JP4247893B2 - Interior parts for automobiles and manufacturing method thereof - Google Patents

Description

  The present invention relates to automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk room trims, rear side trims and the like, and a method for manufacturing the same. The present invention relates to an automobile interior part that can be easily manufactured by adding the same and a method of manufacturing the same.

  For example, the configuration of automobile interior parts will be described with reference to FIGS. The door trim 1 has a shape retaining property and a mounting rigidity to a vehicle body panel, and 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. Yes.

  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. A laminated sheet material in which a cushion material is laminated is used, and recently, an elastomer sheet such as a TPO (thermoplastic olefin) sheet tends to be frequently used in consideration of environmental aspects and recycling aspects.

  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 molding upper 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 of 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, 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).

  In FIG. 20, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state. Actually, however, the molten resin M is injected into the cavity after the mold upper and lower molds 5 and 6 are clamped. It may be filled.

  Furthermore, as shown in FIG. 21, the outer peripheral terminal of the door trim 1 product is subjected to simultaneous press molding of the skin 3 on the surface of the core material 2, and then pierced in a separate process after the mold blade in the mold or molding. Cut processing is performed. Further, as shown in FIG. 22, after the core material 2 is press-molded, the skin 3 is integrated by vacuum pressing, press-bonding or the like in a separate process, and then the terminal 3 a of the skin 3 is wound around the back surface side of the core material 2. Processing is also conventionally performed.

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 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.

  Furthermore, at the outer peripheral edge of the door trim 1, as shown in FIG. 21, when the outer skin simultaneous press molding is performed, the outer peripheral terminal processing is difficult, and in the case of the skin 3 of the skin 3 or the skin 3 of the laminated sheet material specification, In addition to the appearance of the foam layer being exposed to the outside and the disadvantage of reducing the appearance performance, as shown in FIG. 22, the process of winding the skin 3 in a separate process requires a lot of man-hours and costs. Up is inevitable.

  The present invention has been made in view of such circumstances, and can provide an automotive interior part that can promote weight reduction, can achieve high rigidity, and can reduce the cost. In particular, the appearance of the product outer peripheral terminal can be enhanced. And it aims at providing the interior component for motor vehicles which improved the external appearance performance which can also perform a terminal processing work easily, and its manufacturing method.

  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. High rigidity is required at places where rigidity is required, i.e. it can be closely contacted with the peripheral part of the product, the panel, the mating part with the mating part, or a part where a certain clearance is secured, or where a part is attached and where a load is applied By arranging resin ribs, the weight of the product is reduced compared to the conventional resin core material with a large projected area, and the terminal of the outer periphery of the product is a beautiful terminal by devising the mold shape. It has been found that processing can be achieved, and the present invention has been completed.

That is, an automotive interior component according to the present invention is a lightweight foam resin base material having shape retention, a resin rib laminated and integrated on the back surface of the foam resin base material, and the foam resin base material. It is an automotive interior part consisting of a decorative material laminated and integrated on the surface, and a vertical wall portion is set on at least a part of the product outer periphery of the foamed resin base material, and when molding the foamed resin base material, A groove is formed in the vertical wall portion of the foamed resin base material by providing protrusions along the product terminal line on the inner wall surface of the molding die on one side of the molding die , and this groove portion is thin-walled. A decorative material is wound on the surface of the foamed resin base material that has been subjected to compression processing, and the groove is cut as a product terminal so as to hide the cut end.

Furthermore, another embodiment of the present invention includes a foamed resin base material that is lightweight and has shape retention, a resin rib that is laminated and integrated on the back surface of the foamed resin base material, and a surface of the foamed resin base material. Automotive interior parts consisting of decorative materials laminated and integrated with each other, and by molding mold clamping, the foamed resin base material is molded into the required shape, and the molding mold along the peripheral edge of the product A parting surface in which the product terminal portion is set so as to have a product surface substantially perpendicular to the operation direction of the product, and has a mold clearance smaller than the mold clearance of the product terminal portion along the outer periphery of the product terminal portion. By setting, the winding white to be wound on the back surface of the foam resin base material is extended, and the rigidity is strengthened by folding and fixing this winding white paper to the back surface of the foam resin base material. It is characterized by.

  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.

  And if the foamed resin base material that is lightweight and has shape retention properties is close to a flat shape, the heat softening step is omitted and it is molded into a desired shape by a mold, but it is applied to a three-dimensional product. In this case, after the foamed resin sheet is heat-softened, the foamed resin sheet is molded into a required curved shape in a molding die, and the shape is maintained. Here, “shape retention” refers to having rigidity enough to retain the shape 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, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / Styrene (ABS) resin or the like can be used.

  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.

  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, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, Acrylonitrile / butadiene / styrene (ABS) resin 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 as a decorating material laminated and integrated on the surface of the foamed resin base material in order to enhance the appearance design, woven fabrics, non-woven fabrics, knitted fabrics, sheets, films, foams, nets and the like can be used. Although the material which comprises these decorating materials is not specifically limited, It is more preferable to use the raw material which has air permeability, such as a woven fabric, a nonwoven fabric, and a knitted fabric, in order to utilize the sound absorption performance of a foamed resin base material. In addition, when a TPO sheet is used as a decorating material, the material can be unified with an olefin resin, so that the recycling work can be performed smoothly.

  Furthermore, the peripheral edge of the interior part has two forms, a type that is cut and a type that is rolled. First, in the structure to be cut, a vertical wall portion is set on the periphery of the foamed resin base material, and among the molding dies for forming the vertical wall portion, the mold surface of one side of the molding die is used. By providing the ridges, a groove is formed in the vertical wall portion of the foamed resin base material, and this groove is used as a base point for the cutting process, thereby avoiding the exposure of the cut end to the outside. Next, in the type that performs the wrapping process, the wrapping sill is set to a plane that is substantially orthogonal to the operation direction of the molding die, and a flat squeezing squeezing is performed by the mold clearance of the molding die. It is characterized by forming.

  And according to the interior part for automobiles according to the present invention, the decorative material having the decorating property is laminated on the front surface side of the foamed resin base material having the shape-retaining property, and the resin is meant to reinforce the rigidity on the back surface side. Since the ribs are laminated and integrated, the conventional resin core material can be eliminated.

  Therefore, since the conventional resin core material with a very large projected area can be eliminated, 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.

  Furthermore, with respect to the peripheral edge portion of the interior part, in the case of the terminal cut processing structure, the winding man-hour can be abolished, the man-hour can be shortened, and the cut end is not exposed to the outside, so the appearance appearance is good. It will be a thing. In addition, in the case of the wrapping treatment structure, since the product surface is substantially orthogonal to the mold opening / closing direction (operation direction) of the molding die, the stretching force does not act on the decorative material. Because the drawing pattern does not deform or flow out, and the press pressure of the molding die works sufficiently, it has excellent transferability of the drawing, and there is no unevenness in the terminal part during winding, Since the appearance is good and there is no need to set a protrusion or the like on the mold, the mold processing can be simplified.

  In addition, the porous sound-absorbing function of the foamed resin base material provides interior parts with excellent sound-absorbing performance. When polyolefin resin is used as the material for the foamed resin base material and resin ribs, Since it is unified, the separation process can be abolished and the recycling work can be simplified.

  Furthermore, the rib thickness of the resin rib can be varied as appropriate, for example, by setting the rib thickness to be thicker at sites where a large external force is applied to the product, and by reducing the rib thickness at sites where external force is relatively difficult to apply. Can do. Therefore, it is sufficient to use the minimum necessary amount of resin material, which can contribute to weight reduction and cost reduction of the product. Moreover, the clip seat or the attachment seat for attaching various escutcheon parts can also be integrally formed in the resin rib.

Next, a method for manufacturing an automotive interior part according to the present invention includes a lightweight foamed resin base material having shape retention, a resin rib laminated and integrated on the back surface of the foamed resin base material, and the foamed resin. In automotive interior parts consisting of a decorative material laminated on the surface of a base material, the foamed resin sheet, which is the material of the foamed resin base material, is heat-softened and then combined with the original sheet of the decorative material and molded metal When setting the foamed resin sheet into the required shape along the product cavity shape of the molding die by clamping the molding dies together and molding the foamed resin sheet to be set inside, the molding die on one side By forming ridges on the inner wall surface along the product terminal line, grooves are formed in the vertical wall portion of the foamed resin base material, either immediately before or after the mold is clamped Is it possible to inject molten resin into the groove of the mold at the timing? Integration process of foamed resin base material and resin rib by injection filling and resin rib laminated on the back side of the foamed resin base material, and removing the integrated laminate product from the mold, It is characterized by comprising a terminal processing step for interior parts to be subjected to terminal cut processing with the groove portion provided along the cutting base as a cutting base point.

  Here, the molding die used in the method of the present invention includes a movable side die, a fixed side die, and an injection machine. For example, it is composed of a molding upper mold that can move up and down by a predetermined stroke, a molding lower mold that is positioned below the molding upper mold, and an injection machine that is connected to the molding lower mold.

  When the molding upper and lower molds are used, the molten resin supplied from the injection machine passes through the resin passages such as the manifold and gate provided in the molding lower mold, and more specifically the mold surface of the molding lower mold. The upper mold is lowered to the bottom dead center and the upper and lower molds are clamped, and then the molten resin is provided on the mold surface of the lower mold with a predetermined injection pressure. The groove portion may be injected and filled, but may be performed before mold clamping as the injection filling timing of the molten resin.

  Furthermore, the mold surface shape of the molded upper and lower molds is set to a curved surface shape that matches the product shape, but in particular the vertical wall part of the molded lower mold so that the vertical wall part can be formed along the peripheral edge. Thus, the inner wall surface of the upper mold is formed so as to correspond to the predetermined clearance, and in particular, the ridge toward the other side is provided on the inner wall surface of the upper mold along the product terminal line. Therefore, by molding the upper and lower molds, the foamed resin sheet is formed into a desired curved surface shape along the mold surface shape of the molding die, and the surface of the vertical wall portion of the foamed resin base material along the product terminal line. The groove is recessed on the side. Further, the molten resin is injected and filled on the back surface side of the foamed resin base material, so that the resin ribs are laminated and integrated on the back surface of the foamed resin base material.

  Therefore, according to the method of the present invention, since only the resin rib is molded as compared with the conventional resin core material having a large projected area, the injection pressure can be set lower than the conventional one, so that the load on the molding die can be reduced. In addition, the resin material can be saved and the cooling time can be shortened as compared with the conventional resin core material, so that the product molding cycle can be shortened.

  Furthermore, with regard to the terminal treatment, it is possible to simultaneously form a groove portion that becomes a cut line at the time of molding the foamed resin base material, and if this groove portion is cut in the next step, an interior part with an excellent terminal appearance that does not have a cut end appear outside. Easy to produce.

Next, another embodiment of the method of the present invention is a lightweight foam resin base material having shape retention, a resin rib laminated and integrated on the back surface of the foam resin base material, and the foam resin base material. In the manufacturing method for automotive interior parts, which is made up of decorative material laminated on the surface and wound around the periphery of the foam resin base material, the foam resin sheet that is the material of the foam resin base material is heated. After the softening treatment, set the foamed resin sheet in the mold so that it overlaps the original sheet of the decorating material, and clamp the molds together, along the product cavity shape of the mold The molded resin base is molded into a required shape, and the product terminal portion is set to have a product surface substantially orthogonal to the operation direction of the molding die along the peripheral edge of the molding die. The inter-type clearance of the product terminal part on the outer periphery of the part By also setting the parting surface having a small inter-type clearances, while being formed into thin flat shape entrainment white is along the periphery of the foamed resin base material, clamping shortly before the molding die, or mold clamping Molding of foamed resin base material and resin rib by laminating and integrating the resin rib on the back side of the foamed resin base material by injecting and filling molten resin from the injection machine into the groove of the molding die at any later timing After the process and mold of the integrated laminated product are opened, the mold is removed, and the entrainment scissors are folded back and fixed to the back side of the foamed resin base material, so that the rigidity of the product terminal part can be enhanced and the appearance It is characterized by comprising a terminal treatment process for interior parts that can enhance the appearance .

  Here, the molding die used in this method is provided with a vertical wall portion on the foamed resin base material so as to be able to set a winding wall along the peripheral edge portion of the foamed resin base material, and along the peripheral edge of the vertical wall portion. Therefore, a molding die that can be molded so as to have a product surface that is substantially perpendicular to the operation direction of the molding die is used at the peripheral edge of the product so that the winding shiro can be integrated. And the thickness adjustment of the entraining scissors is performed by the mold clearance of the molding die, so that the mold processing is easy and the stretching force does not act on the foamed resin base material. No wringing pattern will leak when making

  Therefore, it is only necessary to wrap and fix the winding white on the back surface of the foamed resin base material, so that a sharp outer peripheral line can be secured and the terminal portion has a double structure, so that the rigidity is enhanced and there is no risk of deformation.

  As described above, the interior parts for automobiles according to the present invention are required to have rigidity such as a lightweight and shape-retaining foamed resin base material, a back surface of the foamed resin base material, and an outer peripheral edge of the product. Because it is composed of resin ribs that are laminated and integrated with the surface of the foamed resin base material, and a decorative material that is laminated on the surface of the foamed resin base material, the conventional heavy resin core material can be eliminated. And since it is a porous material, it has the effect that the interior component for motor vehicles excellent in the sound absorption performance can be provided.

  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.

  In addition, in the case of an automobile interior part according to the present invention having a structure in which cut processing is performed along the product terminal, the cut end is visible to the outside by cutting the groove formed in the vertical wall portion of the foamed resin base material. The edge part which does not occur can be formed easily, and it has the effect that it is excellent in external appearance design property, and a winding process can be made unnecessary.

  On the other hand, in the structure in which the car interior parts according to the present invention are wound, a molding die that can be molded so as to have a product surface substantially orthogonal to the operation direction of the molding die is used at the product peripheral portion. In addition, since the thickness dimension of the wrapping white is adjusted by the mold clearance of the molding die, there is no unevenness in the wrapping portion and the drawn pattern engraved on the surface of the decorating material flows out. In this case, a beautiful product appearance can be obtained, and the peripheral portion has a double structure, so that the rigidity can be enhanced.

  BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of an automobile interior part and a method for manufacturing the same according to the present invention will be described below by exemplifying a vehicle door trim and a method for manufacturing the same.

  1 to 12 show a first embodiment of the present invention, FIG. 1 is a front view showing a two-tone type automobile door trim, FIG. 2 is a cross-sectional view showing the configuration of the automobile door trim, and FIG. 4 is a front view showing a resin rib and a door trim lower of the door trim upper in the door trim, FIG. 4 is a cross-sectional view showing a configuration of a terminal portion of the door trim upper in the door trim for the automobile, and FIGS. FIG. 5 is an overall view of the molding die, and FIG. 6 is a cross-sectional view showing a portion corresponding to a door trim upper edge portion of the molding die. FIGS. 7 to 10 show a method for manufacturing the automobile door trim. FIG. 7 shows a preheating process for the foamed resin sheet, FIG. 8 shows a process for setting the foamed resin sheet in the mold, and FIG. FIG. 10 is an explanatory view showing a terminal processing step of the door trim upper, respectively. FIGS. 11 and 12 show a modification of the first embodiment. FIG. 11 is a sectional view showing an edge portion of the door trim upper in the door trim, and FIG. 12 is an explanatory view showing the terminal processing step.

  First, a first embodiment of the present invention will be described with reference to FIGS. 1 and 2, a two-tone type automobile door trim 10 is composed of an upper and lower divided part 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 parts 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. 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. The speaker grill 15 is formed integrally or separately on the side.

  By the way, the door trim 10 for automobiles according to the present invention is applied to the structure of the door trim upper 20 which is a laminated structure to reduce the weight of the product, improve the appearance of the outer peripheral terminal portion, and form the molding process, terminal It is characterized by a simplified processing process.

  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 resin laminated and integrated on the back surface side of the foamed resin base material 21. The rib 22 and the decorating material 23 having a decorating function laminated and integrated on the surface side of the foamed resin base material 21 are roughly configured. 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 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, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. can be used. As the foaming agent, 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, are set in a predetermined pattern extending in an intersecting manner as shown in FIG. 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 as a synthetic resin that can be preferably used normally, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin, A polyamide resin, a polyacetal resin, a polycarbonate resin, an ionomer resin, an acrylonitrile / butadiene / styrene (ABS) resin, or the like may be selected as appropriate. 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 made of a laminated structure and the door trim lower made of a single synthetic resin, and has an excellent appearance design due to an accent effect on the appearance. ing. 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 that has been occupied over the entire circumference of the product as in the past can be abolished, and the resin rib 22 is skeleton-like in relation to the use of the lightweight foamed resin base material 21, and a load is applied. Parts, for example, parts excluding the clip seat, the waist upper surface, the arm rest upper surface, etc. have a thinning structure, so that the weight of the product can be reduced by 40% or more compared to the conventional example. In addition, the resin material can be saved significantly, which can contribute to cost reduction.

  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. In order to maintain the sound absorption of the foamed resin base material 21, the decorative material 23 laminated in advance on the surface of the foamed resin base material 21 or integrated and laminated at the time of molding is a woven fabric. Sheet materials having air permeability such as nonwoven fabric and knitted fabric are preferred. In addition to the breathable sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric, the decorative material 23 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, when a TPO sheet is used, it can be unified with an olefin resin material, which is advantageous in terms of recycling.

  Next, the outer peripheral terminal structure of the door trim upper 20 in the door trim 10 will be described with reference to FIG. That is, as described above, the door trim upper 20 is integrated with the resin ribs 22 that reinforce the rigidity on the back surface of the lightweight foamed resin base material 21 having shape retention, and on the surface of the foamed resin base material 21. The decorative material 23 having a decorative property is laminated and integrated. Further, along the product outer periphery of the door trim upper 20, a vertical wall portion 24 for making the product appear three-dimensional is formed downward, and in the product terminal portion A, the decorative material 23 is a foamed resin base material 21. Since the cut end of the foamed resin base material 21 is not exposed, the appearance appearance is maintained well, and the product terminal portion A abuts against the vehicle body panel 16 in a face-contact state. ing.

  Next, the outline | summary of the manufacturing method of the door trim 10 including the terminal processing process of the outer periphery terminal part of the door trim upper 20 is demonstrated below. First, the overall structure of the molding die 40 will be described with reference to FIG. 5, the portion corresponding to the door trim upper 20 will be described with reference to FIG. 6, and FIG. .

  In FIG. 5, 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. It consists of two injection machines 43a and 43b connected to each other.

  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. In addition, manifolds 422a and 422b and gates 423a and 423b are provided to supply molten resin to the mold surface of the core portion 421, and the injection machine passes through the resin passages of the manifolds 422a and 422b and gates 423a and 423b. The molten resins M1 and M2 supplied from 43a and 43b are supplied into a groove 424 formed on the upper surface of the core 421 and into a 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.

  FIG. 6 is a sectional view taken along the line VI-VI of the molding die shown in FIG. 5, and is a molding die for molding the foamed resin base material 21, the resin rib 22, and the decorating material 23 that constitute the door trim upper 20. In particular, the mold 40 is provided with a groove portion 424 corresponding to the resin rib 22 having a predetermined pattern shape on the mold surface of the core portion 421 in the lower molding die 42.

  Further, in the molding die 40 in the portion corresponding to the door trim upper 20, as shown in FIG. 6, the vertical wall portion 24 is formed along the outer peripheral edge of the door trim upper 20, and the vertical wall portion is formed. In order to form the groove portion 25 in 24, a protrusion 414 is formed on the molding upper die 41, and this protrusion 414 forms the groove portion 25 in the foamed resin base material 21.

  Next, each step of the method for manufacturing the door trim 10 described above will be described with reference to FIGS. First, as shown in FIG. 7, the heater device 50 heats and softens the laminate of the decorating material 23 on one surface of the foamed resin sheet S to a predetermined temperature. 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.

  Subsequently, as shown in FIG. 8, the heat-softened foamed resin sheet S (with the decorative material 23 laminated) is formed between the cavity portion 411 of the molding upper mold 41 and the molding lower mold 42 at the location corresponding to the door trim upper 20. Set in the upper half of the cavity defined by the core part 421.

  Then, after the foamed resin sheet S is set, the lifting cylinder 412 of the molding upper die 41 operates to lower the molding upper die 41 by a predetermined stroke, so that the molding upper and lower dies 41 and 42 are molds as shown in FIG. The foamed resin sheet S is shaped along the desired mold surface shape to form the foamed resin base material 21 and the resin ribs in the door trim upper 20 from the first injection machine 43a through the manifold 422a and the gate 423a. In order to form 22, molten resin M <b> 1 is injected and filled into the groove portion 424 of the core portion 421.

  At the same time, in order to mold the door trim lower 30, the molten resin M2 is injected and filled into the substantially lower half of the cavity from the second injector 43b through the manifold 422b and the gate 423b, and the door trim lower 30 is molded into a required shape.

  Therefore, the resin ribs 22 in the door trim upper 20 are molded into a required shape by injecting and filling the molten resins M1 and M2 into the cavities from the first injection machine 43a and the second injection machine 43b, respectively. A door trim lower 30 is formed. As the molten resins M1 and M2, 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 resins M1 and M2 may be set before the mold upper and lower molds 41 and 42 are clamped.

  Further, in the molding step of the foamed resin base material 21 and the resin rib 22 shown in FIG. 9, particularly, the portion corresponding to the side edge of the door trim upper 20 is foamed by laminating a decorating material 23 on the surface as shown in FIG. In the resin base material 21, the vertical wall portion 24 is formed by the shear portion of the molding upper and lower molds 41 and 42, and the groove portion 25 is formed by the protrusion 414 of the molding upper die 41.

  Thus, in order to manufacture the two-tone type door trim 10, two injection machines 43 a and 43 b are connected to the molding lower mold 42, and the molten resin M <b> 1 passes through each resin passage for the door trim upper 20 and the door trim lower 30. , M2 can be injection-filled to produce a two-tone door trim 10 with a single molding die 40 and a reduced number of processes.

  And in the manufacturing method of the door trim 10 mentioned above, especially about the door trim upper 20, the foaming resin base material 21 and the decorating material 23 are shape | molded by desired curved shape between the shaping | molding upper-lower molds 41 and 42, and it shape | molds. When the molten resin M1 is injected and filled into the groove portion 424 of the lower mold 42 and the resin rib 22 is integrally formed, the groove portion 25 is formed in the foamed resin base material 21 by the ridges 414 formed on the upper mold 41. .

  Therefore, after the molding of the door trim upper 20 and the door trim lower 30 is completed, after the molding upper die 41 is raised and the mold is opened, the molded product is taken out from the molding die 40, and as shown in FIG. In the outer peripheral terminal, the groove 25 is subjected to a terminal cutting process, so that the thickness of the foamed resin base material 21 in the cut portion, that is, the product terminal part A can be regulated to be very thin, and the decorating material 23 surrounds the foamed resin base material 21. Since the cut end is not exposed to the outside, the terminal processing of the door trim upper 20 with a good appearance of the outer peripheral terminal is completed.

  In the molding process of the foamed resin base material 21, a vacuum suction mechanism is attached to the molding upper mold 41, and the molding upper and lower molds 41, 42 in a state where the foamed resin base material 21 is held by the molding upper mold 41 by the vacuum suction mechanism. A groove 25 is formed in the foamed resin base material 21 by clamping the molds together. Therefore, if a vacuum suction mechanism is attached to the molding upper die 41, the foamed resin sheet S is clamped while being held by the molding upper die 41 when the molding upper die 41 is moved up and down. It can be formed with high accuracy. In this method, the material of the resin rib 22 in the door trim upper 20 and the material of the door trim lower 30 can be made different, and the material can be appropriately changed according to each required item.

  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 a main manifold communicating with the injection machine 43 and a branch manifold serving as a resin passage for supplying the molten resin M2 to the door trim lower 30 are set. You can do it.

  11 and 12 show a modification of the first embodiment. An extension flange 241 extending in a direction parallel to the mounting surface of the interior part 20 is formed at the tip of the vertical wall portion 24, and this extension flange. A feature is that a resin plate 26 integrated with the resin rib 22 is inserted on the back surface of 241. For example, in this modified example, an extension flange 241 that extends horizontally is formed on both ends of the door trim upper 20 on the front end side of the vertical wall portion 24, and a groove portion 25 that becomes a product terminal line is set at the end of the extension flange 241. ing. Further, a resin plate 26 is inserted on the back side of the extension flange 241 to enhance the rigidity and maintain the cutting posture during the cutting process. The resin plate 26 is integrally formed by allowing resin to communicate from the resin rib 22.

  That is, as shown in FIG. 12, the foamed resin base material 21 and the decorating material 23 are molded into a required shape by clamping the molding upper and lower molds 41 and 42, and at the same time, the resin plate 26 is integrally formed with the resin rib 22. The foamed resin base material 21 is integrally formed, particularly on the back surface side of the extension flange 241. And the insert position of this resin plate 26 is set to the same height position as the groove part 25 formed by the protruding item | line 414 of the shaping | molding upper mold | type 41. FIG.

  Therefore, after the molding, after the molded product is removed from the molding die 40, when the terminal cutting process is performed with the groove 25 as the cutting base point, the resin plate 26 is set on the cutting jig 60, and the cutting target is obtained. Since the groove portion 25 can be positioned with high accuracy, the cutting performance can be improved, and the strength of the extension flange 241 can be strengthened by the resin plate 26, which leads to strengthening of the rigidity of the terminal portion. There is an advantage that the shape can be maintained for a long time.

  The molding die 40 is a vertically movable type in which the molding upper die 41 is a movable die and the molding lower die 42 is a fixed die, but the moving direction of the movable die is horizontal. A mold 40 can also be used.

  Next, FIGS. 13 to 17 show a second embodiment of the present invention, which is applied to a two-tone type door trim 10 comprising a door trim upper 20 and a door trim lower 30, and the same parts as the first embodiment and a method for manufacturing the same. The same reference numerals are given to the same parts of the molding die used for the above, and detailed description thereof is omitted.

  Compared with the first embodiment where the terminal portion of the product is cut, the second embodiment is a type in which the peripheral portion of the product is wound on the back side. That is, as shown in FIG. 13, the structure of the door trim upper 20 is a lightweight and molded resin base material 21 that is molded into a required shape and has shape retention, and a resin that is laminated and integrated on the back side thereof. The point comprised from the rib 22 and the decorating material 23 laminated and integrated on the surface side of the foamed resin base material 21 is the same as that of the first embodiment. However, the difference is that at both side edge portions of the door trim upper 20, a flat wrapping white 27 is wound and fixed to the back side of the foamed resin base material 21.

  In this terminal processing structure, there is no conventional unevenness, the appearance of the outer peripheral terminal winding part is good, and the press pressure is sufficiently applied, so that the drawn pattern appears uniformly to the product terminal. The appearance of patterns and the like can be improved. In addition, about the integration process of the foamed resin base material 21, the resin rib 22, and the decorating material 23, since it is the same as that of 1st Example, the detailed description is abbreviate | omitted.

  Here, based on FIGS. 14 and 15, only the forming process of the winding scissors 27 will be described. As shown in FIG. 14, in the shape of the molded upper and lower molds 41 and 42, the door trim upper 20 is vertically formed on both side edges. The mold surface shape of the upper and lower molds 41 and 42 is set to match the wall 24 and the extension flange 241 at the tip of the wall 24, and the peripheral edge of the product is formed by the molding upper and lower molds 41 and 42. Molds of the upper and lower molds 41 and 42 so as to have parting surfaces 415 and 427 facing outward from the extension flange 241 so as to have a product surface substantially orthogonal to the mold opening direction (operation direction). The surface shape is set, and the mold clearances on the parting surfaces 415 and 427 are set so as to correspond to the thickness of the winding scissors 27.

  FIG. 15 shows the shape of the edge portion of the door trim upper 20 formed by the upper and lower molds 41 and 42 shown in FIG. 14, and the foamed resin base material 21 corresponding to the winding white 27 is flat. And can be easily wound in the direction of the arrow on the back surface side of the foamed resin base material 21 and can be easily wound and formed into a flat shape. The surface of the molding upper die 41 is a flat surface, so that even if the drawing pattern appears on the surface of the decorating material 23 up to the terminal, the drawing pattern is preferable. Can be maintained well, and it is not necessary to form protrusions or the like on the molding die 40, so that the molding process of the molding die 40 can be simplified.

  Next, FIGS. 16 and 17 show a modification of the second embodiment. The winding white 27 has a thickness that is controlled to be flat in two stages, or a notch 28 along the winding line. It is the feature that is provided. For example, as shown in FIG. 16, if the winding scissors 27 are formed in two-stage crushing (the winding scissors formed in two stages for reference are indicated by reference numerals 27a and 27b in the figure), the actual winding scissors 27b The thickness between the vehicle body panel 16 and the vehicle body panel 16 becomes smaller, which is preferable in appearance. In addition, as shown in FIG. 17, if a notch 28 is set in the winding sill 27, this notch 28 acts as a winding base point, so that there is an advantage that the winding operation becomes easy.

  The embodiment described above is applied to the door trim upper 20 in the two-tone type automobile door trim 10. However, the embodiment can also be applied to an integrated door trim, and a rear parcel shelf as an interior part other than the door trim 10. It can be applied to all interior parts such as trunk trim and rear side trim.

It is a front view which shows the door trim for motor vehicles which applied 1st Example of this 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 which abbreviate | omitted the foamed resin base material in the door trim for motor vehicles shown in FIG. It is the IV-IV sectional view taken on the line in FIG. FIG. 2 is an overall view of a molding die used in the method for manufacturing the automobile door trim shown in FIG. 1. FIG. 6 is a sectional view taken along line VI-VI in FIG. 5. It is explanatory drawing which shows the preheating process of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process to the shaping die of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material and resin rib in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the terminal process process of the door trim upper in the manufacturing method of the door trim for motor vehicles shown in FIG. It is principal part sectional drawing of the door trim upper which shows the modification of 1st Example which concerns on this invention. It is explanatory drawing which shows the terminal process process of the door trim upper shown in FIG. It is principal part sectional drawing which shows the door trim upper to which 2nd Example of this invention is applied. It is explanatory drawing which shows the state at the time of shaping | molding of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the door trim upper shown in FIG. It is principal part sectional drawing which shows the modification of 2nd Example of this invention. It is principal part sectional drawing which shows the modification of 2nd Example of this invention. It is a front view which shows the conventional door trim. It is the XIX-XIX sectional view taken on the line in FIG. It is a schematic diagram which shows the shaping die which shape | molds the conventional door trim. It is explanatory drawing which shows the prior art example of the terminal part in the door trim for motor vehicles by press molding. It is explanatory drawing which shows the prior art example of the terminal part in the door trim for motor vehicle of a skin-wrapping type.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Two-tone type automobile door trim 20 Door trim upper 21 Foamed resin base material 22 Resin rib 23 Decorating material 24 Vertical wall part 25 Groove part 26 Resin plate 27 Roll-in white 28 Notch 30 Door trim lower 40 Forming die 41 Molding upper mold 42 Molding Lower die 43 (43a, 43b) Injection machine 414 Projection 415, 427 Parting surface 50 Heater device S Foamed resin sheet M1, M2 Molten resin

Claims (4)

A foamed resin base material (21) that is lightweight and has shape retention, a resin rib (22) laminated and integrated on the back surface of the foamed resin base material (21), and the foamed resin base material (21) An automotive interior part (20) comprising a decorative material (23) laminated and integrated on the surface, wherein a vertical wall (24) is provided on at least a part of the product outer periphery of the foamed resin base material (21). When the foamed resin base material (21) is molded , protrusions (414) are provided along the product terminal line on the inner wall surface of the molding die (41) on one side of the molding die (41, 42). As a result, a groove portion (25) is formed in the vertical wall portion (24) of the foamed resin base material (21) , and the groove portion (25) is compressed into a thin-walled foamed resin base material (21). The decorative material (23) is wound around the surface of the groove, and the groove (25 Automobile interior part, characterized by comprising cutting processing as a product terminal. A foamed resin base material (21) that is lightweight and has shape retention, a resin rib (22) laminated and integrated on the back surface of the foamed resin base material (21), and the foamed resin base material (21) An automotive interior part (20) composed of a decorative material (23) laminated and integrated on the surface, and the foamed resin base material (21) has a required shape by clamping the molding dies (41, 42). The product terminal portion is set so as to have a product surface that is substantially orthogonal to the operation direction of the molding die (41, 42) along the product peripheral portion, and on the outer periphery of the product terminal portion. A parting surface (415, 427) having an inter-type clearance smaller than the inter-type clearance of the product terminal portion is set, so that an entrainment white (27 ) has been extended, this entrainment white (27 The by fixing folded to the back surface of the foamed resin base material (21), automobile interior parts, characterized in that with enhanced stiffness. A foamed resin base material (21) that is lightweight and has shape retention, a resin rib (22) laminated and integrated on the back surface of the foamed resin base material (21), and the foamed resin base material (21) In an automotive interior part (20) comprising a decorative material (23) laminated on the surface,
The foamed resin sheet (S), which is the material of the foamed resin base material (21), is heat-softened and then set in the molding die (41, 42) together with the original sheet of the decorating material (23). A resin sheet (S) setting step;
When the molding dies (41, 42) are clamped together and the foamed resin base material (21) is molded into a required shape along the shape of the product cavity of the molding dies (41, 42), the molding dies on one side By forming the ridge (414) on the inner wall surface of the mold (41) along the product terminal line , a groove (25) is formed in the vertical wall (24) of the foamed resin base material (21), The molten resin (M1) is injected and filled from the injection machine (43a) into the groove (424) of the molding die (42) either before or after the clamping of the molding die (41, 42). Then, an integrated step of the resin foam (22) and the resin rib (22), the resin rib (22) is laminated and integrated on the back side of the resin foam base (21),
The integrated laminated product is demolded from the molding die (40), and the terminal processing step of the interior part (20) to be terminal-cut using the groove (25) provided along the outer periphery of the product as a cutting base point;
A method for producing an interior part for an automobile, comprising: A foamed resin base material (21) that is lightweight and has shape retention, a resin rib (22) laminated and integrated on the back surface of the foamed resin base material (21), and the foamed resin base material (21) In the manufacturing method of the interior part (20) for an automobile, which is composed of a decorating material (23) laminated on the surface and in which a winding sheet (27) is set around the peripheral edge of the foamed resin base material (21).
The foamed resin sheet (S), which is the material of the foamed resin base material (21), is heat-softened and then superposed on the original sheet of the decorating material (23) and set in the molding die (41, 42). A resin sheet (S) setting step;
The molding dies (41, 42) are clamped together to mold the foamed resin base material (21) into a required shape along the product cavity shape of the molding dies (41, 42), and the molding dies (41 , 42), the product terminal portion is set so as to have a product surface substantially perpendicular to the operation direction of the molding die (41), and the product terminal portion mold is formed on the outer periphery of the product terminal portion. By setting the parting surfaces (415, 427) having an inter-mold clearance smaller than the inter-space clearance, the winding white (27) is formed in a thin flat shape along the peripheral edge of the foamed resin base material (21). On the other hand, the molten resin (M1) is injected into the groove (424) of the molding die (42) at any timing immediately before or after the clamping of the molding die (41, 42). The resin rib (22 A molding step of a foamed resin base material (21) foamed resin base material integrally laminated on the back surface side of (21) and the resin rib (22),
After the molds (41, 42) of the integrated laminated product are opened, the molds are removed, and the entrainment scissors (27) are folded back and fixed to the back side of the foamed resin base material (21), thereby the product terminal portion. A terminal treatment process for interior parts (20) that can enhance the rigidity of the interior parts and enhance the appearance appearance ;
A method for producing an interior part for an automobile, comprising:

Images