modifier for increasing the wettability between the base material and the skin material and performing reliable welding can be applied as necessary.

In the above embodiment, polypropylene resin was used as the skin material. However, other olefin resins such as vinyl chloride, polyethylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic resin were used. Acid polymer or polyamide resin, A
A thermoplastic resin such as an SA resin may be used alone or in combination of two or more. In addition, a gloss imparting agent for imparting gloss to the skin material, a flame retardant, or the like can be appropriately added in consideration of appearance, performance, and the like of the finished product.

[Brief description of the drawings]

FIG. 1 is a perspective view of a vehicle door trim according to an embodiment of the present invention as viewed from obliquely above a rear side.

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

3 (a) to 3 (c) are process diagrams for explaining a method of manufacturing the vehicle door trim shown in FIG. 1.

FIG. 4 is a perspective view of a vehicle door trim according to another embodiment of the present invention, as viewed obliquely from the upper rear side.

FIG. 5 is a perspective view of a vehicle door trim according to still another embodiment of the present invention, as viewed from obliquely above the rear side.

FIG. 6 is a perspective view of a vehicle door trim according to still another embodiment of the present invention, as viewed from obliquely above the rear side.

FIGS. 7A to 7C are process diagrams for explaining a method of manufacturing the vehicle door trim shown in FIG. 4;

FIGS. 8A to 8D are process diagrams for explaining a conventional method of manufacturing a vehicle door trim.

[Explanation of symbols]

11: wood base material, 12: skin material, 12a: skin portion, 1
2b: buffer part, 12b1: gas flow hole, 20: lower mold, 20
b: slide type, 21: upper die, 22: discharge device, 23:
Gas supply pipe.

────────────────────────────────────────────────── ─── Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI B29L 22:00 B29L 31:30 31:30 B60J 5/00 501A (72) Inventor Hiroyuki Kato 25, Yoshifuji-cho, Yoshihara-cho, Toyota-shi, Aichi Prefecture Address Araco Co., Ltd. (56) References JP-A-6-78034 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 43/00-43/58 B60J 5/00 -5/14

Claims (3)

(57) [Claims] 1. A resin formed on a front surface of a base material molded into a predetermined shape.
It is integrally formed by laminating skin materials composed of
A skin portion which entirely covers the surface, the gas in a part of the resin material forming the skin material at a predetermined portion of the back side of the substrate
To form a hollow and apply pressure to the surface of the skin.
Gas flow that releases gas existing inside when it touches
Vehicle door trim, characterized in that a buffer section provided with holes. 2. A substrate molded into a predetermined shape is formed into a substrate-side molding die.
Set and melt the resin-based material as the skin material on the top surface
After being supplied in the state, the mold on the skin material side is lowered and the base material is lowered.
The molten resin-based material supplied to the upper surface of the
And penetrate the base material at a predetermined portion of the base material and
The molten state filled in the slide mold provided in the mold on the substrate side
Gas supply pipe where the gas ejection port is located inside the resin-based material
By inserting a high pressure gas by inserting
Form a skin that covers the entire front surface and
A hollow cushioning portion is formed on the back side of Kimotozai, provided at the molten state
After cooling and curing the supplied resin-based material, the gas
Withdraw the supply pipe to form a gas flow hole in the buffer section
Of manufacturing a vehicle door trim as described above. 3. A substrate molded into a predetermined shape is formed into a substrate-side molding die.
Lower the mold on the skin material side in the set state
Skin in the gap between the molding surface of the material side mold and the surface of the substrate
Inject resin-based material in the molten state and
Penetrating the base material at a predetermined portion of the base material and forming the base material side mold
High by inserting the gas supply pipe gas port is located inside of the resin material in a molten state of being filled in a slide-type in which is provided on the
By injecting a pressurized gas, the front surface of the
Forming a skin portion to cover the surface and the back side of the base material
A hollow buffer portion is formed in the resin material, and after cooling and curing the resin-based material supplied in a molten state , the gas supply pipe is removed.
A method for manufacturing a vehicle door trim, wherein a gas flow hole is formed in the buffer portion .