JP3963264B2 - Interior parts for automobiles and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an automobile interior part mounted on a side wall panel of a vehicle, such as a door trim and a rear side trim, and a manufacturing method thereof, and more particularly, to an automotive interior part that is lightweight and can reduce the number of mounting steps and a manufacturing method thereof.
[0002]
[Prior art]
Usually, various interior parts for automobiles are mounted in the vehicle interior, and a typical example of the interior parts is an automotive door trim mounted on a side wall panel of the vehicle.
[0003]
The configuration of the automobile door trim will be described with reference to FIGS. 12 and 13. The automobile door trim 1 is swelled indoors, and the armrest 1a is placed at the center of the vehicle so that the passenger rests on the elbow. A door pocket 1b capable of accommodating equipment is formed below and a speaker grille 1c is formed on the front side thereof.
[0004]
As shown in FIG. 13, the automobile door trim 1 is molded into a required shape, laminated with a resin core material 3 having shape retention and mounting rigidity with respect to the door panel 2, and a good surface texture and It is composed of an epidermis 4 having a touch feeling.
[0005]
Furthermore, a side collision pad 5 is fixed to the back surface of the door trim 1 at a portion where the occupant's waist and shoulders are likely to collide when an impact from the side is applied to the vehicle. As this side impact pad 5, a molded foam molded body molded in a block shape such as a urethane foam or a foamed bead molded body, or a synthetic resin molded body has been conventionally used. (For example, refer to Patent Document 1).
[0006]
As means for fixing the side collision pad 5 to the back surface of the door trim 1, heat welding fixing, hot melt welding fixing, screw fixing and the like are employed. The outline of the manufacturing method of the door trim 1 is that a raw sheet of the skin 4 is set in advance in a mold, and after the mold is clamped, a molten resin is injected and filled into a product cavity to obtain a required curved surface shape. The door core 1 is manufactured by forming the resin core 3 on the surface and laminating and integrating the skin 4 on the surface side of the resin core 3.
[0007]
[Patent Document 1]
Japanese Patent Laid-Open No. 10-278709 (Page 2, FIGS. 8 and 9)
[0008]
[Problems to be solved by the invention]
Thus, in the conventional door trim 1, the skin 4 is laminated and integrated on the surface of the resin core material 3, and the side impact pad 5 is provided on the back side of the impact area where the occupant's waist or shoulder is likely to collide. Since it is configured to be mounted, the number of parts is large, and a mold for molding the side pad 5 is required in addition to the mold for the door trim 1, which requires a lot of mold facilities, increases the number of mounting steps, and costs. It has been pointed out that there is a problem of inviting up.
[0009]
Furthermore, since the door trim 1 uses the resin core material 3 which is heavy and the molded urethane which is heavy as the material of the side collision pad 5, the weight of the entire door trim 1 is large and the weight of the door trim 1 is large. In other words, there are problems in that the workability of attachment to the door panel 2 is hindered and the fuel efficiency is lowered. And, when using polyolefin resin as the resin core material 3 as a raw material and using molded urethane as the side bump pad 5, batch processing is difficult to perform recycling, and it is necessary to peel both. There was a problem that the recycling cost increased.
[0010]
The present invention has been made in view of such circumstances, and relates to an automotive interior part attached to a side wall panel of a vehicle and a method for manufacturing the same, and can reduce the number of parts, reduce the number of mounting steps, and reduce the weight. It is an object of the present invention to provide an automobile interior part and a method for manufacturing the same that are suitable for recycling.
[0011]
[Means for Solving the Problems]
As a result of earnest research, the present inventors have given the function as a core material by imparting shape retention to the foamed resin sheet that has been used conventionally as the skin, and more. The present invention has been completed by disposing resin ribs at places where rigidity is required and providing a side impact shock absorber integrally with the resin ribs.
[0012]
That is, the automobile interior part according to the present invention is formed by compressing a foamed resin sheet and is laminated and integrated on the back surface of the foamed resin base material that is lightweight and has shape retention. Resin ribs along a predetermined pattern with a reduced projected area, and the resin ribs When molded, this resin rib is integrally molded , Abutting against or opposite to the vehicle body panel to absorb shocks at the time of a side collision Lightweight It is characterized by comprising a side impact shock absorber.
[0013]
Here, the interior parts for automobiles can be applied to door trims, rear side trims, and the like that are mounted on a side wall panel of a vehicle.
[0014]
When the foamed resin base material having shape retention is close to a flat shape, the heat softening process is omitted and the molded shape is formed into a desired shape by a mold, but when applied to a three-dimensional product, a foamed resin sheet After heat-softening, is molded into a desired curved surface shape in a molding die and the shape is maintained. If the product shape includes a high development rate, the foamed resin sheet is heated and softened, then a vacuum suction mechanism is provided in the molding die, and vacuum suction is performed along the inner surface of the molding die with a vacuum suction force. You may make it act force.
[0015]
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 type of thermoplastic resin or two or more types 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.
[0016]
As the foaming agent, 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 can be used.
[0017]
The foamed resin base material obtained by molding the foamed resin sheet into a required shape after heat softening treatment preferably has a foaming ratio of 2 to 10 times 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 is preferably in the range of 0.1 μm to 2 mm, and the thickness is 0.5 to 30 mm, preferably 1 to 10 mm.
[0018]
On the other hand, the thermoplastic resin material used as the resin rib can be appropriately selected from a wide range of thermoplastic resins. Generally, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, polyamide resin, acrylonitrile / butadiene / styrene (ABS) can be preferably used. Resin, polycarbonate resin, etc. can be used.
[0019]
Moreover, you may mix various fillers in these thermoplastic resins. Examples of the filler that can be used include inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica, and calcium carbonate. Moreover, various additives, such as antioxidant, a ultraviolet absorber, a coloring agent, a flame retardant, and a low shrinkage agent, may be mix | blended.
[0020]
And, according to the automobile interior part according to the present invention, it is constituted by a foamed resin base material having shape retention, and a resin rib and a side impact shock absorber that are laminated and integrated on the back surface side of the foamed resin base material. In addition, by eliminating the conventional resin core material having a very large projected area, the weight can be reduced, and the resin material can be saved. In addition, side impact shock absorbers are integrally molded with resin ribs instead of side impact pads that have been separately molded and attached by hot melt, welding, screwing, etc. Man-hours can also be reduced.
[0021]
In addition, the porous sound absorbing function of the foamed resin base material provides automotive interior parts with excellent sound absorbing performance, and uses polyolefin resin as the material for the foamed resin base material, resin ribs, and side impact shock absorbers. In this case, the separation process can be abolished by the all olefin resin, so that the recycling work can be simplified.
[0022]
As a preferred embodiment of the present invention, the resin rib may have a L-shaped cross-section or a reverse T-shaped rib shape so that the contact portion is a plate portion on the back surface of the foamed resin base material. In addition, the surface of the interior part does not appear, the appearance is good, and the shape retention of the product can be improved.
[0023]
Furthermore, the rib thickness of the resin rib is appropriately varied, for example, by setting the rib thickness to be thick at a portion where external force is greatly applied to the interior part, and by reducing the rib thickness at a portion where the external force is relatively difficult to be applied. be able to. 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.
[0024]
In addition, a clip seat or a mounting seat for attaching various escutcheon parts can be integrally formed on the resin rib. Moreover, the skin which improves external appearance designability can also be laminated | stacked on the surface of a foamed resin base material. As the skin, a woven fabric, a nonwoven fabric, a knitted fabric, a sheet, a film, a foam, a net-like material, or the like can be used. The material constituting these skins is not particularly limited, but it is preferable to use a material having air permeability such as a woven fabric, a non-woven fabric, and a knitted fabric in order to make use of the sound absorbing performance of the foamed resin base material.
[0025]
Next, the side impact shock absorber integrated with the resin rib may be composed of a grid-like rib integrally formed of the same material as the resin rib, or an elastomer different from the resin rib is used. Also good.
[0026]
In the case of a grid-like rib, it is integrally formed at the time of injection molding of the resin rib, and the grid-like rib is erected so as to extend in the vertical and horizontal directions projecting from the plate portion contacting the back surface of the foamed resin base material to the vehicle body panel side. ing.
[0027]
In the case of using an elastomer, a case body in which an opening facing the panel side is formed integrally with a resin rib, and an elastomer material such as a foam is filled inside the case body can be considered.
[0028]
Next, a method for manufacturing an automotive interior part according to the present invention comprises a foamed resin base material that is formed by compressing a foamed resin sheet and is lightweight and has shape retention, and is laminated on the back surface of the foamed resin base material. Resin ribs with reduced projected area and Lightweight, integrated with resin rib In a method for manufacturing an interior part for an automobile comprising a side impact shock absorber, a foamed resin sheet setting step for setting a foamed resin sheet, which is a material of a foamed resin base material, in a molding die, and molding dies The mold is clamped, and the foamed resin base material is molded into the required shape along the cavity shape of the molding die, and the molten resin is injected and filled into the cavity of the molding die, and the resin rib, plate portion and grid rib And an integration step of laminating and integrating with the back side of the foamed resin base material.
[0029]
Here, the molding die is composed of a molding upper mold capable of moving up and down, a molding lower mold positioned below the molding upper mold, and an injection machine connected to the molding lower mold, and is supplied from the injection machine. The molten resin is supplied onto the mold surface of the molded lower mold through resin passages such as a manifold and gate provided in the molded lower mold, but the molded upper mold descends to the bottom dead center, and the molded upper and lower molds are clamped. After that, the molten resin is injected and filled into the cavity at a predetermined injection pressure.
[0030]
Therefore, the foamed resin sheet is molded along the mold surface shape of the molding die by clamping the upper and lower molds, and the resin ribs and side impact impact absorption are achieved by injection filling the cavity with the molten resin. A body is formed, and these resin ribs and side impact shock absorbers are laminated and integrated on the back side of the foamed resin base material.
[0031]
When the product shape is set to a three-dimensional shape, the foamed resin sheet is set in a molding die after heat softening treatment is performed by a heater or the like in the previous step.
[0032]
Furthermore, after supplying the heat-softened foamed resin sheet into the molding die, the foamed resin sheet is molded into a required shape by clamping the molding die, and a foamed resin base material having shape retention is obtained. .
[0033]
Therefore, the resin rib and the side impact shock absorber can be laminated and integrated on the back surface of the lightweight foamed resin base material having shape retention. If the final product shape is a highly developed shape, it is preferable that the mold is clamped a plurality of times and the molten resin is injected in the final mold clamping process.
[0034]
Further, when the product shape includes a high development rate portion, a vacuum suction mechanism is provided in the molding upper mold, and the foamed resin base material is molded into a required shape by a vacuum suction force along the mold surface of the molding upper mold. You may do it.
[0035]
Therefore, according to the method of the present invention, since only the resin rib and the side impact shock absorber are molded, compared with the conventional resin core material having a large projected area, the load on the molding die can be reduced and the amount of resin can be reduced. The material cost can be saved, and the molding cycle of the product can be shortened because the cooling time is shorter than that of the conventional resin core material.
[0036]
Furthermore, according to the method of the present invention, since the lattice rib is integrally formed as a side impact shock absorber integrally with the resin rib, the side impact pad formed in a separate process as in the prior art is formed in a separate process after molding the interior part. It saves the trouble of mounting, requires less mold facilities, and shortens man-hours.
[0037]
Next, in another embodiment of the method of the present invention, the foamed resin sheet is compression-processed, and the foamed resin base material is lightweight and has shape retention, and laminated on the back surface of the foamed resin base material. Resin rib with reduced projected area and Molded integrally with resin rib In the case body Excellent shock absorption and light weight In a method of manufacturing an interior part for an automobile comprising a side impact shock absorber filled with an elastomer, a foamed resin sheet setting step for setting a foamed resin sheet as a material of the foamed resin base material in a molding die; The molds are clamped together to form the foamed resin base material into the required shape along the cavity shape of the mold, and from the first injection machine through the resin passage to the back surface of the foamed resin base material. Supplying molten resin, laminating and integrating the resin rib and the case body continuous with the resin rib on the back surface of the foamed resin base material, and foaming molten resin into the case body through the resin passage from the second injection machine The method includes a step of forming a side impact shock absorber by injection filling and loading an elastomer into the case body.
[0038]
And according to this embodiment, because it is a one-shot integral molding with two cylinders, and as a side impact shock absorber, it is configured to fill an elastomer such as a foam into the case body integrally molded with the resin rib, By using an elastomer resin excellent in shock absorption, it is possible to cope with high shock absorption.
[0039]
DETAILED DESCRIPTION OF THE INVENTION
BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of an automotive interior part and a method for manufacturing the same according to the present invention will be described below by exemplifying a vehicle door trim and a method for manufacturing the same.
[0040]
1 to 8 show a first embodiment of the present invention, FIG. 1 is a front view showing a first embodiment in which an automotive interior part according to the present invention is applied to an automotive door trim, and FIG. 2 is a configuration of the door trim. FIG. 3 is a front view showing the shape of the resin rib and the side impact shock absorber after removing the foamed resin base material in the door trim, and FIG. 4 is a cross sectional view showing the configuration of the side impact absorber in the door trim. It is. FIG. 5 is an overall view showing the configuration of a molding die for molding the automobile door trim. FIGS. 6 to 8 show the respective steps in the molding process of the automotive door trim. FIG. FIG. 7 is an explanatory view showing a foaming resin sheet setting process, and FIG. 8 is an explanatory view showing a molding process of the automobile door trim.
[0041]
A first embodiment of the present invention will be described with reference to FIGS. First, in FIG. 1 to FIG. 4, an automotive door trim 10 includes a foamed resin base material 20 having a shape-retaining property formed in a desired curved shape, and vertical and horizontal directions laminated on the back side of the foamed resin base material 20. The resin rib 30 extends in a crossing manner, and the side impact shock absorber 40 integrated with the resin rib 30.
[0042]
More specifically, a skin 21 that imparts decorativeness is laminated on the entire surface of the foamed resin base material 20, but may be partially attached to a part of the surface of the foamed resin base material 20. 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 door trim 10.
[0043]
By the way, the foamed resin base material 20 is subjected to heat-softening treatment of the foamed resin sheet so as to have shape retention, and then thermoformed into a desired shape, for example, cold press-molded with a molding die having a desired mold surface. Furthermore, the foamed resin base material 20 may be shaped by vacuum molding for a portion with a higher development rate.
[0044]
The foamed resin sheet has a structure in which a foaming agent is added to a general-purpose thermoplastic resin. The thermoplastic resin includes a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a chloride resin. Vinyl resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, and the like can be used. As the foaming agent, an organic foaming agent such as azodicarbonamide and 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 a polypropylene resin is used. The expansion ratio of the foamed resin base material 20 is set to 2 to 10 times, and the thickness is set to a range of 0.5 to 30 mm, particularly 1 to 10 mm.
[0045]
Next, the resin rib 30 is made of a general-purpose synthetic resin molded body. As synthetic resins that can be preferably used, polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins , Ionomer resin, polyamide resin, acrylonitrile / butadiene / styrene (ABS) resin, polycarbonate resin, etc., and in this embodiment, polypropylene resin is used in consideration of environmental and recycling aspects. Yes.
[0046]
The resin rib 30 is appropriately mixed with a filler such as inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica, and calcium carbonate in the thermoplastic resin. May be.
[0047]
Further, as shown in FIG. 3, the resin rib 30 is disposed so as to extend in the vertical and horizontal directions over substantially the entire surface of the product when the foamed resin base material 20 is removed. An outer peripheral frame along the outer peripheral edge of the door trim 10 may be added to reinforce the rigidity of the peripheral edge of the door trim 10. In this case, no gap or the like is generated between the vehicle body panel 50 and the vehicle body panel 50.
[0048]
Further, as shown in FIG. 3, when molding the resin rib 30 extending in the vertical and horizontal directions, for example, attachment for attaching functional parts such as the inside handle escutcheon 11, the power window switch finisher 12, the speaker grille 13, and the pocket escutcheon 14. A seat (not shown) can be formed integrally, and a clip seat for mounting a clip attached to the vehicle body panel 50 on the back side of the resin rib 30 can be integrally formed.
[0049]
By the way, in the door trim 10 shown by 1st Embodiment which concerns on this invention, the side impact shock absorber 40 is integrated with the resin rib 30 integrally. As shown in FIGS. 3 and 4, the side impact shock absorber 40 protrudes toward the vehicle body panel 50 side from the plate portion 41 that contacts the back surface of the foamed resin base material 20 and the back surface of the plate portion 41. Grid-like ribs extending in the vertical and horizontal directions (encoded as vertical ribs 42 and horizontal ribs 43) are formed.
[0050]
Therefore, by appropriately adjusting the rib thickness, rib height, rib interval and the like of the grid-like ribs 42 and 43, the impact load at the time of a side collision can be effectively controlled. In addition, even if the side impact shock absorber 40 is broken in the case of a side collision, the plate portion 41 has the plate portion 41, so that the sharp edges of the lattice ribs 42 and 43 do not break through the skin 21.
[0051]
As described above, the door trim 10 shown in FIGS. 1 to 4 includes a foamed resin base material 20 having shape retention, a resin rib 30 and a side impact shock absorber 40 laminated and integrated on the back surface of the foamed resin base material 20. Therefore, the resin core material occupied over the entire surface of the product as in the past can be abolished and the weight of the product is related to the conventional example because the lightweight foamed resin base material 20 is used. In addition to being able to achieve a weight reduction of 40% or more, the resin material can also be saved significantly, contributing to cost reduction.
[0052]
In addition, since the side impact shock absorber 40 is integrally formed with the resin rib 30, a step of separately forming a side impact pad with a molding die and a step of attaching the side impact pad to the door trim as in the past. Moreover, since it is configured based on the grid-like ribs 42 and 43, the weight can be reduced as compared with the conventional molded urethane and the recyclability is excellent.
[0053]
Furthermore, since the foamed resin base material 20 has a porous structure, the door trim 10 is excellent in sound absorption performance and can reduce noise in the passenger compartment. In order to maintain the sound absorption of the foamed resin base material 20, the skin 21 laminated and integrated on the surface of the foamed resin base material 20 is made of a sheet material having air permeability such as a woven fabric, a non-woven fabric, and a knitted fabric. preferable. In addition, the skin 21 can use a synthetic resin sheet, a synthetic resin film, a foam, a net-like body, etc. besides breathable sheets, such as a woven fabric, a nonwoven fabric, and a knitted fabric.
[0054]
Next, an embodiment of the method for manufacturing the automobile door trim 10 will be described with reference to FIGS. First, as shown in FIG. 5, a molding die 60 used for molding the door trim 10 includes a molding upper mold 61 that can move up and down by a predetermined stroke, and a molding lower mold 62 on the fixed side that forms a pair with the molding upper mold 61. The injection machine 63 connected to the molding lower mold 62 is generally configured.
[0055]
More specifically, the molding upper die 61 has a cavity portion 611 that matches the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 612 connected to the upper surface of the molding upper die 61. In addition, guide bushes 613 serving as a guide mechanism are provided at the four corners of the molding upper die 61.
[0056]
On the other hand, the molding lower die 62 is provided with a core portion 621 corresponding to the cavity portion 611 of the molding upper die 61. In addition, a manifold 622 and a gate 623 are provided to supply the molten resin to the mold surface of the core portion 621. The molten resin M supplied from the injection machine 63 through the resin passages of the manifold 622 and the gate 623 is provided. Is supplied to the upper surface of the core portion 621. A groove portion 624 corresponding to the pattern of the resin rib 30 is formed on the upper surface of the core portion 621, and the plate portion 41 and the grid-like rib 42 of the side impact shock absorber 40 formed integrally with the resin rib 30 are formed. , 43 is inserted into the lower mold 62.
[0057]
In addition, guide posts 625 serving as a guide mechanism protrude from the four corners of the molded lower mold 62. The guide posts 625 are guided into the guide bush 613 when the molded upper and lower molds 61 and 62 are clamped. As a result, the pressing posture of the molding upper die 61 can be properly maintained.
[0058]
First, as the first step of molding the door trim 10, when the molded upper and lower molds 61 and 62 are in the mold open state, the molded upper and lower molds 61 and 62 are disposed inside the molded upper and lower molds 61 and 62. In this embodiment, as the foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumitomo Chemical Co., Ltd., trade name: Sumiceller foam PP sheet, foaming magnification = 3 times, thickness 2 mm) is used, and FIG. As shown, the foamed resin sheet S is supplied into the molded upper and lower molds 61 and 62 by the heater device 65 in a state where the foamed resin sheet S is heated and softened to 130 ° C.
[0059]
Next, after the foamed resin sheet S is supplied into the molding upper and lower molds 61 and 62 (see FIG. 7), the elevating cylinder 612 is driven to lower the molding upper mold 61 by a predetermined stroke, as shown in FIG. When the molding upper mold 61 is lowered to the bottom dead center and the molding upper and lower molds 61 and 62 are in a clamped state, the resin rib 30 and the side impact shock absorber in the door trim 10 from the injection machine 63 through the manifold 622 and the gate 623. Molten resin M for molding 40 is supplied.
[0060]
As this molten resin M, talc is mixed in an appropriate proportion by Sumitomo Nobrene AX568 (Sumitomo Chemical Industries polypropylene, melt index = 65 g / 10 min).
[0061]
Therefore, in the mold clamping state by the molded upper and lower molds 61 and 62, the foamed resin sheet S is shaped according to the shape of the cavity portion 611 of the molded upper mold 61, and the foamed resin base material 20 is molded into a desired shape. At the same time, the resin rib 30 and the side impact shock absorber 40 are laminated and integrated on the inner surface side of the foamed resin base material 20.
[0062]
In this manner, the foamed resin base material 20 and the resin rib 30 and the side impact shock absorber 40 can be molded in one molding process. In particular, the resin rib 30 and the side impact impact absorber 40 are compared with the conventional resin core material. Therefore, the amount of molten resin M can be saved, and the amount of molten resin can be saved. At the same time, the load on the upper and lower molds 61 and 62 can be reduced, and the injection machine 63 can have a small capacity. Can be realized. In the specification in which the skin 21 is laminated on the surface of the foamed resin base material 20, the raw sheet of the skin 21 may be laminated in advance on one side of the foamed resin sheet S.
[0063]
Further, when the foamed resin base material 20 is molded from the foamed resin sheet S, as described above, after heat-softening treatment at a predetermined temperature by the heater device 65 in advance, the mold resin is melted when the molded upper and lower molds 61 and 62 are clamped. Although it can be shaped into a required shape at the time of injection of M, if a higher curved surface shape and a complicated curved surface shape are required, a vacuum suction mechanism is attached to the upper mold 61 and the upper and lower molds 61 and 62 are formed. The foamed resin base material 20 can also be vacuum molded by applying a vacuum suction force from the molding upper mold 61 before or during mold clamping.
[0064]
Further, the upper mold 61 can be controlled in two steps. That is, by pressing the upper and lower molds 61 and 62 in the first stage, the foamed resin sheet S is press-molded to primarily mold the foamed resin base material 20, and then the upper mold 61 is raised and the molding is performed again. The resin rib 30 and the side impact shock absorber 40 can be integrally formed with the foamed resin base material 20 by lowering the mold 61 and injecting and filling the molten resin M into the cavity in the second molding step.
[0065]
Next, FIG. 9 thru | or FIG. 11 shows 2nd Embodiment of this invention, FIG. 9 sees through the foamed resin base material 20 of the door trim 10 for motor vehicles in 2nd Embodiment, resin rib 30 and the side. FIG. 10 is a cross-sectional view showing a configuration of the second embodiment of the same-side impact shock absorber 40, and FIG. 11 shows a molding method of the door trim 10 in the second embodiment. FIG. In the second embodiment, the same parts as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.
[0066]
In the second embodiment, since only the configuration of the side impact shock absorber 40 is changed, the configurations of the other foamed resin base material 20 and the resin rib 30 are exactly the same as those in the first embodiment.
[0067]
That is, the side impact shock absorber 40 according to the second embodiment includes a case body 44 having an opening toward the vehicle body panel 50 and an elastomer 45 filled in the case body 44. The case body 44 is integrated with the resin rib 30 and is integrally formed at the time of injection molding of the resin rib 30. After the molding of the case body 44 is completed, the material of the elastomer 45 is formed in the internal space of the case body 44. It is comprised by inject | pouring the foaming resin liquid which is.
[0068]
Therefore, in the second embodiment, by using the elastomer 45 having an excellent impact absorbing function, the impact absorbing function at the time of a side collision can be enhanced, and a lightweight material based on foamed resin is used. Thereby, the lightweight side-impact impact absorber 40 can be provided.
[0069]
Next, an outline of the molding process of the door trim 10 according to the second embodiment will be mainly described with reference to FIG. 11, particularly a molding method of the case body 44 and the elastomer 45 constituting the side impact shock absorber 40. For the molding die 60, only the changed points will be described.
[0070]
That is, the molding die 60 used in the second embodiment uses the molding upper die 61 having the same structure as that of the first embodiment for the molding upper die 61, but the configuration of the molding lower die 62 is the core. As in the first embodiment, a groove 624 corresponding to the arrangement pattern of the resin ribs 30 is formed in the portion 621, and a case body that constitutes a part of the side impact shock absorber 40 so as to communicate with the groove 624. 44 is provided in the core portion 621. A slide block 67 is provided in the groove portion 66 so as to be able to advance and retract by driving a cylinder (not shown).
[0071]
Two injection machines 63a and 63b are connected to the molding lower mold 62, and the first injection machine 63a melts the material of the case body 44 in the resin rib 30 and the side impact shock absorber 40. Resin M1 is supplied through the manifold 622a and the gate 623a.
[0072]
On the other hand, from the second injection machine 63b, a foamable molten resin M2 which is a material of the elastomer 45 filled in the case body 44 is supplied through the manifold 622b and the gate 623b. The molten resin M1 and the foamable molten resin M2 from the two injection machines 63a and 63b are supplied from the first injection machine 63a first when the molding upper and lower molds 61 and 62 are clamped. M1 is supplied into the mold, and the resin rib 30 and the case body 44 are integrally molded along the desired pattern shape on the back surface side of the foamed resin base material 20 that is molded into a required shape.
[0073]
Thereafter, the foamable molten resin M2 is supplied from the second injection machine 63b through the manifold 622b and the gate 623b at an interval, and at this time, the slide block 67 moves backward to form an internal space of the case body 44, In this space, the foamable molten resin M2 is supplied and foamed and cured, so that the resin rib 30 and the case body 44 and the side impact shock absorber 40 made of the elastomer 45 are integrally formed on the back side of the foamed resin base material 20. Is done.
[0074]
The door trim 10 described above is a type in which the upper portion and the lower portion are integrally formed. For example, the door trim 10 is applied to a two-tone type door trim in which the door trim upper portion is formed of a laminated structure and the door trim lower portion is formed of a resin molded body. In this case, the door trim upper part is composed of the foamed resin base material 20 and the resin ribs 30 extending in the vertical and horizontal directions that are laminated and integrated on the back side thereof, and the door trim lower part is composed of a synthetic resin molded body. What is necessary is just to employ | adopt the structure of integrally molding the side impact shock absorber 40 mentioned above to a molded object.
[0075]
Further, the configuration of the door trim 10 described in the first embodiment and the second embodiment can also be applied to the rear side trim.
[0076]
【The invention's effect】
As described above, the automotive interior part according to the present invention has a configuration in which the side impact shock absorber is integrated with the resin rib laminated on the back surface of the foamed resin base material that is lightweight and has shape retention. Thus, the conventional heavy resin core material can be eliminated, and there is no need for a separately formed side impact pad, and there is an effect that it is possible to provide an automobile interior part that is lightweight, low in cost and excellent in sound absorption performance.
[0077]
Furthermore, the method for manufacturing automotive interior parts according to the present invention employs a process in which a foamed resin base material is molded into a required shape and at the same time a resin rib and a side impact shock absorber are integrated on the back side of the foamed resin base material. Compared with conventional resin core materials, the projected area of resin ribs and side impact shock absorbers is small, so the load on the molding die is small and the cooling time can be shortened. Compared to the method of attaching side impact pads to the back of interior parts or mechanically fixing, the work efficiency can be improved and the cost can be greatly reduced as the mold equipment is simplified and the man-hours are shortened. Have
[Brief description of the drawings]
FIG. 1 is a front view showing a first embodiment of a door trim to which the present invention is applied.
2 is a cross-sectional view taken along line II-II in FIG.
3 is a front view showing an arrangement pattern of resin ribs and a side impact shock absorber from which a foamed resin base material is removed from the automobile door trim shown in FIG. 1; FIG.
4 is a cross-sectional view showing a configuration of a side impact shock absorber in the door trim shown in FIG. 1. FIG.
FIG. 5 is an explanatory view showing an overall configuration of a molding die for molding the door trim shown in FIG. 1;
6 is an explanatory view showing a heat softening step of the foamed resin sheet in the door trim manufacturing method shown in FIG. 1. FIG.
7 is an explanatory view showing a foamed resin sheet setting step in the door trim manufacturing method shown in FIG. 1; FIG.
8 is an explanatory view showing an injection molding process in the door trim manufacturing method shown in FIG. 1. FIG.
FIG. 9 is a front view showing an arrangement pattern of resin ribs and a side impact shock absorber in a second embodiment of a door trim to which the present invention is applied.
FIG. 10 is a cross-sectional view showing a configuration of a side impact shock absorber according to a second embodiment of the present invention.
FIG. 11 is an explanatory view showing an outline of a method for manufacturing a door trim according to a second embodiment of the present invention.
FIG. 12 is a front view showing a conventional door trim.
13 is a cross-sectional view taken along line XIII-XIII in FIG.
[Explanation of symbols]
10 Door trim
20 Foamed resin substrate
21 epidermis
30 resin ribs
40 side impact shock absorber
41 Plate part
42, 43 lattice ribs
44 Case body
45 Elastomer
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 Nested type
65 Heater device
66 Groove
67 Slide block
M, M1 molten resin
M2 foamable molten resin
S Foamed resin sheet

Claims (7)

The foamed resin sheet (S) is compression-processed, has a lightweight and shape-retaining foamed resin base material (20), and a projected area laminated and integrated on the back surface of the foamed resin base material (20). When the resin rib (30) along the reduced predetermined pattern and the resin rib (30) are formed, the resin rib (30) is integrally formed with the resin rib (30) and is in contact with or opposed to the vehicle body panel (50). An automobile interior part comprising a lightweight side impact impact absorber (40) that absorbs impact during a side impact. The side impact shock absorber (40) is erected from a plate portion (41) that contacts the back surface of the foamed resin base material (20), and from the plate portion (41) toward the vehicle body panel (50), It is composed of grid-like ribs (42, 43) extending in the vertical and horizontal directions. When the side impact shock absorber (40) is broken, the plate portion (41) prevents the sharp edges from being exposed to the surface side. The automobile interior part according to claim 1, wherein the interior part is an automobile interior part. The side impact shock absorber (40) has a case body (44) having an opening on the vehicle body panel (50) side and an impact absorbing function filled in the case body (44), and is a lightweight elastomer ( 45) The automotive interior part according to claim 1, wherein The foamed resin sheet (S) is compression-processed, has a lightweight foam-shaped resin base material (20) having a shape retaining property, and a projected area laminated and integrated on the back surface of the foamed resin base material (20). In the manufacturing method of an interior part for an automobile , which is integrally formed with the reduced resin rib (30) and the resin rib (30), and includes a lightweight side impact shock absorber (40).
A foaming resin sheet (S) setting step for setting the foaming resin sheet (S), which is the material of the foaming resin base material (20), in the molding die (61, 62);
The molding dies (61, 62) are clamped together, and the foamed resin base material (20) is molded into a required shape along the cavity (C) shape of the molding dies (61, 62). The molten resin (M) is injected and filled into the cavities (C) of (61, 62), and the resin rib (30), the plate portion (41), and the grid-like ribs (42, 43) are formed into the foamed resin base material (20 ) And the integration step of stacking and integrating on the back side,
A method for producing an interior part for an automobile, comprising: A foamed resin base material (20) that is formed by compressing the foamed resin sheet (S), has a lightweight and shape-retaining property, and a projected area that is laminated and integrated on the back surface of the foamed resin base material (20). Reduced resin rib (30) and a side impact shock absorber formed by filling a lightweight elastomer (45) with an excellent shock absorbing function in a case body (44) formed integrally with the resin rib (30). 40) and a manufacturing method of an automotive interior part (10),
A foaming resin sheet (S) setting step for setting the foaming resin sheet (S), which is the material of the foaming resin base material (20), in the molding die (61, 62);
The molding dies (61, 62) are clamped together to mold the foamed resin base material (20) into a required shape along the cavity shape of the molding dies (61, 62), and the first injection machine ( The molten resin (M1) is supplied to the back surface of the foamed resin base material (20) through the resin passage from 63a), and the resin rib (30) and the case body (45) connected thereto are connected to the foamed resin base material ( 20) and the step of stacking and integrating the back surface of the second injection machine (63b) and the resin body from the second injection machine (63b) by injecting and filling the foamable molten resin (M2) into the case body (44). Forming a side impact shock absorber (40) by loading the elastomer (45) therein;
A method for producing an interior part for an automobile, comprising: Before the step of setting the foamed resin sheet (S), the foamed resin sheet (S) is heat-softened in a preheating step, and when the molds (61, 62) are clamped, the foamed resin sheet (S) Is formed into a required shape to form a foamed resin base material (20) having shape retention, and a resin rib (30) and a side impact shock absorber (on the back side of the foamed resin base material (20)). 40) is laminated and integrated, The method for manufacturing an interior part for an automobile according to claim 4 or 5 . A vacuum suction mechanism is attached to the molding die (61), and the mold surface of the molding die (61, 62) is fixed to the foamed resin sheet (S) that has been heat-softened when the molding die (61, 62) is clamped. 7. The method according to claim 4, further comprising the step of operating the vacuum suction mechanism when forming along the shape and vacuum forming the foamed resin base material (20) into a required shape by a vacuum suction force. The manufacturing method of the interior component for motor vehicles in any one.

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