JP5354993B2 - Interior parts for automobiles and methods for producing the same - Google Patents

Abstract

Provided are an installation structure on a light decorated back face, used for simply and cheaply installing other parts to the whole or a part of inner-decoration component for automobile and an installation method. A door decoration upper portion-forepart (a laminating structure) (30) of a door decoration (20) is formed by a light laminating body with a foamex substrate (31) with the conformality and a rigid resin rib (31) which is integrated with the substrate and arranged on the back face, and is taken as a structure for installing a waist ornament (other components) (50) on the back side, a part of waist ornament is fused to be integrated by a hump (34) used for fusion splicing and integrated on the resin rib (32), and the part of the waist ornament, corresponding to the end edge portion of the door decoration upper portion-forepart uses the coiling process by means of the coiling material (35) at the circumference of the foamex substrate, the upper terminal (50a) of the waist ornament is kept by the coiling of the coiling material, thus simplifying the conformality shape of the waist ornament.

Description

  The present invention relates to automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and manufacturing methods thereof, and in particular, garnishes, brackets, The present invention relates to an automotive interior part that can be easily and inexpensively attached to a separate part such as a pad, and a manufacturing method thereof.

  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. Alternatively, a laminated sheet material in which a cushioning material such as polyethylene foam is laminated on the back surface of a synthetic resin sheet is used, and recently, an elastomer sheet such as a thermoplastic olefin (TPO) sheet has been used in consideration of environmental and recycling aspects. There is a tendency to be frequently used.

  Next, a conventional example of the method for forming the door trim 1 will be described with reference to FIG. First, a molding die 4 that molds the door trim 1 is connected to a molding upper die 5 that can move up and down by a predetermined stroke, a molding lower die 6 that forms a pair with the molding upper die 5, and a molding lower die 6. It is generally composed of the injection machine 7. When the upper and lower molds 5 and 6 are clamped, a cavity portion 5a is formed in the molded upper mold 5 and a core section 6a is provided in the molded lower mold 6 in order to shape the product shape of the door trim 1. Yes. In order to move the 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. 23, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6a in an open state. However, the molten resin M is injected and filled into the cavity after the mold upper and lower molds 5 and 6 are clamped. May be.

  Recently, as shown in FIGS. 24 and 25, a lightweight door trim 10 that is lightweight and can be manufactured inexpensively has been proposed. This lightweight door trim 10 requires a foamed resin base material 11 having a lightweight and shape-retaining property obtained by press-molding a foamed resin sheet into a required shape, and a peripheral portion and reinforcement of the foamed resin base material 11. The resin ribs 12 are integrated in a portion such as a grid shape, and the surface 13 of the foamed resin base material 11 is integrated with the surface of the foamed resin base material 11 to maintain a good texture and feel. Has been. The configuration and manufacturing method of this type, lightweight door trim 10 are described in detail in Patent Document 2. Further, in this kind of lightweight door trim 10, in order to fix the separate parts 14 such as garnish, brackets, pads, etc. in a predetermined position, for example, as shown in FIG. 15 is installed and the welding boss 15 is inserted into the boss hole 14a of the separate part 14, and then the tip of the welding boss 15 is caulked and fixed by ultrasonic processing or the like, or as shown in FIG. In addition, a method in which the separate component 14 is bonded and integrated on the back surface of the foamed resin base material 11 via the hot-melt adhesive layer 16 is conventionally performed.

JP 10-138268 A

JP 2005-28722 A

  As described above, the lightweight door trim 10 in which the resin ribs 12 having a predetermined pattern shape are integrated on the back surface of the foamed resin base material 11 has a characteristic that it can be manufactured at a low cost and at a low cost. However, in order to attach and fix a separate part 14 such as a garnish, a bracket, or a pad on the back side of the door trim 10, for example, a welding fixing structure using a welding boss 15 or an adhesive fixing structure using a hot melt adhesive layer 16 is used. Although it is conceivable, in the method using the welding boss 15, the setting position of the welding boss 15 is restricted in terms of mold processing to the molding die, so that the setting position of the separate part 14 is limited, and the degree of freedom in design is reduced. In addition to the problem of being restricted, the welding bosses 15 are set at a plurality of locations and the individual welding bosses 15 are caulked, so that the processing is troublesome and it takes a lot of work time. was there.

  In addition, the method using the hot melt adhesive layer 16 shown in FIG. 27 similarly requires a coating process of the hot melt adhesive layer 16, which increases man-hours and leads to an increase in cost. There was no problem.

  The present invention has been made in view of such circumstances, and is a lightweight interior part based on a foamed resin base material, in which separate parts such as a garnish, a bracket, and a pad are attached to the back side of the base material. At the same time, it can be easily and inexpensively installed, and it can be mounted with good appearance, and it can be set at an arbitrary position without being restricted by the installation location of separate parts. It aims at providing the manufacturing method.

  In order to solve the above-mentioned problems, the present inventor has conducted extensive research and, as a terminal treatment structure of a laminated structure, heats and softens the winding periphery provided on the entire periphery of the periphery or a part of the periphery so that the back surface on the main body side Focusing on the fact that the separate part can be fixed easily and inexpensively by replacing the boss fixing structure with the welding boss by fixing the terminal part of the separate part so as to wrap it with this wrapping white when wrapping around The present invention has been completed.

  That is, the present invention is a laminated structure comprising a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a resin rib having a predetermined pattern shape that is integrated on the back surface of the foamed resin base material. In automotive interior parts that employ the body in whole or in part, the foamed resin base material in the laminated structure is press-molded between the upper and lower molds and integrated with the back surface of the foamed resin base material. The resin rib to be molded is molded by injecting and filling molten resin into the groove portion of the molding lower mold, and further, a separate part is disposed on the back side of the foamed resin base material and the resin rib. It is characterized in that it is supported by being wound around a peripheral edge of the laminated structure.

  Here, the interior parts for automobiles can be applied to door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and the like. The laminated structure according to the present invention can also be applied to the entire structure of the interior parts for automobiles. However, the laminated structure according to the present invention is applied only to a part of the interior parts for automobiles, for example, the door trim upper in the upper and lower divided door trims. In the case where the structure is applied, or the door trim upper is composed of the front and rear divided parts, the laminated structure can be applied only to the door trim upper / front side.

  Furthermore, the foamed resin base material having the shape retaining property can be obtained after the foamed resin sheet is heat-softened and then molded into a desired curved shape in a molding die, so that there is no reinforcing material such as a rib. , Has rigidity (shape retention) enough to retain the shape even when removed from the mold. 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 substrate at that time is preferably in the range of 0.1 μm to 2.0 mm, and the thickness is preferably in the range of 0.5 to 30 mm, preferably 1 to 10 mm.

  Next, in order to improve the appearance design of the laminated structure, the skin may be laminated and integrated on the surface of the foamed resin base material. The skin is not limited in material, but may be composed of a laminated sheet material of a top layer that enhances the surface appearance and a cushion layer that imparts cushioning performance. As the top layer, a thermoplastic resin olefin (TPO) sheet, a thermoplastic plastic (TPU) sheet, a synthetic resin sheet such as a vinyl chloride sheet, or a fabric sheet such as a woven fabric, a nonwoven fabric or a knitted fabric can be used as a cushion. As the layer, polypropylene foam, polyethylene foam, polyurethane foam or the like can be used.

  On the other hand, the thermoplastic resin 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, Examples include acrylonitrile / butadiene / styrene (ABS) resin. 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. Furthermore, the said resin rib is arrange | positioned along the predetermined pattern shape on the back surface of a foamed resin base material. As an arrangement place, it arranges partially in the part where load concentrates, such as a peripheral part which tends to generate warpage deformation, undulation deformation, and a waist part and an armrest part where load is easy to apply.

  Furthermore, there are garnishes, brackets, pads, etc. as other parts attached to the back side of the laminated structure. Conventionally, welding fixing with a boss and welding fixing with a hot-melt adhesive are generally used. In the invention, the boss welding fixing is adopted in part, but in the terminal part of the separate part, the terminal process of the laminated structure and the separate part are processed by the winding process along the peripheral edge of the foamed resin base material. It is characterized in that terminal processing is performed simultaneously.

  And, according to the interior parts for automobiles according to the present invention, a laminated structure that is light and can be manufactured at a low cost is adopted for a part of the interior parts, so that the weight of the product can be reduced and the product cost can be reduced. In addition to being able to, the attachment structure of the separate part disposed on the back side of the laminated structure wraps the terminal part of the separate part during the end process of the winding white set along the peripheral edge of the laminated structure. Since the configuration of winding and fixing in a holding shape is adopted, the setting position of the welding boss can be reduced, the cost for processing the mold can be reduced, and the cutting end of the terminal part of the separate part is encapsulated with the winding white As a result, the appearance can be improved and the degree of freedom of modeling can be improved.

  Next, in a further preferred embodiment of the automotive interior part according to the present invention, the winding white in the laminated structure includes a terminal part of the separate part and supports the terminal part of the separate part in addition to the boss hole of the separate part. It is characterized by being integrally welded and fixed to the tip end surface of the inserted welding boss and the side surface of a separate part.

  And according to this embodiment, the winding white provided along the product terminal of the foamed resin base material in the laminated structure is bent by about 90 ° and welded to the side surface of the separate part. The tip of the welding boss inserted through the boss hole is also wound together with the attachment surface of the separate part and welded to the outer surface. Setting the boss improves the position accuracy of attaching the separate part. And it has the effect that more reliable fixation of a separate part is attained.

  Next, a 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 shape that is integrated on the back surface of the foamed resin base material. In a method for manufacturing an interior part for an automobile, in which a laminated structure including a resin rib is used in whole or in part, the laminated structure heat-softens a foamed resin sheet that is a material of a foamed resin base material. After processing, it is put into the molding die, and the foamed resin base material is press-molded into the required shape by clamping the molding die, and after the molding die is clamped, it is melted in the groove portion of the lower molding die The resin rib is injected and filled, and a resin rib having a predetermined pattern shape is integrally formed on the back side of the foamed resin base material. After that, the laminated structure is removed from the molding die, and then the back side of the laminated structure is formed. Place separate parts and place them on the resin rib. The welded boss is inserted into the boss hole of the separate part, and then the welded boss is crimped to integrate the separate part at a predetermined position on the back side of the foamed resin base material and the resin rib. After heating and softening the back side of the winding scissors set at the peripheral terminal portion of the terminal processing device with a heating jig in the terminal processing device, the terminal portion of another part is wrapped by the forward and backward operation of the winding mechanism portion in the terminal processing device It is characterized in that a step of terminal processing of a terminal portion of a separate part is added by performing a folding operation on the winding paper.

  The method of the present invention is a method for producing a laminated structure that constitutes a part or the whole of an automobile interior part. The laminated structure is formed by a molding process, the laminated structure is removed from the molding die, and then the laminated structure is obtained. The separate part mounting process includes attaching a separate part to the back surface of the boss. In particular, the separate part mounting process includes a boss welding and fixing process and a winding scooping process.

  Here, the molding die used for the method of molding the laminated structure is, for example, a molding die having a specification in which the mold opening direction is set in the vertical direction, and a molding upper die that can move up and down, and a lower part of the molding upper die. It is composed of a molding lower mold that is a fixed side located on the side and an injection machine connected to the molding lower mold, and the molten resin supplied from the injection machine is a resin such as a manifold and a gate provided in the molding lower mold The material is supplied into a groove having a predetermined pattern shape formed in the mold surface of the molded lower mold through the passage. Further, if desired, a vacuum suction mechanism may be provided on the molding upper die, and the shape of the product shape is enhanced by applying a vacuum suction force from the molding upper die when the foamed resin base material is drawn. At the same time, it is advantageous for transferring a drawn pattern or the like. On the other hand, an air blow mechanism may be attached to the lower mold, and the air blow mechanism can shorten the cooling cycle by blowing cooling air at the time of molding the foamed resin base material.

  Therefore, after the foamed resin sheet, which is the material of the foamed resin base material, is heated and softened by a heater or the like, the foamed resin sheet is put into a molding die, and then the upper and lower molds are clamped. Press the foamed resin base material into the required shape, and at the same time as forming the foamed resin base material, or after setting a slight time difference, melt the molten resin from the injection machine to the back of the foamed resin base material, such as a manifold, gate, etc. The resin rib having a predetermined pattern shape can be integrated with the back surface of the foamed resin base material by supplying it into the groove portion of the molded lower mold through the resin passage. If desired, the skin can be laminated on the surface of the foamed resin base material by pasting the skin on the foamed resin sheet in advance or by integrating the skin at the time of molding.

  Next, as the equipment used for the mounting structure for attaching separate parts to the back of the laminated structure, the caulking device used for caulking processing of the welding boss and the winding part so as to hold the terminal part of the separate parts are wound. And a terminal processing device that performs processing. As a caulking device, a welding jig for setting the laminated structure to be processed and an ultrasonic horn for ultrasonic processing corresponding to the welding boss provided integrally with the resin rib are connected to the press machine. Is used. In addition, the terminal processing apparatus includes a receiving jig for setting the laminated structure after molding, a heating jig for heat-softening the winding paper corresponding to the edge of the laminated structure, and the foaming resin for the winding paper. It consists of the winding mechanism part which folds back to the back surface side of a base-material main body. The receiving jig includes a setting table for setting the laminated structure, a spacer for fixing the laminated structure set on the setting table, and a receiving jig holder. Moreover, as a heating jig, the structure which can slide a heater support body provided with the box-shaped heater to a horizontal direction, and can raise / lower also with respect to an up-down direction may be employ | adopted. Further, as the winding mechanism, a rectangular parallelepiped winding piece is driven back and forth along the horizontal direction by the advancing / retreating cylinder, and the table supporting the advancing / retreating cylinder is driven along the vertical direction by the table driving cylinder. Is done.

  Therefore, when the formation of the laminated structure is completed, after opening the molding die and taking out the laminated structure, the laminated structure is set on a welding jig in the caulking device, and a separate part is mounted thereon. Put. At this time, the welding boss standing on the resin rib is inserted into the boss hole of a separate part, and the ultrasonic horn connected to the press machine is lowered with respect to the tip of the welding boss to perform the welding process. A separate part is partially welded and fixed via a welding boss provided on the resin rib.

  After that, the laminated structure in which separate parts are integrated is set on the setting jig of the terminal processing device, and the back surface of the winding white surface corresponding to the peripheral edge of the foamed resin base in the laminated structure is heated and softened by the heating jig. Thereafter, the winding frame is driven by a cylinder to operate the winding frame, and the winding process may be performed so as to wrap the terminal portion of the separate part with the winding frame.

  As described above, according to the method of the present invention, in the method for manufacturing a laminated structure, a separate part attaching step for attaching a separate part is added to the laminated structure formed into a required shape. The attachment process consists of a welding caulking process for welding bosses and a terminal processing process for enclosing the terminal part of a separate part using a foaming base of the foamed resin base material. Compared to the conventional boss welding fixing method, The restriction of the location is relaxed, the number of bosses can be reduced, the welding process can be simplified, and the terminal part of another part is wrapped with the foamed resin base material, so the appearance appearance is improved, especially the foamed resin base material Since the terminal processing process of the general winding white in is utilized, the man-hour increase can be suppressed.

  Furthermore, in a preferred embodiment of the method of the present invention, in the terminal processing step of the winding white set at the peripheral terminal of the laminated structure, the terminal portion of the separate part is arranged in the direction perpendicular to the back surface of the laminated structure. In addition, it is welded and fixed to a separate part by bending the winding white by approximately 90 °, and both the front end surface of the welding boss and the side of the separate part are welded integrally with the winding white. And

  In this embodiment, the terminal portion of the separate part is sandwiched between the winding ribs of the resin rib and the foamed resin base material, and the front end surface portion of the welding boss erected from the resin rib is welded to the winding rib. By integrating, the terminal portion of the separate part is securely held by the resin rib and the winding white. Moreover, it has the effect that the position accuracy which attaches another parts can be improved by setting a boss | hub.

  As described above, according to the automotive interior part and the method for manufacturing the same 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 retention. And a resin rib that is integrated with a portion that requires rigidity on the back surface of the foamed resin base material, so that a conventional heavy resin core material can be arranged, so that it is light weight and low cost. In addition to providing automotive interior parts, separate parts such as garnishes, brackets, and pads that are attached to the back of the laminated structure are connected to the terminal part of the separate part during the end treatment of the roll-off white set on the peripheral edge of the laminated structure. As a result, the man-hours can be reduced compared to the conventional boss welding method and hot melt bonding method, and the terminal part of the separate part is made of the foam resin base material. Because the encapsulated short time lump white, has the effect of increasing the appearance of the terminal part inexpensive way.

  DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments of an automobile interior part and a manufacturing method thereof according to the present invention will be described in detail with reference to the accompanying drawings. Note that the gist of the present invention is as described in the scope of claims, and the contents of the embodiments described below are merely examples of the present invention.

  1 to 20 show an embodiment of the present invention. FIG. 1 is a front view showing an automobile door trim, FIG. 2 is a front view showing a door trim upper in the door trim, and FIG. 3 is a configuration of the door trim upper. FIG. 4 is a sectional view showing the structure of the door trim upper / front in the door trim upper, FIG. 5 is an overall view showing the structure of a molding die used for molding the door trim upper / front, and FIGS. Is an explanatory diagram showing the molding process of the door trim upper and front, FIGS. 9 to 14 show each process of attaching different parts to the door trim upper and front, and FIGS. 9 and 10 are caulking processes of the welding boss. Each explanatory view showing a process, FIGS. 11 to 14 are each showing a heat softening process and a winding process of a roll-up white for supporting a terminal part of a separate part. FIG. 15 to FIG. 20 show modified examples of the present invention. FIG. 15 is a sectional view in which the shape of a separate part is changed. FIGS. 16 to 20 show the separate part shown in FIG. It is explanatory drawing which shows each process to attach.

  A configuration of an automotive door trim 20 to which an automotive interior part according to the present invention is applied will be described with reference to FIGS. 1 to 4. As shown in FIG. 1, the automobile door trim 20 is composed of a door trim upper 20A and a door trim lower 20B. The door trim upper 20A is provided with an inside handle unit 21 on the front side of its middle portion. Is attached. On the other hand, the door trim lower 20 </ b> B is formed with an armrest 22 that swells indoors, and a switch panel 23 such as a power window switch and a pull handle unit 24 are provided on the upper surface of the armrest 22. Further, a door pocket 25 capable of storing equipment is provided below the armrest 22, and a speaker grille 26 is provided integrally or separately from the door trim lower 20 </ b> B on the front side of the door pocket 25.

  As described above, the automobile door trim 20 to which the present invention is applied is composed of the upper and lower divided bodies of the door trim upper 20A and the door trim lower 20B, which enhances the design property by the contrast effect on the appearance and makes the molding die compact. Can be achieved. Furthermore, in the present invention, the door trim upper 20A also employs a two-divided configuration in the front-rear direction. That is, as shown in FIGS. 2 to 4, the door trim upper 20 </ b> A is configured by a front / rear two-part structure of a door trim upper front 30 and a door trim upper rear 40. A joint flange 27 for joining to the door trim lower 20B is set on the lower edges of both the door trim upper front 30 and the door trim upper rear 40. And as a structure of the door trim upper front 30, when adopting the structure of a laminated structure that can be manufactured at a low cost at a low cost, and when a separate part such as a garnish, bracket, pad, etc. is arranged on the back side, In this embodiment, the waist garnish 50 is attached, but the feature is that the waist garnish 50 can be easily and inexpensively attached and the appearance can be improved.

  Next, specific configurations of the door trim upper / front 30 and the door trim upper / rear 40 will be described. First, the door trim upper front 30 composed of a laminated structure is molded into a desired curved surface shape, and is integrated with a foamed resin base material 31 having shape retention, and a back surface side of the foamed resin base material 31, It is generally constituted by a resin rib 32 for imparting rigidity and a skin 33 having a decoration function integrated on the surface side of the foamed resin base material 31.

  The foamed resin base material 31 has a shape after heat-softening the foamed resin sheet and heat-molded into a required shape, for example, cold press-molded with a molding die having a desired mold surface so as to have shape retention. Is granted. The foamed resin sheet has a structure in which a foaming agent is added to a general-purpose thermoplastic resin. As the thermoplastic resin, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, and vinyl chloride are used. Resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. can be used, and as foaming agents, organic foaming agents such as azodicarbonamide and sodium bicarbonate Inorganic foaming agents such as 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 foaming resin base material 31 has an expansion ratio of 2 to 10 times, and a thickness of 0.5 to 30 mm, particularly preferably 1 to 10 mm.

  Next, the resin ribs 32 are set in a lattice pattern extending in the vertical and horizontal directions or in an oblique direction. And this resin rib 32 consists of a general purpose synthetic resin molding which added reinforcement fibers, such as glass fiber and a natural fiber, and the synthetic resin which can be preferably used normally is polyethylene-type resin, polypropylene-type resin, polystyrene-type resin, polyethylene The present embodiment may be appropriately selected from terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. In view of environmental and recycling aspects, polypropylene resins are used.

  As described above, the door trim upper / front 30 which is a laminated structure is configured. The door trim upper / rear 40 connected to the door trim upper / front 30 is composed of an injection-molded body of synthetic resin. The same material as the resin rib 32 of the door trim upper / front 30 can be used as the material to be used, and excellent appearance design is guaranteed by the accent effect on the appearance of the door trim upper / front 30 and the door trim upper / rear 40. This is the same as the relationship between the door trim upper 20A and the door trim lower 20B.

  Furthermore, in the automotive door trim 20 according to the present invention, the waist garnish 50 is attached to the back side of the door trim upper front 30. The attachment structure of the waist garnish 50 is simplified. That is, as shown in FIG. 4, the waist garnish 50 is superimposed on the back side of the door trim upper front 30, and the welding boss 34 standing on the back side from the resin rib 32 is inserted into the boss hole 51 of the waist garnish 50. In addition, the lower end portion of the waist garnish 50 is fixed to the back surface of the door trim upper front 30 by crimping the front end portion of the welding boss 34, and the upper half portion of the waist garnish 50 is foamed. The upper terminal 50 a of the waist garnish 50 is wound and fixed by a winding roller 35 provided at the terminal portion of the resin base material 31.

  Therefore, since it is not necessary to set the boss welding location in the upper part, the number of welding bosses 34 for attaching the waist garnish 50 can be reduced, the number of mold processing steps can be reduced, and the entrainment of the foamed resin base material 31 can be reduced. Since the winding operation can be used in combination with a normal peripheral edge terminal processing step, the upper terminal 50a of the waist garnish 50 is encapsulated by the winding white 35 without increasing man-hours. Is also preferable.

  Next, the configuration of the molding die 60 used when molding the door trim upper front 30 will be described with reference to FIG. The molding die 60 is generally composed of a molding upper die 61 that can move up and down by a predetermined stroke, a fixed molding lower die 62 that is paired with the molding upper die 61, and an injection machine 63 connected to the molding lower die 62. Has been. More specifically, the molding upper die 61 has a cavity portion 611 that matches the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 612 connected to the upper surface of the molding upper die 61. In addition, guide bushes 613 are provided at the four corners of the molding upper die 61.

  On the other hand, the molding lower die 62 is provided with a core portion 621 corresponding to the cavity portion 611 of the molding upper die 61. Further, in order to supply molten resin to the mold surface of the core portion 621, a manifold 622 and a gate 623 are provided in the molding lower mold 62, and the injection machine 63 passes through the resin passages of the manifold 622 and the gate 623. The supplied molten resin M is supplied to the upper surface of the core portion 621. In order to form the resin rib 32, a groove 624 through which the molten resin M is supplied is formed on the upper surface of the core 621. In addition, guide posts 625 serving as a guide mechanism are formed in the four corners of the molding lower die 62. The guide posts 625 guide the molding upper die 61 when the molding upper and lower dies 61 and 62 are clamped. Since the guide post 625 is guided in the bush 613, the pressability of the upper mold 61 can be properly maintained.

  Next, each process of the molding method of the door trim upper / front 30 will be described. First, the laminate having the skin 33 laminated on one surface of the foamed resin sheet S is subjected to a heat softening process by a heater device (not shown), and is put into the mold when the molded upper and lower molds 61 and 62 are in the mold open state. In this embodiment, a polypropylene foam sheet (manufactured by Sumika Plustech, trade name: Sumiceller foam PP sheet, expansion ratio = 3 times, thickness 3 mm) is used as the foam resin sheet S. If desired, the foamed resin sheet S and the skin 33 may be set so as to be separately stacked in the molding die 60. Then, after setting the foamed resin sheet S, the molding upper die 61 is lowered by a predetermined stroke by driving the elevating cylinder 612, the molding upper and lower dies 61 and 62 are clamped, and the foamed resin sheet S has a desired mold surface shape. (See FIG. 7).

  Furthermore, injection molding of the resin rib 32 is performed simultaneously with the molding of the foamed resin base material 31 or after a predetermined time has elapsed. That is, when the molding upper and lower molds 61 and 62 are in the clamped state, the molten resin M is injected and filled into the groove portion 624 from the injection machine 63 through the manifold 622 and the gate 623, and the resin rib 32 is molded into a predetermined pattern shape. . As the molten resin M, Sumitomo Nobrene BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 80 g / 10 min) is used. The molten resin M may be mixed with a filler such as talc in an appropriate proportion.

  As described above, the door trim upper / front 30 is molded into a required shape. When the molding is completed, the molding upper and lower molds 61 and 62 are opened, and the door trim upper / front 30 is removed from the molding die 60. The door trim upper front 30 is set on the welding jig 71 in the caulking device 70 shown in FIG. The waist garnish 50 is positioned on the back side of the door trim upper front 30. At this time, the welding boss 34 integrated with the resin rib 32 of the door trim upper front 30 is placed in the boss hole 51 of the waist garnish 50. By inserting and crimping the tip end portion of the welding boss 34 with the ultrasonic horn 72, the lower half of the waist garnish 50 is joined to the upper portion of the door trim by crimping the welding boss 34 as shown in FIG. Fixed to a predetermined position on the back side of the front 30. At this time, the terminal portion of the foamed resin base material 31 extends above the upper terminal 50 a of the waist garnish 50. This part corresponds to the winding white 35.

  Next, in order to complete the attachment of the waist garnish 50 to the door trim upper front 30, the terminal processing device 80 shown in FIG. 11 is used. The terminal processing apparatus 80 includes a setting jig 81 for setting the door trim upper / front 30, a heating jig 82 for heating and softening the winding white 35 in the door trim upper / front 30, and the winding white 35 on the back surface of the main body. A winding mechanism portion 83 that performs winding processing on the side is roughly configured.

  More specifically, the setting jig 81 includes a set base 81a for setting the door trim upper / front 30; a spacer 81b for positioning and fixing the door trim upper / front 30 at a predetermined position; and a receiving jig presser 81c. It is composed of Next, as the heating jig 82, a heater support 82b that supports the heater 82a is connected to the driving cylinder 82c. The heater 82a of the heating jig 82 causes the door trim upper / front 30 winding white 35 to be heated. The back surface of is heated and softened. Further, with respect to the operation of the winding mechanism 83, the winding piece 83a for winding the winding roller 35 is driven back and forth in the horizontal direction by the advancing and retracting cylinder 83b, and the table to which the advancing and retracting cylinder 83b is attached. 83c is driven by a predetermined stroke along the vertical direction by a vertical movement cylinder 83d.

  Therefore, in order to perform the terminal processing of the semi-finished product shown in FIG. 10, as shown in FIG. 11, the set base 81 a of the setting jig 81 of the terminal processing device 80 is placed under the door trim upper front 30 and the waist garnish 50. Set the half part in an integrated state. Then, after being fixed at a predetermined position by the spacer 81b and the receiving jig holder 81c, as shown in FIG. 12, the heating jig 82 is driven to the predetermined position, and along the peripheral portion of the foamed resin base material 31 by the heater 82a. The set back side of the winding roller 35 is heated and softened.

  Thereafter, as shown in FIG. 13, the heater support 82b that supports the heater 82a is moved backward by the drive of the drive cylinder 82c, and instead the winding piece 83a in the winding mechanism 83 is moved by the operation of the advance / retreat cylinder 83b. The sliding operation is performed so that the winding white 35 is bent by approximately 90 °, and the winding process is performed with the upper terminal 50a of the waist garnish 50 as a base point. At this time, as shown in FIG. 14, by the operation of both the advance / retreat cylinder 83b and the up / down operation cylinder 83d, the entrainment scissor 35 can perform the entrainment process at a bending angle of approximately 180 °. And since the terminal processing operation of the winding sill 35 is normally performed along the periphery of the door trim upper front 30, the winding processing operation of the waist garnish 50 can be performed simultaneously with the normal terminal processing, so the man-hour is newly added. It is not added, and the number of bosses can be reduced, and the appearance can be enhanced, and a great effect can be expected.

  Next, FIG. 15 to FIG. 20 show a modification of the present invention. As shown in FIG. 15, this modification is also applied to a form in which the waist garnish 50 is attached to the door trim upper front 30 of the door trim 20. ing. As is apparent from the drawings, the waist garnish 50 is set in a bent shape, and boss holes 51a and 51b (the upper boss hole is 51a and the lower boss hole is 51b) at a plurality of positions on the upper and lower sides, respectively. Correspondingly, welding bosses 34a and 34b corresponding to the resin rib 32 are also set. And about the lower side of the waist garnish 50, the welding boss 34b is inserted into the boss hole 51b of the waist garnish 50, and the lower half portion of the waist garnish 50 is boss-fixed by caulking the tip. The upper end side including the upper terminal 50a of the waist garnish 50 is sandwiched and fixed between the resin rib 32 and the winding white 35, and the winding white 35 is welded and fixed to the front end surface of the welding boss 34a. ing.

  Therefore, by setting the welding boss 34a, the position accuracy for attaching the waist garnish 50 can be further increased, and the terminal portion can be securely and firmly fixed. Also in this case, as shown in FIG. 16, after setting the door trim upper front 30 on the welding jig 71, the boss holes 51a and 51b of the waist garnish 50 are inserted into the bosses 34a and 34b, respectively. However, since the boss holes 51a and 51b each having a positioning function are set on the upper and lower sides of the waist garnish 50, the positioning accuracy can be precisely controlled. As shown in FIG. 17, the lower half of the waist garnish 50 can be fixed to the door trim upper front 30 by welding the tip of the lower welding boss 34 b with the ultrasonic horn 72.

  Next, as shown in FIG. 18, after setting the door trim upper / front 30 on the setting jig 81 of the terminal processing apparatus 80, as shown in FIG. After the back surface of the winding roller 35 is heated and melted, as shown in FIG. 20, the winding frame 83a of the winding mechanism 83 is moved forward and backward by driving the advance / retreat cylinder 83b, so that the winding roller 35 is moved to the waist garnish. If the bending operation is performed along the welding surface 50, the upper end 50a of the waist garnish 50 can be sandwiched between the winding sill 35 and the resin rib 32, and further, the tip end surface of the welding boss 34a and the wrapping sill 35 Are integrated with each other, so that the anchor can be combined to be more firmly held.

  Therefore, also in this modified example, using the terminal processing method in the foamed resin base material 31, the upper terminal 50a of the waist garnish 50 is sandwiched and fixed between the resin rib 32 and the winding white 35, and the welding boss 34a is By integrating with the winding scissor 35, it becomes an anchor structure, which makes it possible to hold it more firmly and the like, while simplifying the structure and ensuring a reliable mounting strength. The bending operation of 90 ° is sufficient, and the operation of the winding mechanism 83 is only the advance / retreat cylinder 83b, so that the winding operation of the winding roller 35 can be simplified.

  The embodiment described above is a type in which the door trim upper 20A and the door trim lower 20B are joined, and the structure of the laminated structure according to the present invention is adopted in the door trim upper / front 30 in which the door trim upper 20A is divided into the front and the rear. In addition, although applied to a structure in which separate parts such as the waist garnish 50 are easily and inexpensively attached, the laminated structure is applied to the entire door trim upper 20A, or an integrated door trim or an interior part other than the door trim, for example, a rear The structure of the present invention and the method of the present invention can be applied to all interior trims such as parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims and the like.

It is a front view which shows the door trim for motor vehicles which applied the structure of the interior component for motor vehicles based on this invention. It is a front view which shows the door trim upper in the door trim for motor vehicles shown in FIG. FIG. 3 is a sectional view taken along line III-III in FIG. 2. It is the IV-IV sectional view taken on the line in FIG. It is explanatory drawing which shows the whole structure of the shaping die used in order to shape | mold the door trim upper front shown in FIG. It is explanatory drawing which shows the setting process of the raw material in the molding method of the door trim upper front shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material in the molding method of the door trim upper front shown in FIG. It is explanatory drawing which shows the molding process of the resin rib in the molding method of the door trim upper front shown in FIG. It is explanatory drawing which shows the state which sets a waist garnish to the door trim upper front shown in FIG. It is explanatory drawing which shows the state which waist garnish is boss-welded and fixed to the door trim upper front shown in FIG. It is explanatory drawing which shows the whole terminal processing apparatus which performs the terminal process of the door trim upper front shown in FIG. It is explanatory drawing which shows the process of heat-softening the winding trim of a door trim upper front using the terminal processing apparatus shown in FIG. It is explanatory drawing which shows the process of winding-in process the door trim upper front wind-up white using the terminal processing apparatus shown in FIG. It is explanatory drawing which shows the process of winding-in process the door trim upper front wind-up white using the terminal processing apparatus shown in FIG. It is sectional drawing which shows the state which attached the waist garnish which changed the shape to the door trim upper front shown in FIG. It is explanatory drawing which shows the state which sets the door trim upper front and waist garnish shown in FIG. 15 to a welding jig. It is explanatory drawing which shows the welding fixation state of the door trim upper front shown in FIG. 15, and a waist garnish. It is explanatory drawing which shows the terminal processing apparatus which performs the terminal process of the door trim upper front shown in FIG. It is explanatory drawing which shows the heating softening state of the winding white in the door trim upper front shown in FIG. It is explanatory drawing which shows the winding process process of the winding white in the door trim upper front shown in FIG. It is a front view which shows the conventional door trim for motor vehicles. FIG. 22 is a sectional view taken along line XXII-XXII in FIG. 21. It is explanatory drawing which shows the whole structure of the shaping die which shape | molds the conventional door trim. It is a front view showing a conventional lightweight automobile door trim. FIG. 25 is a sectional view taken along line XXV-XXV in FIG. 24. It is sectional drawing which shows the state which carried out the boss welding fixation of the separate part to the conventional lightweight vehicle door trim. It is sectional drawing which shows the state which bonded and fixed another component to the conventional lightweight type | mold automobile door trim with the hot-melt-type adhesive agent.

Explanation of symbols

20 Automotive Door Trim 20A Door Trim Upper 20B Door Trim Lower 30 Door Trim Upper / Front 31 Foam Resin Base Material 32 Resin Rib 33 Skin 34 Welding Boss 35 Roll-in White 40 Door Trim Upper / Rear 50 West Garnish 50a Upper Terminal 51, 51a, 51b Boss Hole 60 Molding die 61 Molding upper die 612 Lifting cylinder 62 Molding lower die 622 Manifold 623 Gate 624 Groove 63 Injection machine 70 Caulking device 71 Welding jig 72 Ultrasonic horn 80 Terminal processing device 81 Set jig 81a Set stand 81b Spacer 81c Receiving jig holder 82 Heating jig 82a Heater 82b Heater support 82c Cylinder for driving 83 Rolling mechanism 83a Rolling piece 83b Cylinder 83b for advance / retreat 83c Table 8 d vertically moving action cylinder M molten resin S foamed resin sheet

Claims (3)

A foamed resin base material (31) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (32) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (31). In the interior part (20) for an automobile formed by using the laminated structure (30) in whole or in part,
The foamed resin base material (31) in the laminated structure (30) is press-molded between the upper and lower molds (61, 62), and the resin rib is integrated with the back surface of the foamed resin base material (31). (32) is molded by injecting molten resin (M) into the groove (624) of the molded lower mold (62), and further on the back side of the foamed resin base material (31) and the resin rib (32). A separate part (50) is arranged, and a terminal portion (50a) of the separate part (50) is wound and supported by a winding ring (35) of a peripheral end in the laminated structure (30) .
In addition to winding and supporting the terminal portion (50a) of the separate part (50), the winding sill (35) in the laminated structure (30) is inserted into the boss hole (51) of the separate part (50). An interior part for an automobile, characterized in that it is integrally welded and fixed to the distal end surface of the welded boss (34a) and the side surface of a separate component (50) . A foamed resin base material (31) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (32) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (31). In the manufacturing method of the interior part (20) for automobiles, wherein the laminated structure (30) is adopted in whole or in part,
The laminated structure (30) is obtained by heat-softening the foamed resin sheet (S), which is the material of the foamed resin base material (31), and then charging it into the molding dies (61, 62). 61, 62), the foamed resin base material (31) is press-molded into a required shape, and after the molding die (61, 62) is clamped, the groove portion (624) of the molded lower die (62). The molten resin (M) is injected and filled therein, and a resin rib (32) having a predetermined pattern shape is integrally formed on the back surface side of the foamed resin base material (31). Thereafter, the molding dies (61, 62) are molded. After removing the laminated structure (30) from the mold, a separate part (50) is arranged on the back side of the laminated structure (30), and the welding boss (34) integrated with the resin rib (32) is separated. After inserting into the boss hole (51) of the component (50), the welding boss (34) is caulked. Thus, a separate part (50) is integrated at a predetermined position on the back side of the foamed resin base material (31) and the resin rib (32), and then the winding white set on the peripheral end portion of the laminated structure (30). After heat-softening the back surface side of (35) with the heating jig (82) in the terminal processing apparatus (80), separate parts (50) are obtained by advancing and retracting the winding mechanism (83) in the terminal processing apparatus (80). And a terminal part (50a) of a separate part (50) is added by a bending operation of the winding scissors (35) so as to wrap the terminal part (50a) of Of manufacturing interior parts for automobiles. In the terminal processing step of the winding scissors (35) set at the peripheral edge of the laminated structure (30), the terminal portion (50a) of the separate part (50) extends in the direction perpendicular to the back surface of the laminated structure (30). It is arranged and is welded and fixed to the separate part (50) by bending the winding scissors (35) by approximately 90 °, and the front end surface of the welding boss (34a) and the side surface of the separate part (50) The method of manufacturing an interior part for an automobile according to claim 2 , wherein both of these are integrally welded to the winding sill (35).

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