JP3431915B1

JP3431915B1 - Automotive interior parts and manufacturing method thereof

Info

Publication number: JP3431915B1
Application number: JP2002187172A
Authority: JP
Inventors: 哲行大田; 正彦原; 樹史大野; 洋行相澤; 清彦小原
Original assignee: Kasai Kogyo Co Ltd
Current assignee: Kasai Kogyo Co Ltd
Priority date: 2002-06-27
Filing date: 2002-06-27
Publication date: 2003-07-28
Anticipated expiration: 2022-06-27
Also published as: JP2004025693A

Abstract

【要約】【課題】自動車用内装部品、車両用内装パネル、建築
壁材、住居用内装パネル等に使用する積層構造体及びそ
の製造方法であり、軽量化並びにコストダウンを図ると
ともに、成形金型の負荷を軽減して成形サイクルを短縮
化する。【解決手段】積層構造体１０は、軽量で保形性を有す
る発泡樹脂基材２０と、発泡樹脂基材２０の内面側に積
層一体化され、製品外周に沿う外周フレーム３０と、外
周フレーム３０間に連設される橋渡しリブ４０とから構
成する。よって、軽量な発泡樹脂基材２０を使用するこ
とと、合成樹脂成形体である外周フレーム３０及び橋渡
しリブ４０の投影面積を低減化することで樹脂量を少な
くでき、軽量化及びコストダウンを図る。The present invention relates to a laminated structure used for interior parts for automobiles, interior panels for vehicles, building wall materials, interior panels for houses, and the like, and a method for manufacturing the same. And shorten the molding cycle. SOLUTION: The laminated structural body 10 is lightweight and has a shape-retaining foamed resin base material 20, an outer peripheral frame 30 which is laminated and integrated on the inner surface side of the foamed resin base material 20, and extends along an outer periphery of a product. And a bridging rib 40 interposed therebetween. Therefore, the amount of resin can be reduced by using the lightweight foamed resin base material 20 and reducing the projected area of the outer peripheral frame 30 and the bridging rib 40 that are the synthetic resin molded bodies, thereby achieving weight reduction and cost reduction. .

Description

Detailed Description of the Invention

【０００１】[0001]

【発明の属する技術分野】この発明は、ドアトリム、リ
ヤサイドトリム、ラゲージトリム等の自動車用内装部品
及びその製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to automobile interior parts such as door trims, rear side trims and luggage trims.
And a manufacturing method thereof .

【０００２】[0002]

【従来の技術】例えば、自動車用内装部品の構成をドア
トリムを例示して図１９，図２０を基に説明する。2. Description of the Related Art For example, the structure of an automobile interior component will be described with reference to FIGS.

【０００３】ドアトリム１は、保形性及び車体パネルへ
の取付剛性を備えた樹脂芯材２の表面に、表面外観に優
れた表皮３を積層一体化して構成されている。The door trim 1 is constructed by laminating and integrating a surface skin 3 having an excellent surface appearance on the surface of a resin core material 2 having shape retention and mounting rigidity to a vehicle body panel.

【０００４】上記樹脂芯材２としては、タルクを混入し
たポリプロピレン系樹脂を素材としており、また、表皮
３は、それ自体保形性を備えておらず、塩ビシート等の
合成樹脂シートが使用され、最近では、環境面やリサイ
クル面を考慮して、ＴＰＯ（サーモプラスチックオレフ
ィン）シート等のエラストマーシートが多用される傾向
にある。The resin core material 2 is made of polypropylene resin mixed with talc, and the skin 3 does not have shape retention itself, and a synthetic resin sheet such as a vinyl chloride sheet is used. Recently, in consideration of the environment and the recycling, elastomer sheets such as TPO (thermoplastic olefin) sheets are often used.

【０００５】次に、上記ドアトリム１の成形方法につい
て、従来例を図２１を基に説明する。まず、ドアトリム
１を成形する成形金型４は、所定ストローク上下動可能
な成形上型５と、成形上型５と対をなす固定側の成形下
型６と、成形下型６と接続される射出機７とから大略構
成されている。Next, a conventional method for forming the door trim 1 will be described with reference to FIG. First, a molding die 4 for molding the door trim 1 is connected to a molding upper die 5 that can move up and down by a predetermined stroke, a fixed molding lower die 6 that is paired with the molding upper die 5, and a molding lower die 6. It is generally composed of an injection machine 7.

【０００６】そして、成形上下型５，６を型締めした
際、ドアトリム１の製品形状を形造るために成形上型５
にはキャビティ部５ａが形成され、成形下型６にはコア
部６ａが設けられている。上記、成形上型５を所定スト
ローク上下動作させるために、昇降シリンダ５ｂが連結
され、成形下型６には射出機７からの溶融樹脂の通路と
なるマニホールド６ｂ、ゲート６ｃが設けられている。When the upper and lower molding dies 5 and 6 are clamped, the upper molding die 5 is formed to shape the product shape of the door trim 1.
A cavity 5a is formed in the mold, and a lower mold 6 is provided with a core 6a. In order to move the upper molding die 5 up and down by a predetermined stroke, an elevating cylinder 5b is connected, and the lower molding die 6 is provided with a manifold 6b and a gate 6c which serve as a passage for the molten resin from the injection machine 7.

【０００７】また、上下動作する成形上型５は、適正姿
勢を維持させるために、成形下型６の４隅部にガイドポ
スト６ｄが設けられ、このガイドポスト６ｄに対応して
成形上型５にはガイドブッシュ５ｃが設けられている。Further, the upper molding die 5 which moves up and down is provided with guide posts 6d at the four corners of the lower molding die 6 in order to maintain an appropriate posture, and the upper molding die 5 corresponding to the guide posts 6d. The guide bush 5c is provided in the.

【０００８】従って、成形上下型５，６が型開き状態で
あるとき、表皮３を金型内にセットし、その後、成形上
下型５，６を型締めした後、両金型間の製品キャビティ
内に射出機７からマニホールド６ｂ、ゲート６ｃを通じ
て溶融樹脂Ｍを射出充填することにより、樹脂芯材２を
所要の曲面形状に成形するとともに、樹脂芯材２の表面
に表皮３を一体成形している。Therefore, when the upper and lower molds 5 and 6 are in the mold open state, the skin 3 is set in the mold, and then the upper and lower molds 5 and 6 are clamped, and then the product cavity between the molds. By injecting and filling the molten resin M from the injection machine 7 through the manifold 6b and the gate 6c, the resin core material 2 is molded into a required curved surface shape, and the surface skin 3 is integrally molded on the surface of the resin core material 2. There is.

【０００９】尚、図２１では、説明の便宜上、コア部６
ａの型面にオープン状態で溶融樹脂Ｍが供給されている
が、実際は、溶融樹脂Ｍは成形上下型５，６の型締め後
にキャビティ内に射出充填される。In FIG. 21, the core portion 6 is shown for convenience of explanation.
Although the molten resin M is supplied to the mold surface of a in an open state, in reality, the molten resin M is injected and filled into the cavity after the upper and lower molds 5 and 6 are clamped.

【００１０】[0010]

【発明が解決しようとする課題】しかしながら、従来の
ドアトリム１においては、樹脂芯材２の投影面積が大き
いため、材料コストが高く、かつ製品が重量化するとい
う欠点が指摘されている。However, in the conventional door trim 1, it is pointed out that the projected area of the resin core material 2 is large, so that the material cost is high and the product is heavy.

【００１１】また、樹脂芯材２の投影面積が大きいた
め、成形時における射出圧を高く設定せざるを得ず、高
い射出圧に耐え得る金型構造が必要となることから、金
型作製費用も高く、しかも、大量の溶融樹脂を冷却固化
させるため、成形サイクルが長期化するという不具合も
指摘されている。Also, since the projected area of the resin core material 2 is large, the injection pressure at the time of molding must be set high, and a mold structure capable of withstanding the high injection pressure is required. It is also pointed out that the molding cycle is prolonged because a large amount of molten resin is solidified by cooling.

【００１２】更に、表皮３は、非通気性である合成樹脂
シートをベースとするため、吸音性能に劣り、車室内騒
音に対する吸音性が期待できないという問題点も同時に
指摘されている。Further, since the skin 3 is made of a non-breathable synthetic resin sheet as a base, it has been pointed out that the sound absorbing performance is inferior and the sound absorbing property for the noise inside the vehicle cannot be expected.

【００１３】本発明は、このような事情に鑑みてなされ
たもので、軽量化を促進でき、かつ高剛性でコストダウ
ンを図れる自動車用内装部品を提供でき、しかも、成形
金型費用を低減でき、成形サイクルも短縮化できるとと
もに、吸音性能にも優れ、安全面、環境面、リサイクル
面でも有利である自動車用内装部品及びその製造方法を
提供することを目的とする。The present invention has been made in view of the above circumstances, and it is possible to provide an automobile interior component that can promote weight reduction, have high rigidity, and reduce costs, and further reduce the molding die cost. It is an object of the present invention to provide an automobile interior part which is capable of shortening a molding cycle, has an excellent sound absorbing property, and is advantageous in terms of safety, environment and recycling, and a method for producing the same.

【００１４】[0014]

【課題を解決するための手段】本発明者らは、上記課題
を解決するために、鋭意研究の結果、従来から表皮材料
として使用していた発泡樹脂シートに保形性を付与する
ことで、芯材としての機能をもたせ、より以上に剛性が
必要な箇所、すなわち製品の周縁部分やパネル、あるい
は部品取付箇所には、剛性に優れた合成樹脂成形体を配
置することで、本発明を完成するに至った。In order to solve the above-mentioned problems, the present inventors have earnestly studied and, as a result, imparted shape retention to a foamed resin sheet that has been conventionally used as a skin material, The present invention is completed by arranging a synthetic resin molded body having excellent rigidity at a position which has a function as a core material and requires more rigidity, that is, a peripheral portion of a product, a panel, or a part mounting position. Came to do.

【００１５】すなわち、本願発明は、車体パネルに取り
付けられる自動車用内装部品であって、この自動車用内
装部品は、軽量で、かつ形状を保持する機能をもつ発泡
樹脂基材と、この発泡樹脂基材の裏面側に積層一体化さ
れる外周フレーム及び外周フレーム間に連設され、上記
発泡樹脂基材の裏面に積層される所定パターン形状の橋
渡しリブとから構成され、前記発泡樹脂基材は、発泡樹
脂シートを加熱軟化処理後、成形金型を型締めすること
により、所要形状にプレス成形される一方、外周フレー
ム及び橋渡しリブは、同一の成形金型内に溶融樹脂を射
出充填することにより、該発泡樹脂基材の成形と同一工
程で該発泡樹脂基材の裏面に一体化され、前記外周フレ
ームの形状保持機能により、発泡樹脂基材における製品
端末の少なくとも一部は、車体パネル、あるいは隣接部
品表面に対して密着状に当接可能であることを特徴とす
る。That is, the present invention relates to an automobile interior part that is attached to a vehicle body panel, wherein the automobile interior part is a lightweight resin base material having a function of retaining its shape , and the foamed resin base material. A peripheral frame that is laminated and integrated on the back surface side of the material and is provided between the peripheral frames, and is composed of a bridging rib having a predetermined pattern that is laminated on the back surface of the foamed resin base material. Foam tree
Clamping the molding die after heating and softening the oil sheet
While it is pressed into the required shape,
The ribs and bridging ribs spray molten resin into the same mold.
By filling and discharging, the same process as molding of the foamed resin substrate can be performed.
The foamed resin base material is integrated with the back surface of the foamed resin base material at a later stage, and at least a part of the product end of the foamed resin base material is brought into close contact with the vehicle body panel or the surface of an adjacent part by the shape retaining function of the outer peripheral frame. Characterized by being able to contact.

【００１６】ここで、自動車用内装部品としては、ドア
トリム、リヤパーセルシェルフ、フロアトリム、ラゲー
ジトリム、トランクトリム、リヤサイドトリム等に適用
できる。The interior parts for automobiles are applied to door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, and the like.
I can .

【００１７】保形性を有する発泡樹脂基材は、フラット
形状に近い場合は、加熱軟化工程を省略して、成形型に
より所望形状に成形するが、三次元形状の製品に適用す
る場合は、発泡樹脂シートを加熱軟化処理した後、成形
金型内で所望の曲面形状に成形され、その形状を保持す
る。また、製品形状が高展開率を含む場合には、発泡樹
脂シートを加熱軟化処理した後、成形金型に真空吸引機
構を配設して真空吸引力で成形金型の内面に沿って真空
吸引力を作用するようにしても良い。When the foamed resin substrate having a shape-retaining property is close to a flat shape, the heating and softening step is omitted and it is molded into a desired shape by a molding die. However, when it is applied to a three-dimensional product, After heat-softening the foamed resin sheet, the foamed resin sheet is molded into a desired curved shape in a molding die and the shape is maintained. When the product shape contains a high expansion rate, after heat-softening the foamed resin sheet, a vacuum suction mechanism is installed in the molding die and vacuum suction is performed along the inner surface of the molding die with a vacuum suction force. Power may be applied.

【００１８】上記発泡樹脂シートとしては、熱可塑性樹
脂に発泡剤を添加した素材を使用する。尚、熱可塑性樹
脂は、１種類の熱可塑性樹脂でも２種類以上の熱可塑性
樹脂からなっても良い。好ましくは、ポリエチレン系樹
脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリ
エチレンテレフタレート系樹脂、ポリビニルアルコール
系樹脂、塩化ビニル系樹脂、アイオノマー系樹脂、アク
リロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂な
どが使用できる。As the foamed resin sheet, a material obtained by adding a foaming agent to a thermoplastic resin is used. The thermoplastic resin may be one kind of thermoplastic resin or two or more kinds of thermoplastic resins. Preferably, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin and the like can be used.

【００１９】また、発泡剤としては、アゾ化合物、スル
ホヒドラジド化合物、ニトロソ化合物、アジド化合物等
の有機発泡剤、あるいは重炭酸ナトリウム等の無機発泡
剤の使用が可能である。As the foaming agent, it is possible to use an organic foaming agent such as an azo compound, a sulfohydrazide compound, a nitroso compound or an azide compound, or an inorganic foaming agent such as sodium bicarbonate.

【００２０】上記発泡樹脂シートを加熱軟化処理後、所
要形状に成形して得た発泡樹脂基材は、製品の重量と強
度とのバランスを考慮した場合、２〜１０倍の発泡倍率
が好ましい。そのときの発泡樹脂基材のセル径は、０．
１μｍ〜２ｍｍの範囲であることが好ましく、厚みは
０．５〜３０ｍｍ、好ましくは１〜１０ｍｍのものが良
い。The foamed resin substrate obtained by heat-softening the foamed resin sheet and then molding it into a desired shape preferably has a foaming ratio of 2 to 10 in consideration of the balance between the weight and strength of the product. The cell diameter of the foamed resin base material at that time was 0.
The thickness is preferably in the range of 1 μm to 2 mm, and the thickness is 0.5 to 30 mm, preferably 1 to 10 mm.

【００２１】一方、外周フレームとして使用する熱可塑
性樹脂材料は、広範な熱可塑性樹脂から適宜選択するこ
とができる。通常好ましく使用できるものとして、ポリ
エチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン
系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニ
ルアルコール系樹脂、塩化ビニル系樹脂、アイオノマー
系樹脂、ポリアミド系樹脂、アクリロニトリル／ブタジ
エン／スチレン（ＡＢＳ）樹脂、ポリカーボネート樹脂
等が使用できる。On the other hand, the thermoplastic resin material used for the outer peripheral frame can be appropriately selected from a wide range of thermoplastic resins. Usually, preferably usable are polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, polyamide resin, acrylonitrile / butadiene / styrene (ABS). Resin, polycarbonate resin, etc. can be used.

【００２２】また、これら熱可塑性樹脂中に各種充填剤
を混入しても良い。使用できる充填剤としては、ガラス
繊維、カーボン繊維等の無機繊維、タルク、クレイ、シ
リカ、炭酸カルシウム等の無機粒子などがある。また、
酸化防止剤、紫外線吸収剤、着色剤、難燃剤、低収縮剤
等の各種の添加剤が配合されても良い。Further, various fillers may be mixed in these thermoplastic resins. Examples of fillers that can be used include inorganic fibers such as glass fibers and carbon fibers, and inorganic particles such as talc, clay, silica and calcium carbonate. Also,
Various additives such as an antioxidant, an ultraviolet absorber, a colorant, a flame retardant, and a low shrinkage agent may be blended.

【００２３】また、保形性を有する発泡樹脂基材は、外
周フレームに対して製品周縁部に沿って巻込み処理を行
なっても良く、また、相手部品との関係で隠れる部分な
どは、発泡樹脂基材と外周フレームとを同時切断処理
し、切断木口が現出していても良い。Further, the foamed resin base material having the shape-retaining property may be rolled up along the peripheral edge of the product with respect to the outer peripheral frame, and the portion hidden by the mating parts may be foamed. The resin base material and the outer peripheral frame may be simultaneously cut so that a cut edge is exposed.

【００２４】そして、本願発明に係る自動車用内装部品
によれば、保形性を有する発泡樹脂基材と、この発泡樹
脂基材の裏面側で、かつ製品周縁に沿って積層一体化さ
れる合成樹脂成形体からなる外周フレームと外周フレー
ム間に連設される橋渡しリブとから構成され、発泡樹脂
基材に芯材機能を付与し、より剛性が要求される部位に
合成樹脂成形体からなる外周フレーム及び橋渡しリブを
設けることで、従来の樹脂芯材を廃止することができ
る。従って、従来の投影面積の非常に広い樹脂芯材を廃
止することで、製品の軽量化を図ることができ、しか
も、樹脂材料を節約できることから、材料コストの低減
化も同時に達成できる。According to the automobile interior part of the present invention, the foamed resin base material having a shape-retaining property is laminated and integrated on the back side of the foamed resin base material and along the peripheral edge of the product. Outer frame and outer frame made of synthetic resin molding
It is composed of a bridging rib that is continuously provided between the frames , imparts a core material function to the foamed resin base material, and provides an outer frame and a bridging rib made of a synthetic resin molded body in a portion where higher rigidity is required, The conventional resin core material can be eliminated. Therefore, by eliminating the conventional resin core material having an extremely large projected area, the weight of the product can be reduced, and the resin material can be saved, so that the material cost can be reduced at the same time.

【００２５】また、発泡樹脂基材の多孔質吸音機能によ
り、吸音性能に優れた積層構造体が得られるとともに、
発泡樹脂基材及び外周フレームの素材として、ポリオレ
フィン系樹脂を使用した場合、オールオレフィン系樹脂
により、分離工程が廃止できるため、リサイクル作業を
簡素化できる。Further, due to the porous sound absorbing function of the foamed resin base material, a laminated structure having excellent sound absorbing performance can be obtained, and
When a polyolefin resin is used as the material of the foamed resin base material and the outer peripheral frame, the separation step can be eliminated by using the all-olefin resin, so that the recycling work can be simplified.

【００２６】更に、本願発明の別の実施態様において
は、外周フレームはフラット形状でも良いが、好ましく
は、断面形状が略Ｌ字形等の剛性形状に設定すれば、製
品形状を長期に亘り良好に保持できる。Further, in another embodiment of the present invention, the outer peripheral frame may have a flat shape, but preferably, if the cross-sectional shape is set to a rigid shape such as a substantially L-shape, the product shape will be excellent for a long period of time. Can hold

【００２７】また、好ましい実施態様としては、外周フ
レームのフレーム間に縦横方向に延びる橋渡しリブを設
けるのが良い。この橋渡しリブは、成形金型内で外周フ
レームを成形する際一体に成形できるとともに、特に、
発泡樹脂基材の裏面に当接する部位がプレート部となる
ように断面Ｌ字状、断面逆Ｔ字状のリブ形状を採用すれ
ば、製品表面に筋目が現出されず、外観見栄えが良いと
ともに、製品の形状保持性を高めることができる。In a preferred embodiment, bridging ribs extending in the vertical and horizontal directions may be provided between the frames of the outer peripheral frame. This bridging rib can be integrally molded when molding the outer peripheral frame in the molding die, and in particular,
By adopting a rib shape with an L-shaped cross section and an inverted T-shaped cross section so that the portion that comes into contact with the back surface of the foamed resin base material is the plate portion, no streaks appear on the product surface, and the appearance is good. The shape retention of the product can be improved.

【００２８】更に、橋渡しリブのリブ厚みは、例えば製
品に外力が大きく加わる部位などはリブ厚みを厚く設定
し、比較的外力が加わりにくい部位はリブ厚みを薄肉に
するなど、リブ厚みを適宜可変させることができる。従
って、必要最小限度の樹脂材料を使用すれば足り、製品
の軽量化やコストダウンに寄与できる。Further, the rib thickness of the bridging rib can be appropriately changed by, for example, setting a thick rib thickness in a portion where a large external force is applied to the product, and thinning a rib thickness in a portion where a relatively small external force is applied. Can be made. Therefore, it is sufficient to use the minimum necessary amount of resin material, which can contribute to weight reduction and cost reduction of the product.

【００２９】外周フレーム、あるいは橋渡しリブにクリ
ップ座、あるいは各種エスカッション部品を取り付ける
ための取付座を一体に形成することもできる。また、発
泡樹脂基材の表面に外観意匠性を高める表皮を積層する
こともできる。表皮としては、織布、不織布、編布、シ
ート、フィルム、発泡体、網状物などが使用できる。こ
れら表皮を構成する材料は特に限定されないが、織布、
不織布、編布等、通気性を有する素材を使用したほう
が、発泡樹脂基材の吸音性能を生かす意味で好ましい。A clip seat or a mounting seat for mounting various escutcheon parts may be integrally formed on the outer peripheral frame or the bridging rib. In addition, a skin that enhances the appearance design can be laminated on the surface of the foamed resin substrate. As the surface skin, woven cloth, non-woven cloth, knitted cloth, sheet, film, foam, reticulate material and the like can be used. The material constituting these skins is not particularly limited, but woven fabric,
It is preferable to use a material having air permeability such as a non-woven fabric or a knitted fabric in the sense that the sound absorbing performance of the foamed resin base material is utilized.

【００３０】次いで、本願発明に係る別の自動車用内装
部品は、請求項１又は２に記載の積層構造の内装部品
と、合成樹脂単体品とが接合された自動車用内装部品で
あって、上記内装部品における外周フレームと橋渡しリ
ブが合成樹脂単体品と同一の成形金型内で一体成形され
ていることを特徴とする。Next, another automotive interior part according to the present invention is an automotive interior part in which the laminated structure interior part according to claim 1 or 2 and a synthetic resin alone are joined. It is characterized in that the outer peripheral frame and the bridging ribs in the interior parts are integrally molded in the same molding die as that of the single synthetic resin product.

【００３１】ここでの自動車用内装部品としては、例え
ば上下に製品外観を相違させたツートンタイプのドアト
リム等に適用できる。例えば、ドアトリムアッパーは、
製品表面側に発泡樹脂シートを所要形状に成形してなる
保形性を有する発泡樹脂基材と、発泡樹脂基材の裏面に
外周フレーム、外周フレーム間に連設される橋渡しリブ
等の合成樹脂成形体との積層構造が使用され、ドアトリ
ムロアとしては、合成樹脂をパネル状に成形した合成樹
脂単体品から構成されている。The automobile interior parts herein can be applied to, for example, a two-tone type door trim having a vertically different product appearance. For example, the door trim upper is
A foamed resin base material having a shape-retaining property formed by molding a foamed resin sheet into the required shape on the product surface side, and a synthetic resin such as bridging ribs connected between the outer frame and the outer frame on the back surface of the foamed resin base material. layered structure of the shaped body is used, as the Doatorimuroa, molded synthetic resin synthetic resin panel shape
It is composed of a single piece of fat .

【００３２】従って、ドアトリムアッパーの如き積層構
造体は、従来の積層構造体のものに比べ、軽量な発泡樹
脂基材に芯材機能を付与したため、軽量化に貢献でき、
かつ供給樹脂量が少ないため、コストダウンにも繋が
る。Therefore, a laminated structure such as a door trim upper has a core material function added to a lightweight foamed resin base material as compared with a conventional laminated structure, which contributes to weight reduction.
In addition, the amount of resin supplied is small, which leads to cost reduction.

【００３３】次いで、本願発明に係る自動車用内装部品
の製造方法は、軽量でかつ所要形状に成形され、該形状
を保持する機能をもつ発泡樹脂基材と、該発泡樹脂基材
の裏面に積層一体化される外周フレーム及び橋渡しリブ
とからなる自動車用内装部品の製造方法において、前記
発泡樹脂基材の素材である発泡樹脂シートを予備加熱工
程で加熱軟化処理した後、成形金型内にセットする発泡
樹脂シートのセット工程と、成形金型同士を型締めし
て、成形金型のキャビティ形状に発泡樹脂シートを沿わ
せて、発泡樹脂基材を所要形状に成形するとともに、成
形金型のキャビティ内に溶融樹脂を射出充填して、外周
フレーム及び橋渡しリブを発泡樹脂基材の裏面側に積層
一体化する外周フレーム及び橋渡しリブの一体化工程と
からなることを特徴とする。Next, in the method for manufacturing an automobile interior part according to the present invention, a foamed resin base material which is lightweight and molded into a required shape and has a function of retaining the shape, and a back surface of the foamed resin base material are laminated. in peripheral frame and method of manufacturing automobile interior part comprising a bridging rib are integrated, pre-heating engineering the <br/> which is a material of the foamed resin base foamed resin sheet
After the heat-softening process, the process of setting the foamed resin sheet to be set in the molding die and the molds are clamped together, and the foamed resin sheet is placed along the cavity shape of the molding die to form the foamed resin. The base material is molded into the required shape, and the molten resin is injected and filled into the cavity of the molding die, and the outer peripheral frame and the bridging ribs are laminated and integrated on the back side of the foamed resin base material. And a chemical conversion step.

【００３４】ここで、成形金型は、上下動可能な成形上
型と、成形上型の下方側に位置する成形下型と、成形下
型に連結される射出機から構成され、射出機から供給さ
れる溶融樹脂は、成形下型に設けられたマニホールド、
ゲート等の樹脂通路を通じて成形下型の型面上に供給さ
れるが、成形上型が下死点まで下降して、成形上下型を
型締めした後、溶融樹脂が所定の射出圧でキャビティ内
に射出充填される。Here, the molding die is composed of a molding upper mold that can move up and down, a molding lower mold located below the molding upper mold, and an injection machine connected to the molding lower mold. The molten resin supplied is a manifold provided in the lower molding die,
It is supplied to the mold surface of the lower molding die through a resin passage such as a gate, but after the upper molding die descends to bottom dead center and the upper and lower molding dies are clamped, the molten resin is injected into the cavity with a prescribed injection pressure. Injection filled.

【００３５】従って、成形上下型の型締めにより、発泡
樹脂シートは、成形金型の型面形状に沿って成形される
とともに、溶融樹脂がキャビティ内に射出充填されるこ
とにより、外周フレーム及び橋渡しリブが形成され、こ
れら外周フレーム及び橋渡しリブが発泡樹脂基材の裏面
側に積層一体化される。Therefore, the foamed resin sheet is molded along the mold surface shape of the molding die by clamping the upper and lower molding dies, and the molten resin is injected and filled into the cavity to thereby form the outer peripheral frame and the bridge. Ribs are formed, and the outer peripheral frame and the bridging ribs are laminated and integrated on the back surface side of the foamed resin base material.

【００３６】また、本発明方法の別態様においては、マ
ニホールド、ゲート等を通じて溶融樹脂を射出充填する
タイミングは、成形上型が下死点に到達する前に行なっ
て、型締め時、成形上型のプレス圧によりキャビティ内
に溶融樹脂を行き渡らせ、外周フレーム及び橋渡しリブ
を形成するようにしても良い。Further, in another aspect of the method of the present invention, the timing of injecting and filling the molten resin through the manifold, the gate, etc. is performed before the upper mold reaches the bottom dead center, and when the upper mold is clamped, the upper mold is closed. The molten resin may be spread in the cavity by the pressing pressure of (1) to form the outer peripheral frame and the bridging rib.

【００３７】そして、製品形状が三次元形状に設定され
ている場合には、前工程でヒーター等により加熱軟化処
理を行なった後、発泡樹脂シートを成形金型内にセット
する。Then, when the product shape is set to a three-dimensional shape, the foamed resin sheet is set in a molding die after being subjected to a heat softening treatment by a heater or the like in the previous step.

【００３８】更に、成形金型内に加熱軟化状態の発泡樹
脂シートを供給した後、成形金型を型締めすれば、発泡
樹脂シートが所要形状に成形され、保形性を有する発泡
樹脂基材が得られる。Further, when the foamed resin sheet in a heat-softened state is supplied into the molding die and the molding die is clamped, the foamed resin sheet is molded into a required shape and has a shape-retaining foamed resin substrate. Is obtained.

【００３９】従って、保形性を有する軽量な発泡樹脂基
材の裏面に外周フレーム及び橋渡しリブを積層一体化で
きる。尚、最終製品形状が高展開状であれば、成形金型
の型締めを複数回行ない、最終の型締め工程で溶融樹脂
の射出を行なうと良い。Therefore, the outer peripheral frame and the bridging rib can be laminated and integrated on the back surface of the lightweight foamed resin base material having the shape-retaining property. If the final product has a highly expanded shape, it is preferable to perform mold clamping of the molding die a plurality of times and inject molten resin in the final mold clamping step.

【００４０】更に、製品形状が高展開率部分を含む場合
には、成形上型に真空吸引機構を配設し、成形上型の型
面に沿って真空吸引力により発泡樹脂基材を所要形状に
成形するようにしても良い。Further, when the product shape includes a high expansion rate portion, a vacuum suction mechanism is provided in the upper molding die, and the foamed resin base material is formed into a desired shape by a vacuum suction force along the mold surface of the upper molding die. You may make it shape | mold.

【００４１】従って、本発明方法によれば、従来の投影
面積の広い樹脂芯材に比べ、外周フレーム及び橋渡しリ
ブだけを成形するため、成形金型の負荷が少なくて済む
とともに、樹脂量も少なく、材料費を節約でき、しかも
従来の樹脂芯材に比べ冷却時間も少ないため、製品の成
形サイクルも短縮化できる。Therefore, according to the method of the present invention, since only the outer peripheral frame and the bridging rib are molded, the load of the molding die is small and the amount of resin is small as compared with the conventional resin core material having a large projected area. The material cost can be saved, and the cooling time is shorter than that of the conventional resin core material, so that the molding cycle of the product can be shortened.

【００４２】次いで、本発明方法の別の実施態様は、請
求項３に記載の自動車用内装部品の製造方法であって、
発泡樹脂基材の素材である発泡樹脂シートを予備加熱工
程で加熱軟化処理した後、成形金型内の所定位置にセッ
トする発泡樹脂シートのセット工程と、成形金型同士を
型締めして、成形金型のキャビティ形状に発泡樹脂シー
トを沿わせて、発泡樹脂基材を所要形状に成形するとと
もに、第１の射出機から樹脂通路を経て発泡樹脂基材の
裏面に溶融樹脂を供給して、外周フレーム及びこれと連
設する橋渡しリブを発泡樹脂基材の裏面に積層一体化し
て、積層構造の内装部品を成形する工程と、第２の射出
機から溶融樹脂を樹脂通路を経て発泡樹脂シートのセッ
トをされないエリアのキャビティ内に射出充填すること
により、合成樹脂単体品を前記内装部品と一体化する合
成樹脂単体品の一体化工程とからなることを特徴とす
る。Next, another embodiment of the method of the present invention is the method for manufacturing an automobile interior part according to claim 3 ,
Material preheating Engineering foamed resin sheet is a foamed resin base material
After the heat-softening process, the setting step of the foamed resin sheet is set at a predetermined position in the molding die, and the molding dies are clamped together, and the foamed resin sheet is placed along the cavity shape of the molding die. While molding the foamed resin base material into a required shape, the molten resin is supplied from the first injection machine to the back surface of the foamed resin base material through the resin passage, and the outer peripheral frame and the bridging rib continuous with this are formed into the foamed resin base. A step of stacking and integrating the back surface of the base material to form an internal component having a stacked structure, and injection-filling a molten resin from a second injection machine through a resin passage into a cavity of an area where a foamed resin sheet is not set. According to the present invention, a synthetic resin single-piece product is integrated with the interior component.

【００４３】この方法においても、製品形状が比較的フ
ラットな場合には、加熱工程を省略できる一方、製品形
状が三次元形状の場合には、発泡樹脂シートを加熱軟化
処理した後、成形金型内の必要とされる一部にセットす
れば良い。Also in this method, when the product shape is relatively flat, the heating step can be omitted. On the other hand, when the product shape is three-dimensional, the foamed resin sheet is subjected to the heat softening treatment and then the molding die. You can set it to the required part of the inside.

【００４４】そして、この方法の別態様としては、単一
の射出機から共有の樹脂通路、分岐樹脂通路を経て、外
周フレームと橋渡しリブ用の溶融樹脂を供給し、その
後、同一の射出機から共有の樹脂通路、分岐樹脂通路を
経て、合成樹脂単体品用の溶融樹脂を射出充填するよう
にしても良い。As another aspect of this method, the molten resin for the outer peripheral frame and the bridging rib is supplied from a single injection machine through a common resin passage and a branched resin passage, and then the same injection machine is used. It is also possible to inject and fill the molten resin for the single synthetic resin product through the common resin passage and the branched resin passage.

【００４５】従って、ツートンタイプの自動車用内装部
品を一工程で形成できるため、工数の短縮化を図れる。
また、２シリンダタイプの射出機ではなく、１シリンダ
タイプの射出機で対応した場合には、装置費用を削減で
きる。Therefore, a two-tone type automobile interior part
Since the product can be formed in one process, the number of steps can be shortened.
In addition, when a single cylinder type injection machine is used instead of a two cylinder type injection machine, the device cost can be reduced.

【００４６】[0046]

【発明の実施の形態】以下、本発明に係る自動車用内装
部品及びその製造方法の好適な実施の形態について、自
動車用ドアトリム及びその製造方法を例示して説明す
る。BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, an automobile interior according to the present invention
A preferred embodiment of a component and a manufacturing method thereof will be described by exemplifying an automobile door trim and a manufacturing method thereof.

【００４７】図１乃至図１２は本発明の第１実施形態を
示し、図１は本発明をドアトリムに適用した第１実施形
態を示す外観図、図２は同ドアトリムの構成を示す断面
図、図３は同ドアトリムの周縁部の構成を示す断面図で
ある。また、図４は同ドアトリムの変形例を示すもの
で、発泡樹脂基材を取り除いた外周フレームと橋渡しリ
ブとを示す斜視図、図５は橋渡しリブと発泡樹脂基材と
の関係を示す断面図、図６，図７は外周フレーム及び橋
渡しリブとクリップ座との関係を示す説明図である。更
に、図８乃至図１０は本発明方法をドアトリムの製造方
法に適用した第１実施形態を示す各工程図、図１１，図
１２は本発明に係る自動車用内装部品と隣接部品との合
わせ構造を示す説明図である。1 to 12 show a first embodiment of the present invention , FIG. 1 is an external view showing a first embodiment in which the present invention is applied to a door trim, and FIG. 2 is a sectional view showing the structure of the door trim. FIG. 3 is a sectional view showing a configuration of a peripheral portion of the door trim. FIG. 4 shows a modified example of the door trim, and is a perspective view showing the outer peripheral frame from which the foamed resin base material is removed and the bridging ribs, and FIG. 5 is a sectional view showing the relationship between the bridging ribs and the foamed resin base material. 6 and 7 are explanatory views showing the relationship between the outer peripheral frame, the bridging ribs, and the clip seat. 8 to 10 are process diagrams showing a first embodiment in which the method of the present invention is applied to a method for manufacturing a door trim, and FIGS. 11 and 12 show a structure for combining an automobile interior part and an adjacent part according to the present invention. FIG.

【００４８】そこで、図１乃至図１２に基づいて、本発
明の第１実施形態について説明する。Therefore, the first embodiment of the present invention will be described with reference to FIGS.

【００４９】まず、図１，図２において、自動車用ドア
トリム１０は、所望の曲面形状に成形された保形性を有
する発泡樹脂基材２０と、この発泡樹脂基材２０の裏面
側で、かつドアトリム１０の製品周縁に沿って積層一体
化される合成樹脂成形体からなる外周フレーム３０と、
これも発泡樹脂基材２０の裏面側に積層一体化され、外
周フレーム３０間に連設される橋渡しリブ４０とから大
略構成されている。First, in FIG. 1 and FIG. 2, an automobile door trim 10 includes a foamed resin base material 20 having a shape-retaining property formed into a desired curved surface shape, a back surface side of the foamed resin base material 20, and An outer peripheral frame 30 made of a synthetic resin molded body that is laminated and integrated along the product edge of the door trim 10,
This is also roughly composed of bridging ribs 40 that are laminated and integrated on the back surface side of the foamed resin substrate 20 and that are continuously provided between the outer peripheral frames 30.

【００５０】更に詳しくは、発泡樹脂基材２０の製品表
面の全面、あるいはその一部には、装飾性を付与する表
皮がラミネートされていても良い。また、ドアトリム１
０には、インサイドハンドルエスカッション１１、パワ
ーウインドウスイッチフィニッシャー１２、スピーカグ
リル１３、ポケットエスカッション１４等の各種樹脂部
品が取り付けられている。More specifically, the entire surface of the product of the foamed resin substrate 20 or a part thereof may be laminated with a skin for imparting decorativeness. Also, the door trim 1
Various resin parts such as an inside handle escutcheon 11, a power window switch finisher 12, a speaker grill 13, and a pocket escutcheon 14 are attached to the 0.

【００５１】ところで、上記発泡樹脂基材２０は、保形
性を備えるように発泡樹脂シートを加熱軟化処理後、所
望形状に熱成形、例えば、所望の型面を有する成形金型
でコールドプレス成形されるが、更に高展開率部分につ
いては、真空成形により発泡樹脂基材２０を賦形しても
良い。また、ジャキリッド等のリッド部品のようなフラ
ット形状の部品においては、発泡樹脂シートに加熱軟化
処理を行なわずに、フラット形状に成形することもでき
る。By the way, the foamed resin substrate 20 is formed by heat-softening the foamed resin sheet so as to have shape retention property, and then thermoformed into a desired shape, for example, cold press molding with a molding die having a desired mold surface. However, the foamed resin substrate 20 may be shaped by vacuum forming for a portion having a higher development rate. Further, in a flat-shaped component such as a lid component such as a jack lid, the foamed resin sheet can be molded into a flat configuration without performing the heat softening treatment.

【００５２】上記発泡樹脂シートは、汎用の熱可塑性樹
脂に発泡剤を添加した構成であり、熱可塑性樹脂として
は、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリ
スチレン系樹脂、ポリエチレンテレフタレート系樹脂、
ポリビニルアルコール系樹脂、塩化ビニル系樹脂、アイ
オノマー系樹脂、アクリロニトリル／ブタジエン／スチ
レン（ＡＢＳ）樹脂等が使用でき、発泡剤としては、ア
ゾジカルボンアミド等の有機発泡剤や重炭酸ナトリウム
等の無機発泡剤が使用できる。この実施形態では、ポリ
プロピレン系樹脂に重炭酸ナトリウムを適宜添加した発
泡樹脂シートを使用している。また、この発泡樹脂基材
２０の発泡倍率は、２〜１０倍に設定され、厚みは０．
５〜３０ｍｍ、特に１〜１０ｍｍの範囲に設定されてい
る。The foamed resin sheet has a structure in which a foaming agent is added to a general-purpose thermoplastic resin, and as the thermoplastic resin, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin,
Polyvinyl alcohol-based resin, vinyl chloride-based resin, ionomer-based resin, acrylonitrile / butadiene / styrene (ABS) resin and the like can be used. As the foaming agent, an organic foaming agent such as azodicarbonamide or an inorganic foaming agent such as sodium bicarbonate. Can be used. In this embodiment, a foamed resin sheet in which sodium bicarbonate is appropriately added to polypropylene resin is used. The expansion ratio of the foamed resin substrate 20 is set to 2 to 10 times and the thickness is 0.
It is set in the range of 5 to 30 mm, particularly 1 to 10 mm.

【００５３】次いで、外周フレーム３０は、汎用の合成
樹脂成形体からなり、通常好ましく使用できる合成樹脂
として、ポリエチレン系樹脂、ポリプロピレン系樹脂、
ポリスチレン系樹脂、ポリエチレンテレフタレート系樹
脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、
アイオノマー系樹脂、ポリアミド系樹脂、アクリロニト
リル／ブタジエン／スチレン（ＡＢＳ）樹脂、ポリカー
ボネート樹脂等から適宜選択されて良く、本実施形態で
は、環境面、リサイクル面を考慮してポリプロピレン系
樹脂が使用されている。Next, the outer peripheral frame 30 is made of a general-purpose synthetic resin molded body, and as a synthetic resin which can usually be preferably used, a polyethylene resin, a polypropylene resin,
Polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin,
It may be appropriately selected from an ionomer resin, a polyamide resin, an acrylonitrile / butadiene / styrene (ABS) resin, a polycarbonate resin, etc. In this embodiment, a polypropylene resin is used in consideration of environment and recycling. .

【００５４】また、この外周フレーム３０には、上記熱
可塑性樹脂中に適宜フィラー、例えば、ガラス繊維、カ
ーボン繊維等の無機繊維や、タルク、クレイ、シリカ、
炭酸カルシウム等の無機粒子等の充填剤が混入されてい
ても良い。Further, in the outer peripheral frame 30, fillers such as inorganic fibers such as glass fibers and carbon fibers, talc, clay, silica, and the like are added to the thermoplastic resin.
A filler such as inorganic particles such as calcium carbonate may be mixed.

【００５５】更に、図２に示すように、外周フレーム３
０間には、橋渡しリブ４０が配設されて、発泡樹脂基材
２０の保形性を補ない、ドアトリム１０としての良好な
形状保持性を確保している。この橋渡しリブ４０として
は、外周フレーム３０と一体成形する関係で同一素材を
使用する。Further, as shown in FIG. 2, the outer peripheral frame 3
A bridge rib 40 is provided between 0 to secure good shape retention as the door trim 10 without supplementing the shape retention of the foamed resin substrate 20. As the bridging rib 40, the same material is used because it is integrally molded with the outer peripheral frame 30.

【００５６】また、ドアトリム１０の製品外周に沿う外
周フレーム３０は、図３（ａ）に示すようにフラット状
に形成しても良いが、図３（ｂ）に示すように、断面Ｌ
字状に設定して剛性を強化するほうが好ましい。Further, the outer peripheral frame 30 along the outer periphery of the product of the door trim 10 may be formed in a flat shape as shown in FIG. 3A, but as shown in FIG.
It is preferable to set it in a letter shape to enhance rigidity.

【００５７】このように、図１乃至図３に示すドアトリ
ム１０は、保形性を有する発泡樹脂基材２０と、発泡樹
脂基材２０の裏面で、かつ製品外周に沿って積層一体化
される外周フレーム３０とから構成され、製品の形状保
持性を補強する目的で、所望ならば橋渡しリブ４０を外
周フレーム３０間に連接形成するという構成であるた
め、従来のように製品の全面に亘り占有していた樹脂芯
材を廃止でき、かつ軽量な発泡樹脂基材２０を使用する
関係で、製品の重量について、従来例に比し４０％以上
の軽量化を図ることができるとともに、樹脂材料も大幅
に節約でき、コストダウンにも貢献できる。As described above, the door trim 10 shown in FIGS. 1 to 3 is integrally laminated with the foamed resin base material 20 having shape retention property on the back surface of the foamed resin base material 20 and along the outer periphery of the product. Since it is composed of the outer peripheral frame 30 and the bridging rib 40 is connected between the outer peripheral frames 30 if desired in order to reinforce the shape retention of the product, it occupies the entire surface of the product as in the conventional case. Since the resin core material that has been used can be eliminated and the lightweight resin foam base material 20 is used, the weight of the product can be reduced by 40% or more compared with the conventional example, and the resin material is also used. It can save a lot and contribute to cost reduction.

【００５８】更に、発泡樹脂基材２０は、多孔質構造で
あるため、ドアトリム１０は、吸音性能に優れ、車室内
の騒音を低減することができる。また、発泡樹脂基材２
０の吸音性を維持するために、発泡樹脂基材２０の表面
に積層一体化される表皮は、織布、不織布、編布等の通
気性を備えたシート材料が好ましい。尚、表皮は、織
布、不織布、編布等の通気性シート以外にも合成樹脂シ
ート、合成樹脂フィルム、発泡体、網状体等を使用する
ことができる。Furthermore, since the foamed resin base material 20 has a porous structure, the door trim 10 has excellent sound absorbing performance and can reduce noise in the vehicle interior. In addition, the foamed resin substrate 2
In order to maintain the sound absorbing property of 0, the skin laminated and integrated on the surface of the foamed resin substrate 20 is preferably a sheet material having air permeability such as woven cloth, non-woven cloth, and knitted cloth. In addition to the breathable sheet such as woven cloth, non-woven cloth and knitted cloth, a synthetic resin sheet, a synthetic resin film, a foamed body, a net-like body or the like can be used as the skin.

【００５９】更に、発泡樹脂基材２０の端末処理は、図
２から明らかなように、例えば、ドアトリム１０上縁の
図示しないインナーシールを取り付けるためのフランジ
部分に当たる箇所は切りっ放しで切断木口が露出されて
いても良く、また、ドアトリム１０の下端縁は、目に触
れる箇所であるため、発泡樹脂基材２０を外周フレーム
３０の裏面側に巻込み処理して体裁を整えている。Further, as is apparent from FIG. 2, the end treatment of the foamed resin base material 20 is, for example, a portion of the upper edge of the door trim 10 which is a flange portion for attaching an inner seal (not shown) is left open and a cut wood mouth is cut. The door trim 10 may be exposed, and the lower end edge of the door trim 10 is a portion that is in contact with the eye. Therefore, the foamed resin base material 20 is wound around the rear surface side of the outer peripheral frame 30 to adjust the appearance.

【００６０】このように、ドアトリム１０は、製品の形
状保持は保形性を有する発泡樹脂基材２０で行なうとと
もに、製品周縁部、あるいは他の機能部品の取付部位や
車体パネル取付部位等、より以上の剛性が要求される箇
所は、外周フレーム３０及び橋渡しリブ４０を配置する
ことで所望の剛性を確保するようにしている。As described above, in the door trim 10, the shape of the product is retained by the foamed resin base material 20 having the shape-retaining property, and the peripheral portion of the product, the mounting portion of other functional parts, the mounting portion of the vehicle body panel, etc. At the location where the above rigidity is required, the outer frame 30 and the bridging ribs 40 are arranged to ensure the desired rigidity.

【００６１】従って、軽量でかつ低コストのドアトリム
１０を提供できるという有利さを備える一方、特に、外
周フレーム３０については、車体パネル５０に対して取
り付ける際、外周フレーム３０が強固な剛性を有するた
め、車体パネル５０との間にスキ等が発生することがな
く好ましい。Therefore, while having the advantage of being able to provide the door trim 10 that is light in weight and low in cost, particularly when the outer peripheral frame 30 is attached to the vehicle body panel 50, the outer peripheral frame 30 has a strong rigidity. It is preferable that there is no gap between the vehicle body panel 50 and the like.

【００６２】次いで、図４は発泡樹脂基材２０を取り外
して外周フレーム３０と橋渡しリブ４０を露出させた状
態を示しており、図示するように、この実施態様におい
ては、外周フレーム３０間を連設するように縦横方向に
延びる橋渡しリブ４０が一体に形成されている。Next, FIG. 4 shows a state in which the foamed resin base material 20 is removed to expose the outer peripheral frames 30 and the bridging ribs 40. As shown in the figure, the outer peripheral frames 30 are connected to each other in this embodiment. A bridging rib 40 extending in the vertical and horizontal directions is integrally formed so as to be installed.

【００６３】そして、この橋渡しリブ４０は、図５に示
すように、所望の剛性を確保できる補強構造を備えるこ
とが好ましく、その場合は、プレート部４１を発泡樹脂
基材２０と接触させることで、射出成形時、またはプレ
ス成形時に受ける圧力を広い面積で受け、荷重を分散で
きるため、製品表面にリブ４０に沿う筋目が現れること
がなく、製品外観を良好に保つことができる。As shown in FIG. 5, the bridging rib 40 preferably has a reinforcing structure capable of ensuring a desired rigidity. In this case, the plate portion 41 is brought into contact with the foamed resin base material 20. Since the pressure applied during injection molding or press molding can be received over a wide area to disperse the load, the product appearance can be kept good without the appearance of lines along the ribs 40 on the product surface.

【００６４】図５（ａ）は、橋渡しリブ４０が発泡樹脂
基材２０と当接するプレート部４１を備えた断面逆Ｔ字
状に形成され、かつリブ厚みを厚肉リブ４０ａに設定し
たもので、図５（ｂ）は、断面Ｌ字状をなす橋渡しリブ
４０で同様に発泡樹脂基材２０と接触面積を多く確保で
きるプレート部４１が形成されている。FIG. 5 (a) shows that the bridging rib 40 is formed in an inverted T-shape in cross section having a plate portion 41 that abuts the foamed resin substrate 20, and the rib thickness is set to the thick rib 40a. 5 (b), a plate portion 41 that can similarly secure a large contact area with the foamed resin substrate 20 is formed by a bridging rib 40 having an L-shaped cross section.

【００６５】更に、図４に示すように、縦横方向に延び
る橋渡しリブ４０を成形する際、例えば、インサイドハ
ンドルエスカッション１１、パワーウインドウスイッチ
フィニッシャー１２、スピーカグリル１３、ポケットエ
スカッション１４等の機能部品を取り付けるための取付
座４２を橋渡しリブ４０と一体に形成することもでき
る。Further, as shown in FIG. 4, when molding a bridging rib 40 extending in the vertical and horizontal directions, functional parts such as an inside handle escutcheon 11, a power window switch finisher 12, a speaker grill 13 and a pocket escutcheon 14 are attached. The mounting seat 42 for this can be formed integrally with the bridging rib 40.

【００６６】図４に示すように、４２ａはインサイドハ
ンドルエスカッション１１の取付座、４２ｂはパワーウ
インドウスイッチフィニッシャー１２の取付座、４２ｃ
はスピーカグリル１３の取付座、４２ｄはポケットエス
カッション１４の取付座をそれぞれ示す。尚、パワーウ
インドウスイッチフィニッシャー１２の取付座４２ｂ
は、板状に成形するのが製品表面の感触上、好ましい。As shown in FIG. 4, 42a is a mounting seat for the inside handle escutcheon 11, 42b is a mounting seat for the power window switch finisher 12, and 42c.
Is a mounting seat of the speaker grill 13 and 42d is a mounting seat of the pocket escutcheon 14. Incidentally, the mounting seat 42b of the power window switch finisher 12
It is preferable to form the sheet into a plate shape in terms of the feel of the product surface.

【００６７】更に、図６に示すように、橋渡しリブ４０
の裏面側には、車体パネル５０に取り付けるクリップ５
１を装着するためのクリップ座４３を一体成形すること
もでき、図７に示すように、クリップ座４３は、外周フ
レーム３０から内方に向けて延設形成することもでき
る。Further, as shown in FIG. 6, the bridging rib 40
On the back side of the clip 5 attached to the vehicle body panel 50
The clip seat 43 for mounting 1 can be integrally molded, and as shown in FIG. 7, the clip seat 43 can be formed so as to extend inward from the outer peripheral frame 30.

【００６８】次に、上記自動車用ドアトリム１０の製造
方法の一実施形態について、図８乃至図１０を基に説明
する。まず、ドアトリム１０の成形に使用する成形金型
６０は、所定ストローク上下動可能な成形上型６１と、
成形上型６１と対をなす固定側の成形下型６２と、成形
下型６２に接続される射出機６３とから大略構成されて
いる。Next, an embodiment of a method of manufacturing the automobile door trim 10 will be described with reference to FIGS. 8 to 10. First, a molding die 60 used for molding the door trim 10 includes an upper molding die 61 that can move up and down by a predetermined stroke.
The mold is generally composed of a fixed molding lower die 62 which is paired with the molding upper die 61, and an injection machine 63 which is connected to the molding lower die 62.

【００６９】更に詳しくは、成形上型６１は、製品形状
に合致したキャビティ部６１１が形成されており、成形
上型６１の上面に連結された昇降シリンダ６１２により
所定ストローク上下駆動される。また、成形上型６１の
４隅部には、ガイド機構となるガイドブッシュ６１３が
設けられている。More specifically, the upper molding die 61 is formed with a cavity portion 611 conforming to the shape of the product, and is vertically moved by a predetermined stroke by an elevating cylinder 612 connected to the upper surface of the upper molding die 61. Further, guide bushes 613 serving as guide mechanisms are provided at the four corners of the upper molding die 61.

【００７０】一方、成形下型６２には、成形上型６１の
キャビティ部６１１に対応するコア部６２１が設けられ
ている。また、このコア部６２１の型面に溶融樹脂を供
給するために、マニホールド６２２、ゲート６２３が設
けられており、このマニホールド６２２、ゲート６２３
の樹脂通路を経て射出機６３から供給される溶融樹脂Ｍ
がコア部６２１の上面に供給される。On the other hand, the lower molding die 62 is provided with a core portion 621 corresponding to the cavity portion 611 of the upper molding die 61. Further, a manifold 622 and a gate 623 are provided to supply the molten resin to the mold surface of the core portion 621. The manifold 622 and the gate 623 are provided.
Molten resin M supplied from the injection machine 63 through the resin passage of
Are supplied to the upper surface of the core portion 621.

【００７１】また、成形下型６２の４隅部には、ガイド
機構となるガイドポスト６２４が突設され、このガイド
ポスト６２４は、成形上下型６１，６２が型締めされる
際、ガイドブッシュ６１３内に案内されることで成形上
型６１のプレス姿勢を適正に維持できる。Further, guide posts 624, which serve as guide mechanisms, project from the four corners of the lower molding die 62. The guide posts 624 guide the guide bushes 613 when the upper and lower molding dies 61, 62 are clamped. The pressing posture of the upper molding die 61 can be appropriately maintained by being guided inside.

【００７２】そして、まず、ドアトリム１０を成形する
第１の工程として、発泡樹脂基材２０の素材である発泡
樹脂シートＳを成形上下型６１，６２が型開き状態にあ
るとき、成形上下型６１，６２内にセットするが、この
実施形態では、発泡樹脂シートＳとして、ポリプロピレ
ン製発泡シート（住友化学工業製、商品名：スミセラー
発泡ＰＰシート、発泡倍率＝３倍、厚み２ｍｍ）が使用
され、図９に示すように、ヒーター装置６４により、発
泡樹脂シートＳが１３０℃に加熱軟化処理された状態で
成形上下型６１，６２内に供給される。First, as the first step of molding the door trim 10, when the upper and lower molds 61, 62 are in the mold open state, the foamed resin sheet S, which is the material of the foamed resin base material 20, is formed. , 62, but in this embodiment, as the foamed resin sheet S, a polypropylene foamed sheet (manufactured by Sumitomo Chemical Co., Ltd., trade name: Sumiceller foamed PP sheet, expansion ratio = 3 times, thickness 2 mm) is used. As shown in FIG. 9, the heater device 64 supplies the foamed resin sheet S into the upper and lower molding dies 61 and 62 in a state where the foamed resin sheet S is heat-softened to 130 ° C.

【００７３】次いで、成形上下型６１，６２内に発泡樹
脂シートＳが供給された後、昇降シリンダ６１２が駆動
して、成形上型６１が所定ストローク下降し、図１０に
示すように、成形上型６１が下死点まで下降して、成形
上下型６１，６２が型締め状態になったとき、射出機６
３からマニホールド６２２、ゲート６２３を通じてドア
トリム１０における外周フレーム３０及び橋渡しリブ４
０、所望ならば各種機能部品１１〜１４の各取付座４２
ａ〜４２ｄの各合成樹脂成形体を成形するための溶融樹
脂Ｍが供給される。Next, after the foamed resin sheet S is supplied into the upper and lower molding dies 61, 62, the elevating cylinder 612 is driven to lower the molding upper die 61 by a predetermined stroke, and as shown in FIG. When the mold 61 descends to the bottom dead center and the molding upper and lower molds 61 and 62 are in the mold clamping state, the injection machine 6
3 through the manifold 622 and the gate 623, the outer peripheral frame 30 and the bridging rib 4 in the door trim 10.
0, each mounting seat 42 of various functional parts 11 to 14 if desired
The molten resin M for molding each of the synthetic resin moldings a to 42d is supplied.

【００７４】この溶融樹脂Ｍとしては、住友ノーブレン
ＡＸ５６８（住友化学工業製ポリプロピレン、メルトイ
ンデックス＝６５ｇ／１０分）でタルクが適宜割り合い
で混入されている。As the molten resin M, talc was mixed with Sumitomo Noblen AX568 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 minutes) at an appropriate ratio.

【００７５】従って、この成形上下型６１，６２による
型締め状態において、発泡樹脂シートＳは成形上型６１
のキャビティ部６１１の形状に即して賦形され、発泡樹
脂基材２０が所望形状に成形されるとともに、発泡樹脂
基材２０の内面側に外周フレーム３０及び橋渡しリブ４
０、所望ならば取付座４２ａ〜４２ｄが積層一体化され
る。Therefore, when the upper and lower molding dies 61, 62 are clamped, the foamed resin sheet S is formed on the upper molding die 61.
The foamed resin base material 20 is molded into a desired shape according to the shape of the cavity portion 611 of the outer peripheral frame 30 and the bridging ribs 4 on the inner surface side of the foamed resin base material 20.
0, if desired, the mounting seats 42a to 42d are integrally laminated.

【００７６】このように、発泡樹脂基材２０と外周フレ
ーム３０、橋渡しリブ４０の成形が一成形工程で行な
え、特に、従来の樹脂芯材に比べ、外周フレーム３０、
橋渡しリブ４０、所望ならば機能部品１１〜１４の取付
座４２ｃ〜４２ｄを成形するだけの溶融樹脂Ｍの供給量
で済むため、溶融樹脂量を節約でき、同時に成形上下型
６１，６２の負荷も低減できるとともに、射出機６３が
小容量で済み、射出機６３の小型化を図れる。尚、発泡
樹脂基材２０の表面に表皮をラミネートする仕様におい
ては、発泡樹脂シートＳの片面に表皮の原反シートを予
めラミネート処理しておけば良い。As described above, the foamed resin base material 20, the outer peripheral frame 30, and the bridging ribs 40 can be molded in one molding process. In particular, compared with the conventional resin core material, the outer peripheral frame 30,
Since the amount of the molten resin M required to mold the bridging ribs 40 and, if desired, the mounting seats 42c to 42d of the functional components 11 to 14 is sufficient, the amount of the molten resin can be saved, and at the same time, the loads on the upper and lower molding dies 61 and 62 can be reduced. In addition to the reduction, the injection machine 63 can have a small capacity, and the injection machine 63 can be downsized. Incidentally, in the specification of laminating the surface skin on the foamed resin base material 20, it is only necessary to laminate one surface of the foamed resin sheet S with the raw fabric sheet of the surface skin in advance.

【００７７】また、発泡樹脂シートＳから発泡樹脂基材
２０を成形する場合には、上述したように予めヒーター
装置６４により所定温度に加熱軟化処理した後、成形上
下型６１，６２の型締め時、溶融樹脂Ｍの射出時に所要
形状に賦形することもできるが、より高展開率で複雑な
曲面形状が要求される場合には、成形上型６１に真空吸
引機構を付設し、成形上下型６１，６２の型締め前、あ
るいは型締め時に成形上型６１から真空吸引力を作用さ
せて発泡樹脂基材２０を真空成形することもできる。When the foamed resin base material 20 is molded from the foamed resin sheet S, after heating and softening to a predetermined temperature by the heater device 64 in advance as described above, the mold upper and lower molds 61 and 62 are clamped. It is also possible to shape the molten resin M into a required shape at the time of injection, but when a higher development rate and a complicated curved surface shape are required, a vacuum suction mechanism is attached to the upper molding die 61 to form the upper and lower molding dies. The foamed resin base material 20 can be vacuum-molded by applying a vacuum suction force from the upper molding die 61 before or during mold clamping of 61 and 62.

【００７８】更に、成形上型６１を２段階制御すること
もできる。すなわち、第１段階の成形上下型６１，６２
の型締めにより、発泡樹脂シートＳのプレス成形を行な
い、発泡樹脂基材２０を一次成形し、その後、成形上型
６１を上昇させ、再度成形上型６１を下降させて、第２
の成形工程で予備成形された発泡樹脂基材２０と溶融樹
脂Ｍをキャビティ内に射出充填することで、外周フレー
ム３０及び橋渡しリブ４０、所望ならば機能部品の取付
座４２を一体成形することもできる。尚、ジャキリッド
等の単純形状の積層構造体に使用する発泡樹脂基材２０
は、発泡樹脂シートＳのプレヒート工程は省略でき、発
泡樹脂基材２０は単純形状の成形上下型６１，６２のキ
ャビティ形状に沿って成形されるだけである。Further, the upper molding die 61 can be controlled in two steps. That is, the upper and lower molding dies 61, 62 of the first stage
The foamed resin sheet S is press-molded by the die clamping, the foamed resin base material 20 is primarily molded, and then the upper molding die 61 is raised and the upper molding die 61 is lowered again.
It is also possible to integrally mold the outer peripheral frame 30, the bridging ribs 40 and, if desired, the mounting seat 42 of the functional component by injecting and filling the foamed resin base material 20 and the molten resin M, which have been preformed in the molding step, into the cavity. it can. It should be noted that the foamed resin base material 20 used for a laminated structure having a simple shape such as a jack lid.
The preheating step of the foamed resin sheet S can be omitted, and the foamed resin base material 20 is simply molded along the cavity shape of the simple molding upper and lower molds 61 and 62.

【００７９】上述した成形方法は、成形上下型６１，６
２を型締めした後、射出機６３からマニホールド６２
２、ゲート６２３を通じて溶融樹脂Ｍをキャビティ内に
射出圧力で充填する射出成形方式を採用したが、射出機
６３からの溶融樹脂の供給タイミングは、成形上型６１
が下死点に到達する前にキャビティ内に予め溶融樹脂Ｍ
を供給し、その後、成形上型６１が下死点まで下降した
際、そのときのプレス圧で製品キャビティ内に溶融樹脂
を充填させるスタンピングモールド方式を採用すること
もできる。尚、スタンピングモールド方式を採用すれ
ば、橋渡しリブ４０に多くのプレート部４１を採用する
ときに有利である。The above-mentioned molding method is the same as the molding upper and lower molds 61, 6
After clamping the mold 2 from the injection machine 63 to the manifold 62
2. The injection molding method in which the molten resin M is filled into the cavity with the injection pressure through the gate 623 is adopted, but the timing of supplying the molten resin from the injection machine 63 is the upper die 61.
Before the bottom dead center of the molten resin M
It is also possible to adopt a stamping mold system in which the molten resin is filled into the product cavity by the press pressure at that time when the upper mold 61 is lowered to the bottom dead center. The stamping mold method is advantageous when many plate portions 41 are used for the bridging ribs 40.

【００８０】以上、本発明に係る自動車用内装部品及び
その製造方法として、ドアトリム１０及びその製造方法
について説明したが、ドアトリム以外にも、例えば、図
１１（ａ），（ｂ）に示すように、トランクサイドトリ
ム７０やトランクリヤトリム７１に適用することもでき
る。Although the door trim 10 and the manufacturing method thereof have been described as the automobile interior parts and the manufacturing method thereof according to the present invention, other than the door trim, for example, as shown in FIGS. It can also be applied to the trunk side trim 70 and the trunk rear trim 71.

【００８１】この場合にも、トランクサイドトリム７０
及びトランクリヤトリム７１は、図１１（ｂ）に示すよ
うに、発泡樹脂基材２０と、製品の外周に沿う外周フレ
ーム３０、並びに橋渡しリブ４０とから構成されてい
る。尚、トランクサイドトリム７０やトランクリヤトリ
ム７１のような比較的、単純形状である場合には、発泡
樹脂基材２０及び外周フレーム３０の保形性だけで製品
の形状保持が行なわれるため、橋渡しリブ４０を廃止す
ることもできる。Also in this case, the trunk side trim 70
As shown in FIG. 11B, the trunk rear trim 71 includes a foamed resin base material 20, an outer peripheral frame 30 along the outer periphery of the product, and a bridging rib 40. When the trunk side trim 70 and the trunk rear trim 71 have a relatively simple shape, the shape of the product is retained only by the shape retention of the foamed resin base material 20 and the outer peripheral frame 30, and thus the bridging is performed. The rib 40 can be omitted.

【００８２】そして、本発明をトランクサイドトリム７
０やトランクリヤトリム７１に適用した場合、軽量な発
泡樹脂基材２０を使用し、かつ樹脂芯材を廃止し、外周
フレーム３０及び橋渡しリブ４０を合成樹脂成形体で構
成したため、軽量で低コスト化を図ることができるとと
もに、特に図１１（ｂ）に示すように、トランクサイド
トリム７０とトランクリヤトリム７１との合わせ部分に
おいて、硬質な双方の外周フレーム３０同士を突き合わ
せることで、スキの発生を確実に防止できるという有利
さがある。The present invention is applied to the trunk side trim 7 as well.
When applied to 0 or the trunk rear trim 71, the lightweight foamed resin base material 20 is used, the resin core material is abolished, and the outer peripheral frame 30 and the bridging ribs 40 are composed of a synthetic resin molded body. As shown in FIG. 11 (b), in particular, as shown in FIG. 11 (b), the rigid outer peripheral frames 30 are butted to each other at the joint portion of the trunk side trim 70 and the trunk rear trim 71, so that the There is an advantage that the occurrence can be reliably prevented.

【００８３】また、図１２に示すように、内装部品同士
の合わせの場合には、図１２（ａ）に示す自動車用内装
部品８０，８１同士のジョッグル合わせ、図１２（ｂ）
に示す自動車用内装部品８２，８３の平面同士の合わせ
の双方の場合についても、外周フレーム３０の高い剛性
を生かして、合わせた部分にスキが発生することが少な
く、合わせ部における良好な見栄えが得られる。Further, as shown in FIG. 12, in the case of fitting the interior parts to each other, the interior of the automobile shown in FIG.
Jogguru alignment of the parts 80 and 81 to each other, and FIG. 12 (b)
In both cases where the planes of the automobile interior parts 82 and 83 shown in FIG. 6 are aligned with each other, the high rigidity of the outer peripheral frame 30 is utilized to reduce the occurrence of scratches in the combined portion, and to provide a good appearance in the combined portion. can get.

【００８４】次いで、図１３乃至図１８に基づいて、本
発明の第２実施形態について説明する。図１３，図１４
は、本発明を適用したツートンタイプの自動車用ドアト
リム１００を示すもので、ドアトリム１００は、ドアト
リムアッパー部１１０とドアトリムロア部１２０が両者
の間に境界ライン１３０を介して製品外観を相違させて
構成されている。Next, a second embodiment of the present invention will be described with reference to FIGS. 13 and 14
1 shows a two-tone type vehicle door trim 100 to which the present invention is applied. The door trim 100 is configured such that a door trim upper portion 110 and a door trim lower portion 120 have different product appearances through a boundary line 130 therebetween. Has been done.

【００８５】すなわち、ドアトリムアッパー部１１０
は、発泡樹脂基材２０と、この発泡樹脂基材２０の裏面
側に製品外周に沿う外周フレーム３０、並びに、外周フ
レーム３０間に繋がる橋渡しリブ４０を一体化した合成
樹脂成形体とから構成されている。That is, the door trim upper portion 110
Is composed of a foamed resin base material 20, an outer peripheral frame 30 along the outer periphery of the product on the back side of the foamed resin base material 20, and a synthetic resin molded body in which a bridging rib 40 connected between the outer peripheral frames 30 is integrated. ing.

【００８６】従って、ドアトリムアッパー部１１０は、
第１実施形態のドアトリム１０の構成を準用したもの
で、保形性を備えた軽量化並びにコストダウンを図れ、
吸音性能の向上等が見込める。Therefore, the door trim upper portion 110 is
The structure of the door trim 10 of the first embodiment is applied mutatis mutandis, and it is possible to reduce the weight and cost with shape retention.
Improvement of sound absorption performance can be expected.

【００８７】また、ドアトリムロア部１２０は、合成樹
脂の射出成形体であり、ドアトリム１００の製品面を現
出するため、着色剤が混入され、スピーカグリル１２
１、ポケット開口１２２が開設され、ドアトリムアッパ
ー部１１０とドアトリムロア部１２０との境界ライン１
３０に沿って、境界部の見栄えを高めるために凹溝が形
成され、この凹溝内に発泡樹脂基材２０の端末が収容さ
れることにより接合部の見栄えを高めている。The door trim lower portion 120 is an injection-molded body made of synthetic resin, and in order to expose the product surface of the door trim 100, a coloring agent is mixed therein and the speaker grill 12
1. A pocket opening 122 is opened, and a boundary line 1 between the door trim upper part 110 and the door trim lower part 120
A groove is formed along the line 30 to enhance the appearance of the boundary, and the end of the foamed resin base material 20 is housed in the groove to enhance the appearance of the joint.

【００８８】そして、このツートンタイプのドアトリム
１００の製造方法の一実施形態について、図１５乃至図
１７に基づいて説明する。このツートンタイプのドアト
リム１００を成形する成形金型６０は、成形上型６１、
成形下型６２に加えて、２基の射出機６３ａ，６３ｂが
接続されている。この２基の射出機６３ａ，６３ｂに対
してドアトリム１００のドアトリムアッパー部１１０と
ドアトリムロア部１２０とにそれぞれ溶融樹脂Ｍ１，Ｍ
２を供給するための樹脂通路となるマニホールド６２２
ａ，６２２ｂとゲート６２３ａ，６２３ｂとが独立して
設けられている。尚、その他の構成は、図８に示す成形
金型６０の構成を準用するためここでは省略する。An embodiment of the method for manufacturing the two-tone type door trim 100 will be described with reference to FIGS. A molding die 60 for molding the two-tone type door trim 100 includes an upper molding die 61,
In addition to the lower molding die 62, two injection machines 63a and 63b are connected. With respect to the two injection machines 63a and 63b, molten resin M1 and M are respectively provided in the door trim upper portion 110 and the door trim lower portion 120 of the door trim 100.
Manifold 622 serving as a resin passage for supplying 2
a, 622b and gates 623a, 623b are provided independently. Note that other configurations are omitted here because the configuration of the molding die 60 shown in FIG. 8 is applied correspondingly.

【００８９】次いで、ツートンタイプのドアトリム１０
０の製造方法について説明する。まず、ドアトリムアッ
パー部１１０における発泡樹脂基材２０の素材となる発
泡樹脂シートＳを成形上型６１のキャビティ部６１１と
成形下型６２のコア部６２１で画成されるキャビティの
上半部分に図示はしないがヒーターにより加熱軟化処理
した後セットする。Next, a two-tone type door trim 10
The manufacturing method of 0 will be described. First, the foamed resin sheet S, which is the material of the foamed resin base material 20 in the door trim upper part 110, is shown in the upper half of the cavity defined by the cavity part 611 of the upper molding die 61 and the core part 621 of the lower molding die 62. Not set, but set after heating and softening with a heater.

【００９０】そして、発泡樹脂シートＳをセットした
後、成形上型６１の昇降シリンダ６１２が動作して、成
形上型６１が所定ストローク下降して、成形上下型６
１，６２が型締めされて発泡樹脂シートＳが所望の型面
形状に沿って賦形され、発泡樹脂基材２０が成形される
とともに、第１の射出機６３ａからマニホールド６２２
ａ、ゲート６２３ａを通じてドアトリムアッパー部１１
０における外周フレーム３０及び橋渡しリブ４０とを形
成するために、溶融樹脂Ｍ１がドアトリムアッパー部１
１０におけるキャビティ内に射出充填される。After the foamed resin sheet S is set, the elevating cylinder 612 of the upper molding die 61 operates to lower the upper molding die 61 by a predetermined stroke, and the upper and lower molding die 6 are moved.
1, 62 are clamped, the foamed resin sheet S is shaped along a desired mold surface shape, the foamed resin base material 20 is molded, and the first injection machine 63a to the manifold 622.
a, the door trim upper portion 11 through the gate 623a
In order to form the outer peripheral frame 30 and the bridging ribs 40 at 0, the molten resin M1 is applied to the door trim upper portion 1
Injection filled into the cavity at 10.

【００９１】同時に、ドアトリムロア部１２０を成形す
るために、第２の射出機６３ｂからマニホールド６２２
ｂ、ゲート６２３ｂを通じてキャビティの略下半部分に
溶融樹脂Ｍ２が射出充填され、ドアトリムロア部１２０
が所要形状に成形される。At the same time, in order to mold the door trim lower portion 120, the second injection machine 63b is connected to the manifold 622.
b, the molten resin M2 is injected and filled into the lower half of the cavity through the gate 623b.
Is molded into the required shape.

【００９２】従って、図１７は、ドアトリムアッパー部
１１０における発泡樹脂基材２０を取り外した状態を示
すもので、第１の射出機６３ａ、第２の射出機６３ｂか
らそれぞれ溶融樹脂Ｍ１，Ｍ２をキャビティ内に射出充
填することにより、ドアトリムアッパー部１１０におけ
る外周フレーム３０及び橋渡しリブ４０を所要形状に成
形するとともに、これと一体にドアトリムロア部１２０
が一体に成形される。Therefore, FIG. 17 shows a state in which the foamed resin base material 20 in the door trim upper portion 110 is removed, and the molten resins M1 and M2 are cavity-filled from the first injection machine 63a and the second injection machine 63b, respectively. The outer peripheral frame 30 and the bridging ribs 40 in the door trim upper portion 110 are molded into a required shape by injection filling into the interior of the door trim lower portion 120.
Are integrally molded.

【００９３】このように、ツートンタイプのドアトリム
１００を製造するには、成形下型６２に２基の射出機６
３ａ，６３ｂを連結して、ドアトリムアッパー部１１０
とドアトリムロア部１２０とについて、各樹脂通路を通
じて溶融樹脂Ｍ１，Ｍ２を射出充填することで、単一の
成形金型６０で、かつ工程数が短縮化された形でツート
ンタイプのドアトリム１００を製造することができる。As described above, in order to manufacture the two-tone type door trim 100, the lower molding die 62 is provided with two injection machines 6.
3a and 63b are connected to each other, and the door trim upper portion 110 is connected.
The two-tone door trim 100 is manufactured with a single molding die 60 and the number of steps is shortened by injecting and filling the molten resins M1 and M2 through the resin passages for the door trim lower portion 120 and the door trim lower portion 120. can do.

【００９４】そして、この方式では、ドアトリムアッパ
ー部１１０における外周フレーム３０及び橋渡しリブ４
０の素材とドアトリムロア部１２０の素材を相違させる
ことができ、それぞれの要求される項目に応じて、材料
を適宜変更することができる。In this method, the outer peripheral frame 30 and the bridging ribs 4 in the door trim upper portion 110 are also used.
The material of No. 0 and the material of the door trim lower part 120 can be made different, and the material can be appropriately changed according to each required item.

【００９５】次いで、図１８に示すように、ドアトリム
アッパー部１１０とドアトリムロア部１２０とに分岐し
て供給される溶融樹脂Ｍ１，Ｍ２を１基の射出機６３か
ら供給することもできる。Then, as shown in FIG. 18, the molten resins M1 and M2 branched and supplied to the door trim upper part 110 and the door trim lower part 120 can be supplied from one injection machine 63.

【００９６】この場合は、射出機６３と連通するメイン
マニホールド６２２ｃからそれぞれ分岐マニホールド６
２２ｄ，６２２ｅを分岐させて、個々のゲート６２３
ｄ，６２３ｅを設定するとともに、分岐部分に開閉弁を
設置することで、射出機６３からドアトリムアッパー部
１１０側に供給する溶融樹脂Ｍ１の供給タイミングと、
ドアトリムロア部１２０に溶融樹脂Ｍ２を供給するタイ
ミングをずらして行なえば、単一の射出機６３を通じて
ドアトリムアッパー部１１０とドアトリムロア部１２０
との一体成形が可能となる。In this case, from the main manifold 622c communicating with the injection machine 63 to the branch manifold 6 respectively.
22d and 622e are branched so that individual gates 623
By setting d and 623e and installing an opening / closing valve at the branching portion, the supply timing of the molten resin M1 supplied from the injector 63 to the door trim upper part 110 side,
If the timing of supplying the molten resin M2 to the door trim lower part 120 is shifted, the door trim upper part 110 and the door trim lower part 120 can be passed through the single injector 63.
It is possible to integrally mold with.

【００９７】従って、図１８に示す単一の射出機６３を
使用した場合、溶融樹脂Ｍ１，Ｍ２の供給タイミングを
ずらす必要があるものの、構造が２基の射出機６３ａ，
６３ｂを１基の射出機６３で代用でき、構造の簡素化が
図れる。Therefore, when the single injection machine 63 shown in FIG. 18 is used, it is necessary to shift the supply timings of the molten resins M1 and M2, but the injection machine 63a having two structures is used.
63b can be substituted by one injection machine 63, and the structure can be simplified.

【００９８】[0098]

【発明の効果】以上説明した通り、本発明に係る自動車
用内装部品は、軽量でかつ保形性を有する発泡樹脂基材
と、この発泡樹脂基材の裏面で、かつ製品の外周縁な
ど、剛性が要求される部位に積層一体化される外周フレ
ーム及び橋渡しリブとから構成されるため、従来の重量
の嵩む樹脂芯材を廃止できることから、軽量で低コス
ト、しかも、多孔質素材であるため、吸音性能に優れた
自動車用内装部品を提供できるという作用効果を有す
る。As described above, the automobile according to the present invention
Use interior component includes a foamed resin base material having a light weight and shape retention, the foam on the back surface of the resin base material, and the like outer periphery of the product, the outer peripheral frame and is integrally laminated to the site where rigidity is required Since it is composed of bridging ribs, the conventional heavy resin core material can be eliminated, so it is lightweight and low cost, and because it is a porous material, it has excellent sound absorption performance.
It has an effect that an automobile interior part can be provided.

【００９９】更に、成形金型のキャビティ形状に沿っ
て、発泡樹脂基材を所要形状に成形すると同時に発泡樹
脂基材の裏面側に外周フレーム及び橋渡しリブを成形す
るという工程を採用すれば、樹脂成形体である外周フレ
ームや橋渡しリブの投影面積が少ないため、従来の樹脂
芯材に比べ、成形金型にかかる負荷も少なく、かつ冷却
時間も短縮化でき、歩留まりを高めることができること
から、作業能率を高めることができるとともに、大幅な
コストダウンを招来できるという効果を有する。Further, if a step of molding the foamed resin base material into a desired shape along with the cavity shape of the molding die and simultaneously molding the outer peripheral frame and the bridging rib on the back surface side of the foamed resin base material is adopted, Since the projected area of the outer peripheral frame and bridging ribs, which are molded products, is small, compared to the conventional resin core material, the load on the molding die is less, the cooling time can be shortened, and the yield can be increased. It is possible to improve the efficiency and bring about a significant cost reduction.

[Brief description of drawings]

【図１】本発明を適用したドアトリムの第１実施形態を
示す斜視図である。FIG. 1 is a perspective view showing a first embodiment of a door trim to which the present invention is applied.

【図２】図１中II−II線断面図である。FIG. 2 is a sectional view taken along line II-II in FIG.

【図３】図１に示すドアトリムにおける製品周縁部と車
体パネルとの接合部の関係を示す説明図である。FIG. 3 is an explanatory diagram showing a relationship between a joint portion between a product peripheral portion and a vehicle body panel in the door trim shown in FIG.

【図４】図１に示すドアトリムの変形例を示すもので、
発泡樹脂基材を取り外したドアトリムを示す斜視図であ
る。FIG. 4 shows a modification of the door trim shown in FIG.
It is a perspective view which shows the door trim which removed the foaming resin base material.

【図５】図４に示すドアトリムにおける橋渡しリブと発
泡樹脂基材との接合部を示す断面図である。5 is a cross-sectional view showing a joint between a bridging rib and a foamed resin base material in the door trim shown in FIG.

【図６】本発明を適用したドアトリムにおける橋渡しリ
ブに一体成形したクリップ座を示すドアトリムを裏面側
からみた裏面図である。FIG. 6 is a rear view of the door trim showing the clip seat integrally formed with the bridging rib in the door trim to which the present invention is applied, as seen from the rear surface side.

【図７】同ドアトリムにおける外周フレームにクリップ
座を一体成形した構造を示す断面図である。FIG. 7 is a cross-sectional view showing a structure in which a clip seat is integrally formed with an outer peripheral frame of the door trim.

【図８】図１に示すドアトリムの製造方法における発泡
樹脂シートのセット工程を示す説明図である。8 is an explanatory diagram showing a step of setting a foamed resin sheet in the method for manufacturing the door trim shown in FIG.

【図９】発泡樹脂シートの予備加熱工程を示す説明図で
ある。FIG. 9 is an explanatory diagram showing a preheating step of the foamed resin sheet.

【図１０】図１に示すドアトリムの射出成形工程を示す
説明図である。10 is an explanatory diagram showing an injection molding process of the door trim shown in FIG. 1. FIG.

【図１１】本発明をトランクサイドトリムとトランクリ
ヤトリムに適用した状態を示す（ａ）外観図、（ｂ）接
合部の構成を示す断面図である。11 (a) is an external view showing a state in which the present invention is applied to a trunk side trim and a trunk rear trim, and FIG. 11 (b) is a sectional view showing a structure of a joint.

【図１２】本発明に係る自動車用内装部品と隣接部品と
の合わせを示す（ａ）ジョッグル合わせ、（ｂ）平面同
士の合わせをそれぞれ示す断面図である。FIG. 12 is a cross-sectional view showing (a) joggling and (b) plane-to-plane alignment showing the alignment of an automobile interior part and an adjacent part according to the present invention.

【図１３】本発明を適用したツートンタイプのドアトリ
ムを示す斜視図である。FIG. 13 is a perspective view showing a two-tone type door trim to which the present invention has been applied.

【図１４】図１３中XIV −XIV 線断面図である。14 is a sectional view taken along line XIV-XIV in FIG.

【図１５】図１３に示すツートンタイプのドアトリムの
製造方法における発泡樹脂シートのセット工程を示す説
明図である。FIG. 15 is an explanatory diagram showing a step of setting a foamed resin sheet in the method of manufacturing the two-tone type door trim shown in FIG.

【図１６】図１３に示すツートンタイプのドアトリムに
おける射出成形工程を示す説明図である。16 is an explanatory diagram showing an injection molding process in the two-tone type door trim shown in FIG.

【図１７】図１３に示すツートンタイプのドアトリムに
おけるドアトリムアッパー部の発泡樹脂基材を取り外し
た状態を示す平面図である。17 is a plan view showing a state in which a foamed resin base material of a door trim upper portion in the two-tone type door trim shown in FIG. 13 is removed.

【図１８】図１３に示すツートンタイプのドアトリムの
製造方法の別実施形態を示す説明図である。FIG. 18 is an explanatory view showing another embodiment of the method for manufacturing the two-tone type door trim shown in FIG. 13.

【図１９】従来のドアトリムを示す正面図である。FIG. 19 is a front view showing a conventional door trim.

【図２０】図１９中XX−XX線断面図である。20 is a sectional view taken along line XX-XX in FIG.

【図２１】従来のドアトリムの製造方法を示す概要図で
ある。FIG. 21 is a schematic view showing a conventional door trim manufacturing method.

[Explanation of symbols]

１０ドアトリム１１インサイドハンドルエスカッション１２パワーウインドウスイッチフィニッシャー１３スピーカグリル１４ポケットエスカッション２０発泡樹脂基材３０外周フレーム４０橋渡しリブ４０ａ厚肉リブ４１プレート部４２（４２ａ〜４２ｄ）取付座４３クリップ座５０車体パネル６０成形金型６１成形上型６１１キャビティ部６１２昇降シリンダ６２成形下型６２１コア部６２２マニホールド６２３ゲート６３射出機６３ａ第１の射出機６３ｂ第２の射出機６４ヒーター装置７０トランクサイドトリム７１トランクリヤトリム８０，８１，８２，８３自動車用内装部品１００ツートンタイプのドアトリム１１０ドアトリムアッパー部１２０ドアトリムロア部１３０境界ラインＭ，Ｍ１，Ｍ２溶融樹脂Ｓ発泡樹脂シート 10 door trim 11 Inside handle escutcheon 12 Power window switch finisher 13 speaker grill 14 Pocket Escussion 20 Foamed resin base material 30 outer frame 40 bridging rib 40a thick rib 41 Plate part 42 (42a to 42d) mounting seat 43 clip seat 50 body panel 60 Mold 61 Upper mold 611 cavity 612 Lifting cylinder 62 Lower mold 621 core part 622 manifold 623 gate 63 injection machine 63a First injection machine 63b Second injection machine 64 heater device 70 Trunk side trim 71 Trunk rear trim 80, 81, 82, 83Interior parts for automobiles 100 two-tone type door trim 110 Door trim upper part 120 Door trim lower part 130 boundary line M, M1, M2 molten resin S foam resin sheet

フロントページの続き (51)Int.Cl.⁷ 識別記号ＦＩ // Ｂ２９Ｋ 105:20 Ｂ２９Ｋ 105:20 (72)発明者相澤洋行神奈川県高座郡寒川町宮山3316番地河西工業株式会社内 (72)発明者小原清彦神奈川県高座郡寒川町宮山3316番地河西工業株式会社内 (56)参考文献特開平11−333880（ＪＰ，Ａ) 特開平６−315994（ＪＰ，Ａ) 特開平６−47856（ＪＰ，Ａ) 特開2001−26246（ＪＰ，Ａ) 特開2000−355254（ＪＰ，Ａ) 特開2002−293169（ＪＰ，Ａ) 実開昭61−167639（ＪＰ，Ｕ) (58)調査した分野(Int.Cl.⁷，ＤＢ名) B32B 1/00 - 35/00 B29C 43/00 - 45/84 B60R 13/00 - 13/08 Continuation of the front page (51) Int.Cl. ⁷ Identification code FI // B29K 105: 20 B29K 105: 20 (72) Inventor Hiroyuki Aizawa 3316 Miyayama, Samukawa-cho, Takaza-gun, Kanagawa Kasai Kogyo Co., Ltd. (72) Inventor Kiyohiko Ohara 3316 Miyayama, Samukawa-cho, Takaza-gun, Kanagawa Kasai Kogyo Co., Ltd. (56) Reference JP-A-11-333880 (JP, A) JP-A-6-315994 (JP, A) JP-A-6 -47856 (JP, A) JP 2001-26246 (JP, A) JP 2000-355254 (JP, A) JP 2002-293169 (JP, A) Actual development Sho 61-167639 (JP, U) (58) ) Fields surveyed (Int.Cl. ⁷ , DB name) B32B 1/00-35/00 B29C 43/00-45/84 B60R 13/00-13/08

Claims

(57) [Claims]

1. A vehicle body panel (50) automobile interior part which is attached to (10), the automobile interior part (10) is a lightweight and foamed resin base material having the function of retaining shape ( 20) and the outer peripheral frame (30) that is laminated and integrated on the back surface side of the foamed resin base material (20), and is continuously provided between the outer peripheral frame (30) and the back surface of the foamed resin base material (20). constructed from bridging ribs (40) having a predetermined pattern shape is, the foamed resin base material (2
0) is formed by heat-softening the foamed resin sheet (S) and then molding
By clamping the molds (61, 62), the required shape
While being press molded into, the outer frame (30) and bridge
The transfer rib (40) is in the same molding die (61, 62).
The molten resin (M) is injected and filled into
The foamed resin substrate (2
0), and at least a part of the product terminal of the foamed resin base material (20) is integrated with the rear surface of the vehicle body panel (50) or the surface of the adjacent component due to the shape retaining function of the outer peripheral frame (30). Interior parts for automobiles, which are capable of closely contacting each other.

Wherein said bridging ribs (40) is provided with an enhanced cross-sectional shape of the rigid includes a plate portion (41) which contacts the back surface and the surface of the foamed resin base material (20), the plate portion (4
According to 1), when molding the bridging rib (40), foamed resin base material
The automobile interior component according to claim 1, wherein the load applied to (20) is dispersed .

3. An automobile interior part (100) in which the laminated structure interior part (110) according to claim 1 or 2 and a synthetic resin single-piece product (120) are joined together. The outer peripheral frame (30) and the bridging rib (40) in 110) are the same as those of the single synthetic resin product (120).
An automobile interior part characterized by being integrally molded in a mold (61, 62) .

4. A foamed resin base material (20) which is lightweight and formed into a required shape and has a function of retaining the shape, and an outer peripheral frame (which is laminated and integrated on the back surface of the foamed resin base material (20). the method of manufacturing a 30) and bridging automobile interior part consisting of a rib (40) (10), and heated softening treatment the foamed resin base material (20) material in a foamed resin sheet (S) in the preheating step After, mold
The step of setting the foamed resin sheet (S) to be set in (61, 62) and the molds (61, 62) are clamped to each other to form the cavity (C) of the mold (61, 62). Along with the foamed resin sheet (S), the foamed resin base material (20) is molded into a required shape, and the molten resin is injected and filled in the cavity (C) of the molding die (61, 62) to form the outer periphery. The frame (30) and the bridging rib (40) are attached to the foamed resin substrate (2
0) The step of integrating the outer peripheral frame (30) and the bridging rib (40), which are laminated and integrated on the back surface side of 0), to a method for manufacturing an automobile interior part.

5. A light-weight resin foam base material (20) formed into a required shape and having a function of holding the shape, and an outer peripheral frame laminated and integrated on the back surface of the foam resin base material (20). A method for manufacturing an automobile interior part (10) comprising (30) and a bridging rib (40), wherein a foamed resin sheet (S), which is a material of the foamed resin substrate (20), is heated and softened in a preliminary heating step. After the forming mold
The step of setting the foamed resin sheet (S) to be set in (61, 62) and the molds (61, 62) are clamped to each other to form the cavity (C) of the mold (61, 62). Along with the foamed resin sheet (S), the foamed resin base material (20) is molded into a required shape, and before the molds (61, 62) are clamped, the cavity of the molding die (61, 62) is closed. The molten resin is injected and filled in (C), and then the molding die (61, 6)
Integration of the outer peripheral frame (30) and the bridging ribs (40) by laminating and integrating the outer peripheral frame (30) and the bridging ribs (40) on the back surface side of the foamed resin base material (20) by the press pressure due to the mold clamping. A method for manufacturing an automobile interior part, comprising the steps of:

6. An automobile interior part (1 ) according to claim 3.
00), wherein the foamed resin sheet (S), which is the material of the foamed resin substrate (20), is heat-softened in the preheating step and then placed at a predetermined position in the molding die (61, 62). The step of setting the foamed resin sheet (S) to be set and the molding dies (61, 62) are clamped to each other, and the foamed resin sheet (S) is formed into the cavity (C) shape of the molding dies (61, 62). Along with this, the foamed resin base material (20) is molded into a required shape, and the molten resin (M) is formed on the back surface of the foamed resin base material (20) through the resin passage from the first injection machine (63a).
1) is supplied, and the outer peripheral frame (30) and the bridging ribs (40) continuous with the outer peripheral frame (30) are laminated and integrated on the back surface of the foamed resin substrate (20) to form an interior component (110) having a laminated structure. A synthetic resin single-piece product by the process and the injection molding of the molten resin (M2) from the second injection machine (63b) through the resin passage into the cavity (C) in the area where the foamed resin sheet (S) is not set. (120) is integrated with the interior component (110), a synthetic resin unit product (120) is integrated, and a method of manufacturing an automobile interior component.

7. An automobile interior part (1 ) according to claim 3.
00), wherein the foamed resin sheet (S), which is the material of the foamed resin substrate (20), is heat-softened in the preheating step and then placed at a predetermined position in the molding die (61, 62). The step of setting the foamed resin sheet (S) to be set and the molding dies (61, 62) are clamped to each other, and the foamed resin sheet (S) is formed into the cavity (C) shape of the molding dies (61, 62). Along with this, the foamed resin base material (20) is molded into a required shape, and before the molds (61, 62) are clamped, the foamed resin base material is passed through the resin passage from the first injection machine (63a). The molten resin (M1) is supplied to the back surface of (20),
After that, the molding dies (61, 62) are clamped, and the press pressure is used to laminate the outer peripheral frame (30) and the bridging ribs (40) continuous with the outer peripheral frame (30) on the back surface of the foamed resin base material (20). And molding the interior component (110) having a laminated structure, and a molding die for an area where the foamed resin sheet (S) is not set through the resin passage of the molten resin (M2) from the second injection machine (63b). It is supplied to the (62) plane and the molding die (61, 6
The synthetic resin single-piece (120) which integrates the synthetic resin single-piece (120) with the interior parts (110) by the mold clamping of 2).
0) The integration step of 0), and a method for manufacturing an automobile interior part.

8. A resin passage (622d) for forming an outer peripheral frame (30) and a bridging rib (40) of an automobile interior component (110), and a resin passage (622e) for forming a synthetic resin unit (120). The molten resin (M1, M2) is supplied from one injection machine (63) by branching each of them from a common resin passage (622c). The automobile interior according to claim 6 or 7 , wherein Manufacturing method of parts.