JP4627665B2 - Interior parts for automobiles and manufacturing method thereof - Google Patents

Description

  The present invention relates to an automobile interior part having a structure in which a skin is laminated on a core material, and a method for manufacturing the same.

  One of the methods for manufacturing this type of automobile interior part (for example, instrument panel) is a RIM molding method in which a polyol and an isocyanate are mixed and injected into a closed mold and solidified. (See, for example, Patent Document 1). In the RIM molding method of Patent Document 1, an insert (core material) injection-molded with a thermoplastic resin such as ABS (acrylonitrile butadiene styrene) is set in one mold (core mold), and urethane material is injected into the mold cavity. Then, by reacting and foaming, an integral skin urethane foam (skin) having a skin layer integrally formed on the surface is formed and integrated with the insert.

Further, in Patent Document 2, in an automobile interior member, a core material and a mold mold are first formed by injection molding, and then the mold mold is opened, and then the mold mold is replaced with a mold mold for forming a skin and a foam part. The mold is clamped, and an elastomer layer is formed by injecting a foamable elastomer. After the elastomer skin is formed, a small gap is opened, and the uncured central portion in the mold is foamed. It is disclosed that a foamed article with a soft skin can be obtained.
Japanese Patent Laid-Open No. 5-261799 (0002, 0003, etc.) Japanese Patent Laid-Open No. 5-278771 (Abstract, 0009, 0010)

  Here, for example, for reasons such as cost, there is a case where it is desired to soften only a part of the skin instead of softening the entire skin as in Patent Document 2. On the other hand, from the viewpoint of design, there is a demand for not losing the continuity of the surface of the epidermis.

  Therefore, in order to obtain the above-mentioned partial soft part, it is conceivable to form a concave part in the core material at the part where the soft feeling is to be imparted and to make the skin simply thick. However, even if a thick part is formed with the foamed foam of Patent Document 1 or Patent Document 2, the surface is a non-foamed elastomer, so a soft feeling is sufficient by simply making the urethane foam thick. Difficult to get to.

  In addition, in the method in which the thick part is simply formed on the skin, the weight increases by the thick part and the material cost increases. Particularly in the interior parts for automobiles as described above, since the specific gravity of the skin portion is not small, an increase in weight due to thickening is a problem that cannot be ignored.

Means and effects for solving the problems

  The problems to be solved by the present invention are as described above. Next, means for solving the problems and the effects thereof will be described.

According to a first aspect of the present invention, in an automotive interior part having a structure in which a skin is laminated on at least a core material, the skin has a thick part whose thickness is larger than the surroundings, and the core material A plurality of through-holes penetrating the core member are formed at positions corresponding to the thick-walled portion, and an automotive interior part in which elongated bubbles are formed in the thick-walled portion in a direction through which the through-hole penetrates. Provided.

  With this configuration, the soft feeling can be favorably obtained in the thick portion. Further, even if the thickness of the thick part is reduced, the same soft feeling as before can be obtained, so that it is possible to reduce the weight and cost of the automobile interior part.

  According to the 2nd viewpoint of this invention, the manufacturing method of the interior component for motor vehicles of the structure which laminated | stacked the skin on the core material as follows is provided. At least two molds are used, one of which has a core material, and a cavity with a partially enlarged gap is formed between the core material and the other mold, and a heat containing foaming agent. A cured resin is injected into the cavity and heated. By moving the other mold in a direction away from the core material when the thermosetting resin is uncured, bubbles in the middle of formation in the thermosetting resin are expanded in the direction between the molds.

  With this configuration, it is possible to obtain a good soft feeling in the thick part and to reduce the weight of the thick part.

  According to the 3rd viewpoint of this invention, the manufacturing method of the interior components for motor vehicles as follows is provided. By installing a core material in at least one mold and injecting a thermosetting resin into a cavity formed between the other mold and the core material, an interior part for an automobile in which a skin is laminated on the core material is formed. . In order to form a thick part in a part of the skin, the gap of a part of the cavity is enlarged, and one mold in the part where the gap is large is configured as a slide mold, The slide mold has a plurality of protrusions protruding toward the other mold. After injecting and heating the thermosetting resin, by sliding the slide mold away from the other mold when the thermosetting resin is uncured, the thermosetting resin in the thick part is A space corresponding to the convex portion is generated. By closing the space in the process of curing the thermosetting resin, bubbles are generated in the skin corresponding to the thick portion.

  With this configuration, it is possible to obtain a good soft feeling in the thick part and to reduce the weight of the thick part.

  In the method for manufacturing an automobile interior part, it is preferable that a hole is formed in the core member, and the convex part of the slide mold can pass through the hole.

  With this configuration, the slide type can be smoothly moved, and the above-described space can be easily formed.

  Next, a method for manufacturing an instrument panel (automobile interior part) according to an embodiment of the present invention will be described. FIG.1 and FIG.2 is explanatory drawing which showed the manufacturing method of the instrument panel later on.

[First manufacturing method]
The instrument panel 1 shown in FIG. 1 (c) has a structure in which a skin 3 is laminated on a core material 2, and a softened thick portion 6 is formed on the skin 3 at an appropriate location. ing. This first manufacturing method corresponds to the manufacturing method according to the second aspect of the present invention.

  The instrument panel 1 is manufactured by the following method. As shown in FIG. 1A, the core material 2 is installed on the core mold 11 in the space between the core mold 11 and the cavity mold 12, and in this state, between the core material 2 and the cavity mold 12 A cavity 4 is formed. The cavity mold 12 includes a slide mold 13 that can move toward and away from the core mold 11 (core material 2). For example, hot water of 40 ° C. to 60 ° C. is circulated in the core mold 11 and the cavity mold 12, and the temperature of the mold surface is adjusted to an appropriate temperature.

  As said core material 2, what was injection-molded with thermoplastic resins, such as ABS (acrylonitrile butadiene styrene), can be used like the said patent document 1, for example. A concave portion 5 is formed at a location corresponding to the slide mold 13 of the core material 2, and as a result, a part of the cavity 4 (a portion corresponding to the concave portion 5) has a gap corresponding to the concave portion 5. It is getting bigger. Note that the portion where the gap is large corresponds to the thick portion 6 of the skin 3 of the instrument panel 1.

  Then, as shown in FIG. 1A, in a mold-closed state, a mixture of polyol and isocyanate and a foaming agent added are injected (injected) and heated. In addition, as said foaming agent, it is possible to use water, a chlorofluorocarbon, and nitrogen gas, for example.

  Then, as shown in FIG. 1B, the slide mold 13 is appropriately moved away from the core material 2 when the thermosetting resin is uncured. As a result, the pressure of urethane in the portion of the recess 5 (portion where the gap is large) is greatly reduced, so that the degree of foaming of urethane in the portion can be forcibly increased. Further, the movement of the slide mold 13 causes the bubbles having the gap to be formed in a large part to be stretched in the direction between the molds and to expand.

  In addition, the reaction heat between a polyol and isocyanate is high, and is 100 degreeC or more, Furthermore, a polyurethane is a thermosetting resin. Therefore, in the cavity 4, the resin is generally cured from a portion having a high temperature (a portion far from the mold surface). In this embodiment, the temperature of the mold surface is as low as about 40 ° C. to 60 ° C. The temperature in the vicinity of the mold surface of the resin is low. Therefore, it is possible to move the slide mold 13 in the direction away from the core material 2 before the urethane resin is cured.

  After the resin is cured, the mold is removed and an appropriate post-treatment is performed to complete the instrument panel 1 shown in FIG. In addition, as an example of the post-treatment, a treatment for coating the surface portion of the thick portion 6 may be performed as necessary.

  As shown in FIG.1 (c), in this instrument panel 1, in the thick part 6, many bubbles 17 are generated rather than other parts. In addition, the bubbles 17 in the thick wall portion 6 have an elongated elliptical shape that extends in the thickness direction in accordance with the movement of the slide mold 13 in the uncured stage.

  In addition, the instrument panel 1 was actually manufactured based on the 1st manufacturing method demonstrated above. The position and size of the thick part 6 were 200 mm square parts on the assistant side of the instrument panel 1. The thickness of the skin other than the thick part 6 was 0.7 to 1.2 mm, and the thickness of the thick part 6 was 5 mm. In addition, the clearance gap amount of the recessed part 5 part before the movement of the slide mold | type 13 was 2 mm, and the slide mold | type 13 was moved so that the clearance gap | interval quantity might be 5 mm in the uncured state of resin.

  As a result, the hardness of the thick part 6 was 68 in Asker C. In addition, the hardness of parts other than the thick part 6 was 80 in Asker C. Moreover, when the weight of the manufactured instrument panel 1 was measured, the weight increase compared with the case where the above thick parts 6 were not provided was about 80 grams.

  On the other hand, as a comparative experiment, an instrument panel 1 ′ (FIG. 3) in which the thick portion 6 ′ was simply thickened was manufactured. The dimensional conditions, material, foaming agent and the like of the instrument panel 1 ′ were exactly the same as those of the instrument panel 1 described above. In the instrument panel 1 ′ of this comparative example, the hardness of the thick portion 6 ′ was about 75 for Asker C. The weight increase compared with the case where the thick part 6 'was not provided was about 160 grams. Incidentally, the specific gravity of the portion of the skin 3 of this instrument panel 1 'was 1.07.

  Therefore, it can be seen that the instrument panel 1 manufactured by the first manufacturing method can effectively obtain the soft feeling of the thick portion 6 and can suppress the increase in weight due to the thick portion 6. In particular, a value of 68 was obtained for Asker C as the hardness of the thick-walled portion, and it can be seen that a soft feeling according to a normal foamed urethane interior product (55 to 65 for Asker C) was realized.

[Second manufacturing method]
Next, the 2nd manufacturing method of an instrument panel is demonstrated. This second manufacturing method corresponds to the manufacturing methods according to the third and fourth aspects of the present invention, and the automobile interior part manufactured by this second manufacturing method is the same as that of the present invention. This corresponds to the automotive interior part according to the first aspect. In this manufacturing method, as shown in FIG. 2A, a slide mold 13 ′ is provided not on the cavity mold 12 but on the core mold 11 side. The slide mold 13 ′ is provided at a position corresponding to the above-described concave portion 5 (a portion having a large gap) provided in the core member 2. Further, the slide mold 13 ′ has a configuration in which a plurality of convex portions 14 are provided so as to protrude toward the opposite cavity mold 12 side.

  Note that through holes 15 are respectively formed in the concave portions 5 of the core material 2 at positions corresponding to the plurality of convex portions 14 of the slide mold 13 ′. Thereby, the convex portion 14 can pass through the through hole 15 and protrude into the cavity 4.

  In this second production method, as in the first production method, in a mold-closed state, a mixture of a polyol and an isocyanate added with a blowing agent is injected and heated (FIG. 2 (a)), When the urethane resin is uncured, the slide mold 13 ′ is appropriately moved away from the cavity mold 12. Then, as shown in FIG. 2B, the convex portion 14 comes out of the cavity 4, and the thick portion 6 has a concave portion (space) elongated in the mold direction corresponding to the convex portion 14. 16 is formed. At this stage, the recessed portion 16 communicates with the through hole 15 described above.

  At the stage where the recessed portion 16 is formed, the thermosetting resin still has a certain degree of fluidity. Therefore, with the passage of time, the recessed portion 16 is naturally divided in the longitudinal direction by the action of surface tension and the like. And closed (in other words, closed so as not to communicate with the through hole 15). Then, the resin hardens in a state where the recessed portion 16 is interrupted, and as a result, in the thick portion 6, as shown in FIG. 2 (c), an elongated bubble 17 ′ is formed in the thickness direction. The Rukoto.

  In addition, the instrument panel 1 was actually manufactured also by this 2nd manufacturing method. The dimensional conditions of the instrument panel 1 and the position, size, thickness, etc. of the thick portion 6 are exactly the same as those described above, and as the convex portion 14 of the slide mold 13 ′, the width 30 mm × length 180 mm × height 3 mm What formed six protrusions at equal intervals in a 200 mm square area was used.

  As a result, the hardness of the thick portion 6 was 65 with Asker C. Moreover, when the weight of the manufactured instrument panel 1 was measured, the weight increase compared with the case where the above thick parts 6 were not provided was about 103 grams.

  Therefore, even in the instrument panel according to the second manufacturing method, the thick portion 6 can be effectively softened as compared with the configuration of the comparative experiment described above (the thick portion Asker C is 75 and the weight increase is 160 grams). In addition, it can be seen that an increase in the weight of the thick portion 6 can also be suppressed. In particular, a value of 65 is obtained for Asker C as the hardness of the thick-walled portion, and it can be seen that a soft feeling (about 55 to 65 for Asker C) is obtained as in the case of an interior product of ordinary urethane foam.

  Although the preferred embodiment of the present invention has been described above, the above embodiment can be modified as follows, for example.

  Said thick part 6 is applicable not only to an instrument panel but general interior parts for motor vehicles, such as a glove box, for example. Moreover, the structure which laminated | stacked the skin 3 on the core material 2 is enough, and the raw material of the core material 2 or the skin 3 is not specifically limited. Furthermore, it is sufficient that the thick portion 6 is formed on a part of the skin 3, and the position and size thereof can be variously changed according to the use of the automobile interior part.

  Further, the shape, protrusion amount, number, and arrangement of the convex portions 14 of the slide mold 13 ′ in the second manufacturing method are not limited to those described above. For example, a configuration in which square or circular protrusions are arranged in an array of m rows and n columns can be employed. In addition, the shape and number of the through holes 15 formed in the core member 2 in FIG. 2 may be appropriately determined according to the shape and number of the convex portions 14 described above.

Explanatory drawing of the 1st manufacturing method of an instrument panel. In addition, in FIG.1 (c), sectional drawing of the instrument panel as a finished product is shown. Explanatory drawing of the 2nd manufacturing method of an instrument panel. In addition, in FIG.2 (c), sectional drawing of the instrument panel as a finished product is shown. Sectional drawing which shows the structure of the instrument panel by the conventional manufacturing method.

Explanation of symbols

1 Instrument panel (automobile interior parts)
2 Core material 3 Skin 5 Recessed portion 6 Thick portion 11 Core type 12 Cavity type 13, 13 'Slide type 14 Convex portion 15 Through hole (hole)
16 Recessed part (space)
17, 17 'Bubbles in the thick part

Claims (4)

In automotive interior parts with a structure in which the skin is laminated at least on the core material,
The epidermis has a thick part whose thickness is larger than the surroundings,
In a position corresponding to the thick part of the core material, a plurality of through holes penetrating the core material are formed,
An interior part for an automobile, wherein a long and narrow bubble is formed in the thick part in a direction through which the through hole penetrates . In a method for manufacturing an interior component for automobiles having a structure in which a skin is laminated on at least a core material,
At least two molds are used, one of which has a core material, and a cavity with a partially enlarged gap is formed between the core material and the other mold, and a heat containing foaming agent. Inject and heat the cured resin into the cavity,
An automobile characterized in that, in the stage in which the thermosetting resin is uncured, the other mold is moved in a direction away from the core material, thereby expanding bubbles formed in the thermosetting resin in a direction between the molds. Of manufacturing interior parts for automobiles. By installing a core material in at least one mold and injecting a thermosetting resin into a cavity formed between the other mold and the core material, an interior part for an automobile in which a skin is laminated on the core material is formed. In the manufacturing method of interior parts for automobiles,
In order to form a thick part in a part of the skin, the gap of a part of the cavity is enlarged, and one mold in the part where the gap is large is configured as a slide mold, The slide mold has a plurality of protrusions protruding toward the other mold,
After injecting and heating the thermosetting resin, by sliding the slide mold away from the other mold when the thermosetting resin is uncured, the thermosetting resin in the thick part is Create a space corresponding to the convex part,
A method for producing an interior part for an automobile, wherein the space is closed in the course of curing of the thermosetting resin, thereby generating bubbles in a skin of a portion corresponding to the thick portion. It is a manufacturing method of the interior component for vehicles according to claim 3,
A method for manufacturing an interior part for an automobile, wherein a hole is formed in the core member, and the slide-type convex portion is configured to pass through the hole.

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