JP3400336B2 - Manufacturing method of vehicle 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 vehicle interior parts such as instrument panels and door trims, and more particularly, to a back surface side of a synthetic resin skin material having at least a foam layer and a surface layer of the skin material. The present invention relates to a method for manufacturing a vehicle interior component in which base materials made of a soluble synthetic resin are integrally bonded.

[0002]

2. Description of the Related Art Conventionally, a skin is inserted into an injection mold by forming a cavity facing the foam layer in the injection mold, and a synthetic resin is injected into the cavity to form a skin. It is well known that a base material integrated with a material is molded.

[0003]

However, in the above-mentioned prior art, since the injection pressure directly acts on the foam layer of the skin material during the injection molding of the base material, the volume of the foam layer decreases during the injection molding. Although the volume of the base material is increased due to the compression, and the volume of the cavity increases due to the compression, when the molded product is taken out of the injection mold, the injection pressure is released and the foam layer is formed. The original volume may be restored, and the external shape of the vehicle interior component after completion of molding may be different from the desired design. Further, since the heat from the molten synthetic resin in the cavity is directly transmitted to the foam layer, the foam layer may be crushed, and unevenness may be generated on the surface of the vehicle interior component after completion of molding.

The present invention has been made in view of the above circumstances, and avoids the adverse effects of pressure and heat during injection molding on the foamed layer of the skin material as much as possible, while protecting the design of the product and the skin material. Another object of the present invention is to provide a method for manufacturing a vehicle interior component that enables good integration of a base material.

[0005]

In order to achieve the above object, the invention according to claim 1 is such that a synthetic resin skin material having at least a foam layer is provided on the back surface side of the synthetic material having compatibility with the skin material. In a method for manufacturing a vehicle interior component, the vehicle interior component configured by integrally bonding resin base materials is manufactured by injection molding in a state where the skin material is inserted into an injection mold. , a thin portion to be a part of the skin material side in its thickness direction of the substrate, the substrate configuration that chromatic integrally a plurality of support portions protruding from the thin portion on the opposite side to the surface material The material is pre-molded with synthetic resin, and a specific mold is selected from the multiple molds included in the injection molding mold .
The base material is placed between the specific mold and the thin portion.
Each support part is fixed to the specific mold at a predetermined interval.
Set as specified, and then the thin portion is
Abutting on the skin and between the specific mold and the base material
Clamping of the injection mold so that a cavity is formed
Performed because, by injecting a synthetic resin into the cavity, characterized by molded resin portion of the remaining except for portions base construction material occupied of the base material.

According to such a manufacturing method, by injection of the molten synthetic resin into the cavity, the thin material portion of the base material component interposed between the skin material and the cavity is appropriately melted, and the thin film material and the base material component are formed. The base material is formed by integrating the resin molding portion made of the synthetic resin in the cavity, and the base material and the skin material are integrated. At this time, the support portion of the base material component that is in contact with the skin material forms a predetermined space between a specific die of the plurality of dies included in the injection molding die and the thin portion of the base material component. since the is fixed is <br/> the particular mold as open, to be able to mitigate the effects of the injection pressure to the foam layer at the time of injection molding, foam layer reduced in volume
It is almost never compressed , and heat from the molten synthetic resin in the cavity is not directly transferred to the foam layer. Therefore, as in the past , compression was performed during injection molding.
The foamed layer is restored to its original volume by opening the mold ,
By heat from the molten synthetic resin can be produced such fried it or cause collapse of the foam layer, the skin material and a vehicle molded parts formed by well integrated the substrate in desired design Street.

The invention according to claim 2 is the above-mentioned claim 1.
In addition to the configuration of the invention described above, a projection provided integrally with the vehicle interior component so as to project from the back surface thereof is formed in advance on the base material component by integrally connecting to the thin portion. , Characterized in that the protrusion is used as the support, and in this way, the protrusion, which is required even after the completion of molding, is effectively used as the support for supporting the base material component on the first mold. Therefore, it is possible to minimize the work of cutting out the unnecessary portion of the supporting portion after the completion of the molding of the vehicle interior part, which can contribute to the reduction of the manufacturing man-hour.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below based on an embodiment of the present invention shown in the accompanying drawings.

1 to 8 show an embodiment of the present invention. FIG. 1 is a perspective view of an instrument panel,
2 is a cross-sectional view of the instrument panel taken along line 2-2 of FIG. 1, FIG. 3 is a vertical cross-sectional view of an injection molding die in a mold open state before injection molding, and FIG. 4 is injection molding in a mold closed state. FIG. 5 is a vertical cross-sectional view of the mold, FIG. 5 is an enlarged view of a portion indicated by an arrow 5 in FIG. 4, FIG. 6 is a sectional view corresponding to FIG. 6 in a mold open state after completion of injection molding, and FIG. 8 is a vertical sectional view of the injection molding die in a mold open state after completion of injection molding.

First, in FIG. 1, an instrument panel 10 as an interior part for a vehicle is provided with an instrument mounting opening 11 arranged at a position closer to the left side along the left-right direction and an air conditioner (not shown). An opening 12 arranged on the right side of the opening 11 for attaching a louver that blows air, and both left and right sides above the openings 11 and 12 for attaching a louver that blows air from the air conditioner. And a pair of openings 13 and 13 arranged at the front of the instrument panel 10 in order to blow out the air from the air conditioner upward. It is provided.

In FIG. 2, an instrument panel 1
0 is a skin material 15 made of synthetic resin such as polypropylene
A base material 18 made of a synthetic resin having compatibility with the skin material 15, such as polypropylene, is integrally bonded to the back surface of the.

The skin material 15 comprises a skin layer 16 and a foam layer 1.
7 is laminated, and is formed by slush molding. The base material 18 is formed by integrally molding a resin molding part 20 on the back surface of the base material component 19.
The base material 19 is melted and bonded to the back surface of the foam layer 17.

A resin molding portion 20 on the back surface of the base material 19
Of the foam layer 17 of the base material 19
The melting and bonding to the back surface of the injection mold 21 shown in FIG.
It is made by injection molding of synthetic resin by
This injection mold 21 is a fixed mold 2 as a specific mold.
2 and a movable mold 23 capable of moving toward and away from the fixed mold 22.

On the surface of the movable die 23 facing the fixed die 22, a recess 24 for arranging the foam layer 17 toward the fixed die 22 and setting the skin material 15 is formed. It has a shape corresponding to. By the way, when the skin material 15 is set on the movable mold 23, the skin material 15 is surrounded by the fixed mold 22 around the recess 24.
Also, the surplus portion 15a sandwiched between the movable molds 23 is integrally provided, and the surplus portion 15a is cut off after the molding of the instrument panel 10 is completed. Further, in this embodiment, a bent portion 15b having a shape bent inward is formed at the rear portion of the skin material 15 along the front-rear direction of the vehicle, and the injection molding die 21 accompanying the completion of injection molding is formed. When the molded product is taken out after the mold is opened, the bent portion 15b has the movable mold 2
In order to avoid getting caught in
The portion corresponding to b has a notch 24a on the outer edge of the recess 24.
Is provided.

On the other hand, on the surface of the fixed die 22 facing the movable die 23, a molding projection 25 having a back molding surface 25a corresponding to the shape of the back surface of the instrument panel 10 at the tip is provided.

The base material 19 comprises a thin portion 26, which is a part of the base material 18 on the skin 15 side in the thickness direction, and a thin portion 2.
A plurality of supporting portions 27, 27 ...
And a plurality of protrusions 2 integrally provided on the back surface of the thin portion 26.
, 29, 30, 31 (see FIG. 1) and the like are integrally formed by injection molding of synthetic resin.

The base material 19 has the supporting portions 27, 27, ... And the protruding portions 28, ... so that a predetermined space is provided between the back surface 25a of the fixed die 22 and the thin portion 26. , 29, 30, 31 and the like can be supported by the fixed mold 22 and set on the fixed mold 22, and when the injection mold 21 is in the mold closed state as shown in FIGS. A cavity 32 for forming the resin molding portion 20 is formed between the back surface molding surface 25a and the thin portion 26.

The supporting portions 27, 27, ... Are integrally connected to a plurality of locations on the back surface of the thin portion 26 so as to project from the thin portion 26 on the side opposite to the skin material 15.
It is formed in a cylindrical shape. Moreover, the engaging portions 27a are provided at the tips of the respective support portions 27, 27 ...

On the other hand, each of the supporting portions 27, 2 of the fixed die 22
The fixed die 22 and the movable die 23 are provided at positions corresponding to 7 ...
A plurality of ejector pins 33, 33 ...
Are arranged, and these ejector pins 33, 3 are
At the tip of 3 ..., the locking portions 27 of the support portions 27, 27 ...
a, 27a ... Engagement portions 33a, 33 releasably engaged with
a ... is provided. Thus, when the base material 19 is supported by the fixed mold 22, each ejector pin 33, 3
3 ... Support portions 27, 27 ... and ejector pin 3
The retracting operation is performed so that the engagement connecting portions 3, 33 ... Are drawn into the fixed mold 22.

The projections 28, 28 ... Of the base material 19 function as bosses for fixing the instrument panel 10 to a vehicle body (not shown), so that the instrument panel 10 projects from the back surface thereof. Are provided integrally with each other, and each of the protrusions 28, 28 ... Has a bottomed hole 28a, 28a into which a tap screw or the like not shown is screwed.
... are provided respectively.

On the other hand, the back surface forming surface 25 of the fixed die 22.
The a is provided with fitting recesses 34, 34 ... Into which the tips of the protrusions 28, 28 ... Are fitted, and ejector pins 35, 35 ... Abuttable on the tips of the protrusions 28, 28. ，
The fixed die 22 and the movable die 23 are arranged in the fixed die 22 so as to move in a direction along the approaching / separating direction and penetrate the fixed die 22, and ejector pins 35, 35 are provided.
The tip end of the ... Has the bottomed holes 28a, 2 of the protrusions 28, 28 ...
The small-diameter portions 35a, 35a, which fit in the 8a, are provided coaxially. In order to support the base material component 19 on the fixed die 22, the ejector pins 35, 33 engaged with the support portions 27, 27 ... 35 ... also moves backward.

The projection 29 of the base material 19 functions as a reinforcing rib integrally provided on the back surface side of the instrument panel 10, and the tip of the projection 29 is formed on the back surface forming surface 25a of the fixed die 22. A fitting recess 36 for fitting the parts is provided.

Referring also to FIG. 6, the projection 30 of the base material 19 is integrally provided on the back side of the instrument panel 10 so as to support the bent portion 15b of the skin material 15 from the back side. It functions as a reinforcing part,
The fixed die 22 is supported by being brought into contact with the side surface of the molding projection 25 of the fixed die 22.

The projection 31 of the base material 19 serves as a support frame for mounting an instrument mounted in the opening 11 of the instrument panel 10, as clearly shown in FIG.
The instrument panel 10 is integrally provided on the back side of the instrument panel 10, and a flange portion 31a bent at an angle to the inside is provided at the tip of the protrusion 31. Then the protrusion 31
Is to be inserted and supported on the fixed mold 22 side, but since the flange 31a bent at a right angle is provided at the tip end, a simple fitting concave portion for fitting the protrusion 31 is formed on the fixed mold. 22
It is impossible to form into.

Therefore, the fixed mold 22 has a back surface molding surface 25.
a is provided with a guide hole 38 having an outer end opened,
A slide block 37 capable of switching between a state of supporting the protrusion 31 and a state of releasing the supporting state is slidably inserted into the guide hole 38.

The inner surface of the guide hole 38 has a first inner surface 38a extending along the approaching / separating direction of the fixed mold 22 and the movable mold 23 so as to contact and support the outer surface side of the protrusion 31, and the protrusion 31.
It is possible to abut the collar portion 31a of the first inner surface 3
8a, a step portion 38b that is connected to the inner end at a right angle, and a first inner surface 38a that is connected to the first inner surface 38a through the step portion 38b.
Is formed so as to have a second flat surface 38c extending in parallel with and a third inner surface 38d facing the first and second inner surfaces 38a, 38c, and the third inner surface 38d is formed at the outer end of the guide hole 38. It is formed as an inclined surface that is inclined so as to separate from the first and second inner surfaces 38a, 38c as it approaches the opening.

The slide block 37 has the first inner surface 3
A first outer surface 37a capable of sandwiching the protrusion 31 with 8a;
Step portion 37b that can sandwich the collar portion 31a with the step portion 38b
A second outer surface 37c connected to the first outer surface 37a via the step portion 37b and capable of contacting the second inner surface 38c and extending parallel to the second inner surface 38c, and slanted so as to slidably contact the third inner surface 38d. Having a third outer surface 37d on the outer surface,
The guide hole 38 is formed to have an outer surface shape substantially corresponding to the inner surface shape.

Moreover, the slide block 37 is movable so that the third outer surface 37d is brought into sliding contact with the third inner surface 38d, and when the injection molding die 21 is opened, as shown in FIG. Moves forward so that its tip projects from the back surface molding surface 25a, whereby the state of the protrusion 31 sandwiched between the first inner surface 38a and the first outer surface 37a, and the collar between the step portions 38b, 37ba. The clamped state of the portion 31a is released, and the protrusion 31 can be inserted into and removed from the fixed die 22. Meanwhile, the injection mold 21
When the mold is closed, as shown in FIG. 6, the slide block 37 is moved backward so that its tip is flush with the back surface molding surface 25a, so that the slide block 37 projects between the first inner surface 38a and the first outer surface 37a. The part 31 can be sandwiched, and the flange part 31a can be sandwiched between the step parts 38b and 37ba.

By the way, the movable die 23 is provided with an opening projection 24b for forming the opening 11.
The projection 24b for the opening is provided at the tip of the slide block 37 and the back surface 25a when the injection molding die 21 is closed.
Abut. In addition, other openings 12, 13, 13, 14 ...
In regard to the above, the movable die 23 is also provided with opening projections (not shown), and these opening projections contact the back surface molding surface 25a when the injection molding die 21 is closed.

Next, the manufacturing steps for manufacturing the instrument panel 10 will be sequentially described. First, in the first step, as shown in FIG. 3, the injection mold 21 is opened and the fixed mold 22 is formed. The skin material 15 on which the foam layer 17 is arranged is set in the movable mold 23, and the base material component 19 that has been molded in advance is set in the fixed mold 22.
At this time, the plurality of supporting portions 27, 2 included in the base material component 19
7 ..., and the plurality of protrusions 28, 28 ..., 29, 30,
31 and the like are supported by the fixed die 22 so that a predetermined space is provided between the thin portion 26 of the base material component 19 and the fixed die 22.

In the second step, the injection molding die 21 is closed as shown in FIGS. 4 to 6. By the closing of the die, the thin wall portion 26 of the base material 19 is covered with the skin material 15.
The cavity 32 is formed between the thin portion 26 of the base material 19 and the fixed mold 22 while being in contact with the foam layer 17 of FIG.

In the third step, a synthetic resin is injected into the cavity 32 from a gate (not shown) provided on the fixed die 22. By injecting the synthetic resin into the cavity 32, the remaining resin-molded portion 20 of the base material 18 excluding the portion occupied by the base-material constituting material 19 is formed. At this time, the thin-walled portion 26 is appropriately formed. By melting, the base material 19 and the resin molding portion 20 are integrated to form the base 18, and the base 18 and the skin material 15 are formed.
And will be integrated.

The thickness of the thin portion 26 may be determined according to the type of synthetic resin, the injection temperature and the injection pressure. However, the thickness of the portion near the gate is made relatively large and If the thickness of the distant portion is made relatively small, the thin wall portion 26 is appropriately melted by the molten resin in the cavity 32, and the thin wall portion 26 has a sufficient adhesive function between the skin material 15 and the molten resin 20. Will be fulfilled.

In the fourth step, as shown in FIGS. 7 and 8, the injection molding die 21 is opened after the injection molding is completed, and the ejector pins 33, 33 ...
... to move forward, and slide block 37
By moving forward, the molded product can be taken out from the injection mold 21.

Thus, when the injection molding by the injection molding die 21 is completed, the surplus portion 15a remains connected to the skin material 15, and the tips of the supporting portions 27, 27 ... Since it remains as it is, the surplus portion 15a
And the protruding portions of the respective support portions 27, 27 ... From the back surface of the molten resin 20 are cut off, whereby the instrument panel 10 as a finished product can be obtained.

According to the method of manufacturing the instrument panel 10 as described above, when the skin material 15 and the base material component 19 are mounted in the injection molding die 21, the injection molding is performed.
Since the support portions 27, 27 ... Of the base material component 19 and the protrusions 28, 28 ..., 29, 30, 31 functioning as the support portions are supported by the fixed mold 22, the injection pressure in the cavity 32 is increased. Does not act directly on the foam layer 17 of the skin material 15, the effect of injection pressure on the foam layer 17 is mitigated, and the heat from the molten synthetic resin in the cavity 32 is not directly transferred to the foam layer 17. . Therefore, the foam layer 17 is hardly compressed during injection molding so as to reduce its volume, and the foam layer 17 is also prevented from being restored to its original volume due to opening of the injection mold 21. Further, the collapse of the foam layer 17 due to the heat from the molten synthetic resin is avoided as much as possible, and the instrument panel 10 in which the skin material 15 and the base material 18 are well integrated is manufactured according to the intended design. be able to.

Further, as a supporting portion for supporting the base material component 19 on the fixed die 22, the projections 28, 28 integrally provided so that the instrument panel 10 projects from the rear surface thereof.
..., 29, 30, 31 are integrally formed in the thin-walled portion 26 and are formed in advance in the base material 19, so that the protrusions 28, 28, 29, 30, 31 that are necessary even after the completion of molding ,
It can be effectively used as the support portion, and the work of cutting off the unnecessary portion after the completion of the molding of the instrument panel 10 can be minimized, which can contribute to the reduction of the number of manufacturing steps.

Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments, and various design changes can be made without departing from the present invention described in the claims. It is possible to do.

For example, in the above embodiment, the skin material 15
However, the skin layer 16 and the foam layer 17 are laminated, but the skin material may be any material having at least the foam layer 17. Further, in the above-described embodiment, at the time of injection molding by the injection molding die 21, the fixed parts 22 as the specific mold are used to support the support parts 27, 27 ... protrusions 2 which function as parts
8, 28 ..., 29, 30, 31 are supported, and the base material constituting material 1
Although a predetermined gap is provided between the thin portion 26 and the fixed die 22 of FIG. 9, a cavity 32 is provided between the fixed die 22 and the thin portion 26 when the die is closed while the thin portion 26 is in contact with the skin material 15. Should be formed.

[0040]

As described above, according to the first aspect of the invention, the thin-walled portion and the skin material are provided on the side opposite to the thin-walled portion.
Synthetic resin base material that has multiple supporting parts in one
More molds that are pre-molded and provided in the injection mold
The base material constituting the mold, the specific mold and the thin portion
Each support is fixed to the specific mold with a predetermined space between
The thin-walled part against the skin material.
A cavity in contact and between the particular mold and substrate components
The injection mold is clamped so that
By injecting synthetic resin into the cavity,
Molding the remaining resin molding part excluding the part occupied by the material
Thus, it is possible to reduce the effect of injection pressure on the foam layer during injection molding, so that the foam layer reduces its volume.
Almost no compression occurs, and heat from the molten synthetic resin is not directly transferred to the foam layer . Therefore,
The foam layer compressed during injection molding is
The original volume will not be restored , and the heat from the molten synthetic resin will not cause the foam layer to collapse.
Therefore, it is possible to manufacture a molded part for a vehicle , in which the skin material and the base material are well integrated, according to the intended design.

Further, according to the second aspect of the present invention, the protrusion, which is necessary even after the completion of the molding, can be effectively used as a supporting portion for supporting the base material constituting material on the first mold, and the vehicle interior It is possible to contribute to the reduction of manufacturing man-hours by minimizing the work of cutting out unnecessary portions of the supporting portion after the molding of the parts is completed.

[Brief description of drawings]

FIG. 1 is a perspective view of an instrument panel.

2 is a cross-sectional view of the instrument panel taken along line 2-2 of FIG.

FIG. 3 is a vertical cross-sectional view of an injection molding die that is in a mold open state before injection molding.

FIG. 4 is a vertical sectional view of an injection molding die in a mold closed state.

5 is an enlarged view of a portion indicated by an arrow 5 in FIG.

FIG. 6 is a cross-sectional view of a portion of the injection molding die taken along line 6-6 in FIG. 1 in a mold closed state.

FIG. 7 is a sectional view corresponding to FIG. 6 in a mold open state after completion of injection molding.

FIG. 8 is a vertical cross-sectional view of the injection molding die in a mold open state after completion of injection molding.

[Explanation of symbols]

10 ... Instrument panel 15 as vehicle interior parts ... Skin material 17 ... Foam layer 18 ... Base material 19 ... Base material 20 ... Resin molding part 21 ... Injection molding die 22 ... Fixed die 23 as a specific die ... Movable die 26 ... Thin portion 27 ... Support portions 28, 29, 30, 31 ... Projection 32 ... cavity

Claims (2)

(57) [Claims] 1. A skin material (15) made of synthetic resin having at least a foam layer (17) on the back surface side of the skin material (15).
A state in which the skin material (15) is inserted into an injection molding die (21) of a vehicle interior part (10) configured by integrally combining a base material (18) made of a synthetic resin compatible with A method for manufacturing an interior part for a vehicle, which is manufactured by injection molding according to the method of claim 1, wherein the skin material (1
5) side thin portion (26) and a part of the skin material (1)
5) and a plurality of supporting portions protruding from the thin portion on the opposite side (26) (27 to 31) and base construction material for organic integrally
(19) is molded in advance with a synthetic resin, and a plurality of molds (22,
23) in the specific mold (22) , the base material (1
9) the specific mold (22) and the thin portion (26)
A predetermined space is provided between the supporting portions (27 to 3).
Set so that 1) is fixed to the specific mold (22)
And, then, the thin portion (26) of said skin material (15) This
In contact with the specific mold (22) and the base material (1)
9) so that a cavity (32) is formed between them.
Out performs clamping of the mold (21), it is injected the cavity (32) within the synthetic resin, the remainder of the resin except for the portion where the substrate constituting member (19) occupies one of the base (18) A method of manufacturing an interior part for a vehicle, comprising molding a molding part (20). 2. A projection (28-31) integrally provided with an interior part (10) for a vehicle so as to project from the back surface thereof.
Are integrally formed with the thin wall portion (26) and formed in advance on the base material component (19), and the protrusions (28 to 3) are formed.
2. The method for manufacturing a vehicle interior component according to claim 1, wherein 1) is used as the support portion.