JP4133377B2

JP4133377B2 - Interior parts for automobile, manufacturing method thereof and molding die

Info

Publication number: JP4133377B2
Application number: JP2003021702A
Authority: JP
Inventors: 哲行大田; 正彦原; 樹史大野; 洋行相澤; 伸明関
Original assignee: Kasai Kogyo Co Ltd
Current assignee: Kasai Kogyo Co Ltd
Priority date: 2003-01-30
Filing date: 2003-01-30
Publication date: 2008-08-13
Anticipated expiration: 2023-01-30
Also published as: JP2004231030A

Description

【０００１】
【発明の属する技術分野】
この発明は、ドアトリム、リヤパーセルシェルフ、フロアトリム、トランクトリム、リヤサイドトリム等の自動車用内装部品及びその製造方法並びに成形金型に係り、特に、軽量化が図れ、廉価に製作できるとともに、優れた成形精度が確保できる自動車用内装部品及びその製造方法並びに成形金型に関する。
【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２０，図２１を基に説明する。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製品面のほぼ全面にいきわたっている樹脂芯材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。
【０００３】
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裏面にポリエチレンフォーム等のクッション材が積層された積層シート材料が使用され、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裏面にポリエチレンフォーム等のクッション材が積層された積層シート材料が多用される傾向にある。
【０００４】
次に、上記ドアトリム１の成形方法における従来例について図２２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。
【０００５】
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。
【０００６】
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。
【０００７】
従って、成形上下型５，６が型開き状態にあるとき、表皮３を金型内にセットし、その後、成形上下型５，６を型締めする直前か、または型締めした後のいずれかのタイミングで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（例えば、特許文献１参照。）。
【０００８】
尚、図２２では、説明の便宜上、コア部６ａ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、上述したように、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ても良い。
【０００９】
【特許文献１】
特開平１０−１３８２６８号公報（第２頁、図３、図４）
【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問題点が指摘されている。
【００１１】
また、樹脂芯材２の投影面積が大きいことから、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り、金型の作製費用も嵩み、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し、生産性を低下させる大きな要因となっている。
【００１２】
この発明は、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、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、加えて、材料ロスが少なく、しかも成形性を高めた自動車用内装部品及びその製造方法並びにそれに使用する成形金型を提供することを目的とする。
【００１３】
【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、相手部品との合わせ部で密接可能、または一定クリアランスを確保する箇所、あるいは部品取付箇所並びに荷重がかかる部位には、剛性に優れた樹脂リブを配置することで対応するとともに、特に、樹脂リブの射出充填時におけるシール性を高めることで本発明を完成するに至った。
【００１４】
すなわち、本発明に係る自動車用内装部品は、所要形状に成形され、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に一体化される所定パターン形状の樹脂リブとからなる自動車用内装部品であって、前記樹脂リブの両側縁に沿う発泡樹脂基材には、厚み方向寸法を低減した圧縮部が設けられていることを特徴とする。
【００１５】
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。
【００１６】
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、成形金型内で所要形状に成形することで、リブ等の補強材がなくても、成形後、脱型しても形状を保持する程度の剛性（保形性）を有している。また、製品形状が高展開率部分を含む場合には、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成形金型の内面に沿って発泡樹脂シートに真空吸引力を作用させるようにしても良い。
【００１７】
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。
【００１８】
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。
【００１９】
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〜２．０ｍｍ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。
【００２０】
一方、樹脂リブ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。
【００２１】
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。
【００２２】
更に、樹脂リブの両側縁に沿って、発泡樹脂基材の裏面側が厚み方向寸法を低減した圧縮部として形成されている。
【００２３】
次いで、本発明に係る自動車用内装部品の別の実施態様は、所要形状に成形され、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に一体化される所定パターン形状の樹脂リブとからなる自動車用内装部品であって、前記発泡樹脂基材裏面の一部には、上記樹脂リブから染み出すシート状の樹脂漏出部が形成されることにより、剛性強化部位が設定されていることを特徴とする。
【００２４】
この場合においても、樹脂リブの両側縁における発泡樹脂基材には、基本的に圧縮部が設定されているが、特に、シート状の樹脂漏出部と一体化する樹脂リブの縁部については圧縮部が設定されておらず、樹脂漏出部が形成されない部位と樹脂漏出部が形成される部位の境界に位置する樹脂リブは、その両側縁における発泡樹脂基材によるシール性に差異が設定されている。
【００２５】
また、外観意匠性を高めるために、発泡樹脂基材の表面に加飾材を積層一体化しても良い。上記加飾材としては、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。これら加飾材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、発泡樹脂基材の室内騒音を吸音対象とした吸音性能を生かす上で好ましい。
【００２６】
そして、本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の裏面側に剛性を補強する意味で樹脂リブが積層一体化されるという構成であるため、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。
【００２７】
更に、樹脂リブ両側縁における発泡樹脂基材には圧縮部が設定され、かつこの圧縮部は高剛性であるため、樹脂リブが幅方向に沿って撓むことがなく、樹脂リブの変形を防止することができる。
【００２８】
次いで、上記自動車用内装部品の製造方法は、所要形状に成形され、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に一体化される所定パターン形状の樹脂リブとからなる自動車用内装部品の製造方法において、成形金型内に、発泡樹脂基材の素材である発泡樹脂シートをセットする発泡樹脂シートのセット工程と、前記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沿って発泡樹脂基材を所要形状に成形するとともに、成形金型の型締め前か、型締め後のいずれかのタイミングで、前記樹脂リブの配設パターンに沿って成形下型に形成されている溝部内に射出機から樹脂通路を通じて溶融樹脂を射出充填し、このとき、該溝部の側縁に肉盛りが施されていることにより、溝部のシール性を確保するための圧縮部を発泡樹脂基材に形成し、発泡樹脂基材の裏面に樹脂リブを積層一体化する発泡樹脂基材及び樹脂リブの成形工程とからなることを特徴とする。
【００２９】
ここで、上記自動車用内装部品を製造する際に成形金型は、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する直前、または型締め後のいずれかのタイミングで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。
【００３０】
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、溶融樹脂が成形下型の型面に穿設された溝部内に射出充填されることにより、樹脂リブが発泡樹脂基材の裏面側に積層一体化される。
【００３１】
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。
【００３２】
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。
【００３３】
従って、保形性を有する軽量な発泡樹脂基材の裏面に樹脂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。
【００３４】
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。
【００３５】
また、成形下型には、樹脂リブの縦横方向に沿う格子状パターンに対応して、溝部が開設されており、この溝部内に射出機から樹脂通路を経て溶融樹脂が射出充填されるが、この溶融樹脂の射出充填時においては、キャビティ内に発泡樹脂シートが挟み込まれており、特に、溝部の側縁に沿って肉盛りが施されていることにより、溝部側縁の発泡樹脂基材には圧縮部が形成され、この圧縮部は高剛性であるとともに、シール性能に優れているため、溝部から溶融樹脂が外部に漏れ出すことがなく、ゲート点数を少なくして、樹脂圧を高めても、外部への樹脂漏れを可及的に防止できる。
【００３６】
従って、従来の投影面積の広い樹脂芯材に比べ、樹脂リブだけを成形すれば良いため、射出圧力を従来に比べて低く設定できることにより、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、冷却時間も短縮化でき、製品の成形サイクルを短縮化できる。
【００３７】
更に、発泡樹脂基材の多孔質吸音性能により、車室内外の騒音を有効に吸音できる吸音性能に優れた内装部品が得られるとともに、発泡樹脂基材及び樹脂リブ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統一でき、分離工程が廃止でき、リサイクル作業を廃止できる。
【００３８】
加えて、樹脂リブの射出充填時、溝部のシール性能を良好に維持できるため、樹脂漏れによる材料ロスがなく、ゲート点数を低減できるとともに、射出圧力を上げて樹脂流動長を長く設定できる等の利点がある。
【００３９】
次いで、本発明方法の別の実施態様は、所要形状に成形され、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側に一体化される縦横方向に沿う所定パターン形状の樹脂リブとからなり、所望の剛性強化部位における発泡樹脂基材の裏面にシート状の樹脂漏出部を一体化した自動車用内装部品の製造方法において、成形金型内に、発泡樹脂基材の素材である発泡樹脂シートをセットする発泡樹脂シートのセット工程と、前記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沿って発泡樹脂基材を所要形状に成形するとともに、成形金型の型締め前か、型締め後のいずれかのタイミングで、前記樹脂リブの配設パターンに沿って成形下型に形成されている溝部内に、射出機から樹脂通路を通じて溶融樹脂を射出充填する際、剛性強化部位を画成する樹脂リブの両側縁において、発泡樹脂シートに対するシール性に差異をもたせることで、樹脂リブから強制的に溶融樹脂を発泡樹脂基材の裏面側に漏出させることにより、発泡樹脂基材の裏面に樹脂リブ並びに樹脂漏出部を一体化する発泡樹脂基材及び樹脂リブの成形工程とからなることを特徴とする。
【００４０】
この場合、樹脂リブに対応するために、成形下型のコア部型面に設けられている溝部は、側縁に肉盛りをして、シール性を高めれば、樹脂漏れを回避でき、その逆に肉盛りを省略した縁部については、シート状の樹脂漏出部を発泡樹脂基材の裏面に強制的に作り出すことができる。
【００４１】
そして、この実施態様によれば、内装部品の製品表面側から面直方向に力が加わり易い部位など、剛性が要求される部分においては、強制的に発泡樹脂基材の裏面所定部位にシート状の樹脂漏出部を樹脂リブと一体化して形成できるため、樹脂リブを所要形状に成形すると同時に発泡樹脂基材における所望箇所の剛性を強化することができる。
【００４２】
【発明の実施の形態】
以下、本発明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並びに該方法に使用する成形金型を例示して説明する。
【００４３】
図１乃至図１３は本発明の第１実施形態を示し、図１は自動車用ドアトリムを示す正面図、図２は同自動車用ドアトリムの構成を示す断面図、図３は同自動車用ドアトリムにおける樹脂リブの形状を示す正面図、図４，図５は同自動車用ドアトリムにおける樹脂リブ周縁部分の形状を示す各断面図、図６は同自動車用ドアトリムの成形に使用する成形金型の構成を示す全体図、図７，図８は同成形金型における成形下型の溝部形状を示す各断面図、図９乃至図１１は同自動車用ドアトリムの製造方法の各工程を示すもので、図９は発泡樹脂シートの予熱工程を示す説明図、図１０は発泡樹脂シートの成形金型へのセット工程を示す説明図、図１１は成形金型の型締めによる成形工程を示す説明図である。また、図１２，図１３は成形金型におけるゲート部付近の構成を示す断面図並びに平面図である。
【００４４】
次に、図１４乃至図１９は、本発明の第２実施形態を示し、図１４は第１実施形態と同様に自動車用ドアトリムに適用した場合の樹脂リブの形状を示す平面図、図１５は第２実施形態における樹脂リブの周辺部分の構成を示す断面図、図１６は図１５に示す樹脂リブを成形するための成形金型の要部を示す説明図、図１７は剛性強化部位を変更した樹脂リブの形状を示す平面図、図１８は同樹脂リブの周辺部分の構成を示す断面図、図１９は図１８に示す樹脂リブを成形するための成形金型の要部を示す説明図である。
【００４５】
まず、図１乃至図１３に基づいて、本発明の第１実施形態について説明する。
【００４６】
本実施形態による自動車用ドアトリム１０は、インサイドハンドルエスカッション１１を始めとして、アームレスト部１２にパワーウインドウスイッチフィニッシャー１３並びにプルハンドル１４等の付属部品が装着され、アームレスト部１２の下側にポケット開口１５が開設され、このポケット開口１５廻りにポケットエスカッション１６が嵌め込み固定され、そのフロント側にスピーカグリル１７が一体、あるいは別体に設けられている。
【００４７】
更に詳しくは、図２に示すように、自動車用ドアトリム１０は、所要形状に成形され、保形性を有する発泡樹脂基材２０と、この発泡樹脂基材２０の裏面側に積層一体化される樹脂リブ３０と、発泡樹脂基材２０の表面側に積層一体化される加飾機能をもつ加飾材２１とから大略構成されている。
【００４８】
また、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、所要形状に熱成形、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。尚、ジャッ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ができる。
【００４９】
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発泡剤として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。
【００５０】
次いで、樹脂リブ３０は、発泡樹脂基材２０の裏面側に配設され、特に、図３に示すように、縦横方向に延びる格子状パターンに設定されている。この樹脂リブ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。
【００５１】
また、この樹脂リブ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。
【００５２】
更に、図４，図５に示すように、樹脂リブ３０は、幅寸法に対して高さ寸法が長寸に設定される関係で、図４，図５中矢印Ａ方向に撓み変形を誘発し易い傾向にあるが、この撓み変形を有効に防止するように、発泡樹脂基材２０において、樹脂リブ３０の両側縁に沿って圧縮部２２が設定されている。
【００５３】
図４では、圧縮部２２は、一般部から樹脂リブ３０の側縁に向けて発泡樹脂基材２０の厚みが徐変するように設定され、かつ図５の圧縮部２２は、方形状に設定されている。尚、圧縮部２２の形状は限定されないが、圧縮部２２のもつ機能としては、圧縮部２２を設定することで、密度が高まり、剛性が強化されるために、樹脂リブ３０の変形を抑えることができる。尚、この実施形態においては、図４に示す圧縮部２２は、後述する成形金型に肉盛りを施すことにより、圧縮部２２を徐変状に形成するが、図中ａ寸法は、０．５〜１．５ｍｍ、図中ｂ寸法は、３〜１０ｍｍに設定されている。また、図５に示す方形状の圧縮部２２は、ａ寸法が０．５〜１．５ｍｍ、ｂ寸法も同様に３〜１０ｍｍに設定されている。尚、自動車用ドアトリム１０の一般部の板厚は３ｍｍに設定されている。
【００５４】
このように、本発明に係る自動車用ドアトリム１０は、保形性を有する発泡樹脂基材２０と、発泡樹脂基材２０の裏面に積層一体化される樹脂リブ３０と、加飾性を有する加飾材２１とから構成されているため、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。
【００５５】
更に、発泡樹脂基材２０は、多孔質構造であるため、吸音性能に優れ、車室内外の騒音を低減することができる。また、発泡樹脂基材２０の特に車室内騒音を対象とした吸音性能を高めるために、発泡樹脂基材２０の表面に積層一体化される加飾材２１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、加飾材２１は、織布、不織布、編布等の通気性シート以外にも、塩ビシートやＴＰＯシート等の合成樹脂シート、合成樹脂フィルム、発泡体、網状体を使用することもできる。また、ＴＰＯシートを使用すれば、使用材料をポリオレフィン系樹脂で統一できるため、リサイクルが容易に行なえる。
【００５６】
そして、所定パターンに沿う樹脂リブ３０は、その基部側縁にあたる発泡樹脂基材２０に圧縮部２２が設定され、樹脂リブ３０を支持する発泡樹脂基材２０の支持面の剛性が強化されているため、樹脂リブ３０の高さ寸法を幅寸法に対して長寸に設定しても、幅方向に沿う撓み変形を有効に防止でき、樹脂リブ３０の初期形状を長期に亘り良好に維持できるという利点がある。
【００５７】
次いで、図６乃至図１３に基づいて、上記ドアトリム１０の製造方法の概要について以下に説明する。図６は、成形金型４０の全体構成を示し、図７，図８は、樹脂リブ３０を形成する溝部の形状をそれぞれ示す断面図である。図６において、ドアトリム１０の成形に使用する成形金型４０は、所定ストローク上下動可能な成形上型４１と、成形上型４１と対をなす固定側の成形下型４２と、成形下型４２に接続される射出機４３とから大略構成されている。
【００５８】
更に詳しくは、成形上型４１は、製品形状に合致したキャビティ部４１１が形成されており、成形上型４１の上面に連結された昇降シリンダ４１２により所定ストローク上下駆動される。また、成形上型４１の４隅部には、ガイド機構となるガイドブッシュ４１３が設けられている。
【００５９】
一方、成形下型４２には、成形上型４１のキャビティ部４１１に対応するコア部４２１が設けられている。また、このコア部４２１の型面に溶融樹脂を供給するために、マニホールド４２２、ゲート４２３が設けられており、このマニホールド４２２、ゲート４２３の樹脂通路を経て射出機４３から供給される溶融樹脂Ｍがコア部４２１上面の溝部４２４に供給される。
【００６０】
また、成形下型４２の４隅部には、ガイド機構となるガイドポスト４２５が突設され、このガイドポスト４２５は、成形上下型４１，４２が型締めされる際、ガイドブッシュ４１３内に案内されることで成形上型４１のプレス姿勢を適正に維持できる。
【００６１】
更に、本発明方法に使用する成形金型４０は、樹脂リブ３０を成形するために成形下型４２のコア部４２１に設ける溝部４２４は、例えば、図４に示す樹脂リブ３０周縁部の形状を成形するためには、図７に示す成形金型４０が使用され、図５に示す樹脂リブ３０周縁部の形状を成形するためには図８に示す成形金型４０が使用されている。
【００６２】
例えば、図７に示すように、樹脂リブ３０を成形するための溝部４２４の基部両側縁に沿って、コア部４２１の型面には、肉盛り４４が外側から溝部４２４に向かうに連れて徐々に厚みが増すように付設されている。また、図８に示す成形金型４０においては、溝部４２４の基部の両側縁に沿ってコア部４２１の型面上に断面矩形状の肉盛り４４が設けられている。
【００６３】
上記肉盛り４４は、キャビティ内に発泡樹脂シートＳが収容された状態で溝部４２４に溶融樹脂が供給されたとき、発泡樹脂シートＳを圧縮することで、溝部４２４のシール性を高め、樹脂漏れを可及的に防止する機能をもつ。
【００６４】
次いで、図９乃至図１１に基づいて、自動車用ドアトリム１０の製造方法について説明する。まず、図９に示すように、ヒーター装置５０により、発泡樹脂シートＳ（加飾材２１をラミネートしている）を加熱軟化処理する。この発泡樹脂シートＳとしては、ポリプロピレン製発泡シート（住化プラステック製、商品名：スミセラー発泡ＰＰシート、発泡倍率＝３倍、厚み３ｍｍ）が使用されている。
【００６５】
そして、図１０に示すように、成形金型４０が型開き状態にあるとき、成形金型４０内に加熱軟化処理を施した発泡樹脂シートＳをセットする。その後、成形上型４１の昇降シリンダ４１２が動作して、図１１に示すように、成形上型４１が所定ストローク下降して、成形上下型４１，４２が型締めされて、発泡樹脂シートＳが所望の型面形状に賦形され、発泡樹脂基材２０が所要形状に成形されるとともに、射出機４３からマニホールド４２２、ゲート４２３を通じて成形下型４２におけるコア部４２１に設けた溝部４２４に溶融樹脂Ｍが射出充填され、樹脂リブ３０が発泡樹脂基材２０の内面側に一体成形される。
【００６６】
この溶融樹脂Ｍとしては、住友ノーブレンＢＵＥ８１Ｅ６（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。尚、溶融樹脂Ｍの射出のタイミングを成形上下型４１，４２の型締め前に設定しても良い。
【００６７】
そして、このとき、成形下型４２に設けられている溝部４２４の両側縁部に肉盛り４４が形成されているため、溝部４２４のシール性が良好に維持されていることから、溶融樹脂Ｍが溝部４２４から外部に漏れることがなく、材料ロスを確実に防止できるとともに、射出機４３の射出圧を高く設定しても、樹脂漏れがないため、ゲート４２３の設定数を低減することも可能となる。
【００６８】
更に、本発明方法によれば、発泡樹脂シートを予め賦形した後、射出成形金型内にセットする方法とは異なり、成形と同時に樹脂リブ３０と圧縮部２２とを形成できるため、圧縮部２２と樹脂リブ３０との間に位置ズレが生じることがない。
【００６９】
また、溝部４２４の両側縁に沿って肉盛り４４を設定する以外にも、例えば図１２，図１３に示すように、ゲート４２３の外周に一定距離をおいて肉盛り４５を設けた場合、ブッシュ４２６面に樹脂バリｍが染み出すが、肉盛り４５により、外部に樹脂が漏れるのを可及的に防止できる。
【００７０】
この場合、発泡樹脂シートＳに圧縮部２２を形成したことによる発泡樹脂基材２０の剛性と圧縮部２２により高剛性部の面積が広くなることによる剛性アップとの複合効果により、図４または図５中の矢印Ａ方向の撓みに強くなる。
【００７１】
次いで、図１４乃至図１６は、本発明の第２実施形態を示すもので、例えば、図１４に樹脂リブ３０の配設パターンを示すが、特に、乗員の身体が触れ易く、剛性が必要とされる剛性強化部位Ａについては、図１５に示すように、発泡樹脂基材２０の裏面に薄肉シート状の樹脂漏出部３１が樹脂リブ３０と一体に形成されている。また、この剛性強化部位Ａを画成する樹脂リブ３０の外周縁は、発泡樹脂基材２０に圧縮部２２が形成されている。
【００７２】
上記構造のドアトリム１０を成形するには、図１６に示すように、成形下型４２におけるコア部４２１に形成される溝部４２４について、特に、樹脂漏出部３１を強制的に形成できるように、樹脂リブ３０の剛性強化部位Ａ側の側縁と反対側縁におけるシール性に差異をもたせている。すなわち、溝部４２４の外側縁部に沿っては肉盛り４４が設定されているが、内側縁部に沿っては肉盛り４４が省略されている。
【００７３】
従って、成形上下型４１，４２を型締めして、発泡樹脂基材２０を所要形状に成形すると同時に、溝部４２４内に溶融樹脂Ｍを射出充填したとき、肉盛り４４により、樹脂リブ３０は、樹脂リブ３０の外側縁部から外方に向けて樹脂漏れが生じることがなく、逆に、肉盛り４４を設定していない部位については、溶融樹脂Ｍが強制的に外部に漏れ出し、シート状の樹脂漏出部３１が形成される。
【００７４】
このように、樹脂リブ３０を形成するために、コア部４２１に設けた溝部４２４の両側縁に沿うシール性を調整することで、樹脂漏れをなくすか、あるいは強制的に発泡樹脂基材２０の裏面にシート状の樹脂漏出部３１を一体化することが可能となり、樹脂リブ３０の成形と同時に剛性強化部位Ａを成形できる。
【００７５】
本例の場合、製品に圧縮部２２を設けることにより、外縁部側の発泡樹脂シートの剛性が強化され、製品の内縁部側は樹脂漏出部３１があるためリブ３０が図４または図５の矢印Ａ方向に撓むことが防止される。
【００７６】
更に、本発明の第２実施形態の変形例について、図１７乃至図１９を基に説明する。すなわち、この変形例は、図１７に示すように、剛性強化部位Ａが広いエリアに設定されているため、剛性強化部位Ａを包囲する樹脂リブ３０ａと、剛性強化部位Ａ内に延在する樹脂リブ３０ｂとが存在する。
【００７７】
そして、上記樹脂リブ３０ａ，３０ｂと発泡樹脂基材２０との関係は、図１８に示すように、剛性強化部位Ａを包囲する樹脂リブ３０ａの外側縁に沿って発泡樹脂基材２０裏面に圧縮部２２が形成されているとともに、剛性強化部位Ａを包囲する樹脂リブ３０ａの内側縁から剛性強化部位Ａ内に延在する樹脂リブ３０ｂにかけて、発泡樹脂基材２０裏面にシート状の樹脂漏出部３１が形成されている。
【００７８】
また、広範囲に剛性強化部位Ａを設定する場合には、図１９に示すように、上記樹脂リブ３０ａに対応する溝部４２４ａの外側縁部に肉盛り４４を設定し、溝部４２４ａの内側縁部は肉盛り４４を省略するとともに、上記樹脂リブ３０ｂに対応する溝部４２４ｂの両側縁部についても肉盛り４４が省略されている。
【００７９】
従って、肉盛り４４が形成された部分のシール性と、肉盛り４４が省略された部分のシール性の差異により、図１８に示すように、剛性強化部位Ａだけにシート状の樹脂漏出部３１が形成され、簡単な手法で剛性を強化できる。
【００８０】
【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樹脂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効果を有する。
【００８１】
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樹脂リブを成形するという工程を採用すれば、樹脂成形体である樹脂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作用効果を有する。
【００８２】
また、本発明に係る自動車用内装部品は、樹脂リブの両側縁に沿う発泡樹脂基材に圧縮部が設定され、この圧縮部については、密度が高く、かつ剛性が強化されているため、樹脂リブの幅方向に沿う撓み変形を有効に防止でき、初期形状を長期に亘り安定して維持できるという効果を有する。
【００８３】
次いで、本発明に係る自動車用内装部品の製造方法は、成形上下型の型締めにより発泡樹脂基材を所要形状に成形すると同時に、成形下型の溝部に溶融樹脂を射出充填することで、発泡樹脂基材の裏面に所定パターン形状の樹脂リブを一体化するとともに、溝部の側縁に肉盛りを施すことで、溝部のシール性能を高め、樹脂漏れを可及的に防止できることから、材料ロスが少なく、かつゲート点数を低減でき、樹脂の流動長を長く設定できる等の効果を有する。
【００８４】
更に、本発明に係る自動車用内装部品の別の態様によれば、剛性強化部位には、樹脂リブと一体にシート状の樹脂漏出部を発泡樹脂基材裏面の一部に一体化するというものであるため、材料ロスとなる樹脂に補強機能をもたせ、材料の有効利用を図るとともに、該内装部品の製造方法については、肉盛りを省略し、樹脂リブを形成する溝部の側縁のシール性能に差異を設定することで、溝部からの樹脂漏れを防止するか、あるいは樹脂漏れを強制的に現出させて剛性アップを図るというものであるから、実用性に優れるという効果を有する。
【図面の簡単な説明】
【図１】本発明に係る自動車用内装部品を適用した自動車用ドアトリムの第１実施形態を示す正面図である。
【図２】図１中II−II線断面図である。
【図３】図１に示すドアトリムにおける樹脂リブの配設パターンを示す正面図である。
【図４】図１に示すドアトリムにおける樹脂リブ及びその周縁部の形状を示す断面図である。
【図５】図４の変形例を示す断面図である。
【図６】図１に示すドアトリムの製造方法に使用する成形金型の全体構成を示す説明図である。
【図７】図６に示す成形金型における溝部及びその周縁部を示す拡大断面図である。
【図８】図６に示す成形金型における溝部及びその周縁部の変形例を示す断面図である。
【図９】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予熱工程を示す説明図である。
【図１０】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。
【図１１】図１に示すドアトリムの製造方法における発泡樹脂基材並びに樹脂リブの成形工程を示す説明図である。
【図１２】図６に示す成形金型におけるゲート部付近の構成を示す断面図である。
【図１３】図１２に示すゲート部付近の平面図である。
【図１４】本発明に係る自動車用内装部品を適用した自動車用ドアトリムの第２実施形態を示すもので、樹脂リブの配設パターンを示す正面図である。
【図１５】図１４中XV−XV線断面図である。
【図１６】図１５に示す発泡樹脂基材並びに樹脂リブを成形するための成形金型を示す部分断面図である。
【図１７】本発明に係る自動車用内装部品を適用した自動車用ドアトリムの第２実施形態の変形例を示す樹脂リブの正面図である。
【図１８】図１７中XVIII −XVIII 線断面図である。
【図１９】図１８に示す発泡樹脂基材並びに樹脂リブを成形するための成形金型を示す部分断面図である。
【図２０】従来のドアトリムを示す正面図である。
【図２１】図２０中XXI −XXI 線断面図である。
【図２２】従来のドアトリムの製造方法の概要を示す説明図である。
【符号の説明】
１０自動車用ドアトリム
１１インサイドハンドルエスカッション
１２アームレスト部
１３パワーウインドウスイッチフィニッシャー
１４プルハンドル
１５ポケット開口
１６ポケットエスカッション
１７スピーカグリル
２０発泡樹脂基材
２１加飾材
２２圧縮部
３０樹脂リブ
３１樹脂漏出部
４０成形金型
４１成形上型
４２成形下型
４３射出機
４４，４５肉盛り
Ａ剛性強化部位
Ｓ発泡樹脂シート
Ｍ溶融樹脂[0001]
BACKGROUND OF THE INVENTION
The present invention relates to automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, rear side trims, and manufacturing methods thereof, and molding dies. The present invention relates to an automotive interior part that can ensure molding accuracy, a manufacturing method thereof, and a molding die.
[0002]
[Prior art]
For example, the configuration of automobile interior parts will be described with reference to FIGS. The door trim 1 is formed by laminating and integrating a skin 3 excellent in surface appearance on the surface of a resin core material 2 that extends over almost the entire product surface having shape retention and mounting rigidity to a vehicle body panel. .
[0003]
The resin core material 2 is made of a polypropylene resin mixed with talc, and the skin 3 does not have shape retention itself, and the back surface of the synthetic resin sheet such as a vinyl chloride sheet is made of polyethylene foam or the like. Laminated sheet material is used in which cushioning material is laminated. Recently, in consideration of the environment and recycling, laminated material in which cushioning material such as polyethylene foam is laminated on the back side of elastomer sheet such as TPO (thermoplastic olefin) sheet. Sheet materials tend to be used frequently.
[0004]
Next, a conventional example of the method for forming the door trim 1 will be described with reference to FIG. First, a molding die 4 that molds the door trim 1 is connected to a molding upper die 5 that can move up and down by a predetermined stroke, a molding lower die 6 that forms a pair with the molding upper die 5, and a molding lower die 6. It is generally composed of the injection machine 7.
[0005]
When the upper and lower molds 5 and 6 are clamped, a cavity portion 5a is formed in the molded upper mold 5 and a core section 6a is provided in the molded lower mold 6 in order to shape the product shape of the door trim 1. Yes. In order to move the upper molding die 5 up and down by a predetermined stroke, an elevating cylinder 5b is connected, and the molding lower die 6 is provided with a manifold 6b and a gate 6c that serve as a passage for molten resin from the injection machine 7.
[0006]
Further, in order to maintain an appropriate posture, the upper molding die 5 that moves up and down is provided with guide posts 6d at the four corners of the lower molding die 6, and the molding upper die 5 has guides corresponding to the guide posts 6d. A bush 5c is provided.
[0007]
Therefore, when the molding upper and lower molds 5 and 6 are in the mold open state, either the skin 3 is set in the mold, and then either immediately before or after the molding upper and lower molds 5 and 6 are clamped The molten resin M is injected and filled from the injection machine 7 through the manifold 6b and the gate 6c into the product cavity between the molds at the timing, thereby forming the resin core material 2 into a required curved shape and the resin core material 2 The skin 3 is integrally formed on the surface (for example, see Patent Document 1).
[0008]
In FIG. 22, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state. However, as described above, the molten resin M is a cavity after the upper and lower molds 5 and 6 are clamped. It may be injected and filled inside.
[0009]
[Patent Document 1]
Japanese Patent Laid-Open No. 10-138268 (Page 2, FIGS. 3 and 4)
[0010]
[Problems to be solved by the invention]
However, in the conventional door trim 1, since the projected area of the resin core material 2 is large, there are problems that the material cost is high and the product is heavy.
[0011]
In addition, since the projected area of the resin core material 2 is large, it is necessary to set the injection pressure at the time of molding high, and a mold structure that can withstand the high injection pressure is required, and the production cost of the mold is increased, In addition, since a large amount of molten resin is cooled and solidified, the molding cycle becomes longer, which is a major factor for reducing productivity.
[0012]
The present invention has been made in view of such circumstances, and can provide automobile interior parts that can promote weight reduction, have high rigidity, and can reduce costs. In addition, there is little material loss and high moldability. Another object of the present invention is to provide an automobile interior part, a method for producing the same, and a molding die used therefor.
[0013]
[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. Resin with excellent rigidity at places where rigidity is required, i.e., close to product peripheral parts, panels, mating parts with mating parts, places where a certain clearance is secured, places where parts are attached, and places where loads are applied The present invention has been completed by arranging the ribs, and improving the sealing performance particularly when the resin ribs are injected and filled.
[0014]
That is, the interior part for automobiles according to the present invention is a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a resin rib having a predetermined pattern shape that is integrated on the back surface of the foamed resin base material. The foamed resin base material along both side edges of the resin rib is provided with a compression portion with a reduced thickness direction dimension.
[0015]
Here, the interior parts for automobiles can be applied to door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, and the like.
[0016]
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 the material, it is molded into the required shape in the molding die, so that it can maintain its shape even if it is removed from the mold after molding even if there is no reinforcing material such as ribs (shape retention) have. Also, if the product shape includes a high expansion ratio part, after the foamed resin sheet is heat-softened, a vacuum suction mechanism is provided in the molding die and the foamed resin sheet is vacuumed along the inner surface of the molding die. A suction force may be applied.
[0017]
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.
[0018]
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.
[0019]
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 2.0 mm, and the thickness is 0.5 to 30 mm, preferably 1 to 10 mm.
[0020]
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.
[0021]
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.
[0022]
Furthermore, along the both side edges of the resin rib, the back surface side of the foamed resin base material is formed as a compressed portion with a reduced thickness direction dimension.
[0023]
Next, another embodiment of the automotive interior part according to the present invention is a molded resin base material that is molded into a required shape and is lightweight and has shape retention, and a predetermined integrated with the back surface of the foam resin base material. It is an interior part for automobiles composed of pattern-shaped resin ribs, and a sheet-like resin leakage portion that oozes out from the resin ribs is formed on a part of the back surface of the foamed resin base material, thereby increasing rigidity. Is set.
[0024]
Even in this case, the foamed resin base at both side edges of the resin rib is basically provided with a compression portion, but particularly the edge of the resin rib integrated with the sheet-like resin leakage portion is compressed. The resin rib located at the boundary between the part where the resin leaking part is not formed and the part where the resin leaking part is formed has a difference in the sealing performance by the foamed resin base material on both side edges thereof. Yes.
[0025]
In order to enhance the appearance design, a decorative material may be laminated and integrated on the surface of the foamed resin base material. As the decorating material, 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 materials constituting these decorating materials are not particularly limited. However, the use of air-permeable materials such as woven fabrics, non-woven fabrics, and knitted fabrics makes better use of the sound absorbing performance of the indoor noise of the foamed resin base material. Is preferable.
[0026]
According to the automotive interior part of the present invention, since the resin rib is laminated and integrated on the back side of the foamed resin base material having shape retention, the conventional resin is laminated. The core material can be abolished. Therefore, by eliminating the conventional resin core material having a very 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.
[0027]
In addition, a compression part is set in the foamed resin base on both sides of the resin rib, and since this compression part is highly rigid, the resin rib does not bend along the width direction and prevents deformation of the resin rib. can do.
[0028]
Next, the automobile interior part manufacturing method includes a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a resin rib having a predetermined pattern shape that is integrated on the back surface of the foamed resin base material. In a method for manufacturing an interior part for an automobile comprising the steps of: setting a foamed resin sheet in which a foamed resin sheet that is a material of a foamed resin base material is set in a molding die; and clamping the molding dies together The foamed resin base material is molded into the required shape along the cavity shape of the molding die, and along the resin rib arrangement pattern either before or after the mold clamping. The molten resin is injected and filled into the groove formed in the lower mold from the injection machine through the resin passage. At this time, the groove is sealed on the side edge to ensure the sealing performance of the groove. Pressure to do Part is formed on the foamed resin base material, characterized in that comprising the molding step of the foamed resin base material and the resin rib integrally laminated resin ribs on the back surface of the foamed resin base material.
[0029]
Here, when manufacturing the interior parts for automobiles, the molding die is 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. The molten resin supplied from the injection machine is supplied onto the mold surface of the molded lower mold through a resin passage such as a manifold and gate provided in the molded lower mold, but the molded upper mold reaches the bottom dead center. The melted resin is injected and filled into the cavity at a predetermined injection pressure at any timing immediately before or after the mold upper and lower molds are clamped.
[0030]
Accordingly, by molding the upper and lower molds, the foamed resin sheet is molded along the shape of the mold surface of the molding die, and the molten resin is injected and filled into the groove formed in the mold surface of the lower mold. Thus, the resin rib is 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 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]
Further, in the molding lower mold, grooves are formed corresponding to the lattice pattern along the vertical and horizontal directions of the resin ribs, and molten resin is injected and filled into the grooves via a resin passage from the injection machine. At the time of injection filling of the molten resin, a foamed resin sheet is sandwiched in the cavity, and in particular, by embedding along the side edge of the groove part, the foamed resin base material on the side edge of the groove part is provided. Since the compression part is formed, and this compression part is highly rigid and has excellent sealing performance, the molten resin does not leak out from the groove part, reducing the number of gates and increasing the resin pressure. However, it is possible to prevent resin leakage to the outside as much as possible.
[0036]
Therefore, compared to the conventional resin core material with a large projected area, only the resin ribs need to be molded. Therefore, the injection pressure can be set lower than the conventional one, so that the load on the molding die can be reduced and the amount of resin can be reduced. The material cost can be reduced, and the cooling time can be shortened and the molding cycle of the product can be shortened as compared with the conventional resin core material.
[0037]
In addition, the porous sound-absorbing performance of the foamed resin base material provides interior parts with excellent sound-absorbing performance that can effectively absorb noise inside and outside the vehicle, and uses polyolefin resin as the material for the foamed resin base material and resin ribs. In this case, all olefin resins can be unified, the separation process can be eliminated, and the recycling work can be eliminated.
[0038]
In addition, since the sealing performance of the groove portion can be maintained well during injection filling of the resin rib, there is no material loss due to resin leakage, the number of gates can be reduced, and the resin flow length can be set longer by increasing the injection pressure, etc. There are advantages.
[0039]
Next, another embodiment of the method of the present invention is a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a predetermined along the longitudinal and lateral directions that is integrated on the back side of the foamed resin base material. In a manufacturing method of an interior part for an automobile, in which a sheet-shaped resin leakage part is integrated with the back surface of a foamed resin base material in a desired rigidity-enhanced portion, a foamed resin base is formed in a molding die. A foam resin sheet setting process for setting a foam resin sheet, which is a material of the material, and clamping the molds together to mold the foam resin base material into the required shape along the cavity shape of the mold The molten resin passes through the resin passage from the injection machine into the groove formed in the lower mold along the resin rib arrangement pattern at any timing before or after the mold is clamped. Injection filling The resin ribs are forced to leak from the resin ribs to the back side of the foamed resin base material by making a difference in the sealing performance against the foamed resin sheet at both side edges of the resin ribs that define the rigidity-enhanced parts. Thus, it is characterized by comprising a foamed resin base material and a resin rib molding step in which the resin rib and the resin leakage portion are integrated on the back surface of the foamed resin base material.
[0040]
In this case, in order to cope with the resin rib, the groove provided in the core part mold surface of the molded lower mold can be prevented from leaking the resin by embedding the side edge to improve the sealing property, and vice versa. As for the edge portion where the overlay is omitted, a sheet-like resin leakage portion can be forcibly created on the back surface of the foamed resin base material.
[0041]
And according to this embodiment, in a portion where rigidity is required, such as a portion where force is easily applied in the direction perpendicular to the product surface side of the interior part, a sheet-like shape is forcibly formed on the back surface of the foamed resin substrate. Since the resin leakage portion can be formed integrally with the resin rib, the resin rib can be formed into a required shape, and at the same time, the rigidity of a desired location in the foamed resin base material can be enhanced.
[0042]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described by exemplifying an automobile door trim, a manufacturing method thereof, and a molding die used in the method.
[0043]
1 to 13 show a first embodiment of the present invention, FIG. 1 is a front view showing an automobile door trim, FIG. 2 is a sectional view showing the configuration of the automobile door trim, and FIG. 3 is a resin in the automobile door trim. FIG. 4 and FIG. 5 are sectional views showing the shape of the periphery of the resin rib in the automobile door trim, and FIG. 6 shows the configuration of a molding die used for molding the automobile door trim. FIGS. 7 and 8 are cross-sectional views showing the groove shape of the molding lower mold in the molding die, and FIGS. 9 to 11 show the steps of the method for manufacturing the door trim for the automobile. FIG. 10 is an explanatory view showing a preheating process of the foamed resin sheet, FIG. 10 is an explanatory view showing a setting process of the foamed resin sheet to a molding die, and FIG. 11 is an explanatory view showing a molding process by clamping the molding die. 12 and 13 are a cross-sectional view and a plan view showing the configuration in the vicinity of the gate portion in the molding die.
[0044]
Next, FIGS. 14 to 19 show a second embodiment of the present invention. FIG. 14 is a plan view showing the shape of a resin rib when applied to an automobile door trim as in the first embodiment. FIG. Sectional drawing which shows the structure of the peripheral part of the resin rib in 2nd Embodiment, FIG. 16 is explanatory drawing which shows the principal part of the shaping die for shape | molding the resin rib shown in FIG. 15, FIG. 17 changes a rigidity reinforcement site | part. FIG. 18 is a sectional view showing the configuration of the peripheral portion of the resin rib, and FIG. 19 is an explanatory view showing the main part of a molding die for molding the resin rib shown in FIG. It is.
[0045]
First, a first embodiment of the present invention will be described with reference to FIGS.
[0046]
The automotive door trim 10 according to the present embodiment includes an inside handle escutcheon 11 and other accessories such as a power window switch finisher 13 and a pull handle 14 attached to the armrest portion 12. A pocket escutcheon 16 is fitted and fixed around the pocket opening 15, and a speaker grill 17 is provided integrally or separately on the front side.
[0047]
More specifically, as shown in FIG. 2, the automobile door trim 10 is molded into a required shape and laminated and integrated with the foamed resin base material 20 having shape retention and the back side of the foamed resin base material 20. The resin rib 30 and a decorative material 21 having a decorative function laminated and integrated on the surface side of the foamed resin base material 20 are roughly configured.
[0048]
In addition, the foamed resin base material 20 is heat-softened on the foamed resin sheet so as to have shape retention, and then thermoformed into a required 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. In addition, in flat parts like lid parts, such as a jack lid, it can shape | mold into a flat shape, without performing a heat softening process to a foamed resin sheet.
[0049]
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 as a foaming agent 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.
[0050]
Next, the resin ribs 30 are disposed on the back surface side of the foamed resin base material 20, and in particular, as shown in FIG. 3, are set in a lattice pattern extending in the vertical and horizontal directions. The resin rib 30 is made of a general-purpose synthetic resin molded body, and as a synthetic resin that can be preferably used usually, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin, An ionomer resin, a polyamide resin, an acrylonitrile / butadiene / styrene (ABS) resin, a polycarbonate resin, or the like may be appropriately selected. In this embodiment, a polypropylene resin is used in consideration of the environment and the recycling. .
[0051]
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.
[0052]
Further, as shown in FIGS. 4 and 5, the resin rib 30 induces a bending deformation in the direction of arrow A in FIGS. 4 and 5 because the height dimension is set longer than the width dimension. Although it tends to be easy, in the foamed resin base material 20, the compression portions 22 are set along both side edges of the resin rib 30 so as to effectively prevent the bending deformation.
[0053]
In FIG. 4, the compression part 22 is set so that the thickness of the foamed resin base material 20 gradually changes from the general part toward the side edge of the resin rib 30, and the compression part 22 of FIG. Has been. In addition, although the shape of the compression part 22 is not limited, since the density increases and rigidity is strengthened by setting the compression part 22 as a function which the compression part 22 has, the deformation | transformation of the resin rib 30 is suppressed. Can do. In this embodiment, the compression portion 22 shown in FIG. 4 forms the compression portion 22 in a gradually changing shape by embedding a molding die to be described later. 5 to 1.5 mm, the dimension b in the figure is set to 3 to 10 mm. Further, in the rectangular compression portion 22 shown in FIG. 5, the a dimension is set to 0.5 to 1.5 mm, and the b dimension is similarly set to 3 to 10 mm. In addition, the plate | board thickness of the general part of the door trim 10 for motor vehicles is set to 3 mm.
[0054]
As described above, the automotive door trim 10 according to the present invention includes the foamed resin base material 20 having shape retention, the resin rib 30 laminated and integrated on the back surface of the foamed resin base material 20, and the decorative door. Since it is composed of the decorative material 21, 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 in relation to using the lightweight foamed resin base material 20, The weight can be reduced by 40% or more compared to the conventional example, and the resin material can be saved greatly, which can contribute to cost reduction.
[0055]
Furthermore, since the foamed resin base material 20 has a porous structure, it has excellent sound absorption performance and can reduce noise inside and outside the vehicle interior. Further, in order to enhance the sound absorption performance of the foamed resin base material 20 particularly for vehicle interior noise, the decorative material 21 laminated and integrated on the surface of the foamed resin base material 20 is a woven fabric, a nonwoven fabric, a knitted fabric, or the like. A sheet material having air permeability as described above is preferable. In addition to the breathable sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric, the decorative material 21 may be a synthetic resin sheet such as a vinyl chloride sheet or a TPO sheet, a synthetic resin film, a foam, or a net-like body. . In addition, if a TPO sheet is used, the material used can be unified with a polyolefin-based resin, so that it can be easily recycled.
[0056]
And as for the resin rib 30 along a predetermined pattern, the compression part 22 is set to the foamed resin base material 20 which hits the base side edge, and the rigidity of the support surface of the foamed resin base material 20 which supports the resin rib 30 is reinforced. Therefore, even if the height dimension of the resin rib 30 is set to be long with respect to the width dimension, it is possible to effectively prevent bending deformation along the width direction and maintain the initial shape of the resin rib 30 well over a long period of time. There are advantages.
[0057]
Next, an outline of a method for manufacturing the door trim 10 will be described below with reference to FIGS. FIG. 6 shows the overall configuration of the molding die 40, and FIGS. 7 and 8 are cross-sectional views showing the shapes of the grooves that form the resin ribs 30. In FIG. 6, a molding die 40 used for molding the door trim 10 includes a molding upper mold 41 that can move up and down by a predetermined stroke, a molding lower mold 42 that is paired with the molding upper mold 41, and a molding lower mold 42. And an injection machine 43 connected to the main body.
[0058]
More specifically, the molding upper die 41 has a cavity portion 411 that matches the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 412 connected to the upper surface of the molding upper die 41. In addition, guide bushes 413 serving as a guide mechanism are provided at the four corners of the molding upper die 41.
[0059]
On the other hand, the molding lower die 42 is provided with a core portion 421 corresponding to the cavity portion 411 of the molding upper die 41. In addition, a manifold 422 and a gate 423 are provided to supply the molten resin to the mold surface of the core portion 421. The molten resin M supplied from the injection machine 43 through the resin passages of the manifold 422 and the gate 423 is provided. Is supplied to the groove portion 424 on the upper surface of the core portion 421.
[0060]
In addition, guide posts 425 that serve as a guide mechanism protrude from the four corners of the molded lower mold 42, and the guide posts 425 are guided into the guide bush 413 when the molded upper and lower molds 41 and 42 are clamped. As a result, the pressing posture of the molding upper die 41 can be properly maintained.
[0061]
Further, in the molding die 40 used in the method of the present invention, the groove portion 424 provided in the core portion 421 of the lower molding die 42 for molding the resin rib 30 has, for example, the shape of the peripheral portion of the resin rib 30 shown in FIG. In order to mold, the molding die 40 shown in FIG. 7 is used, and in order to mold the shape of the peripheral portion of the resin rib 30 shown in FIG. 5, the molding die 40 shown in FIG. 8 is used.
[0062]
For example, as shown in FIG. 7, along the both side edges of the base portion of the groove portion 424 for molding the resin rib 30, the build-up 44 gradually increases on the mold surface of the core portion 421 from the outside toward the groove portion 424. It is attached so that thickness may increase. Further, in the molding die 40 shown in FIG. 8, a build-up 44 having a rectangular cross section is provided on the mold surface of the core portion 421 along both side edges of the base portion of the groove portion 424.
[0063]
When the molten resin is supplied to the groove portion 424 in a state where the foamed resin sheet S is accommodated in the cavity, the buildup 44 compresses the foamed resin sheet S, thereby improving the sealing performance of the groove portion 424 and causing resin leakage. It has a function to prevent as much as possible.
[0064]
Next, a method for manufacturing the automobile door trim 10 will be described with reference to FIGS. 9 to 11. First, as shown in FIG. 9, the heater device 50 heat-softens the foamed resin sheet S (the decorative material 21 is laminated). As the foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumika Plustech, trade name: Sumiceller foam PP sheet, expansion ratio = 3 times, thickness 3 mm) is used.
[0065]
Then, as shown in FIG. 10, when the molding die 40 is in the mold open state, the foamed resin sheet S subjected to heat softening treatment is set in the molding die 40. Thereafter, the raising / lowering cylinder 412 of the molding upper die 41 is operated, the molding upper die 41 is lowered by a predetermined stroke, the molding upper and lower dies 41 and 42 are clamped, and the foamed resin sheet S is moved as shown in FIG. The foamed resin base material 20 is molded into a desired shape by molding into a desired mold surface shape, and molten resin is injected into the groove portion 424 provided in the core portion 421 of the molded lower die 42 from the injection machine 43 through the manifold 422 and the gate 423. M is injected and filled, and the resin rib 30 is integrally formed on the inner surface side of the foamed resin base material 20.
[0066]
As this molten resin M, talc is mixed in an appropriate proportion with Sumitomo Noblen BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min). The injection timing of the molten resin M may be set before the mold upper and lower molds 41 and 42 are clamped.
[0067]
And at this time, since the build-up 44 is formed in the both-sides edge part of the groove part 424 provided in the shaping | molding lower mold | type 42, since the sealing performance of the groove part 424 is maintained favorably, the molten resin M is There is no leakage from the groove 424 to the outside, and material loss can be reliably prevented, and even if the injection pressure of the injection machine 43 is set high, there is no resin leakage, so the number of gates 423 can be reduced. Become.
[0068]
Furthermore, according to the method of the present invention, unlike the method in which the foamed resin sheet is pre-shaped and then set in the injection mold, the resin rib 30 and the compression portion 22 can be formed at the same time as the molding. There is no positional displacement between the resin 22 and the resin rib 30.
[0069]
In addition to setting the build-up 44 along both side edges of the groove 424, for example, as shown in FIGS. 12 and 13, when the build-up 45 is provided at a constant distance on the outer periphery of the gate 423, the bush Although the resin burrs m ooze out on the surface 426, the build-up 45 can prevent the resin from leaking to the outside as much as possible.
[0070]
In this case, due to the combined effect of the rigidity of the foamed resin base material 20 due to the formation of the compression part 22 in the foamed resin sheet S and the rigidity increase due to the area of the high rigidity part being widened by the compression part 22, FIG. 5 is strong against bending in the direction of arrow A.
[0071]
Next, FIG. 14 to FIG. 16 show a second embodiment of the present invention. For example, FIG. 14 shows an arrangement pattern of the resin ribs 30. As shown in FIG. 15, a thin sheet-like resin leakage portion 31 is integrally formed with the resin rib 30 on the back surface of the foamed resin base material 20 for the rigidity-enhanced portion A to be formed. Further, a compression portion 22 is formed on the foamed resin base material 20 at the outer peripheral edge of the resin rib 30 that defines the rigidity-enhanced portion A.
[0072]
In order to mold the door trim 10 having the above-described structure, as shown in FIG. 16, the resin spilled portion 31 can be forcibly formed especially in the groove portion 424 formed in the core portion 421 in the molded lower mold 42. The rib 30 has a difference in sealing performance between the side edge on the rigid reinforcement portion A side and the opposite side edge. That is, the build-up 44 is set along the outer edge of the groove 424, but the build-up 44 is omitted along the inner edge.
[0073]
Therefore, when the molded upper and lower molds 41 and 42 are clamped to form the foamed resin base material 20 into a required shape, and simultaneously when the molten resin M is injected and filled into the groove 424, the resin rib 30 is Resin leakage does not occur from the outer edge of the resin rib 30 outward, and conversely, the melted resin M forcibly leaks to the outside of the portion where the build-up 44 is not set, and the sheet shape The resin leakage portion 31 is formed.
[0074]
As described above, in order to form the resin rib 30, by adjusting the sealing performance along both side edges of the groove portion 424 provided in the core portion 421, the resin leakage is eliminated or the foamed resin base material 20 is forcedly formed. The sheet-like resin leakage portion 31 can be integrated with the back surface, and the rigidity-enhancing portion A can be formed simultaneously with the formation of the resin rib 30.
[0075]
In the case of this example, by providing the compression part 22 in the product, the rigidity of the foamed resin sheet on the outer edge side is reinforced, and the rib 30 is shown in FIG. Bending in the direction of arrow A is prevented.
[0076]
Further, a modification of the second embodiment of the present invention will be described with reference to FIGS. That is, in this modified example, as shown in FIG. 17, since the rigidity-enhanced portion A is set in a wide area, the resin rib 30 a that surrounds the rigidity-enhanced portion A and the resin that extends into the rigidity-enhanced portion A There are ribs 30b.
[0077]
Then, the relationship between the resin ribs 30a, 30b and the foamed resin base material 20 is compressed to the back surface of the foamed resin base material 20 along the outer edge of the resin rib 30a surrounding the rigidity-enhancing portion A as shown in FIG. A sheet-like resin leakage portion is formed on the back surface of the foamed resin base material 20 from the inner edge of the resin rib 30a surrounding the rigidity-enhanced portion A to the resin rib 30b extending into the rigidity-enhanced portion A. 31 is formed.
[0078]
Further, when setting the rigidity-enhancing portion A in a wide range, as shown in FIG. 19, a buildup 44 is set on the outer edge of the groove 424a corresponding to the resin rib 30a, and the inner edge of the groove 424a is While the build-up 44 is omitted, the build-up 44 is also omitted from both side edges of the groove 424b corresponding to the resin rib 30b.
[0079]
Accordingly, due to the difference between the sealing performance of the portion where the build-up 44 is formed and the sealing performance of the portion where the build-up 44 is omitted, as shown in FIG. Is formed, and rigidity can be enhanced by a simple method.
[0080]
【The invention's effect】
As described above, the automotive interior part according to the present invention is a lightweight and shape-retaining foamed resin base material, and the rear surface of the foamed resin base material and a part requiring rigidity such as the outer periphery of the product. Because it is composed of laminated resin ribs, the conventional heavy resin core material can be abolished, so it is a lightweight, low-cost, porous material that can be used for automobile interior parts with excellent sound absorption performance. It has the effect that it can be provided.
[0081]
Furthermore, if the process of molding the resin foam on the back side of the foamed resin base material at the same time as molding the foamed resin base material into the required shape along the cavity shape of the molding die, the resin rib that is a resin molded body Compared to conventional resin core materials, the projected area is less, the load on the mold is less, the cooling time can be shortened, and the yield can be increased. This has the effect of reducing the cost.
[0082]
Further, in the automotive interior part according to the present invention, the compression part is set in the foamed resin base material along both side edges of the resin rib, and the density of the compression part is high and the rigidity is reinforced. The bending deformation along the rib width direction can be effectively prevented, and the initial shape can be stably maintained over a long period of time.
[0083]
Next, the method for manufacturing an automotive interior part according to the present invention includes forming a foamed resin base material into a required shape by clamping the molded upper and lower molds, and simultaneously injecting and filling molten resin into the groove portion of the molded lower mold. By integrating resin ribs with a predetermined pattern shape on the back of the resin base material and embedding the side edges of the groove, the sealing performance of the groove can be improved and resin leakage can be prevented as much as possible. And the number of gates can be reduced, and the flow length of the resin can be set long.
[0084]
Furthermore, according to another aspect of the interior part for automobiles according to the present invention, a sheet-like resin leakage portion integrated with the resin rib is integrated into a part of the back surface of the foamed resin base material in the rigidity-enhanced portion. Therefore, the resin that causes material loss has a reinforcing function to effectively use the material, and the manufacturing method of the interior part omits the build-up and seals the side edge of the groove portion that forms the resin rib. By setting the difference in the above, the resin leakage from the groove portion is prevented or the resin leakage is forced to appear to increase the rigidity, so that the practicality is excellent.
[Brief description of the drawings]
FIG. 1 is a front view showing a first embodiment of an automotive door trim to which an automotive interior part according to the present invention is applied.
2 is a cross-sectional view taken along line II-II in FIG.
FIG. 3 is a front view showing an arrangement pattern of resin ribs in the door trim shown in FIG. 1;
4 is a cross-sectional view showing the shape of a resin rib and its peripheral edge in the door trim shown in FIG. 1. FIG.
FIG. 5 is a cross-sectional view showing a modification of FIG.
6 is an explanatory view showing an overall configuration of a molding die used in the door trim manufacturing method shown in FIG. 1. FIG.
7 is an enlarged cross-sectional view showing a groove and its peripheral edge in the molding die shown in FIG. 6;
8 is a cross-sectional view showing a modification of the groove portion and the peripheral portion thereof in the molding die shown in FIG. 6. FIG.
FIG. 9 is an explanatory view showing a preheating step of the foamed resin sheet in the door trim manufacturing method shown in FIG. 1;
10 is an explanatory view showing a foamed resin sheet setting step in the door trim manufacturing method shown in FIG. 1; FIG.
FIG. 11 is an explanatory view showing a molding step of a foamed resin base material and resin ribs in the door trim manufacturing method shown in FIG. 1;
12 is a cross-sectional view showing a configuration in the vicinity of a gate portion in the molding die shown in FIG.
13 is a plan view of the vicinity of the gate portion shown in FIG.
FIG. 14 is a front view showing an arrangement pattern of resin ribs, showing a second embodiment of an automotive door trim to which an automotive interior part according to the present invention is applied.
15 is a cross-sectional view taken along line XV-XV in FIG.
16 is a partial cross-sectional view showing a molding die for molding the foamed resin base material and the resin rib shown in FIG. 15;
FIG. 17 is a front view of a resin rib showing a modification of the second embodiment of the automotive door trim to which the automotive interior part according to the present invention is applied.
18 is a cross-sectional view taken along line XVIII-XVIII in FIG.
19 is a partial cross-sectional view showing a molding die for molding the foamed resin base material and resin ribs shown in FIG. 18;
FIG. 20 is a front view showing a conventional door trim.
21 is a cross-sectional view taken along line XXI-XXI in FIG.
FIG. 22 is an explanatory view showing an outline of a conventional door trim manufacturing method.
[Explanation of symbols]
10 Automotive door trim
11 Inside handle escutcheon
12 Armrest part
13 Power window switch finisher
14 Pull handle
15 pocket opening
16 pocket escutcheon
17 Speaker grill
20 Foamed resin substrate
21 decorating materials
22 Compression unit
30 resin ribs
31 Resin leakage
40 Mold
41 Upper mold
42 Molded lower mold
43 Injection machine
44,45 meat
A Stiffening area
S Foamed resin sheet
M Molten resin

Claims

A foamed resin base material (20) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (30) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (20). Automotive interior parts (10),
An interior part for an automobile, wherein the foamed resin base material (20) along both side edges of the resin rib (30) is provided with a compression portion (22) having a reduced size in the thickness direction.

A foamed resin base material (20) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (30) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (20). Automotive interior parts (10),
By forming a sheet-like resin leakage portion (31) that oozes out from the resin rib (30) on a part of the back surface of the foamed resin base material (20), a rigidity reinforcing portion (A) is set. Automotive interior parts characterized by

A foamed resin base material (20) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (30) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (20). In the manufacturing method of the automotive interior part (10),
A foaming resin sheet (S) setting step for setting a foamed resin sheet (S) that is a material of the foamed resin base material (20) in the molding die (41, 42);
The molding dies (41, 42) are clamped together to mold the foamed resin base material (20) into a required shape along the cavity shape of the molding dies (41, 42), and the molding dies (41 , 42) before or after mold clamping, and injected into the groove (424) formed in the molded lower mold (42) along the arrangement pattern of the resin rib (30). The molten resin (M) is injected and filled from the machine (43) through the resin passages (422, 423). At this time, the side edge of the groove (424) is provided with the build-up (44), so that the groove ( 424) A foamed resin base in which a compression part (22) for ensuring the sealing property is formed on the foamed resin base material (20), and a resin rib (30) is laminated and integrated on the back surface of the foamed resin base material (20). Forming step of the material (20) and the resin rib (30);
A method for producing an interior part for an automobile, comprising:

A foamed resin base material (20) which is molded into a required shape and is lightweight and has shape retention, and a resin rib having a predetermined pattern shape along the vertical and horizontal directions integrated on the back side of the foamed resin base material (20) 30), and in the manufacturing method of the automotive interior part (10) in which the sheet-like resin leakage portion (31) is integrated with the back surface of the foamed resin base material (20) in the desired rigidity-enhanced part (A),
A foaming resin sheet (S) setting step for setting a foamed resin sheet (S) that is a material of the foamed resin base material (20) in the molding die (41, 42);
The molding dies (41, 42) are clamped together to mold the foamed resin base material (20) into a required shape along the cavity shape of the molding dies (41, 42), and the molding dies (41 42) in the groove (424) formed in the lower mold (42) along the arrangement pattern of the resin rib (30) at any timing before or after the mold clamping, When the molten resin (M) is injected and filled from the injection machine (43) through the resin passages (422, 423), the foamed resin sheets (S) are formed on both side edges of the resin rib (30) that defines the rigidity-enhanced portion (A). ) By forcing the molten resin (M) to leak from the resin rib (30) to the back side of the foamed resin base material (20). Resin rib (30) on the back and resin leakage A forming step of the foamed resin base material integrating the 31) (20) and the resin rib (30),
A method for producing an interior part for an automobile, comprising:

A foamed resin base material (20) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (30) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (20). In the molding die (40) for molding the automotive interior part (10),
The molding die (40) includes a molding upper die (41) capable of moving up and down by a predetermined stroke, a molding lower die (42) located below the molding upper die (41) and connected to the injection machine (43). The upper mold (41) has a cavity (411) and a lower mold so that the foamed resin sheet (S) can be molded into a required shape when the upper and lower molds (41, 42) are clamped. (42) is provided with a core part (421), and a groove part (424) along the arrangement pattern of the resin rib (30) is formed on the mold surface of the core part (421), and the groove part (424) The both side edges are provided with a build-up (44) that compresses the foamed resin sheet (S) to improve sealing performance and prevent the molten resin (M) from exuding to the outside. Molding mold.

A foamed resin base material (20) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (30) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (20). In the molding die (40) for molding the automobile interior part (10) in which the sheet-like resin leakage portion (31) is integrated with the back surface of the foamed resin base material (20) in the desired rigidity-enhanced part (A) ,
The molding die (40) includes a molding upper die (41) capable of moving up and down by a predetermined stroke, a molding lower die (42) located below the molding upper die (41) and connected to the injection machine (43). The upper mold (41) has a cavity (411) and a lower mold so that the foamed resin sheet (S) can be molded into a required shape when the upper and lower molds (41, 42) are clamped. (42) is provided with a core part (421), while a groove part (424) along the arrangement pattern of the resin rib (30) is formed on the mold surface of the core part (421), and a resin leakage part The build-up (44) is omitted for the side edge of the groove (424) on the side forming (31), and the build-up (44) is provided for the other side of the groove (424). Mold characterized by