JP3894985B2

JP3894985B2 - Cabin side member having air bag door and method for manufacturing the same

Info

Publication number: JP3894985B2
Application number: JP17548596A
Authority: JP
Inventors: 浩鈴木
Original assignee: Inoac Corp
Current assignee: Inoac Corp
Priority date: 1996-06-13
Filing date: 1996-06-13
Publication date: 2007-03-22
Anticipated expiration: 2016-06-13
Also published as: JPH101004A

Description

【０００１】
【発明の属する技術分野】
この発明は、自動車の車室側部材に関し、特にはエアバッグドア部を有する車室側部材およびその製法に関する。
【０００２】
【従来の技術】
例えば自動車の助手席側に設けられるエアバッグ装置は、図１２に示すように、折り畳まれたエアバッグＡがキャニスタと呼ばれる収容容器Ｃ内に、インフレータと呼ばれる作動装置Ｉとともに収容されて、助手席前面の車室側部材Ｐであるインストルメントパネル内に格納されている。エアバッグ収容容器Ｃの上部は、エアバッグＡが車室内に展開するための開口部Ｏとして構成されていて、この展開開口部Ｏがエアバッグドア部Ｄによって覆われている。そして、自動車の衝突によって作動装置Ｉが作動し、膨張したエアバッグＡがエアバッグドア部Ｄを裏側から押し開いて車室内に展開する。
【０００３】
前記車室側部材には、前記エアバッグドア部Ｄを別部材で別成形し、これを車室側部材の該当空所に取り付ける後付けタイプと、車室側部材と一体にエアバッグドア部Ｄを成形する一体タイプとがある。
前記後付けタイプは、エアバッグドアの組み付けの煩わしさや、組み付け時のバラツキ等の問題があり、それに対して一体タイプはそのような問題がない利点がある。この発明は、後者の一体タイプに関するものである。
【０００４】
従来における一体タイプの車室側部材の例として、図１２および図１３に示すものがある。この車室側部材（インストルメントパネル）Ｐは、合成樹脂発泡層１０１の上面に表皮１０２を一体に有し、該表皮１０２のエアバッグ展開開口部Ｏに対応する所定位置にはエアバッグドア部Ｄを画定する薄肉の破断予定部１０５が形成されている。
この表皮１０２の薄肉の破断予定部１０５は、表皮１０２の成形後に高周波ウェルダーや熱刃またはコールドプレスカッター等によって切り込みやＶ溝を入れることにより形成される。
図中、符号１０６は車室側部材Ｐの裏側芯材、１０７はエアバッグドア部Ｄの裏面に設けられたエアバッグドア用芯材、１０９はエアバッグ収容容器Ｃと芯材１０６（およびエアバッグドア用芯材１０７）とを固定する取付部材、Ｔは車室側部材Ｐの開裂予定部である。
【０００５】
この構造の車室側部材Ｐにあっては、前記したように、エアバッグＡが作動膨張すると、エアバッグ展開開口部Ｏ上部の車室側部材Ｐにおけるエアバッグドア部Ｄが裏面側から押され、その押上力によって表皮１０２の薄肉の破断予定部１０５に応力が集中して破断し、車室側部材の開裂予定部Ｔから開裂して、図１４のように、エアバッグドア部Ｄが開く。図１４の符号１０５ａ，１０５ｂは表皮１０２の破断した破断予定部、Ｔａ，Ｔｂは破断した開裂予定部を表す。そのエアバッグドア部Ｄの解放に伴ってエアバッグＡが車室内に展開する。
【０００６】
ところで、前記車室側部材Ｐの表皮１０２においてエアバッグドア部Ｄを画定する薄肉の破断予定部１０５は、その厚みを薄くする程エアバッグ膨張時に確実かつスムーズに破断できるようになる。
また、一般に自動車のインストルメントパネルのような車室側部材Ｐにあっては、車室内に照射される太陽光線や車室内の高熱により、時間の経過とともに表皮１０２が劣化、収縮し、しかも、その劣化、収縮は、表皮１０２の薄い部分に亀裂等の外観不良を引き起こし易いことが知られている。従って、前記薄肉の破断予定部１０５は、前記外観不良を防ぎかつエアバッグ膨張時の破断を確実かつスムーズにできる厚みに設定され、しかもその厚みで正確に形成される必要がある。
【０００７】
しかし、従来における薄肉の破断予定部１０５は、前記のように表皮１０２の成形後に高周波ウェルダーや熱刃またはコールドプレスカッター等によって切り込みやＶ溝を入れることにより形成されるため、厚みにバラツキを生じ易く、正確な厚みにするのが容易とは言い難かった。
【０００８】
【発明が解決しようとする課題】
この発明は、前記のような問題点に鑑みなされたもので、車室側部材の表皮に破断予定部を設けた場合において、該破断予定部が表皮の劣化、収縮により亀裂等の外観不良を引き起こすおそれがなく、しかもエアバッグの膨張時には確実に破断する、新規な構造のエアバッグドア部を有する車室側部材およびその製法を提供しようとするものである。
【０００９】
【課題を解決するための手段】
請求項１の発明は、合成樹脂発泡層上面にエアバッグドア部を画定する破断予定部が形成された表皮を一体に有する車室側部材において、前記表皮の裏面側には前記破断予定部に沿って断面略凸形状の合成樹脂成形体が設けられ、該合成樹脂成形体の突部によって前記表皮の破断予定部が表面まで分断されており、前記表皮は前記破断予定部のエアバッグドア部外側の裏面に係合突部を備え、前記合成樹脂成形体は前記破断予定部のエアバッグドア部側となる低部が、前記破断予定部のエアバッグドア部外側となる低部よりも前記合成樹脂成形体の突部からの幅が狭くされているとともに、前記破断予定部のエアバッグドア部外側となる低部表面に前記表皮の係合突部がはまる係合凹部が窪みまたは孔形状で設けられていることを特徴とするエアバッグドア部を有する車室側部材に係る。
【００１０】
この請求項１の発明によれば、エアバッグの膨張によりエアバッグドア部の裏面が押されると、表皮があらかじめ合成樹脂成形体の突部によって破断予定部で分断しているため、その破断予定部で車室側部材がスムーズかつ確実に開裂し、エアバッグドア部が車室内に開く。なお、破断予定部内を分断している合成樹脂成形体の突部が破断予定部と溶着していても、その溶着部分では強度が他部より弱いため、速やかに開裂する。しかも、表皮の破断予定部は合成樹脂成形体の突部によって塞がれているため、内側の合成樹脂発泡層が外部から見えず、車室側部材の外観を損なうこともない。
また、表皮の破断予定部はあらかじめ分断していて、薄肉ではなく、しかも合成樹脂成形体の突部によって塞がれているため、劣化により表皮が収縮しても破断予定部に応力が集中せず、亀裂等を生じにくいので、長期に渡って車室側部材の外観が良好である。しかも、その破断予定部は薄肉にして形成される必要がないため、破断予定部形成時に厚みのバラツキを生じず、常に一定品質が得られる。
【００１１】
さらに請求項１の発明によれば、前記表皮と断面凸形状の合成樹脂成形体とが、表皮裏面に形成された係合突部と合成樹脂成形体の低部に形成された係合凹部とによって、表皮の破断予定部のエアバッグドア部外側の裏面で係合しているため、車室側部材の製造時に合成樹脂体の位置がずれるおそれがなく、車室側部材の製造が容易になる。しかも、前記係合が、表皮裏面の破断予定部の外側、すなわち表皮裏面におけるエアバッグドア部の外側でなされているため、エアバッグ膨張時に、破断予定部の内側に区画形成されたエアバッグドア部の開きを妨げず、スムーズな解放を実現する。
【００１２】
一方、請求項２の発明は、車室側部材の製法に関するもので、表皮用樹脂材料による表皮のパウダースラッシュ成形時、パウダースラッシュ成形型の型面に形成された樹脂皮膜が未だ硬化する前に、該樹脂皮膜の表皮破断予定部に沿って、断面略凸形状の合成樹脂成形体の突部を圧入して該突部によって破断予定部が表面まで分断されかつ合成樹脂成形体と一体になった表皮を得る工程と、前記合成樹脂成形体によって破断予定部が分断された表皮の裏面側に、合成樹脂発泡材料を注入して合成樹脂発泡層を形成することにより、前記合成樹脂成形体が前記表皮と合成樹脂発泡層との間に埋設されかつエアバッグドア部を画定する破断予定部を備えた表皮を上面に有する車室側部材を得る工程とを含むことを特徴とするエアバッグドア部を有する車室側部材の製法に係る。
【００１３】
この請求項２の発明によれば、表皮のパウダースラッシュ成形時、未だ硬化前の樹脂皮膜の表皮破断予定部の裏面に断面凸形状の合成樹脂成形体の突部を圧入して、表面まで分断した破断予定部を有する表皮を形成するため、薄肉の破断予定部を形成する場合のようにその厚みがバラツクおそれがなく、一定品質の車室側部材を容易に得られる。また、得られる車室側部材は、請求項１の発明と同様に、エアバッグ膨張時にエアバッグドア部がスムーズに開くのみならず、劣化により破断予定部に亀裂等を生じるおそれがない。
【００１４】
また、請求項３の発明は、請求項２の表皮を得る工程において、あらかじめ合成樹脂成形体の突部の一側の低部表面に窪みまたは孔形状からなる係合凹部を形成しておき、該係合凹部を未だ硬化する前の樹脂皮膜の表皮破断予定部のエアバッグドア部外側となる裏面に位置させて、当該表皮破断予定部の裏面に沿って前記合成樹脂成形体の突部を圧入することにより、前記係合凹部にはまる係合突部を表皮の破断予定部のエアバッグドア部外側裏面に形成することを特徴とするエアバッグドア部を有する車室側部材の製法に係る。
【００１５】
この請求項３の発明によれば、表皮の破断予定部のエアバッグドア部外側の裏面に合成樹脂成形体が係合するため、表皮成形後の合成樹脂発泡層形成時に合成樹脂成形体の位置ずれ等を生じず、車室側部材の製造が容易となる。さらに、得られる車室側部材は、請求項１の発明と同様、エアバッグ膨張時にエアバッグドアのスムーズな解放を実現する。
【００１６】
【発明の実施の形態】
以下添付の図面に従ってこの発明を詳細に説明する。
図１は請求項１に記載された発明の一実施例を示す車室側部材の概略斜視図、図２は同実施例においてエアバッグ装置が取り付けられた部分の断面図、図３は図２の矢印３部分の拡大断面図、図４は同実施例における合成樹脂成形体の斜視図、図５は同実施例におけるエアバッグドア部が開いた状態を示す断面図である。
【００１７】
また、図６ないし図１１は請求項２および３に記載されたエアバッグドア部を有する車室側部材の製法に関するもので、図６は表皮の成形に用いられるパウダースラッシュ成形型を示す断面図、図７は図６のパウダースラッシュ成形型による樹脂皮膜成形時を示す断面図、図８はパウダースラッシュ成形型内の樹脂皮膜に合成樹脂成形体を圧入する際を示す断面図、図９はその圧入時を段階的に示す拡大断面図、図１０は表皮の裏面側に合成樹脂発泡材料を注入する状態を示す断面図、図１１はその発泡成形状態を示す断面図である。
【００１８】
図１ないし図３に示すように、請求項１に記載された発明は、インストルメントパネルのような車室側部材１０に係り、特に、合成樹脂発泡層１１の上面に、エアバッグドア部Ｄを画定する破断予定部１５が形成された表皮１２を一体に有するものに係る。符号Ｔは車室側部材の開裂予定部、２０は車室側部材の芯材、２１はその芯材２０の裏側に一体に設けられた裏打ち部材である。
なお、この車室側部材１０に取り付けられるエアバッグ装置は、先の従来技術の項で説明したものと同様の構造を有するもので、符号Ａはエアバッグ、Ｉはエアバッグの作動装置、Ｃはエアバッグ収容容器、Ｏはエアバッグ展開開口部である。
【００１９】
合成樹脂発泡層１１は、車室側部材１０の表面感触を良好とするためのもので、ポリウレタン発泡体等からなり、表皮１２の破断予定部１５と対応する位置の裏面にはスリット１１ａが形成され、エアバッグ膨張時にそのスリット１１ａ部分から開裂するようにされている。
【００２０】
また、表皮１２は車室側部材１０の表面を構成するもので、軟質塩化ビニル樹脂（ＰＶＣ）または熱可塑性ポリウレタン樹脂（ＴＰＵ）等からなり、公知のパウダースラッシュ成形によって所定の車室側部材表面形状に形成されている。
【００２１】
前記表皮１２の裏面側には、図３からよりよく理解されるように、表皮１２の破断予定部１５を表皮１２表面まで分断する断面凸形状の合成樹脂成形体３０が破断予定部１５に沿って設けられている。
【００２２】
この合成樹脂成形体３０は、後記する表皮１２のパウダースラッシュ成形時、硬化前の樹脂皮膜に突部３１が圧入されて破断予定部１５を分断し、またその後は破断予定部１５を塞いで表皮１２裏側の合成樹脂発泡層１１を隠蔽して車室側部材１０の外観を良好とするものである。この合成樹脂成形体３０の形状は、前記破断予定部１５を分断する突部３１とその両側の低部３２，３３とより構成される断面凸形状からなり、射出成形等によって前記破断予定部１５の形状に応じて形成されている。例えば、図１のように破断予定部１５が略Ｕ字形のものにあっては略Ｕ字形に形成される。
この合成樹脂成形体３０の材質は、表皮１２と同質のものあるいは異質のもの等適宜のものとされるが、表皮１２のパウダースラッシュ成形時に破断予定部１５を分断できるような硬さのもの、例えば軟質塩化ビニル樹脂等のようなものが好ましい。
【００２３】
また、この実施例の合成樹脂成形体３０は、破断予定部１５のエアバッグドア部Ｄ側となる低部３２が、破断予定部１５のエアバッグドア部Ｄ外側となる低部３３よりも突部３１からの幅が狭くされている。それによって、表皮１２のパウダースラッシュ成形時、未だ硬化前、特には溶融状態にある樹脂皮膜の表皮破断予定部裏面にこの合成樹脂成形体３０の突部３１が圧入された際に生じる表皮１２と合成樹脂成形体３０との溶着を、破断予定部１５のエアバッグドア部Ｄ側で小、外側で大となるようにし、エアバッグ膨張時にエアバッグドア部Ｄが合成樹脂成形体３０から速やかに分離して開くようにされている。
【００２４】
さらに、この実施例の合成樹脂成形体３０は、図３および図４からよりよく理解されるように、前記破断予定部１５のエアバッグドア部Ｄ外側となる低部３３の表皮１２側表面に係合凹部３４が形成され、該係合凹部３４に表皮裏面の係合突部１６がはまることによって、破断予定部１５のエアバッグドア部Ｄ外側で表皮１２と合成樹脂成形体３０の固着力が高められている。したがって、表皮１２の成形後に行う合成樹脂発泡層１１の成形時に、合成樹脂成形体３０が表皮１２から外れたり、位置がずれたりせず、作業が容易になる。また、相対的に破断予定部１５のエアバッグドア部Ｄ側で弱くなるため、エアバッグ膨張時にエアバッグドア部Ｄがより速やかに合成樹脂成形体３０から分離して開くようになる。前記係合凹部３４は、この実施例のように奥が拡大した略円形の窪みの他に、図示しない溝状の窪み、あるいは貫通孔等であってもよい。
また、前記合成樹脂成形体３０の係合凹部３４側の表面には接着剤を塗布しておいて、表皮１２をパウダースラッシュ成形する際、合成樹脂成形体３０の突部３１を樹脂皮膜に圧入する時に、前記接着剤により合成樹脂成形体３０の係合凹部３４側を樹脂皮膜（表皮１２）に接着してもよい。
なお、図４は、表皮１２の破断予定部１５を形成する前の合成樹脂成形体３０の形状を示し、その突部３１の表面３１ａが円弧状に膨らんだ状態となっている。
【００２５】
芯材２０は、車室側部材１０の裏面を補強するため等に設けられるもので、硬質塩化ビニル樹脂やポリプロピレン等から射出成形等によって形成されたものが用いられる。この実施例では、エアバッグドア部Ｄの裏側位置となる芯材２０裏面に、裏打ち部材２１が一体に埋設されている。この裏打ち部材２１はエアバッグの膨張によりエアバッグドア部Ｄが開く際に、芯材２０の一部がヒンジ部２３を構成できるようするためのもので、前記芯材２０よりも柔軟な材質、例えばポリオレフィン系熱可塑性エラストマー（ＴＰＯ）からなり、縁にエアバッグ収容容器Ｃを固定するための取付部２２を有する。なお、この芯材２０には前記ヒンジ部２３を残してスリット２４が前記表皮１２の破断予定部１５に対応して形成されている。また、前記取付部２２には所定位置に取付孔（ずしせず）が形成されていてボルト等でエアバッグ収容容器Ｃが取り付けられる。
【００２６】
このような構造からなる前記車室側部材１０にあっては、表皮１２の破断予定部１５があらかじめ断面凸形状の合成樹脂成形体３０の突部３１によって分断されていて、従来の薄肉の破断予定部のように極端に薄い部分が存在しないため、表皮１２の劣化により表皮１２が収縮しても破断予定部１５に応力が集中せず、該破断予定部１５に亀裂が生じるのを防ぐことができる。その結果、外観品質を良好に保つことができる。
【００２７】
また、エアバッグＡの作動時には、図５に示すように、エアバッグＡの膨張による押上力が芯材２０裏面の裏打ち部材２１に加わって、表皮１２破断予定部１５に応力が集中し、該破断予定部１５で区画されるエアバッグドア部Ｄを合成樹脂成形体３０から分離させるとともに、合成樹脂発泡層１１のスリット１１ａ部分を破断させ、車室側部材１０が開裂予定部Ｔから開裂し、エアバッグドア部Ｄが車室内に押し広げられる。
【００２８】
次に、前記構造の車室側部材の製法例について、図６ないし図１１を用いて説明する。なお、前記と同じ部材については同じ符号を用いて示す。
この製法は、合成樹脂成形体によって破断予定部が分断された表皮を得る工程と、前記表皮裏面側に合成樹脂発泡層を一体に形成する工程とを含む。
【００２９】
まず表皮を得る工程がなされる。この工程では、図６および図７に示すように公知のパウダースラッシュ成形型５０によってパウダースラッシュ成形がなされる。
パウダースラッシュ成形では、図６に示すように、パウダースラッシュ成形型５０と組み合わされるバケット５１のパウダー収容部５２に軟質塩化ビニル樹脂等の熱可塑性樹脂パウダーからなる表皮用樹脂材料６０が収容される。
【００３０】
次いで、熱循環パイプ５３，５３, …に加熱オイル等の熱媒を供給して成形型５０を加熱しながら、バケット５１と成形型５０を矢印ａのように所定回数回転させる。その回転によって、図７に示すように、バケット５１内の表皮用樹脂材料６０が成形型５０の型面５４に接触して、該型面５４の熱により溶融し、型面５４に所定厚みで層状に付着して型面形状の樹脂皮膜６１が形成される。
【００３１】
そして、前記バケット５１が成形型５０から外され、樹脂皮膜６１が未だ硬化する前、例えば溶融状態（例えば材料温度が１９０ないし２１０℃）にある間、あるいは軟化状態にある間に、図８および図９（９−Ａないし９−Ｃ）に示すように、表皮破断予定部に沿って前記合成樹脂成形体３０の突部３１が樹脂皮膜６１に圧入される。
【００３２】
その際、この実施例の合成樹脂成形体３０は、幅の狭い低部３２が表皮破断予定部のエアバッグドア部側、幅の広い低部３３側が表皮破断予定部のエアバッグドア部外側とされる。また、この樹脂皮膜６１内への圧入は、突部３１の表面３１ａが成形型５０の型面５４と圧着するまでなされる。
このとき、この実施例では、前記合成樹脂成形体３０の低部３３表面に係合凹部３４が設けられているため、前記圧入時に該低部３３表面と圧着する樹脂皮膜６１の裏面（型面５４とは反対側の面）が係合凹部３４内に入り込み前記係合突部１６を形成する。
なお、この圧入に際し、成形体の保持および昇降のための装置７５が用いられる。その装置７５として、シリンダ装置を用い、その作動部材先端に合成樹脂成形体３０を載置してもよい。
【００３３】
前記合成樹脂成形体３０の突部３１を、型面５４に圧着するまで硬化前の樹脂皮膜６１に圧入することにより、（９−Ｃ）図に示すように、合成樹脂成形体３０の突部３１が埋設されて該突部３１によって分断された破断予定部１５を有する表皮１２が得られる。なお、前記合成樹脂成形体３０の突部３１表面は、樹脂皮膜６１に圧入される際に樹脂皮膜６１の熱により軟化し、型面５４に圧着されることにより樹脂皮膜６１（表皮１２）の表面と一つの面を構成する。
【００３４】
また、前記合成樹脂成形体３０の突部３１の圧入を、溶融状態の樹脂皮膜６１に対して行う場合には、樹脂皮膜６１に圧入された突部３１は表皮１２の破断予定部１５と溶着する。その場合でも溶着部位は強度が低いため、エアバッグ膨張時に表皮の破断予定部１５で速やかに分離する。
他方、前記合成樹脂成形体３０の突部３１の圧入を、軟化状態の樹脂皮膜６１に対して行う場合には、樹脂皮膜６１に圧入された突部３１が表皮１２の破断予定部１５と溶着しないが、その場合でもその圧入によって破断予定部１５と突部３１が密着し合成樹脂成形体３０が表皮１２裏面に保持される。さらに、この実施例のように、前記合成樹脂成形体３０の低部３３表面に係合凹部３４が設けられたものにあっては、前記圧入時に表皮１２の裏面が係合凹部３４内に入り込み前記係合突部１６を形成するため、それによっても合成樹脂成形体３０が表皮１２裏面に固定される。
【００３５】
次いで、前記合成樹脂成形体３０の突部３１によって破断予定部１５が表面まで分断されかつ合成樹脂成形体３０と一体になった表皮１２の裏面側に、図２で示した合成樹脂発泡層１１が一体に形成される。
まず、図１０のように、発泡成形型８０の下型８１の型面８３に、前記表皮１２を裏面が内側（上向き）となるように配置する。他方発泡成形型８０の上型８２の型面８４には、前記裏打ち部材２１と一体になった前記構造の芯材２０を、適宜手段で保持して配置する。
【００３６】
そして、前記下型８１の表皮１２の裏面側に注入機のヘッド９０よりポリウレタン原料等の合成樹脂発泡原料９１を所定量注入した後、上型８２を閉じて発泡成形を行う。
合成樹脂発泡原料９１は発泡硬化して前記合成樹脂発泡層１１を形成して、合成樹脂成形体３０が表皮１２と合成樹脂発泡層１１との間に埋設され、かつ上面（型８０内では下側）にエアバッグドア部Ｄを画定する破断予定部１５を備えた表皮１２を有する前記車室側部材１０が得られる。
【００３７】
このように、前記製法によれば、合成樹脂成形体の突部によって分断された破断予定部を有する表皮の裏面側に合成樹脂発泡層を一体に有する車室側部材を、簡単かつ容易にしかも一定品質で得られる。
【００３８】
なお、前記の車室側部材およびその製法の例においては、裏打ち部材２１と一体になった芯材２０を用いたが、それに代えて、図１２で示したような芯材１０６とエアバッグドア用芯材１０７とよりなるものを用いてもよい。
【００３９】
【発明の効果】
以上図示し説明したように、この発明の車室側部材によれば、表皮の破断予定部が合成樹脂成形体の突部により分断されていて、該破断予定部が薄肉でなく、しかも前記突部によって塞がれているため、表皮の劣化により表皮が収縮しても破断予定部に応力が集中せず、亀裂等の外観不良を生じるおそれがない。
【００４０】
さらに、この発明の車室側部材によれば、表皮の破断予定部が合成樹脂成形体の突部によって分断されているため、従来の薄肉の破断予定部のように、その成形時に薄肉の厚みがバラツクこともなく、エアバッグ膨張時に破断予定部で車室側部材が確実かつスムーズに開裂してエアバッグドアを開くようにできる。
【００４１】
また、この発明の製法によれば、前記効果のある車室側部材を簡単かつ容易に、しかも一定品質で得ることができる。
【図面の簡単な説明】
【図１】この発明の一実施例を示す車室側部材の概略斜視図である。
【図２】同実施例においてエアバッグ装置が取り付けられた部分の断面図である。
【図３】図２の矢印３部分の拡大断面図である。
【図４】同実施例で用いられる合成樹脂成形体の斜視図である。
【図５】同実施例におけるエアバッグドア部が開いた状態を示す断面図である。
【図６】エアバッグドア部を有する車室側部材の製法一例においてパウダースラッシュ成形型を示す断面図である。
【図７】パウダースラッシュ成形型による樹脂皮膜成形時を示す断面図である。
【図８】合成樹脂成形体の圧入時を示す断面図である。
【図９】その圧入時を段階的に示す拡大断面図である。
【図１０】表皮の裏面側に合成樹脂発泡材料を注入する状態を示す断面図である。
【図１１】その発泡成形状態を示す断面図である。
【図１２】従来のエアバッグドア部を有する車室側部材の要部の断面図である。
【図１３】図１２の符号１３部分の拡大断面図である。
【図１４】従来の車室側部材においてエアバッグドアが開いた状態の断面図である。
【符号の説明】
１１合成樹脂発泡層
１２表皮
１５表皮の破断予定部
１６表皮の係合突部
３０合成樹脂成形体
３１合成樹脂成形体の突部
３２合成樹脂成形体の低部
３３合成樹脂成形体の低部
３４合成樹脂成形体の係合凹部
６０表皮用樹脂材料
６１樹脂皮膜
９１合成樹脂発泡原料[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a vehicle compartment side member of an automobile, and more particularly, to a vehicle compartment side member having an airbag door portion and a manufacturing method thereof.
[0002]
[Prior art]
For example, as shown in FIG. 12, an airbag device provided on the passenger seat side of an automobile has a folded airbag A housed in a housing container C called a canister together with an actuating device I called an inflator. It is stored in the instrument panel which is the front passenger compartment side member P. The upper part of the airbag container C is configured as an opening O through which the airbag A is deployed in the vehicle compartment, and the deployment opening O is covered with an airbag door D. Then, the actuation device I is actuated by the collision of the automobile, and the inflated airbag A pushes and opens the airbag door portion D from the back side to be deployed in the vehicle interior.
[0003]
In the vehicle compartment side member, the airbag door portion D is separately formed as a separate member and attached to the corresponding space of the vehicle compartment side member, and the airbag door portion D is integrated with the vehicle compartment side member. There is an integral type that molds.
The retrofit type has problems such as troublesome assembly of the airbag door and variations during the assembly, whereas the integral type has the advantage that there is no such problem. The present invention relates to the latter integrated type.
[0004]
As an example of a conventional integral-type compartment-side member, there are those shown in FIGS. The vehicle compartment side member (instrument panel) P has a skin 102 integrally on the upper surface of the synthetic resin foam layer 101, and an airbag door portion at a predetermined position corresponding to the airbag deployment opening O of the skin 102. A thin fracture target portion 105 that defines D is formed.
The thinly-scheduled fracture portion 105 of the skin 102 is formed by cutting or forming a V-groove with a high-frequency welder, a hot blade, a cold press cutter, or the like after the skin 102 is formed.
In the figure, reference numeral 106 denotes a back side core material of the passenger compartment side member P, 107 denotes an air bag door core material provided on the back surface of the air bag door portion D, 109 denotes an air bag housing container C and the core material 106 (and air bags). An attachment member T for fixing the bag door core member 107) is a scheduled opening portion of the passenger compartment side member P.
[0005]
In the passenger compartment side member P having this structure, as described above, when the airbag A is activated and inflated, the airbag door portion D of the passenger compartment side member P at the upper part of the airbag deployment opening O is pushed from the back side. Then, due to the pushing-up force, stress concentrates on the thin-walled planned breaking portion 105 of the skin 102, and breaks from the planned breaking portion T of the passenger compartment side member. As shown in FIG. open. Reference numerals 105a and 105b in FIG. 14 represent fractured portions of the skin 102, and Ta and Tb represent fractured portions to be broken. As the air bag door portion D is released, the air bag A is deployed in the passenger compartment.
[0006]
By the way, as the thickness of the thinly-scheduled breaking portion 105 that defines the airbag door portion D in the skin 102 of the passenger compartment side member P is reduced, it can be surely and smoothly broken when the airbag is inflated.
In general, in a vehicle compartment side member P such as an instrument panel of an automobile, the skin 102 deteriorates and shrinks over time due to sunlight rays or high heat in the vehicle interior, It is known that the deterioration and shrinkage tend to cause appearance defects such as cracks in the thin portion of the skin 102. Therefore, it is necessary that the thin-walled planned break portion 105 is set to a thickness that can prevent the appearance defect and can surely and smoothly break when the airbag is inflated, and be accurately formed with the thickness.
[0007]
However, the conventional thin-walled fracture portion 105 is formed by cutting or cutting a V-groove with a high-frequency welder, a hot blade, or a cold press cutter after the skin 102 is molded as described above, resulting in variations in thickness. It was easy, and it was difficult to say that it was easy to make the thickness accurate.
[0008]
[Problems to be solved by the invention]
The present invention has been made in view of the above-described problems, and when a planned fracture portion is provided in the skin of the vehicle compartment side member, the planned fracture portion has a poor appearance such as a crack due to deterioration or shrinkage of the skin. It is an object of the present invention to provide a vehicle compartment side member having an airbag door portion having a novel structure that can be surely broken when the airbag is inflated and a method for manufacturing the same.
[0009]
[Means for Solving the Problems]
The invention according to claim 1 is a vehicle compartment side member integrally having a skin that is formed with a planned fracture portion that defines an airbag door portion on the upper surface of the synthetic resin foam layer. A synthetic resin molded body having a substantially convex cross section is provided along the projected portion of the synthetic resin molded body, and the skin is cut to the surface by the projection, and the skin is the airbag door portion of the planned broken portion. comprising an engaging protrusion on the rear surface of the outer, the synthetic resin molded article is low part of the air bag door portion of the breakable portion than said lower portion comprising an air bag door portion outside of the breakable portion The width of the synthetic resin molded body from the projection is narrowed, and the engagement recess into which the engagement projection of the skin fits on the lower surface of the airbag door portion outside the portion to be broken is hollow or hole-shaped It is provided by According to the cabin side member having a Abaggudoa portion.
[0010]
According to the first aspect of the present invention, when the back surface of the airbag door portion is pushed due to the expansion of the airbag, the skin is divided in advance at the portion to be broken by the projection of the synthetic resin molded body. The vehicle compartment side member is smoothly and reliably cleaved at the portion, and the airbag door portion opens into the vehicle compartment. In addition, even if the protrusion of the synthetic resin molded body that divides the inside of the planned fracture portion is welded to the planned fracture portion, the welded portion is weaker than the other portions, so that it is quickly split. In addition, since the planned rupture portion of the skin is closed by the protrusion of the synthetic resin molded body, the inner synthetic resin foam layer cannot be seen from the outside, and the appearance of the passenger compartment side member is not impaired.
In addition, the planned fracture portion of the skin is divided in advance, is not thin, and is blocked by the projection of the synthetic resin molding, so that stress concentrates on the planned fracture portion even if the skin contracts due to deterioration. In addition, since cracks and the like are not easily generated, the appearance of the passenger compartment side member is good for a long time. In addition, since the portion to be broken does not need to be formed thin, there is no variation in thickness when the portion to be broken is formed, and a constant quality can always be obtained.
[0011]
Further, according to the invention of claim 1, the skin and the synthetic resin molded body having a convex cross section include an engagement protrusion formed on the back surface of the skin and an engagement recess formed in the lower part of the synthetic resin molded body. Accordingly, because of the engagement with the rear surface of the air bag door portion outside of the breakable portion of the skin, there is no possibility that shift the position of the synthetic resin body at the time of manufacture of the vehicle compartment side member, be easily produced in the passenger compartment-side member Become. In addition, since the engagement is made outside the planned break portion on the back surface of the skin, that is, outside the airbag door portion on the back surface of the skin, the airbag door is defined inside the planned break portion when the airbag is inflated. Smooth release is achieved without obstructing the opening of the part.
[0012]
On the other hand, the invention of claim 2 relates to a manufacturing method of a vehicle compartment side member, and before the powder slush molding of the skin with the resin material for the skin, the resin film formed on the mold surface of the powder slush molding mold is not yet cured. The protrusion of the synthetic resin molding having a substantially convex cross section is press-fitted along the planned skin rupture portion of the resin film, and the rupture portion is divided to the surface by the protrusion and integrated with the synthetic resin molding. A synthetic resin foam layer is formed by injecting a synthetic resin foam material on the back side of the skin where the portion to be ruptured is divided by the synthetic resin molded body. And a step of obtaining a vehicle compartment side member having an upper surface with an outer skin that is embedded between the outer skin and the synthetic resin foam layer and has a planned fracture portion defining the airbag door portion. Have part According to production method of that cabin side member.
[0013]
According to the second aspect of the present invention, at the time of powder slush molding of the skin, the protruding portion of the synthetic resin molded body having a convex cross section is press-fitted into the back surface of the skin rupture planned portion of the resin film that has not yet been cured, and is divided to the surface. In order to form the skin having the planned breakage portion, there is no fear that the thickness varies as in the case of forming the thin breakage planned portion, and a vehicle interior side member of a certain quality can be easily obtained. Further, as in the first aspect of the invention, the obtained passenger compartment-side member not only smoothly opens the airbag door portion when the airbag is inflated, but also does not cause a crack or the like in the planned fracture portion due to deterioration.
[0014]
Further, in the invention of claim 3, in the step of obtaining the skin of claim 2, an engagement recess made of a depression or a hole is formed in advance on the lower surface of one side of the projection of the synthetic resin molded body, The engaging recess is positioned on the back surface of the outer skin door portion of the resin film before being cured, and the protrusion of the synthetic resin molded body is projected along the back surface of the skin skin break portion. According to the manufacturing method of the vehicle compartment side member having the airbag door portion, the engagement protrusion that fits into the engagement recess is formed on the outer back surface of the airbag door portion of the skin rupture scheduled portion by press-fitting. .
[0015]
According to the invention of claim 3, since the synthetic resin molded body is engaged with the back surface outside the airbag door part of the planned skin rupture portion, the position of the synthetic resin molded body is formed when the synthetic resin foam layer is formed after the skin molding. A shift or the like does not occur, and manufacture of the compartment side member is facilitated. Furthermore, the vehicle compartment side member obtained achieves a smooth release of the airbag door when the airbag is inflated, as in the first aspect of the invention.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is a schematic perspective view of a passenger compartment side member showing an embodiment of the invention described in claim 1, FIG. 2 is a sectional view of a portion where an airbag device is attached in the embodiment, and FIG. FIG. 4 is a perspective view of the synthetic resin molded body in the embodiment, and FIG. 5 is a cross-sectional view showing a state in which the airbag door portion in the embodiment is opened.
[0017]
FIGS. 6 to 11 relate to a method for producing a vehicle compartment side member having an airbag door portion according to claims 2 and 3, and FIG. 6 is a cross-sectional view showing a powder slush mold used for molding a skin. FIG. 7 is a cross-sectional view showing the resin film molding by the powder slush mold of FIG. 6, FIG. 8 is a cross-sectional view showing the case where the synthetic resin molding is press-fitted into the resin film in the powder slush mold, and FIG. FIG. 10 is a cross-sectional view showing a state in which a synthetic resin foam material is injected into the back side of the skin, and FIG. 11 is a cross-sectional view showing the foam-molded state.
[0018]
As shown in FIG. 1 to FIG. 3, the invention described in claim 1 relates to a passenger compartment side member 10 such as an instrument panel, and in particular, on the upper surface of the synthetic resin foam layer 11, an airbag door portion D is provided. It is related to what has the skin 12 in which the fracture | rupture scheduled part 15 which demarcates was formed was formed. Reference numeral T denotes a planned tearing portion of the passenger compartment side member, 20 denotes a core member of the passenger compartment side member, and 21 denotes a backing member provided integrally on the back side of the core member 20.
The airbag device attached to the passenger compartment side member 10 has the same structure as that described in the section of the prior art. Reference numeral A denotes an airbag, I denotes an airbag operating device, C Is an airbag housing container, and O is an airbag deployment opening.
[0019]
The synthetic resin foam layer 11 is for improving the surface feel of the passenger compartment side member 10 and is made of polyurethane foam or the like. A slit 11a is formed on the back surface of the skin 12 at a position corresponding to the planned fracture portion 15. When the airbag is inflated, the slit 11a is cleaved.
[0020]
The skin 12 constitutes the surface of the passenger compartment side member 10 and is made of a soft vinyl chloride resin (PVC) or a thermoplastic polyurethane resin (TPU) or the like. It is formed into a shape.
[0021]
On the back surface side of the skin 12, a synthetic resin molded body 30 having a convex cross section that divides the planned fracture portion 15 of the skin 12 to the surface of the skin 12, along the planned fracture portion 15, as will be better understood from FIG. 3. Is provided.
[0022]
The synthetic resin molded body 30 has a protrusion 31 pressed into a resin film before being cured during powder slush molding of the skin 12 which will be described later, thereby dividing the planned fracture portion 15, and thereafter blocking the planned fracture portion 15 to cover the skin. 12 The synthetic resin foam layer 11 on the back side is concealed to improve the appearance of the passenger compartment side member 10. The shape of the synthetic resin molded body 30 is a convex cross section composed of a protrusion 31 that divides the planned fracture portion 15 and low portions 32 and 33 on both sides thereof, and the planned fracture portion 15 is formed by injection molding or the like. It is formed according to the shape. For example, as shown in FIG. 1, when the planned fracture portion 15 has a substantially U shape, it is formed in a substantially U shape .
The material of the synthetic resin molded body 30 is appropriately the same as or different from the skin 12, and has a hardness that can break the planned fracture portion 15 during powder slush molding of the skin 12. For example, a soft vinyl chloride resin or the like is preferable.
[0023]
Collision Moreover, the synthetic resin molded body 30 in this embodiment, lower portion 32 of the air bag door portion D side of the breakable portion 15, than the air bag door portion D outside become lower portion 33 of the breakable portion 15 The width from the portion 31 is narrowed. As a result, when the skin 12 is powder slush-molded, the skin 12 generated when the protrusion 31 of the synthetic resin molded body 30 is press-fitted to the back surface of the resin film that has not yet been cured, in particular, the surface of the resin film that is in a molten state. the welding of the synthetic resin molded body 30, a small, set to be larger at the outer, rapidly air bag door portion D when the airbag inflation is a synthetic resin molded body 30 in the air bag door portion D side of the breakable portion 15 It is designed to open separately.
[0024]
Further, the synthetic resin molded body 30 of this embodiment is formed on the surface of the lower portion 33 on the skin 12 side, which is the outer side of the airbag door portion D of the planned fracture portion 15, as can be better understood from FIGS. 3 and 4. The engagement recess 34 is formed, and the engagement protrusion 16 on the back surface of the skin is fitted into the engagement recess 34, whereby the adhesion force between the skin 12 and the synthetic resin molded body 30 on the outer side of the airbag door portion D of the planned fracture portion 15. Has been increased. Therefore, when the synthetic resin foam layer 11 is molded after the skin 12 is molded, the synthetic resin molded body 30 is not detached from the skin 12 and the position is not shifted, and the operation is facilitated. Further, since the air bag door D is weakened relatively on the side of the air bag door D of the portion 15 to be broken, the air bag door D is more quickly separated from the synthetic resin molded body 30 when the air bag is inflated. The engaging recess 34 may be a groove-like recess (not shown), a through hole, or the like, in addition to the substantially circular recess whose back is enlarged as in this embodiment.
Further, an adhesive is applied to the surface of the synthetic resin molded body 30 on the side of the engaging recess 34, and when the skin 12 is powder slush molded, the protrusion 31 of the synthetic resin molded body 30 is press-fitted into the resin film. When doing so, the engaging recess 34 side of the synthetic resin molded body 30 may be adhered to the resin film (skin 12) with the adhesive.
FIG. 4 shows the shape of the synthetic resin molded body 30 before forming the planned fracture portion 15 of the skin 12, and the surface 31 a of the projection 31 is in an arcuate state.
[0025]
The core member 20 is provided to reinforce the back surface of the passenger compartment-side member 10, and is formed of a hard vinyl chloride resin, polypropylene, or the like by injection molding or the like. In this embodiment, a backing member 21 is integrally embedded on the back surface of the core member 20 which is the back side position of the airbag door portion D. This backing member 21 is for allowing a part of the core member 20 to form the hinge portion 23 when the airbag door portion D is opened by inflation of the airbag, and is made of a material that is more flexible than the core member 20. For example, it is made of a polyolefin-based thermoplastic elastomer (TPO) and has an attachment portion 22 for fixing the airbag container C to the edge. A slit 24 is formed in the core member 20 so as to correspond to the planned fracture portion 15 of the skin 12, leaving the hinge portion 23. Further, the attachment portion 22 is formed with an attachment hole (not squeezed) at a predetermined position, and the airbag housing container C is attached with a bolt or the like.
[0026]
In the vehicle compartment side member 10 having such a structure, the planned fracture portion 15 of the skin 12 is divided in advance by the projection 31 of the synthetic resin molded body 30 having a convex cross section, and the conventional thin-walled fracture is performed. Since there is no extremely thin portion as in the planned portion, even if the skin 12 contracts due to deterioration of the skin 12, stress is not concentrated on the planned fracture portion 15 to prevent the planned fracture portion 15 from cracking. Can do. As a result, the appearance quality can be kept good.
[0027]
Further, during the operation of the airbag A, as shown in FIG. 5, the pushing force due to the expansion of the airbag A is applied to the backing member 21 on the back surface of the core member 20, and stress concentrates on the skin 12 planned fracture portion 15. The airbag door portion D defined by the planned breakage portion 15 is separated from the synthetic resin molded body 30, and the slit 11a portion of the synthetic resin foam layer 11 is broken, so that the passenger compartment side member 10 is cleaved from the planned cleavage portion T. The airbag door part D is spread out into the vehicle interior.
[0028]
Next, an example of a method for manufacturing the passenger compartment side member having the above structure will be described with reference to FIGS. In addition, about the same member as the above, it shows using the same code | symbol.
This manufacturing method includes a step of obtaining a skin in which a portion to be broken is divided by a synthetic resin molded body, and a step of integrally forming a synthetic resin foam layer on the back side of the skin.
[0029]
First, the process of obtaining the epidermis is performed. In this step, powder slush molding is performed by a known powder slush molding die 50 as shown in FIGS.
In powder slush molding, as shown in FIG. 6, a skin resin material 60 made of thermoplastic resin powder such as soft vinyl chloride resin is accommodated in a powder accommodating portion 52 of a bucket 51 combined with a powder slush mold 50.
[0030]
Next, while supplying a heat medium such as heated oil to the heat circulation pipes 53, 53,... And heating the mold 50, the bucket 51 and the mold 50 are rotated a predetermined number of times as indicated by an arrow a. By the rotation, as shown in FIG. 7, the skin resin material 60 in the bucket 51 comes into contact with the mold surface 54 of the mold 50 and melts by the heat of the mold surface 54, and the mold surface 54 has a predetermined thickness. A mold-shaped resin film 61 is formed by adhering in a layered manner.
[0031]
And before the said bucket 51 is removed from the shaping | molding die 50 and the resin film 61 is still hardened, for example, while it is in a molten state (for example, material temperature is 190 to 210 degreeC), or while it is in a softened state, FIG. As shown in FIG. 9 (9 -A to 9 -C), the protrusion 31 of the synthetic resin molded body 30 is press-fitted into the resin film 61 along the planned skin fracture portion.
[0032]
At that time, in the synthetic resin molded body 30 of this embodiment, the narrow low portion 32 is the airbag door portion side of the skin rupture scheduled portion, and the wide low portion 33 side is the outer side of the airbag door portion of the skin rupture planned portion. Is done. The press-fitting into the resin film 61 is performed until the surface 31 a of the protrusion 31 is pressure-bonded to the mold surface 54 of the mold 50.
At this time, in this embodiment, since the engaging recess 34 is provided on the surface of the lower portion 33 of the synthetic resin molded body 30, the back surface (mold surface) of the resin film 61 that is pressure-bonded to the surface of the lower portion 33 during the press-fitting. 54) enters the engagement recess 34 to form the engagement protrusion 16.
In this press-fitting, a device 75 for holding and raising / lowering the molded body is used. As the device 75, a cylinder device may be used, and the synthetic resin molded body 30 may be placed on the tip of the operating member.
[0033]
By pressing the protrusion 31 of the synthetic resin molded body 30 into the uncured resin film 61 until it is pressed against the mold surface 54, the protrusion of the synthetic resin molded body 30 is shown in FIG. A skin 12 having a planned fracture portion 15 in which 31 is embedded and divided by the projection 31 is obtained. Note that the surface of the protrusion 31 of the synthetic resin molded body 30 is softened by the heat of the resin film 61 when pressed into the resin film 61 and is crimped to the mold surface 54 to thereby form the resin film 61 (skin 12). Make up one surface with the surface.
[0034]
Further, in the case where the protrusion 31 of the synthetic resin molded body 30 is pressed into the molten resin film 61, the protrusion 31 pressed into the resin film 61 is welded to the planned fracture portion 15 of the skin 12. To do. Even in this case, since the strength of the welded portion is low, the welded portion is quickly separated at the planned rupture portion 15 of the skin when the airbag is inflated.
On the other hand, when the press-fitting of the protrusion 31 of the synthetic resin molded body 30 is performed on the softened resin film 61, the protrusion 31 press-fitted into the resin film 61 is welded to the planned fracture portion 15 of the skin 12. However, even in that case, due to the press-fitting, the planned fracture portion 15 and the projection 31 are brought into close contact with each other, and the synthetic resin molded body 30 is held on the back surface of the skin 12. Further, as in this embodiment, in the case where the engagement recess 34 is provided on the surface of the lower portion 33 of the synthetic resin molded body 30, the back surface of the skin 12 enters the engagement recess 34 during the press-fitting. In order to form the engaging protrusion 16, the synthetic resin molded body 30 is also fixed to the back surface of the skin 12.
[0035]
Next, the synthetic resin foamed layer 11 shown in FIG. 2 is formed on the back side of the skin 12 where the planned fracture portion 15 is divided to the surface by the protrusion 31 of the synthetic resin molded body 30 and integrated with the synthetic resin molded body 30. Are integrally formed.
First, as shown in FIG. 10, the skin 12 is arranged on the mold surface 83 of the lower mold 81 of the foam mold 80 so that the back surface is inside (upward). On the other hand, on the mold surface 84 of the upper mold 82 of the foam mold 80, the core material 20 having the structure integrated with the backing member 21 is appropriately held and disposed.
[0036]
Then, after a predetermined amount of a synthetic resin foam raw material 91 such as a polyurethane raw material is injected from the head 90 of the injection machine to the back surface side of the skin 12 of the lower mold 81, the upper mold 82 is closed and foam molding is performed.
The synthetic resin foam raw material 91 is foam-cured to form the synthetic resin foam layer 11, and the synthetic resin molded body 30 is embedded between the outer skin 12 and the synthetic resin foam layer 11, and the upper surface (lower in the mold 80 is lower). The vehicle compartment side member 10 having the skin 12 provided with the planned fracture portion 15 that defines the airbag door portion D on the side) is obtained.
[0037]
As described above, according to the above manufacturing method, the vehicle compartment side member integrally including the synthetic resin foam layer on the back surface side of the skin having the planned fracture portion divided by the protrusion of the synthetic resin molded body can be easily and easily realized. Obtained with constant quality.
[0038]
In the above-described case member and the manufacturing method thereof, the core member 20 integrated with the backing member 21 is used. Instead, the core member 106 and the airbag door as shown in FIG. 12 are used. A material composed of the core material 107 may be used.
[0039]
【The invention's effect】
As illustrated and described above, according to the passenger compartment side member of the present invention, the planned fracture portion of the skin is divided by the projection of the synthetic resin molded body, the planned fracture portion is not thin, and the projection Therefore, even if the epidermis contracts due to deterioration of the epidermis, the stress is not concentrated on the part to be ruptured, and there is no possibility of causing appearance defects such as cracks.
[0040]
Furthermore, according to the vehicle compartment side member of the present invention, since the planned fracture portion of the skin is divided by the projection of the synthetic resin molded body, the thickness of the thin wall at the time of molding is reduced like the conventional thin-walled fracture portion. There is no variation, and the compartment side member can be reliably and smoothly cleaved at the portion to be broken when the airbag is inflated to open the airbag door.
[0041]
Moreover, according to the manufacturing method of this invention, the said vehicle interior side member with the said effect can be obtained simply and easily, and with fixed quality.
[Brief description of the drawings]
FIG. 1 is a schematic perspective view of a passenger compartment side member showing an embodiment of the present invention.
FIG. 2 is a cross-sectional view of a portion where the airbag device is attached in the same embodiment.
FIG. 3 is an enlarged cross-sectional view of a portion indicated by an arrow 3 in FIG.
FIG. 4 is a perspective view of a synthetic resin molding used in the same example.
FIG. 5 is a cross-sectional view showing a state in which the airbag door portion in the same embodiment is opened.
FIG. 6 is a cross-sectional view showing a powder slush mold in an example of a method for producing a passenger compartment side member having an airbag door portion.
FIG. 7 is a cross-sectional view showing the time of forming a resin film with a powder slush mold.
FIG. 8 is a cross-sectional view showing when a synthetic resin molded body is press-fitted.
FIG. 9 is an enlarged sectional view showing the press-fitting step by step.
FIG. 10 is a cross-sectional view showing a state in which a synthetic resin foam material is injected into the back side of the skin.
FIG. 11 is a cross-sectional view showing the state of foam molding.
FIG. 12 is a cross-sectional view of a main part of a passenger compartment side member having a conventional airbag door portion.
13 is an enlarged cross-sectional view of reference numeral 13 in FIG.
FIG. 14 is a cross-sectional view showing a state in which an airbag door is opened in a conventional compartment-side member.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 Synthetic resin foam layer 12 Skin 15 The skin expected break part 16 Skin engaging protrusion 30 Synthetic resin molding 31 Synthetic resin molding 32 Lower part of synthetic resin 33 Lower part of synthetic resin molding 34 Engaging recess of synthetic resin molded body 60 Resin material for skin 61 Resin film 91 Synthetic resin foam raw material

Claims

In the vehicle compartment side member integrally having an outer skin (12) formed with a planned fracture portion (15) defining the airbag door portion (D) on the upper surface of the synthetic resin foam layer (11),
A synthetic resin molded body (30) having a substantially convex cross section is provided on the back side of the skin (12) along the planned fracture portion (15), and the skin is formed by the protrusion (31) of the synthetic resin molded body. The planned fracture portion (15) is divided to the surface,
The skin (12) includes an engagement protrusion (16) on the back surface of the outer side of the airbag door portion of the planned break portion (15),
The synthetic resin molded body (30) is the breakable portion has an air bag door portion and becomes lower portion (15) (32), said air bag door portion outside become lower portion of the breakable portion (15) (33 ) Is narrower than the protrusion (31) of the synthetic resin molded body, and the surface of the lower skin (33) on the outer side of the airbag door portion of the planned breaking portion (15) A vehicle compartment side member having an airbag door portion, wherein the engagement recess (34) into which the mating protrusion (16) fits is provided in a hollow or hole shape.

During powder slush molding of the skin with the resin material for the skin, before the resin film formed on the mold surface of the powder slush mold is still cured, a composite with a substantially convex cross section along the planned skin rupture portion of the resin film A step of press-fitting a protrusion of the resin molded body to obtain a skin in which the portion to be broken is divided to the surface by the protrusion and integrated with the synthetic resin molded body;
By injecting a synthetic resin foam material to form a synthetic resin foam layer on the back surface side of the skin where the portion to be broken is divided by the synthetic resin molded article, the synthetic resin molded article is formed of the skin and the synthetic resin foam layer. And a step of obtaining a vehicle compartment side member having a skin on the upper surface with a to-be-ruptured portion that is embedded between and demarcating the air bag door portion. The manufacturing method.

3. In the step of obtaining the skin of claim 2, before forming a concave recess or a hole-shaped engagement recess in advance on the lower surface of one side of the projection of the synthetic resin molded body, and before curing the engagement recess of the air bag door portion outer skin breakable portion of the resin film by positioning the rear surface by press-fitting the projections of the molded synthetic resin along the back surface of the skin breakable portion, the engaging recess A method for producing a vehicle compartment side member having an airbag door portion, wherein an engaging projection to be fitted is formed on an outer back surface of an airbag door portion of a skin rupture scheduled portion.