JP4521817B2 - Manufacturing method for interior parts for automobiles - Google Patents

Description

  The present invention relates to a method for manufacturing automotive interior parts such as door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, roof trims, etc., and in particular, the appearance and strength of the outer peripheral terminal portion are excellent, The present invention relates to a method for manufacturing automobile interior parts that can be easily and inexpensively manufactured.

  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 attachment rigidity to the door panel, and is configured by laminating and integrating a skin 3 excellent in surface appearance on the surface of the resin core material 2 that extends over almost the entire product surface. . The resin core material 2 is made of polypropylene resin mixed with talc, and the skin 3 does not have a shape-retaining property itself and is a single sheet material of a synthetic resin sheet such as a vinyl chloride sheet. Or, a laminated sheet material in which a cushioning material such as polyethylene foam is laminated on the back side of a synthetic resin sheet is used, and recently, an elastomer such as a thermoplastic olefin (hereinafter referred to as TPO) sheet in consideration of environmental aspects and recycling aspects. Sheets tend to be used frequently.

  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 mold 5 that moves up and down is provided with guide posts 6d at the four corners of the lower mold 6 and guides the upper mold 5 in correspondence with 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. 14, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state, but actually, 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.

  Further, regarding the processing of the outer peripheral terminal of the door trim 1 product, as shown in FIG. 15, after the outer skin 3 is simultaneously press-molded on the surface of the core material 2, the core material 2 and the outer skin 3 are formed by the mold blade in the mold. The piercing cut process is performed in a separate process after the piercing cut process or molding. Also, as shown in FIG. 16, after the core material 2 is press-molded, the skin 3 is integrated in a separate process by vacuum pressure bonding, press pressure bonding, or the like, 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.

  Further, at the outer peripheral edge of the door trim 1, as shown in FIG. 15, when the outer skin simultaneous press molding is performed, the outer peripheral terminal processing is difficult, the appearance is not good, and the appearance performance is deteriorated. As shown in FIG. 3, the method of winding the skin 3 in a separate process requires a large number of man-hours and inevitably increases costs.

  The present invention has been made in view of such circumstances, and is a method for manufacturing an interior part for automobiles that can promote weight reduction, can achieve high rigidity, and can reduce costs. In particular, an object of the present invention is to provide a method for manufacturing an interior part for an automobile having improved appearance performance by enhancing the appearance and rigidity of the outer peripheral terminal portion of the product.

  As a result of earnest research, the present inventors have given the function as a core material by imparting shape retention to the foamed resin sheet that has been used conventionally as the skin, and more. Resin with excellent rigidity at locations where high rigidity is required, i.e. it can be intimately contacted with the peripheral part of the product, the panel, the mating part with the mating part, or where a certain clearance is secured, or where the part is attached and where the load is applied The ribs are arranged and the other parts are hollowed out to reduce the weight compared to the conventional resin core material with a large projected area. It is found that the terminal treatment can be achieved easily and beautifully by softening and melting the winding polymerization part along the heating jig with a heating jig and simplifying the operation of the heating jig and the winding mechanism part, Which resulted in the completion of the invention.

  That is, the method for manufacturing an automotive interior part according to the present invention includes a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a predetermined pattern that is laminated and integrated on the back surface of the foamed resin base material. In a manufacturing method of an interior part for an automobile, in which a laminated structure composed of resin ribs having a shape is adopted in whole or in part, the manufacturing method of the laminated structure is a foamed resin sheet that is a material of a foamed resin base material After heat softening treatment, after setting in the mold, the molds are clamped together, and when the foamed resin base material is molded into the required shape along the cavity shape of the mold, A laminated structure in which molten resin is injected and filled from the injection machine into the groove of the molding die either before or after mold clamping, and the resin rib is laminated and integrated on the back side of the foamed resin base material. And the molding process The molded laminated structure is removed from the molding die, the laminated structure is set on the receiving jig, and then the heater of the heating jig having a refractive structure is used as the foamed resin base material at the edge of the laminated structure. To the position where it comes close to or abuts on the back side of the paper, and then the winding piece in the winding mechanism located outside the receiving jig is raised. The heater is erected while being heated along the side of the heater of the heating jig, then the heating jig is refracted, and the winding piece is rotated to bend the heating paper while heating it. Furthermore, it comprises a terminal processing step of a laminated structure in which the heating jig is retracted during the folding operation of the winding paper, and then the winding paper is wound and welded to the back surface of the main body side by the winding piece. And

  Here, the automobile interior parts can be applied to door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, roof trims, and the like. In addition, when the foamed resin base material constituting a part of the laminated structure is close to a flat shape, the heat softening step is omitted and a desired shape is formed by a mold, but this 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 sufficient 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 in order to improve an external appearance design property, you may laminate | stack and integrate a decorating material on the surface of a foamed resin base material. As this decorating material, a synthetic resin sheet such as a TPO sheet, a thermoplastic plastic urethane (hereinafter referred to as TPU) sheet or a vinyl chloride sheet, or a fabric sheet such as a woven fabric, a nonwoven fabric or a knitted fabric, or a synthetic resin film, a foam or a net-like material It can also be used in the form of a single sheet such as an article, or in the form of a laminated sheet material in which a back surface of a synthetic resin sheet or a fabric sheet is lined with a cushion layer such as polyethylene foam, polypropylene foam or polyurethane foam. 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, 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.

  And according to the manufacturing method of the interior component for automobiles according to the present invention, the laminated structure employed for the whole interior component or a part thereof is strengthened on the back side of the foamed resin base material having shape retention. In this sense, since the resin ribs are laminated and integrated, the conventional resin core material can be eliminated. Therefore, by eliminating the conventional resin core material having a very large projected area, the weight of the product can be reduced and the resin material can be saved, so that the material cost can be reduced at the same time. Furthermore, for the outer peripheral edge of the laminated structure, the winding point of the outer portion of the laminated structure is wound around the rising point, so that the cut end is not conspicuous on the outside, the appearance design is excellent, and the terminal In the portion, the foamed resin base material has a double structure, and the rigidity can be enhanced.

  Here, the molding die used in the method of the present invention is connected to a molding upper mold that can move up and down by a predetermined stroke, a molding lower mold that is a fixed side located below the molding upper mold, and a molding lower mold. It consists of an injection machine. The molten resin supplied from the injection machine is supplied to the mold surface of the molded lower mold through a resin passage such as a manifold and a gate provided in the molded lower mold, and more specifically, into a groove formed on the mold surface of the molded lower mold. Is done. In addition, after the upper mold is lowered to the bottom dead center and the upper and lower molds are clamped, the molten resin may be injected and filled into the groove provided on the mold surface of the lower mold with a predetermined injection pressure. The injection timing of the molten resin may be performed before mold clamping.

  By clamping the upper and lower molds, the foamed resin sheet is molded into a desired curved surface shape along the mold surface shape of the molding die, and the resin is injected on the back surface of the foamed resin base material by injection filling with molten resin. Ribs are laminated and integrated. At this time, after performing the heat softening process with a heater or the like in the previous step, the foamed resin sheet is set in a molding die. And simultaneously with shaping | molding of a foamed resin base material, what is necessary is just to laminate and integrate the resin rib on the back surface of a foamed resin base material. In the case where the final product shape has a high development rate portion, it is preferable to perform mold clamping of the molding die a plurality of times and perform injection filling of the molten resin in the final mold clamping process. In addition, if the product shape includes a portion with a higher development ratio, a vacuum suction mechanism is provided in the molding upper mold, and the foamed resin base material is molded into the required shape by the vacuum suction force along the mold surface of the molding upper mold. Good to do.

  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. At the same time, the amount of resin is small, material costs can be saved, and the cooling time is shorter than that of conventional resin cores, so that the product molding cycle can be shortened.

  Next, as a terminal processing apparatus used for terminal processing of a laminated structure, a foamed resin base material that is molded into a required shape and is lightweight and has shape retention properties, and laminated on the back surface of the foamed resin base material are integrated. A terminal processing apparatus for performing a terminal treatment of a foamed resin base material along an edge of the laminated structure after forming a laminated structure composed of resin ribs having a predetermined pattern shape with a molding die, The apparatus includes: a receiving jig for setting the laminated structure; a heating jig provided with a heater for heating and softening the foamed resin base material in the laminated structure set on the receiving jig; In order to perform a folding operation while heating the winding roller, the winding mechanism unit has a rotatable winding piece that winds the winding base of the resin base material on the back side of the main body. Follow the turning movement of the insert Wherein the refractive structures heating jig is employed to.

  Here, the receiving jig is composed of a set base for setting the laminated structure and a receiving jig presser for fixing the laminated structure set on the set base. Further, a refractive structure is adopted for the heating jig. For example, the upper arm and the lower arm are connected in a refractive manner at the joint (first link), the upper arm is supported in a refractive manner at the joint (second link) with respect to the support member, and the support member is It is supported by a cylinder so that it can move up and down. A heater is installed on the outer surface of the lower arm. The shape of the lower arm is such that the lower surface and the inner surface (opposite of the heater installation surface) do not interfere with the receiving jig during refraction. An inclined surface is set across the side surface.

  Further, as the winding mechanism part, a winding piece is rotatably attached to the support block so as to wind the winding white from the winding fulcrum part, and the support block is raised by raising the vertical movement cylinder. When the winding piece rises at the same time, the winding frame rises, and when the winding piece rotates, the lower arm of the heating jig is also connected and refracted to It is possible to perform the winding process while heating the winding white by being sandwiched between the lower arm and the winding piece.

  Therefore, as a terminal processing method of the laminated structure, the laminated structure is taken out from the molding die, the laminated structure is set on the set stand and set by the receiving jig holder, and then the heating jig is moved up and down the cylinder. Thus, the heater of the heating jig is operated so as to be in contact with or close to the back surface side of the foamed resin base material at the edge of the laminated structure. After that, when the support block in the winding mechanism part rises, the winding piece also rises at the same time, and the standing piece is operated while the winding piece is heated along the side surface of the heater by the winding piece. In addition, the lower arm of the heating jig is refracted, and the winding piece is rotated at the same time, so that the winding paper is sandwiched between the heater and the winding piece, and the winding process is performed while heating the winding paper. After that, after the lower arm of the heating jig is turned and retracted, the winding piece is turned and welded and fixed to the back surface of the main body.

  Therefore, since the terminal processing portion of the laminated structure is a double structure in which a winding scissor is wound, rigidity can be strengthened, deformation does not occur, a cut end or the like is not exposed, and appearance is preferable. In addition, there is no need for a separate adhesive application process, drying process, etc., and after the heat softening treatment of the foamed resin base material, when the heat softened part is cooled and solidified, the wrapping white is integrated, so an adhesive-less structure Therefore, the terminal processing man-hour can be simplified.

  Furthermore, by adopting a refracting structure in the heating jig and adopting a swivel piece as a rotating system, the winding process can be performed simultaneously while heating the winding scissors, and the scissors are cooled. The winding white can be quickly welded and fixed. In addition, since the heater is detached in the vertical direction with respect to the melting surface of the entraining scissors, the melted portion is not dragged and unevenness is not generated on the melting surface of the entraining scissors. Can be kept constant. And since the substrate can be rolled up while being heated, and the turning operation of the winding piece and the retracting operation of the heating jig can be performed in parallel, the time spent on the heating and winding process can be shortened. Can do.

  As described above, according to the method for manufacturing an automotive interior part according to the present invention, the laminated structure constituting the whole or a part of the automotive interior part is lightweight and has a shape retaining property. And the resin rib that is laminated and integrated on the back side of this foamed resin base material and the parts that require rigidity, such as the outer periphery of the product. It is possible to provide an automobile interior part that is lightweight, low-cost, and excellent in sound absorption performance.

  Furthermore, according to the method for manufacturing an automotive interior part according to the present invention, the foamed resin base material is molded along the cavity shape of the molding die, and at the same time, the resin rib is integrated on the back surface side of the foamed resin base material. Because of the configuration, the projected area of the resin rib is less than that of the conventional resin core material, so the load on the molding die is small, the cooling time can be shortened, and the yield can be increased, thus increasing the work efficiency. , It has the effect of bringing about a significant cost reduction.

  Further, according to the method for manufacturing an automotive interior part according to the present invention, after forming the laminated structure, the laminated structure is taken out from the molding die, and the laminated structure is set on a setting jig, and then wound. The winding piece in the mechanism part rises, and the foaming resin base winding roll is raised along the side of the heater while being heated up. By adopting a rotation mechanism for the winding piece of the mechanism portion, the winding white can be sandwiched between the heater of the heating jig and the winding piece, and the winding process can be performed while heating. Furthermore, in the middle of the winding operation, the heater is retracted in the vertical direction from the melting surface of the scissors, and the winding piece is rotated to shorten the cycle spent on the terminal processing and foaming is performed. Resin base rolls can be quickly welded without being cooled, and can be smoothly welded and fixed with the melt surface of the rolls kept smooth. It has the effect that it can be performed.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a preferred embodiment of a method for manufacturing an automotive interior part according to the present invention will be described with reference to a method for manufacturing a vehicle door trim.

  1 to 11 show an 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 cross-sectional view showing the configuration of the terminal processing portion of the door trim upper in the door trim for the automobile, FIGS. 5 and 6 are explanatory diagrams showing the molding process of the door trim for the automobile, and FIG. 7 is used for the terminal processing of the door trim upper. FIG. 8 to FIG. 11 are explanatory diagrams showing terminal processing steps in the door trim upper, respectively.

  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 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 on the back side thereof, as shown in FIG. 2, a pocket back cover (made of a resin molded body) 14 is attached. On the side, the speaker grill 15 is formed integrally with or separately from the door trim lower 30.

  By the way, the automotive door trim 10 according to the present invention applies the method of the present invention to the door trim upper 20 that 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 and terminal processing. It is characterized by simplifying the 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 door panel.

  The foamed resin substrate 21 is heat-molded into a required shape after heat-softening the foamed resin sheet so as to have shape retention, for example, cold press-molded with a molding die having a desired mold surface. About the high expansion | deployment rate part, you may shape the foaming resin base material 21 by vacuum forming. 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 resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, acrylonitrile / butadiene / styrene (ABS) resins, etc. can be used. As foaming agents, azo compounds, sulfohydrazide compounds, nitroso compounds, azides Organic foaming agents such as compounds and inorganic foaming agents such as sodium bicarbonate can be used. In this embodiment, a foamed resin sheet in which sodium bicarbonate is appropriately added as a foaming agent to a polypropylene resin is used. The expansion ratio of the foamed resin base material 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 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 are terminals along the outer peripheral edge of the door trim upper 20. In the (winding portion), there is a portion where the resin rib 22 is not provided. As the pattern of the resin rib 22, any pattern may be selected as long as it is crossed, 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 30 made of a single synthetic resin, and has excellent appearance design due to the accent effect on the appearance. It has. 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 weight of the resin core material occupied over the entire circumference of the product as in the past can be eliminated and the lightweight foamed resin base material 21 is used. In addition, the weight can be reduced by 40% or more, the resin material can be saved significantly, 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. 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. A fabric sheet having air permeability such as a nonwoven fabric or a knitted fabric is preferred. The decorative material 23 is not only a fabric sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric, but also a single sheet such as a synthetic resin sheet such as a TPO sheet, a TPU sheet, and a vinyl chloride sheet, a synthetic resin film, a foam, and a mesh. Can be used. Moreover, the laminated sheet material which backed cushion layers, such as a polyethylene foam, a polypropylene foam, a polyurethane foam, can be used for the back surface of a synthetic resin sheet or a fabric sheet. In addition, when a TPO sheet is used, since it can unify with an olefin resin material, it is advantageous in terms of recycling.

  Next, the terminal processing structure along the outer periphery 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, a vertical wall flange portion 211 extends downward (door panel 16) along the product outer periphery of the door trim upper 20, and the front end portion of the vertical wall flange portion 211 is parallel to the door panel 16. An extension part 212 extends horizontally, and the extension part 212 is wound around and fixed to the foamed resin base material 21 side of the extension part 212 based on the winding fulcrum part 213. The terminal processing unit A is in contact with the door panel 16 in a face-contact state.

  Therefore, the terminal processing part A of the door trim upper 20 does not expose the cut end, and the wrapping white 24 is folded and fixed to the back surface side of the extension part 212. In particular, the winding fulcrum part 213 corresponds to the outer peripheral line of the door trim upper 20, so that a sharp outer peripheral line can be secured, the appearance is excellent, and the winding white 24 is fixed to the back surface of the extension part 212. Due to the double structure, there is an advantage that the rigidity of the terminal portion can be enhanced, there is no fear of undulation deformation and the like, it can be tightly adhered to the door panel 16 and the alignment accuracy can be increased. Further, even when the mating shape is provided with a certain clearance with the counterpart part, the mating accuracy can be increased.

  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 molding die 40 used for molding the door trim 10 will be described with reference to FIGS. As shown in FIG. 5, a molding die 40 used for molding the door trim 10 includes a molding upper die 41 that can move up and down by a predetermined stroke, a fixed molding lower die 42 that forms a pair with the molding upper die 41, and molding. This is mainly composed of two injection machines 43 a and 43 b connected to the lower mold 42. 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 the molten resin to the mold surface of the core portion 421. 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.

  Subsequently, each process of the manufacturing method of the door trim 10 mentioned above is demonstrated. First, what laminated the decorating material 23 on the one side of the foamed resin sheet S with a heater apparatus (not shown) is heat-softened to predetermined temperature. As this foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumika Plustech, trade name: Sumiceller foam PP sheet, foaming magnification = 3 times, thickness 3 mm) is used in this embodiment. Subsequently, as shown in FIG. 5, 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 setting the foamed resin sheet S, the molding upper die 41 is lowered by a predetermined stroke by driving the elevating cylinder 412 in the molding upper die 41, and the molding upper and lower dies 41, 42 are clamped as shown in FIG. Then, the foamed resin sheet S is shaped along a desired mold surface shape, and the foamed resin base material 21 is molded. Further, in order to form the resin rib 22 in the door trim upper 20 from the first injector 43a through the manifold 422a and the gate 423a, the molten resin M1 is injected and filled into the groove portion 424 of the core portion 421. Subsequently, in order to mold the door trim lower 30, the molten resin M2 is injected and filled into the door trim lower molding cavity 425 through the manifold 422b and the gate 423b from the second injection machine 43b, and the door trim lower 30 is molded into a required shape. Is done.

  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, Sumitomo Nobrene BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min) is used, and talc is mixed in an appropriate proportion. 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. As described above, in order to manufacture the two-tone type automobile door trim 10, the two injection machines 43 a and 43 b are connected to the molding lower mold 42, and the door trim upper 20 and the door trim lower 30 are melted through the resin passages. By injection-filling the resins M1 and M2, the two-tone type automobile door trim 10 can be formed with a single molding die 40 and with a reduced number of steps.

  And in the manufacturing method of the door trim 10 mentioned above, especially the door trim upper 20 requires the terminal processing process mentioned later. In order to perform this terminal processing step, a terminal processing device 50 shown in FIG. 7 is used. The overall configuration of the terminal processing device 50 will be described with reference to the drawings. The terminal processing device 50 includes a receiving jig 60 for setting the door trim upper 20, a heating jig 70 for heating and softening the foamed resin base material 21 at the part to be wrapped in the door trim upper 20, and the winding white 24 as an extension. A winding mechanism unit 80 that performs a winding process on the back surface side of 212 is roughly configured.

  More specifically, the receiving jig 60 includes a set base 61 for setting the door trim upper 20 and a receiving jig presser 62 for positioning and fixing the door trim upper 20 at a predetermined position. Furthermore, a refractive structure is employed as the heating jig 70, and the upper arm 71 and the lower arm 72 are joined by a first link 73. Further, the upper arm 71 is joined to the support member 75 attached to the piston rod 74 a of the cylinder 74 via the second link 76. A heater 77 is attached to the outer surface of the lower arm 72. The lower surface of the lower arm 72 has a lower surface and an inner surface (heater 77) so as to avoid interference with the receiving jig 60 during refraction. An inclined surface 72a is set across the side surface opposite to the mounting surface. In addition, the temperature range of the heater is set to a relatively low temperature such as 150 to 170 ° C. Further, in the winding mechanism unit 80, a winding piece 81 for winding the winding roller 24 is rotatably supported by a support block 82 via a link 83, and the support block 82 is used for up and down movement. It is connected to the cylinder 84.

  Next, based on FIG. 8 thru | or FIG. 11, the terminal processing method of the door trim upper 20 using the terminal processing apparatus 50 mentioned above is demonstrated. First, as shown in FIG. 8, the door trim upper 20 is set on the setting base 61 of the receiving jig 60, and the door trim upper 20 is received and securely fixed to the jig 60 at a predetermined position by the receiving jig presser 62. Thereafter, the upper arm 71 and the lower arm 72 are both lowered by the extension operation of the cylinder 74, and the heating jig 70 is heated and softened by the heater 77 around the winding fulcrum 213 in the foamed resin base material 21.

  Thereafter, as shown in FIG. 9, when the vertical movement cylinder 84 in the winding mechanism unit 80 is driven, the support block 82 is raised, and the winding piece 81 supported by the support block 82 is also raised. The winding piece 81 is erected while heating the winding holder 24 by placing the winding holder 24 along the side surface of the heater 77 in the heating jig 70. 10 and 11 show the characteristics of the method of the present invention. As shown in FIG. 10, the winding piece 81 operates the bending jig 24 to stand up, and then the heating jig 70 refracts. At the same time, the winding piece 81 rotates. That is, the cylinder 74 extends in the heating jig 70, and the lower arm 72 refracts based on the first link 73. Then, in conjunction with the refraction operation of the lower arm 72, the winding piece 81 in the winding mechanism unit 80 rotates based on the link 83, so that the winding white 24 is connected to the heater 77 and the winding piece 81. The bending operation is performed while being heat-treated.

  Further, as shown in FIG. 11, the lower arm 72 is detached from the first link 73 so that the heater 77 is separated from the melting surface of the winding shell 24 in the vertical direction during the folding operation of the winding shell 24. Then, after retracting to a position that is in a straight line with the upper arm 71, the winding piece 81 is rotated, and the winding shiro 24 can be firmly crimped and fixed to the back side of the main body.

  As described above, by adopting the refractive structure of the upper arm 71 and the lower arm 72 as the configuration of the heating jig 70 and adopting the configuration in which the winding piece 81 in the winding mechanism unit 80 is rotatably supported. In addition, the entrainment process can be performed while heating the entrainment scissor 24, the terminal processing time can be shortened, and the entrainment scissor 24 is not cooled, so there is no need to set the set temperature of the heater 77 so high. Moreover, it can be processed in a short time. In addition, since the melting surface of the wrapping white 24 forms a uniform smooth surface, the appearance and thickness of the wrapping processing section A can be properly maintained, and a wrapping process with good appearance can be performed in a short time.

  Although the embodiment described above is applied to the method of manufacturing the door trim upper 20 in the two-tone type automobile door trim 10, it can also be applied to an integrated door trim. Further, the present invention can be applied to all interior parts other than the door trim 10, such as a rear parcel shelf, a floor trim, a luggage trim, a trunk trim, a rear side trim, and a roof trim.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front view showing a first embodiment of a vehicle door trim manufactured by applying a method for manufacturing an interior component for a vehicle according to 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 sectional drawing which shows the structure of the terminal process part of the door trim upper in the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process of the raw material in the shaping die in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the formation process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the whole structure of the terminal processing apparatus used for the terminal processing process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim upper shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim upper shown in FIG. It is a front view which shows the conventional door trim. FIG. 13 is a sectional view taken along line XIII-XIII in FIG. 12. It is a schematic diagram which shows the shaping | molding method of the conventional door trim. It is explanatory drawing which shows the prior art example of the terminal part of the door trim by press molding. It is explanatory drawing which shows the prior art example of the terminal part in a skin-wrapping type door trim.

Explanation of symbols

10 Two-tone type automotive door trim 20 Door trim upper (laminated structure)
21 Foamed resin base material 212 Extension part 213 Winding fulcrum part 22 Resin rib 23 Decorating material 24 Winding white 30 Door trim lower (single resin product)
40 Molding mold 41 Molding upper mold 42 Molding lower mold 43a, 43b Injection machine 50 Terminal processing device 60 Receiving jig 61 Set stand 62 Receiving jig holder 70 Heating jig 71 Upper arm 72 Lower arm 73 First link 74 Cylinder 75 Support member 76 Second link 77 Heater 80 Winding mechanism portion 81 Winding piece 82 Support block 83 Link 84 Vertical movement cylinder S Foamed resin sheet M1, M2 Molten resin A Terminal processing portion

Claims (2)

From 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 manufacturing method of the interior part (10) for automobiles formed by employing the laminated structure (20) as a whole or a part of
The manufacturing method of the laminated structure (20) is that the foamed resin sheet (S), which is the material of the foamed resin base material (21), is heat-softened, set in the molding die (41, 42), and then molded. When the molds (41, 42) are clamped together and the foamed resin base material (21) is molded into a required shape along the cavity shape of the molds (41, 42), the molds (41, 42) are used. The molten resin (M1) is injected and filled from the injection machine (43) into the groove (424) of the molding die (41, 42) at any timing immediately before or after the mold clamping. (22) forming step of the laminated structure (20) in which the foamed resin base material (21) is laminated and integrated on the back side;
The laminated structure (20) molded in the molding step is removed from the molding dies (41, 42), and the laminated structure (20) is set on the receiving jig (60), and then has a refractive structure. The heater (77) of the heating jig (70) is moved to a position close to or in contact with the back side of the foamed resin base material (21) at the edge of the laminated structure (20). 60) The winding piece (81) in the winding mechanism part (80) located outside of (60) is raised, and the winding piece (24) of the foamed resin base material (21) is heated by this winding piece (81). After standing up while heating along the side surface of the heater (77) of the jig (70), the heating jig (70) is refracted and the winding piece (81) is rotated to wind the winding. Bending process (24) is heated and bent, and further 24) The end of the laminated structure (20) in which the heating jig (70) is retracted in the middle of the bending operation of 24), and then the winding sheet (24) is wound and welded to the back surface of the main body by the winding piece (81). Processing steps;
A method for producing an interior part for an automobile, comprising: From 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) After forming the laminated structure (20) to be formed by the molding dies (41, 42), a terminal processing device (50) that performs terminal treatment of the foamed resin base material (21) along the edge of the laminated structure (20). ) And
The terminal processing apparatus (50) includes a receiving jig (60) for setting the laminated structure (20), and a foamed resin base material (20) in the laminated structure (20) set on the receiving jig (60). 21) A heating jig (70) provided with a heater (77) for heat-softening, and a roll (24) for the heat-softened foamed resin base material (21) are wound on the back side of the main body. The winding mechanism (80) having a movable winding piece (81) is configured to rotate the winding piece (81) in order to perform a bending operation while heating the winding roll (24). A terminal processing apparatus for a laminated structure, wherein a refractive structure is employed in the heating jig (70) so as to follow the operation.

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