JP4232967B2 - Manufacturing method for interior parts for automobiles - Google Patents

Description

This invention is a door trim, a rear parcel shelf, floor trim, trunk trim relates rear side trim, a pillar garnish, a method of manufacturing automobile interior parts of the roof trim and the like, in particular, excellent in light weight, and appearance design properties, moldability methods for the production of automobile interior parts.

  For example, the configuration of automobile interior parts will be described with reference to FIGS. The door trim 1 has shape retention and attachment rigidity to a vehicle body panel, and is configured by laminating and integrating a skin 3 excellent in surface appearance on the surface of a resin core material 2 extending over almost the entire product surface. . Reference numeral 2a denotes an inner seal mounting flange for mounting the inner seal.

  The resin core material 2 is made of a polypropylene resin mixed with talc, and the skin 3 does not have shape retention itself, such as polyethylene foam on the back surface of a synthetic resin sheet such as a vinyl chloride sheet. In recent years, a cushioning material such as polyethylene foam is laminated on the back side of an elastomer sheet such as a TPO (thermoplastic olefin) sheet in consideration of environmental and recycling aspects. The laminated sheet material tends to be frequently used.

  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.

  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. 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.

  Therefore, when the molding upper and lower molds 5 and 6 are in the mold open state, the skin 3 is set in the mold, and then the molding upper and lower molds 5 and 6 are clamped and then injected into the product cavity between both molds. By injecting and filling the molten resin M from the machine 7 through the manifold 6b and the gate 6c, the resin core material 2 is formed into a required curved shape, and the skin 3 is integrally formed on the surface of the resin core material 2 (for example, , See Patent Document 1). In FIG. 10, 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, the molten resin M is injected and filled into the cavity after the mold upper and lower molds 5 and 6 are clamped. May be.

Japanese Patent Laid-Open No. 10-138268 (Page 2, FIGS. 3 and 4)

  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. 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 cost of creating the mold increases. 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.

The present invention has been made in view of such circumstances, and can provide interior parts for automobiles that can promote weight reduction and contribute to cost reduction, and in particular, automobiles that enhance the appearance and feel of the product surface. and to provide a manufacturing method of use interior parts.

  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. In places where rigidity is required, that is, peripheral parts and panels of products, parts mounting places and parts where loads are applied, resin ribs with excellent rigidity are arranged, and other parts are made into a hollow shape, In addition to providing interior trim parts that are lighter and less expensive than conventional resin cores with a large projected area, the molding temperature is particularly high considering the properties of the foamed resin sheet and the decorative sheet that is affixed to the surface. Thus, the present inventors have found that the appearance performance and quality performance of the product surface can be maintained satisfactorily by making the difference between the two and the present invention has been completed.

That is, the present invention provides a foamed resin base material that is molded into a required shape, is lightweight and has shape retention, a resin rib having a predetermined pattern shape laminated and integrated on the back surface of the foamed resin base material, and the foam In a method for manufacturing an interior part for an automobile that includes at least a part of a laminated structure composed of a decorative material affixed to the surface of a resin substrate, heat-softening a foamed resin sheet laminated with a hot melt film on one side , After the heat-softened foamed resin sheet and the decorating material that is not heat-treated or heat-treated at a low temperature of 120 ° C. or less are placed in the mold, the molds are clamped together, 40 kgf / cm ² less was press-molded at low pressure, after integrating the hot-melt film foamed resin base material as a bonding medium and decorative material, to the pattern of drilled processed resin rib forming lower die Cormorant molten resin into the groove by injection filling, characterized by forming a laminated structure by laminating and integrating a resin rib on the back side of the foamed resin base material.

  Here, as an interior part for an automobile, as long as it has a structure including at least a part of a laminated structure, for example, a door trim, a rear parcel shelf, a floor trim, a luggage trim, a trunk trim, a rear side trim, Applicable to pillar garnish, roof trim, etc.

  Furthermore, the laminated structure is molded into a desired curved shape, is lightweight and has a shape-retaining foamed resin base material, and a resin rib having a predetermined pattern shape laminated and integrated on the back surface of the foamed resin base material. However, the foamed resin substrate retains its shape by heat-softening the foamed resin sheet and then molding the foamed resin sheet into a required curved shape within a molding die. The term “shape retention” as used herein refers to having sufficient rigidity to retain the shape at least when the mold is removed after molding, even without a reinforcing material such as a rib. 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.

  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, polyacetal resin, polyethylene terephthalate resin, polyvinyl alcohol resin, polyamide resin, vinyl chloride resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) Resin, polycarbonate resin and the like can be used. As the foaming agent, an azo compound such as azodicarbonamide, an organic foaming agent such as a sulfohydrazide compound, a nitroso compound or an azide compound, or an inorganic foaming agent such as sodium bicarbonate can be used.

  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.

  On the other hand, the thermoplastic resin material used as the resin rib can be appropriately selected from a wide range of thermoplastic resins. Usually, those that can be preferably used include polyethylene resins, polypropylene resins, polystyrene resins, polyacetal resins, polyethylene terephthalate resins, polyvinyl alcohol resins, polyamide resins, vinyl chloride resins, ionomer resins, acrylonitrile / butadiene / Styrene (ABS) resin, polycarbonate resin and the like can be used.

  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.

  And in order to improve an external appearance design property, the decorating material is laminated | stacked and integrated on the surface of the foamed resin base material. The decorating material can be appropriately selected from a fabric sheet, a synthetic resin sheet, and the like, but a fabric sheet such as a woven fabric, a non-woven fabric, and a knitted fabric can be used in consideration of touch feeling, appearance, and the like. And if the fabric sheet which has air permeability is used, when utilizing the sound absorption performance of a foamed resin base material, it is preferable. Further, as a decorating material, a soft feeling may be imparted by lining a back surface of the fabric sheet with a cushion layer such as a polyolefin resin foam such as polyethylene foam. In addition, while using olefin resin as the material of the foamed resin base material and resin rib, and using olefin resin as the material of the decorating material, all resins can be unified into olefin resin, so recycling work It can be done smoothly.

And according to the interior parts for automobiles manufactured by the method of the present invention, as a structure of the laminated structure, a lightweight foamed resin base material, a hollow resin rib disposed on the back side thereof, and a foamed resin Since it is comprised from the decorating material affixed on the base-material surface, weight reduction can be achieved by abolishing the conventional heavy resin core material. Furthermore, since a temperature difference is set between the molding temperature of the foamed resin sheet and the decorating material, the decorative material does not fall down, so that good appearance performance and quality performance can be ensured.

  Here, the molding die is composed of a pair of split dies and an injection machine attached to the mold on one side. For example, it is comprised from the shaping | molding upper die which can be moved up and down, the shaping | molding lower die which is a fixed side located in the downward side of a shaping | molding upper die, and the injection machine connected with a shaping | molding lower die. When the molding upper and lower molds are used, the molten resin supplied from the injection machine passes through resin passages such as a manifold and a gate provided in the molding lower mold, that is, on the mold surface of the molding lower mold, that is, the mold of the molding lower mold. Molten resin is supplied to a groove portion (corresponding to a resin rib shape) formed in the surface.

  In addition, the foamed resin base material and the decorative material are integrally press-molded by this molding die, but the foamed resin sheet that is the material of the foamed resin base material is heated to 160 to 220 ° C. by the heater device and decorated. The material is kept in a low-temperature heating state of 120 ° C. or less even if the heating step is abolished or heated.

When the mold is opened, the heat-softened foamed resin sheet is overlaid with a decorative material that has been heat-treated or heated at a low temperature, and the mold is clamped to the product shape. It becomes. Also, pressing pressure of the mold at this time is 0~40kgf / cm ^2, compared to the pressing pressure 80 ± 20kgf / cm ² at the time of a conventional press molding, can be set low press pressure.

  Therefore, according to the method of the present invention, the press pressure of the molding die is about half or less of the press pressure at the time of conventional mold press molding, the molding load is small, and the molding temperature applied to the decorating material is also low. Therefore, in particular, the appearance performance and quality performance can be satisfactorily maintained when a fabric sheet such as a woven fabric or a non-woven fabric that is liable to fall down is used as a decorating material.

As described above, the method of manufacturing an automotive interior part according to the present invention is a lightweight and shape-retaining foamed resin base material, and a resin rib laminated and integrated on the back surface of the foamed resin base material, Because the entire structure and at least a part of the laminated structure composed of the decorative material affixed to the surface of the foamed resin base material is used, the conventional heavy resin core material can be eliminated. It is possible to provide interior parts for automobiles.

Furthermore, the manufacturing method of the automotive interior component according to the present invention is a material for the foamed resin base foamed resin sheet is softened by heat, Kakazarizai will either abolish the heating step, or heating to be low-temperature Since both materials are put into a molding die in a state of being heated, they are integrally press-molded into a product shape by clamping the molding die. When the sheet is used, molding defects such as hair fall do not occur, and a good product feel and product appearance can be obtained, and the design can be improved.

  Compared with the conventional mold press molding method, the foamed resin base material can be molded with a press pressure of about half or less, and this is also a factor that can maintain the quality performance and appearance performance of the decorative material satisfactorily. At the same time, it has the effect that the molding load is small and it can contribute to labor saving.

Hereinafter, the preferred embodiments of the method for manufacturing the automotive interior component according to the present invention will be described with the method for manufacturing the automotive door trim.

1 to 7 show an embodiment of the present invention, FIG. 1 is a front view showing a two-tone type automobile door trim manufactured by the method of the present invention , and FIG. 2 is a cross-sectional view showing the configuration of the automobile door trim. FIG. 3 is a front view showing a resin rib of a door trim upper and a door trim lower in the door trim for the automobile, FIG. 4 is an explanatory view showing an outline of a method for manufacturing interior parts for automobiles according to the present invention, and FIGS. It is explanatory drawing which shows each process of the manufacturing method of the interior component for motor vehicles which concerns on.

  1 and 2, a two-tone type automobile door trim 10 is composed of an upper and lower divided body of a door trim upper 20 made of a laminated structure and a door trim lower 30 made of a single resin product. As functional components to be mounted on the door trim 10, an inside handle escutcheon 11 and a power window switch escutcheon 12 are attached to the door trim upper 20. On the other hand, the door trim lower 30 is provided with a door pocket opening 13, and a pocket back cover (made of a resin molded body) 14 is attached to the rear side of the door trim lower 30, as shown in FIG. A speaker grill 15 is formed integrally or separately on the front side of the.

By the way, the door trim 10 for automobiles manufactured by the method of the present invention is characterized by reducing the weight of the door trim upper 20 that is a laminated structure and improving the appearance performance and feel of the door trim upper 20. That is, as shown in FIG. 2, the door trim upper 20 is molded into a desired curved surface shape and has a foamed resin base material 21 having shape retention, and a reinforcement integrated and laminated on the back surface side of the foamed resin base material 21. The resin rib 22 having a function and a decorating material 23 having a decorating function laminated and integrated on the surface side of the foamed resin base material 21 are roughly constituted. In the figure, reference numeral 16 denotes a vehicle body panel.

  In addition, the foamed resin base material 21 is heat-softened to heat 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. In addition, the foamed resin base material 21 may be shaped by vacuum forming for a portion with a higher development rate.

  The foamed resin sheet has a configuration 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 polyacetal resin, a polyethylene terephthalate resin, a polyvinyl alcohol. Resin, polyamide resin, vinyl chloride resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, polycarbonate resin, etc. can be used, and foaming agents include organic foaming agents such as azodicarbonamide and bicarbonate An inorganic foaming agent such as sodium 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 21 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.

  Next, the resin ribs 22 are disposed on the back surface side of the foamed resin base material 21 and, in particular, as shown in FIG. 3, are set in a predetermined pattern extending in an intersecting manner, and a portion to which a load is applied (for example, a clip seat). The portion excluding the upper surface of the waist portion, the upper surface of the armrest portion, etc.) has a thinned shape. In addition, as for this pattern, arbitrary patterns may be selected as long as it is intersecting, such as a vertical and horizontal direction, an oblique direction, or a combination thereof. The resin rib 22 is made of a general-purpose synthetic resin molded body, and a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyacetal resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a polyamide as a synthetic resin that can be preferably used normally. Resin, vinyl chloride resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, polycarbonate resin, etc., and in this embodiment, polypropylene resin in consideration of environmental and recycling aspects. Is used. The resin rib 22 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.

  As described above, the door trim 10 shown in FIGS. 1 to 3 includes the door trim upper 20 formed of a laminated structure and the door trim lower 30 of a single resin, and has an excellent appearance design due to an accent effect on the appearance. I have. Further, the door trim upper 20 includes a foamed resin base material 21 having shape retention, a resin rib 22 laminated and integrated on the back surface of the foamed resin base material 21, and a decorating material 23 having a decorating property. Therefore, the resin core material occupied over the entire circumference of the product can be abolished as before, and the weight of the product is reduced compared to the conventional example because the lightweight foamed resin base material 21 is used. In addition, the resin material can be saved and the cost can be reduced. Furthermore, since the foamed resin base material 21 has a porous structure, the door trim upper 20 is excellent in sound absorption performance and can reduce noise in the vehicle interior.

  Further, the decorative material 23 to be affixed to the surface of the foamed resin base material 21 is a fabric sheet such as a woven fabric, a nonwoven fabric or a knitted fabric, or a cushion layer such as a polyolefin resin foam such as polyethylene foam on the back surface of these fabric sheets. Laminated sheet material can be used, but PVC sheet, TPO (thermoplastic olefin) sheet, synthetic resin sheet such as synthetic leather, or polyolefin resin foam such as polyethylene foam on the back side of these synthetic resin sheet, etc. A laminated resin sheet material backed with a cushion layer can be used.

In particular, in order to effectively utilize the characteristics of the method of the present invention , it is preferable to use a fabric sheet having a pile such as a woven fabric, a nonwoven fabric, and a knitted fabric. In addition, while using a polyolefin resin as the decorating material 23 and using an olefin resin as the material of the foamed resin base material 21 and the resin rib 22, all the materials can be unified with the olefin resin. Is advantageous.

  By the way, the said door trim 10 is comprised from the upper and lower divided body of the door trim upper 20 and the door trim lower 30, and especially the decorating material 23 in the door trim upper 20 sets a temperature difference with the foaming resin base material 21 and molding temperature. In particular, good molding performance can be obtained. In particular, when a fabric sheet such as a woven fabric, a nonwoven fabric, or a knitted fabric is used as the decorating material 23, the hair fall does not occur at all. Since the product surface appearance can be obtained, there is an advantage that the commercial value can be improved.

  Next, an outline of the method of the present invention will be described with reference to FIG. First, the structure of the molding die 40 will be described. The molding die 40 used for molding the door trim 10 is a molding upper die 41 that can move up and down by a predetermined stroke, and a molding under molding on the fixed side that makes a pair with the molding upper die 41. The mold 42 and the two injection machines 43a and 43b connected to the molded lower mold 42 are generally configured.

  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.

  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. Further, in order to supply molten resin to the mold surface of the core portion 421, manifolds 422a and 422b and gates 423a and 423b are provided in the molding lower mold 42. Resins of the manifolds 422a and 422b and gates 423a and 423b are provided. The molten resins M1 and M2 supplied from the injection machines 43a and 43b through the passages are supplied into the groove 424 formed on the upper surface of the core 421 and into the cavity 425 for forming the door trim lower 30. In addition, guide posts 426 that serve as a guide mechanism protrude from the four corners of the molded lower mold 42, and the guide posts 426 guide 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.

  Then, when the molding upper mold 41 and the molding lower mold 42 are in the mold open state, the foamed resin sheet S that is the material of the foamed resin base material 21 is introduced. Heat softening treatment is performed at 160 to 220 ° C. On the other hand, when the foamed resin sheet S is put into the molding die 40, the decorating material 23 is superimposed on one surface of the foamed resin sheet S, but the decorating material 23 is not subjected to heat treatment. A hot melt film H is laminated in advance on one surface of the foamed resin sheet S. The hot melt film H functions as an adhesive medium, and the foamed resin base material 21 and the decorating material 23 are press-molded. Sometimes integrated.

  That is, as shown in FIG. 4, when the foamed resin sheet S subjected to the heat softening treatment is put into the molding die 40, the decorative material 23 to be integrated is not subjected to the heat treatment, and the decorative material is used. Since the product surface of 23 is not excessively softened, it is possible to avoid appearance defects such as hair fall. Instead of omitting the heating, low-temperature heating at 120 ° C. or lower can be performed. As described above, whether to perform low-temperature heating or not to heat at all is determined in consideration of the product shape and the physical properties (tensile strength, elongation rate, etc.) of the material.

  Next, each step in which the method of the present invention is applied to the two-tone type door trim 10 will be described with reference to FIGS. First, as shown in FIG. 5, the foamed resin sheet S is heat-softened by a heater device 50 such as an infrared heater, and the foamed resin sheet S is put into a mold 40 in a mold open state. The decorative material 23 is placed on one side of the resin sheet S (the surface on which the hot melt film H is laminated), and then the mold is placed in the molding die 40. 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. The foam resin sheet S and the decorating material 23 are set at the upper half of the cavity defined by the cavity portion 411 of the molding upper die 41 and the core portion 421 of the molding lower die 42 at the location corresponding to the door trim upper 20. Set to.

Then, after setting the foamed resin sheet S, the lifting cylinder 412 of the molding upper die 41 is operated, the molding upper die 41 is lowered by a predetermined stroke, and the molding upper and lower dies 41 and 42 are molded as shown in FIG. The foamed resin sheet S is shaped along a desired mold surface shape, the foamed resin base material 21 is formed into a required shape, and a decorative material 23 set on the upper surface of the foamed resin base material 21 is tightened. Are integrated. At this time, a pressing pressure of molding upper and lower dies 41, 42 is carried out molding at a low pressure press 0~40kgf / cm ^2, making it possible to halve the pressing pressure compared to 80 ± 20kgf / cm ² conventional press molding It is possible to reduce the load on molding.

  Therefore, at the time of this press molding, the material of the decorating material 23 is low in pressure and only the residual heat from the foamed resin sheet S is applied to the decorating material 23 and does not adversely affect the decorating material 23. As described above, even when a fabric sheet such as a woven fabric, a non-woven fabric, or a knitted fabric is used, it is possible to effectively solve the conventional problem that the hair falls due to heating and pressing pressure, and the door trim upper 20 is excellent in touch and appearance. Can be formed.

  Further, the foamed resin base material 21 and the decorating material 23 are integrally press-molded by clamping the molding upper and lower molds 41 and 42, and then the resin ribs 22 in the door trim upper 20 from the first injection machine 43a through the manifold 422a and the gate 423a. In order to form the molten resin M1, the groove portion 424 is injected and filled.

  At this time, compared to the conventional resin core material having a large projected area, the resin injection is sufficient to form the hollow resin ribs 22, so that the injection pressure of the resin can be lowered and the injection pressure can be overcome. It is not necessary to apply a high press pressure to the upper mold, and it is sufficient that a press pressure sufficient to form the foamed resin base material 21 and the decorating material 23 is applied. Conventional problems can be solved effectively. The injection timing of the molten resin M1 can be set before the mold upper and lower molds 41 and 42 are clamped. Further, as the molten resin M1, a resin in which talc is mixed at an appropriate ratio using Sumitomo Noblen BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min) is used.

  Then, as described above, after the integral press molding of the foamed resin base material 21 and the decorating material 23, the molding of the door trim upper 20 is completed by integrally molding the resin rib 22 on the back surface side of the foamed resin base material 21.

  Next, as shown in FIG. 7, in order to mold the door trim lower 30, molten resin M2 is injected and filled from the second injection machine 43b into the door trim lower 30 molding cavity 425 through the manifold 422b and the gate 423b. Lower 30 is formed into a required shape. In this embodiment, the molten resin M2 used as the material of the door trim lower 30 is Sumitomo Nobrene BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min). In comparison, since the door trim lower 30 appears on the surface of the product, the appearance performance may be improved by mixing the pigment or the like to give a desired color, or by engraving the surface on the surface.

  Further, the molten resins M1 and M2 branched and supplied to the door trim upper 20 and the door trim lower 30 can be supplied from one injection machine 43 as the same material. In this case, a branch manifold serving as a passage for the molten resin M1 supplied to the door trim upper 20 side from the main manifold communicating with the injection machine 43 and a branch manifold for the resin passage supplying the molten resin M2 to the door trim lower 30 side are provided. The molten resins M1 and M2 may be supplied separately, with a time difference.

  In the above-described process, the molding of the foamed resin base material 21 and the integration of the resin ribs 22 were simultaneously performed using the same molding die 40. However, the foamed resin base material 21 and the resin ribs 22 were separated. It is also possible to mold each of the molds separately and integrate them using a crimping mold. However, in consideration of cost, work efficiency, etc., it is preferable to adopt a process of simultaneously molding the foamed resin base material 21 and the resin rib 22.

  In the embodiment described above, a laminated structure is used for the door trim upper 20 in the door trim 10 of the upper and lower split structure composed of the door trim upper 20 and the door trim lower 30. However, the entire door trim 10 may be constituted by a laminated structure. In addition, the laminated structure of the foamed resin base material 21, the resin rib 22, and the decorating material 23 is applied to all interior parts such as a rear parcel shelf, a floor trim, a trunk trim, a rear side trim, a pillar garnish, and a roof trim. be able to.

It is a front view showing a two-tone type automobile door trim manufactured by applying the method of the present invention. It is the II-II sectional view taken on the line in FIG. It is a front view which shows the resin rib and door trim lower of the door trim upper in the door trim for motor vehicles shown in FIG. It is the schematic which shows one Example which applied the manufacturing method of the interior component for motor vehicles based on this invention to the manufacturing method of a door trim. It is explanatory drawing which shows the setting process to the shaping die of the raw material in the manufacturing method of the door trim which concerns on this invention. It is explanatory drawing which shows the formation process of the door trim upper in the manufacturing method of the door trim which concerns on this invention. It is explanatory drawing which shows the formation process of the door trim lower in the manufacturing method of the door trim which concerns on this invention. It is a front view which shows the conventional door trim. It is the IX-IX sectional view taken on the line in FIG. It is a schematic diagram which shows the manufacturing method of the conventional door trim.

Explanation of symbols

10 Automotive Door Trims 16 Car Body Panels 20 Door Trim Upper (Laminated Structure)
21 Foamed resin base material 22 Resin rib 23 Decorating material 30 Door trim lower (single resin)
40 Molding mold 41 Molding upper mold 42 Molding lower mold 424 Groove (for resin rib molding)
425 Cavity (for door trim lower molding)
43a, 43b Injection machine 50 Heater device S Foamed resin sheet M1, M2 Molten resin

Claims (1)

A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (22) having a predetermined pattern shape laminated and integrated on the back surface of the foamed resin base material (21) In the method for producing an automotive interior part (10) comprising at least a part of a laminated structure (20) comprising a decorating material (23) attached to the surface of the foamed resin substrate (21),
A foamed resin sheet (S) laminated with a hot melt film (H) on one side is heat-softened, and the heat-softened foamed resin sheet (S) is not subjected to heat treatment or at a low temperature of 120 ° C. or lower. After the heat-treated decorative material (23) is put into the molding dies (41, 42), the molding dies (41, 42) are clamped together and press-molded at a low pressure of 40 kgf / cm ² or less. The resin rib (22) formed in the lower mold (42) after the foamed resin base material (21) and the decorating material (23) are integrated by using the hot melt film (H) as an adhesive medium. The molten resin (M1) is injected and filled into the groove (424) along the pattern shape, and the resin rib (22) is laminated and integrated on the back side of the foamed resin base material (21) to form a laminated structure (20). Of automotive interior parts characterized by Production method.

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