JP4393890B2 - Manufacturing method of automobile interior parts and mold for manufacturing - Google Patents

Description

  The present invention relates to a method for manufacturing an automobile interior product made of a core material covered with a skin such as a resin, and a manufacturing mold.

2. Description of the Related Art Conventionally, methods for manufacturing automobile interior parts and molds for manufacturing have been publicly known.
For example, there is one disclosed in Patent Document 1 below. In this method of manufacturing a molded article with a skin comprising a laminate of a skin and a core material, a process of setting the core material on an upper mold for molding, and then a liquid urethane on the surface of the lower mold for molding is disclosed. And immediately after applying or spraying the liquid urethane, the upper mold for molding is closed with respect to the lower mold for molding, and the liquid urethane is cured and adhered to the core material as a skin. And a mold for use in the manufacturing method of a skin-integrated automobile interior product characterized by comprising only a step of performing, a step of taking out an integrated molded body with a skin from a molding die.
JP 2000-351351 A

  However, the thing of patent document 1 has the process of apply | coating or spraying liquid urethane to the surface of the shaping | molding lower mold | type. In this process, liquid urethane can be uniformly applied, but it is necessary to apply it thinly and several times so that the adhesive such as a vertical surface does not flow down, and the operation is complicated.

  SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a method and a manufacturing mold for easily manufacturing an automobile interior product having a skin having a substantially uniform thickness.

In the present invention, a core material molded in a predetermined shape is set in a first molding die, the first molding die is closed with respect to the second molding die, and the core material and the second molding material are closed. A method for manufacturing an automobile interior product, which is manufactured by injecting a molten resin mixed in advance into a space formed between a mold and covering the surface of the core material to form a skin, the core material Has a flange on the outer periphery, and the first mold has a convex portion that matches the core material, and a concave portion that is provided on the outer periphery of the convex portion and matches the flange. The mold for molding 2 has a recess that has a shape along the convex part of the core material, and a seat part that is provided at an edge of the recess and sandwiches the flange together with the concave part of the first mold. When the first molding die is closed with respect to the second molding die, the concave portion of the first molding die and the second molding The flange between the type of seat is sandwiched directly mold closing direction, the predetermined interval in forming a space, wherein the core material is first molded between the second mold and the core material after being temporarily fixed by use type fastener, Ru Monodea closing the first mold to the second mold.

The present invention also includes a core material that has been previously molded into a predetermined shape and provided with a flange on the outer periphery, and a molten resin mixed in advance on the surface of the core material to cover the surface of the core material. A mold for manufacturing an automobile interior product comprising a laminate with a formed skin, and having a convex part that matches the core material and a concave part that is provided on the outer periphery of the convex part and matches the flange. And a first molding die on which the core material is temporarily fixed, a fixture on which the first molding die temporarily fixes the core material, and a shape along the convex portion of the core material. And a second molding die that is provided at an edge of the concave portion and has a seat portion that sandwiches the flange together with the concave portion of the first molding die, and the concave portion of the first molding die and the second molding die. sandwiched directly in the mold closing direction the flange between the mold seat, and the second mold Serial Ru der to form a space of a predetermined distance between the fixed the core in a fixture.

  According to the present invention, since the positioning of the flange can be accurately performed between the first molding die and the second molding die, the gap between the core material and the die is surely a desired interval, and the core material and the die The molten resin easily flows between the two. As a result, the entire surface of the core material can be covered almost uniformly with the molten resin easily and reliably.

Hereinafter, an example of an embodiment according to the present invention will be described with reference to the drawings. FIG. 1 shows a manufacturing process of an automobile interior product according to an embodiment of the present invention, and shows each process (FIGS. 1A to 1D) in a sectional view.
First, a core material, a mold for manufacturing, and a molten resin used for manufacturing an automobile interior product according to an embodiment of the present invention will be described. As shown in FIG. 1, the core material 1 has a curved cross section, for example. A mold for manufacturing automobile interior parts includes an upper mold 2 for molding and a lower mold 3 for molding formed of a material such as an epoxy resin containing aluminum powder or a steel material (for example, iron).

The core material 1 is formed in advance, and examples thereof include those for automobile instrument panels. A flange 1a is provided on the outer periphery of the core material 1 in the outward direction, and a hole (not shown) into which a pin pushed out from a pin device 2a described later is fitted. The flange 1a is preferably provided continuously on the outer periphery of the core material 1, but may be provided partially (for example, about 4 to 8 places at equal intervals). Further, the flange 1a only needs to have a width larger than that necessary to be sandwiched and held, may have a certain width, or may have a width changed as necessary.
The core material 1 is made of polypropylene (PP), made of PP and talc resin, made of acrylonitrile butadiene styrene copolymer (ABS), polypropylene and glass filler (injection-molded into a predetermined shape in advance). PPG), acrylonitrile styrene copolymer and glass filler (ASG).

The molding upper die 2 is a part of a mold for manufacturing an automobile interior product having a convex portion 2b on the molding lower die 3 side that substantially matches the concave portion side shape of the core material 1. Further, the molding upper die 2 is provided on the molding lower die 3 side on the outer periphery of the convex portion 2 b and has a concave portion 2 c having a shape substantially matching the flange 1 a of the core material 1. In the convex portion 2b, at least two pin devices 2a in which pins that fit into holes (not shown) of the core material 1 are pushed out by an air cylinder are embedded. In addition, the hole (not shown) of the core material 1 and the pin of the pin device 2a are provided in the core material 1 and the pin device 2a so that the positions match.
Although not shown, instead of fixing with a pin, a hole for a hook is provided in the core material 1, and the hole is rotated by a predetermined angle through the hook so as to be hooked on the surface of the core material 1, and the core material 1 is formed for molding. You may fix by pulling up a hook so that it may draw near to upper model 2.

The molding lower mold 3 is a part of a mold for manufacturing an automobile interior product having a recess 3a on the molding upper mold 2 side, which is a shape that follows the shape of the projection 1 of the core 1. Further, the lower mold 3 has a seat portion 3b in which the flange 1a of the core material 1 provided continuously at the edge thereof can be sandwiched together with the concave portion 2c of the upper mold 2 for molding. The concave portion 3a has a predetermined gap distance between the convex portion side shape portion of the core material 1 and the concave portion 3a when the flange 1a is sandwiched between the molding upper mold 2 and the seat portion 3b. Is formed.
In addition, when the flange 1a is provided partially (for example, about 4-8 places at equal intervals), the molten resin injected in the state of FIG. 1 (c) does not flow out of the space 4. If the seat part 3b is formed along the edge of the recessed part 3a of the shaping | molding lower mold | type 3, it is good also as what match | combined the inner peripheral part of the seat part 3b with the shape and its position of the flange 1a. Moreover, although the lower mold 3 for molding is formed by placing a seat 3b, which is a separate part for the convenience of processing, on the main body of the lower mold 3 for molding, the lower mold 3 is formed by integrating the seat and the main body. It may be formed as a mold 3.

  Examples of the molten resin used in the present embodiment include thermosetting resins such as thermosetting urethane and two-component silicon. In the case of a thermosetting resin, after being injected into a mold, it is cured by heating to form the skin 5 of FIG. Examples of the thermosetting urethane include polyether urethane and polyester urethane.

Next, a method for manufacturing an automobile interior product according to an embodiment of the present invention will be described.
First, after fitting the convex portion 2b and the concave portion 2c of the molding upper mold 2 with the concave portion-side shape portion of the core material 1 and the flange 1a, the air cylinder of the pin device 2a is operated to insert the pin into the molding upper die. 2 and is inserted into a hole in the core material 1 (not shown) that matches the push-out position of the pin, and the core material 1 is fixed (see FIGS. 1A to 1B).
Next, the molding upper mold 2 in which the core material 1 is fitted is closed toward the molding lower mold 3 side, and the flange 1a of the core material 1 is seated between the recess 2c of the molding upper mold 2 and the molding lower mold 3. The core material 1 is fixed at a desired position by being sandwiched between the portions 3b (see FIGS. 1B to 1C). At this time, a space 4 into which the molten resin can be poured is formed.
Then, a molten resin is poured from a flow path (not shown) that connects the space 4 and the outside to form the skin 5. In addition, when this molten resin is a thermosetting resin, it heat-hardens and forms the skin 5 (refer FIG.1 (c)-(d)).
Next, although not shown, if the molding upper mold 2 is opened in the direction opposite to the molding lower mold 3 side, the pin is removed from the core material, and the molded product is removed from the molding upper mold 2, the automobile interior product will be Complete.

  According to this embodiment, since the positioning of the flange can be accurately performed between the molding upper mold 2 and the molding lower mold 3, the gap between the core material 1 and the molding lower mold 3 is surely set to a desired distance. Thus, a molten resin such as thermosetting urethane easily flows between the core material 1 and the lower mold 3 for molding. As a result, the entire surface of the core material 1 can be easily and reliably covered with the substantially uniform skin 5 made of a molten resin such as thermosetting urethane.

  Although not shown in the drawings, as a modification of the mold for manufacturing automobile interior parts, the convex portion of the molding upper mold 2 in FIG. 1 may be a concave portion and the concave portion of the molding lower die 3 may be a convex portion. . In this case, the same skin as in the above embodiment can be formed on the concave portion side of the core material 1 by the same method as described in the above embodiment.

Example 1
Next, the manufacturing method of the instrument panel for motor vehicles is demonstrated as an Example of this invention. First, a mold for manufacturing a core material and an instrument panel for an automobile will be described.
The core material is injection-molded in advance using a raw material composed of polypropylene and talc resin, and the surface of the core material is subjected to flame treatment to improve the adhesion with thermosetting urethane, whereby the surface energy is 40 to 50 × 10 ^{−. It} was raised to 5N. The core material was placed on a special cart to suppress deformation.
Next, using a raw material composed of polypropylene and talc resin, a flange having a width of 20 mm was formed on the outer periphery of the core material, flame-treated in the same manner as described above, and placed on a dedicated carriage.

  As a mold for manufacturing an instrument panel for automobiles, a mold that is substantially the same as that shown in FIG. 1 and made of iron and processed into a mold for manufacturing a desired instrument panel for automobiles is used. Using.

Next, the manufacture of the automotive instrument panel in Example 1 will be described.
The core material is fitted into the molding upper mold of the automobile instrument panel manufacturing mold, and the four pin devices that move the pins are operated by the air cylinder embedded in the molding upper mold. It was fixed (the same state as FIG. 1B). In this state, the upper mold for molding is closed toward the lower mold for molding, thereby sandwiching the flange provided on the outer periphery of the core material between the upper mold for molding and the lower mold for molding (similar to FIG. 1C). State). And thermosetting urethane was inject | poured into the clearance gap between a core material and the shaping | molding lower mold | type, it was made to harden | cure by heating, and the skin was shape | molded.

(Comparative Example 1)
Next, a comparative example will be described.
Unlike Example 1, the core material used was one without a flange. Other shapes and materials were the same.
As a mold for manufacturing an instrument panel for automobiles, a mold obtained by processing iron in a mold without a flange in the core material of Example 1 (a part corresponding to the recess 2c in FIG. 1) was used.

Next, the manufacture of an automotive instrument panel in Comparative Example 1 will be described.
The core material is fitted into the molding upper mold of the automobile instrument panel manufacturing mold, and the four pin devices that move the pins are operated by the air cylinder embedded in the molding upper mold. Fixed. In this state, the molding upper mold was closed toward the molding lower mold, thermosetting urethane was injected into the gap between the core material and the molding lower mold, and was cured by heating to mold the skin.

Twenty-six automotive instrument panels were produced by the method of Example 1, and 28 automotive instrument panels were produced by the method of Comparative Example 1 for comparison. In the method of Example 1, the core material was not exposed in all 26 pieces, and when the skin variation of the instrument panel for automobiles was measured at 29 positions, the average thickness was 0.91 mm, and the standard deviation σ of the skin thickness _n-1 was 0.19. In the method of Comparative Example 1, the thermosetting urethane injected into 5 out of 28 automotive instrument panels did not flow sufficiently and was partially exposed. Moreover, when the skin dispersion | variation in the instrument panel for motor vehicles of the comparative example 1 was measured in the position of 29 points | pieces, the average thickness was 0.82 mm and the standard deviation (sigma) _{n-1 of} skin thickness was 0.38.

Since the standard deviation σ _{n-1 of the} skin thickness was smaller in Example 1 than in Comparative Example 1, it was confirmed that a uniform skin could be formed. Moreover, in Example 1, it was confirmed that the instrument panel for motor vehicles which a core material does not expose can be produced.
Therefore, according to this example, it was confirmed that the entire surface of the core material could be covered with a substantially uniform skin made of thermosetting urethane easily and surely.

  The present invention can be changed in design without departing from the scope of the claims, and is not limited to the above-described embodiments and examples.

  In addition to instrument panels, it can be applied to automobile interior parts such as door rims and console boxes.

The manufacturing process of the automotive interior goods which concerns on embodiment of this invention is shown, Comprising: Each process is shown with sectional drawing.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Core material 1a Flange 2 Molding upper mold 2a Pin apparatus 2b Convex part 2c, 3a Concave part 3 Molding lower mold 3b Seat part 4 Space 5 Skin

Claims (2)

A core material molded in a predetermined shape is set in the first molding die, the first molding die is closed with respect to the second molding die, and between the core material and the second molding die. A method of manufacturing an automobile interior product manufactured by forming a skin by injecting a molten resin mixed in advance into a space formed in the space to cover the surface of the core material,
The core is provided with a flange on the outer periphery,
The first molding die has a convex portion that matches the core material, and a concave portion that is provided on the outer periphery of the convex portion and matches the flange.
The second molding die includes a concave portion having a shape along the convex portion of the core material, and a seat portion provided on an edge of the concave portion and sandwiching the flange together with the concave portion of the first molding die. ,
When the first molding die is closed with respect to the second molding die, the flange is directly in the mold closing direction between the concave portion of the first molding die and the seat portion of the second molding die. When forming a space having a predetermined interval between the second molding die and the core material ,
A method for manufacturing an automobile interior part , wherein the first molding die is closed with respect to the second molding die after the core material is temporarily fixed to the first molding die by a fixture . A core formed in advance in a predetermined shape and provided with a flange on the outer periphery, and a skin formed by injecting molten resin mixed in advance on the surface of the core to cover the surface of the core A mold for manufacturing automobile interior parts made of a laminate,
A first molding die having a convex portion that matches the core material, a concave portion that is provided on an outer periphery of the convex portion and that matches the flange, and the core material is temporarily fixed;
A fixture for temporarily fixing the core material by the first molding die;
A concave portion having a shape along the convex portion of the core material, and a second molding die having a seat portion provided on an edge of the concave portion and sandwiching the flange together with the concave portion of the first molding die,
The flange is directly sandwiched between the recess of the first mold and the seat of the second mold in the mold closing direction, and between the second mold and the core fixed by the fixture. A mold for manufacturing automobile interior parts that forms a space at a predetermined interval.

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