JP5714333B2 - Method for manufacturing vehicle interior member - Google Patents

Method for manufacturing vehicle interior member Download PDF

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JP5714333B2
JP5714333B2 JP2011000778A JP2011000778A JP5714333B2 JP 5714333 B2 JP5714333 B2 JP 5714333B2 JP 2011000778 A JP2011000778 A JP 2011000778A JP 2011000778 A JP2011000778 A JP 2011000778A JP 5714333 B2 JP5714333 B2 JP 5714333B2
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base material
foam
mold
molding die
cavity
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JP2012139967A (en
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健嗣 棚橋
健嗣 棚橋
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Inoac Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/58—Moulds
    • B29C44/586—Moulds with a cavity increasing in size during foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1219—Foaming between a movable mould part and the preformed part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3008—Instrument panels

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  • Injection Moulding Of Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)

Description

この発明は、一面に突出形成された突条部を有する基材と、該基材における突条部が設けられた位置を該突条部の先端部を除いて覆う発泡体とを備えた車両内装部材の製造方法に関するものである。 The present invention includes a vehicle including a base material having a protrusion formed on one surface and a foam covering a position where the protrusion is provided on the base member excluding a tip portion of the protrusion. The present invention relates to a method for manufacturing an interior member.

色や硬さ等の物性が異なる合成樹脂を積層して構成される複層部材が、例えばテープレコーダーの操作ボタンなどに用いられている(例えば、特許文献１参照)。図８(ｄ)に示すように、操作ボタン１００は、上面に突起１０２ａが設けられた第１の樹脂成形体１０２と、第１の樹脂成形体１０２の突起１０２ａ以外の上面を被覆する第２の樹脂成形体１０４とから構成され、第２の樹脂成形体１０４の上面が突起１０２ａの上端面と揃うようになっている。そして、操作ボタン１００では、第２の樹脂成形体１０４に囲われて上面に露出する突起１０２ａの上端面が、例えば巻き戻しモード表示マーク等の所定の意匠形状に形成されている。このような、複層部材は、所謂二色成形法によって成形される。   A multi-layer member formed by laminating synthetic resins having different physical properties such as color and hardness is used for an operation button of a tape recorder, for example (see, for example, Patent Document 1). As shown in FIG. 8D, the operation button 100 includes a first resin molded body 102 having a protrusion 102a on the upper surface, and a second surface that covers the upper surface of the first resin molded body 102 other than the protrusion 102a. The upper surface of the second resin molded body 104 is aligned with the upper end surface of the protrusion 102a. In the operation button 100, the upper end surface of the protrusion 102a that is surrounded by the second resin molded body 104 and exposed on the upper surface is formed in a predetermined design shape such as a rewind mode display mark. Such a multilayer member is molded by a so-called two-color molding method.

二色成形による操作ボタン１００の製造方法を説明すると、図８(ａ)に示すように、第１の金型１１０と突起１０２ａに合わせた凹部を有する第２の金型１１２とにより画成される第１のキャビティ１１４に第１の樹脂原料を注入して、第１の樹脂成形体１０２を形成する。図８(ｂ)に示すように、第２の金型１１２を取り外し、第１の樹脂成形体１０２を保持した第１の金型１１０に対して、第３の金型１１６を第１の樹脂成形体１０２の突起１０２ａの上端面に突き当てて接合する。図８(ｃ)に示すように、第１の樹脂成形体１０２の上面と第３の金型１１６との間に画成される第２のキャビティ１１８に対して第２の樹脂原料を注入して、第２の樹脂成形体１０４を突起１０２ａの上端面が露出するように第１の樹脂成形体１０２の上面に形成する。   The manufacturing method of the operation button 100 by two-color molding will be described. As shown in FIG. 8A, the operation button 100 is defined by a first mold 110 and a second mold 112 having a concave portion matched with the protrusion 102a. The first resin raw material is injected into the first cavity 114 to form the first resin molded body 102. As shown in FIG. 8B, the second mold 112 is removed, and the third mold 116 is replaced with the first resin with respect to the first mold 110 holding the first resin molded body 102. It abuts and joins the upper end surface of the protrusion 102a of the molded body 102. As shown in FIG. 8C, the second resin material is injected into the second cavity 118 defined between the upper surface of the first resin molded body 102 and the third mold 116. Then, the second resin molded body 104 is formed on the upper surface of the first resin molded body 102 so that the upper end surface of the protrusion 102a is exposed.

特開昭６０−１８４８１９号公報JP 60-184819 A

前述した製造方法では、夫々の樹脂成形体１０２,１０４に合わせて、片方の金型１１２,１１６を取り替える必要があり、第１の金型１１０および第２の金型１１２の組と、第１の金型１１０および第３の金型１１６の組との２組が使用される。従って、金型代が嵩むと共に、金型１１２,１１４を取り替える手間がかかり、製造効率を上げるのが難しい。しかも、突起１０２ａの上端面を第２の樹脂成形体１０４で覆わないようするために、第３の金型１１６を先に成形した樹脂成形体１０２の突起１０２ａの上端面に突き当てて該上端面を塞ぐ必要がある。このため、突起１０２ａの上端面に凹凸等の模様を形成すると、第２のキャビティ１１８の封止がうまくできず、第２の樹脂成形体１０４が突起１０２ａの上端面にはみ出したり、突き当てた第３の金型１１６によって模様が潰れてしまったりする問題が指摘される。   In the manufacturing method described above, it is necessary to replace one mold 112, 116 in accordance with the respective resin molded bodies 102, 104. The first mold 110 and the second mold 112, and the first mold Two sets of the mold 110 and the third mold 116 are used. Therefore, the mold cost increases, and it takes time and labor to replace the molds 112 and 114, and it is difficult to increase the production efficiency. In addition, in order not to cover the upper end surface of the protrusion 102a with the second resin molded body 104, the third mold 116 is abutted against the upper end surface of the protrusion 102a of the resin molded body 102 that has been previously molded. It is necessary to close the end face. For this reason, if a pattern such as an unevenness is formed on the upper end surface of the protrusion 102a, the second cavity 118 cannot be sealed well, and the second resin molded body 104 protrudes or hits the upper end surface of the protrusion 102a. A problem that the pattern is crushed by the third mold 116 is pointed out.

すなわち本発明は、従来の技術に係る製造方法に内在する前記問題に鑑み、これらを好適に解決するべく提案されたものであって、１組の成形型で車両内装部材を効率よく成形し得る車両内装部材の製造方法を提供することを目的とする。 That is, the present invention has been made in view of the problems inherent in engagement Ru Manufacturing method of the conventional art, which has been proposed to solve these suitably, efficiently forming a vehicle interior member in a pair of mold An object of the present invention is to provide a method for manufacturing a vehicle interior member.

前記課題を克服し、所期の目的を達成するため、本願の請求項１に係る発明の車両内装部材の製造方法は、
一面に突出すると共に互いに離間して所定ラインに沿って並ぶように形成された複数の突条部を有する基材と、この基材における突条部が設けられた一面を該突条部の先端部を除いて覆う発泡体とを備え、発泡体から露出する複数の突条部の先端部によって擬似的なステッチ模様を形成する車両内装部材の製造方法であって、
前記突条部の夫々に合わせて設けられて、閉塞端に該突条部の先端部に糸目模様を付ける凹凸が形成された凹溝部を有する第１成形型と、第２成形型との間に、前記基材の外形に合わせた第１のキャビティを画成し、
前記第１のキャビティに樹脂原料を注入することで、先端部に糸目模様が施された複数の突条部を形成した基材を成形し、
前記突条部における先端部側の一部を前記凹溝部に挿入して該突条部により凹溝部を塞いだ状態を保つように、第１成形型および第２成形型を該突条部の突出方向に沿って相対的に離間する第１のコアバックを行うことで、前記基材と第１成形型との間に第２のキャビティを画成し、
前記第２のキャビティに発泡樹脂原料を注入し、
前記突条部における先端部側の一部を前記凹溝部に挿入して該突条部により凹溝部を塞いだ状態を保つように、前記第１成形型および第２成形型を前記突条部の突出方向に沿って相対的に離間する第２のコアバックを行い、前記第２のキャビティを広げた第３のキャビティを画成することで、発泡樹脂原料を発泡膨張させて、突条部の先端部に施した糸目模様が露出するように該突条部の周りを囲うと共に前記基材の一面を覆って前記発泡体を成形するようにしたことを要旨とする。
請求項１に係る発明によれば、１組の成形型を用いるだけで、基材と発泡体とからなる車両内装部材を簡単に成形することができる。また、同じ成形型をコアバックすることで基材および発泡体を成形しているので、基材に設けた突条部の先端面に凹凸等の模様を施しても当該模様が発泡体の成形に際して潰されたりすることを回避できる。
基材の突条部を形成する第１成形型の凹溝部が、コアバックしても突条部で塞がれているので、基材の突条部を発泡体で覆うことなく車両内装部材の表面に適切に臨ませることができる。また、基材に設けた突条部の先端面に凹凸等の模様を施しても、第１成形型の凹溝部に挿入された突条部の先端面が成形面から離れているので、発泡体の成形に際して当該模様が潰されたりすることを回避できる。 In order to overcome the above-mentioned problems and achieve the intended purpose, a method for manufacturing a vehicle interior member according to claim 1 of the present application is as follows.
A base material having a plurality of ridges formed so as to protrude on one surface and be spaced apart from each other and aligned along a predetermined line, and the one surface provided with the ridge portions on the base material at the tip of the ridge portion A vehicle interior member for forming a pseudo stitch pattern by the tip portions of a plurality of protrusions exposed from the foam .
Provided in accordance with the each of the protrusions, a first mold having a concave groove which irregularities are formed to give a fine line pattern at the tip portion of the protruding strip portion the closed end, between the second mold And defining a first cavity adapted to the outer shape of the substrate,
By injecting a resin raw material into the first cavity, a base material formed with a plurality of protrusions with a thread pattern on the tip is formed ,
A part of the tip side of the projecting portion so as to maintain the state of closing the concave groove portion by the projecting strip portion is inserted into the groove portion, a projecting streak portion first mold and a second mold By performing a first core back relatively spaced along the protruding direction, a second cavity is defined between the base material and the first mold,
Injecting a foamed resin material into the second cavity,
The first molding die and the second molding die are placed on the projecting portion so that a part of the projecting portion on the front end side is inserted into the recessed groove portion and the recessed groove portion is closed by the projecting portion. The second core back relatively spaced along the projecting direction of the first is performed, and the third cavity is defined by expanding the second cavity, so that the foamed resin material is expanded and expanded . The gist of the invention is that the foam is molded so as to surround the protruding portion and to cover one surface of the base material so that the thread pattern applied to the tip portion of the base material is exposed .
According to the first aspect of the present invention, a vehicle interior member composed of a base material and a foam can be easily formed by using only one set of molds. In addition, since the base and the foam are molded by core-backing the same mold, even if a pattern such as irregularities is formed on the tip surface of the protrusion provided on the base, the pattern is molded into the foam. It is possible to avoid being crushed at the time.
Since the groove portion of the first mold that forms the base ridge is covered with the ridge even if the core is backed, the vehicle interior member without covering the base ridge with foam. Can be properly exposed to the surface. Moreover, even if a pattern such as irregularities is formed on the tip surface of the ridge portion provided on the base material, the tip surface of the ridge portion inserted into the concave groove portion of the first mold is separated from the molding surface, so foaming It is possible to avoid the pattern from being crushed when the body is molded.

請求項２に係る発明では、前記第１成形型において前記第２成形型側に膨らむように形成された前記凹溝部の開口縁によって、前記発泡体を前記突条部の周りで凹むように成形することを要旨とする。
請求項３に係る発明では、前記第１成形型において前記第２成形型側に膨らむように形成された前記凹溝部の開口縁によって、前記基材の一面を前記突条部の周りで凹むように成形すると共に、該基材の根元部分および一面側の凹みに対応して凹むように形成された第２成形型によって、基材における前記一面と反対面を、該基材の根元部分および一面側の凹みに対応して膨らむように成形することを要旨とする。 In the invention according to claim 2, the foam is molded so as to be recessed around the ridge portion by the opening edge of the concave groove portion formed so as to swell toward the second molding die side in the first molding die. The gist is to do .
In the invention according to claim 3, the one surface of the base material is recessed around the ridge portion by the opening edge of the concave groove portion formed so as to swell toward the second molding die side in the first molding die. And the second molding die formed so as to be recessed corresponding to the base portion of the base material and the recess on the one surface side, the surface opposite to the one surface of the base material is made the base portion and one surface of the base material. The gist is to form it so as to swell corresponding to the recess on the side.

請求項４に係る発明では、前記第２のコアバックは、前記発泡樹脂原料の表面にスキン層が形成された段階で行われることを要旨とする。
請求項４に係る発明によれば、発泡樹脂原料の表面にスキン層が形成された段階で第２のコアバックを行うことで、該発泡樹脂原料の漏出を防止しつつ発泡膨張させることができる。 The gist of the invention according to claim 4 is that the second core back is performed at a stage where a skin layer is formed on the surface of the foamed resin material.
According to the invention according to claim 4 , by performing the second core back when the skin layer is formed on the surface of the foamed resin raw material, the foamed resin raw material can be foamed and expanded while preventing leakage of the foamed resin raw material. .

本発明に係る車両内装部材の製造方法によれば、１組の成形型で車両内装部材を効率よく成形し得る。 According to the manufacturing method for a vehicle interior member according to the present invention may be molded efficiently vehicle interior member of a set of molds.

本発明の好適な実施例に係る製造方法によって得られたパネル部材を備えたインストルメントパネルを示す概略斜視図である。It is a schematic perspective view which shows the instrument panel provided with the panel member obtained by the manufacturing method which concerns on the suitable Example of this invention. 図１のＡ−Ａ線断面図である。It is the sectional view on the AA line of FIG. 実施例のパネル部材の要部を破断して示す概略斜視図である。It is a schematic perspective view which fractures | ruptures and shows the principal part of the panel member of an Example. 図３のＢ−Ｂ線断面図である。FIG. 4 is a sectional view taken along line BB in FIG. 3. 図３のＣ−Ｃ線断面図である。It is CC sectional view taken on the line of FIG. 実施例の製造方法における基材成形工程を示す説明断面図であって、(ａ)は第１成形型および第２成形型で第１のキャビティを画成した状態を示し、(ｂ)は第１のキャビティに樹脂原料を注入した状態を示し、(ｃ)は第１のキャビティで基材を成形した状態を示す。It is explanatory sectional drawing which shows the base-material formation process in the manufacturing method of an Example, (a) shows the state which defined the 1st cavity with the 1st shaping | molding die and the 2nd shaping | molding die, (b) is the 1st. A state in which a resin raw material is injected into one cavity is shown, and (c) shows a state in which a base material is molded in the first cavity. 実施例の製造方法における発泡体成形工程を示す説明断面図であって、(ａ)は第１のコアバックを行って第２のキャビティを画成した状態を示し、(ｂ)は第２のキャビティに発泡樹脂原料を注入した状態を示し、(ｃ)は発泡樹脂原料の表面にスキン層が形成された状態を強調して示し、(ｄ)は第２のコアバックを行って発泡体を発泡成形した状態を示し、(ｅ)はパネル部材を成形型から取り出した状態を示す。It is explanatory sectional drawing which shows the foam formation process in the manufacturing method of an Example, (a) shows the state which performed the 1st core back and defined the 2nd cavity, (b) showed 2nd (C) highlights the state in which a skin layer is formed on the surface of the foamed resin raw material, and (d) shows a state in which the foam is obtained by performing a second core back. FIG. 5E shows a state where foam molding is performed, and FIG. 5E shows a state where the panel member is taken out from the mold. 従来の複層部材の製造工程を示す説明断面図であって、(ａ)は第１の金型と第２の金型とによって第１の樹脂成形体を成形する状況を示し、(ｂ)は第２金型を取り外して第３の金型をセットする状況を示し、(ｃ)は第１の金型と第３の金型とによって第２の樹脂成形体を成形する状況を示し、(ｄ)は得られた複層部材を示す。It is explanatory sectional drawing which shows the manufacturing process of the conventional multilayer member, Comprising: (a) shows the condition which shape | molds a 1st resin molded object with a 1st metal mold | die and a 2nd metal mold | die, (b) Shows the situation where the second mold is removed and the third mold is set, (c) shows the situation where the second resin molded body is molded by the first mold and the third mold, (d) shows the obtained multilayer member.

次に、本発明に係る車両内装部材の製造方法につき、好適な実施例を挙げて、添付図面を参照して以下に説明する。なお、実施例では、車両の乗員室の前側に設置されるインストルメントパネルを例として挙げて説明する。 Next, a method for manufacturing a vehicle interior member according to the present invention will be described below with reference to the accompanying drawings with a preferred embodiment. In the embodiment, an instrument panel installed on the front side of the passenger compartment of the vehicle will be described as an example.

図１または図２に示すように、実施例のインストルメントパネル１０は、上部本体２０と下部本体１８とを上下に組み付けて、フロントウインドウから前部座席の前側にかけて延在する所要の意匠形状に構成されている。実施例の下部本体１８は、合成樹脂製の成形部材からなる板部材を主体とした単層構造であって、主に前部座席の前側下部を構成している。   As shown in FIG. 1 or FIG. 2, the instrument panel 10 according to the embodiment has an upper body 20 and a lower body 18 that are vertically assembled to have a required design shape that extends from the front window to the front side of the front seat. It is configured. The lower main body 18 of the embodiment has a single-layer structure mainly composed of a plate member made of a synthetic resin molded member, and mainly constitutes the front lower portion of the front seat.

前記上部本体２０は、図２に示すように、下部本体１８の上部に連結されると共にフロントウインドウの下部に突き合わせられる本体部材２２と、この本体部材２２に組み付けられた複層部材としてのパネル部材３０とから構成される。本体部材２２は、図２に示すように、基盤となるベース材２４と、このベース材２４の後側(乗員席側)上面に設けられた後側加飾部２６と、ベース材２４の前側(フロントウインドウ側)上面に設けられた前側加飾部２８とを備えている。また、本体部材２２には、ベース材２４における後側加飾部２６と前側加飾部２８との間に設置部２２ａが設けられ、この設置部２２ａに対してパネル部材３０が前後の加飾部２６,２８に挟まれて取り付けられる。後側加飾部２６は、外方に露出して表面をなすＴＰＯ(オレフィン系エラストマー)等の柔軟な表皮材２６ａと、この表皮材２６ａおよびベース材２４の間に設けられ、弾力性を有するウレタン等のフォーム体２６ｂとから構成され、本体部材２２の後側部分は、ベース材２４、フォーム体２６ｂおよび表皮材２６ａからなる３層構造になっている。一方、前側加飾部２８は、外方に露出して表面をなすＴＰＯ(オレフィン系エラストマー)等の柔軟な表皮材のみから構成され、本体部材２２の前側部分が、ベース材２４および表皮材としての前側加飾部２８からなる２層構造になっている。   As shown in FIG. 2, the upper main body 20 is connected to the upper portion of the lower main body 18 and is abutted against the lower portion of the front window, and a panel member as a multilayer member assembled to the main body member 22. 30. As shown in FIG. 2, the main body member 22 includes a base material 24 serving as a base, a rear decoration portion 26 provided on the upper surface of the rear side (passenger seat side) of the base material 24, and the front side of the base material 24. (Front window side) The front decoration part 28 provided in the upper surface is provided. Further, the main body member 22 is provided with an installation portion 22a between the rear decoration portion 26 and the front decoration portion 28 in the base material 24, and the panel member 30 is provided with front and rear decorations with respect to the installation portion 22a. It is sandwiched between the parts 26 and 28 and attached. The rear decoration portion 26 is provided between a flexible skin material 26a such as TPO (olefin elastomer) which is exposed to the outside and forms a surface, and the skin material 26a and the base material 24, and has elasticity. It is comprised from foam bodies 26b, such as urethane, and the rear side part of the main body member 22 has a three-layer structure comprising the base material 24, the foam body 26b, and the skin material 26a. On the other hand, the front decoration portion 28 is composed only of a flexible skin material such as TPO (olefin elastomer) that is exposed to the outside and forms the surface, and the front side portion of the main body member 22 serves as the base material 24 and the skin material. It has a two-layer structure consisting of the front side decorative portion 28.

図２または図３に示すように、実施例のパネル部材３０は、基材３２と、この基材３２の乗員室側となる一面(以下、表面という)を覆う発泡体３６とから構成された２層構造になっている。また、パネル部材３０は、基材３２の表面に突出形成された突条部３４が該パネル部材３０の表面を構成する発泡体３６の間から外方に露出するように形成されている。ここで、パネル部材３０では、複数の突条部３４が該パネル部材３０の外縁等の所定ラインに沿って並ぶように設けられ、複数の突条部３４が発泡体３６をあたかも糸で縫製したような疑似ステッチを構成するようになっている(図１参照)。   As shown in FIG. 2 or FIG. 3, the panel member 30 of the example is composed of a base material 32 and a foam 36 that covers one surface (hereinafter referred to as a surface) of the base material 32 on the passenger compartment side. It has a two-layer structure. In addition, the panel member 30 is formed such that the protruding portion 34 that protrudes from the surface of the base member 32 is exposed outward from between the foams 36 that constitute the surface of the panel member 30. Here, in the panel member 30, a plurality of protrusions 34 are provided so as to be arranged along a predetermined line such as an outer edge of the panel member 30, and the plurality of protrusions 34 sew the foam 36 as if with a thread. Such pseudo stitches are configured (see FIG. 1).

前記基材３２は、パネル部材３０の形状を維持し得る剛性を有する硬質な合成樹脂の板状体であって、ポリプロピレン(ＰＰ)やポリエチレン(ＰＥ)等の合成樹脂からインジェクション成形等により所定形状に形成されている。実施例の基材３２には、本体部材２２の後側加飾部２６に突き当てられる後縁に沿って突条部３４が複数設けられている(図１参照)。複数の突条部３４は、先端３４ａの長手辺が所定ラインに沿って並ぶように、互いに離間して配置されている(図３または図４参照)。各突条部３４は、基材３２の表面から突出するよう形成された小突起であって、先端の角が円弧状に面取りされた形状になっている。突条部３４は、先端３４ａの面取り部分を除いて向かい合う面が平行に形成されており、根元部分から面取り部分の下端にかけて横断面形状が同じになるよう構成されている(図４または図６(ｃ)参照)。なお、各突条部３４においてパネル部材３０の表面に露出する先端３４ａには、斜めに延在する細かい凹凸によって糸目模様(図示せず)が施されている。また、実施例の基材３２は、表面側が突条部３４の根元部分で凹むように形成される一方、裏面側が突条部３４の根元部分および当該凹みに対応して膨らむように形成されている(図３参照)。   The substrate 32 is a hard synthetic resin plate having rigidity capable of maintaining the shape of the panel member 30, and is formed from a synthetic resin such as polypropylene (PP) or polyethylene (PE) by injection molding or the like. Is formed. The base material 32 of the embodiment is provided with a plurality of ridges 34 along the rear edge that abuts against the rear decoration portion 26 of the main body member 22 (see FIG. 1). The plurality of ridges 34 are spaced apart from each other so that the long sides of the tips 34a are aligned along a predetermined line (see FIG. 3 or FIG. 4). Each protrusion 34 is a small protrusion formed so as to protrude from the surface of the base material 32, and has a shape in which a corner of the tip is chamfered in an arc shape. The protrusions 34 are formed so that the surfaces facing each other except the chamfered portion of the tip 34a are formed in parallel, and the cross-sectional shape is the same from the root portion to the lower end of the chamfered portion (FIG. 4 or FIG. 6). (See (c)). A thread pattern (not shown) is formed on the tip 34a exposed on the surface of the panel member 30 in each protrusion 34 by fine unevenness extending diagonally. Further, the base material 32 of the embodiment is formed so that the front surface side is recessed at the root portion of the ridge portion 34, while the back surface side is formed so as to swell corresponding to the root portion of the ridge portion 34 and the recess. (See FIG. 3).

前記発泡体３６は、パネル部材３０の表面を構成する部材であって、例えばＴＰＯ(オレフィン系エラストマ)やスチレン係エラストマに対して化学発泡剤や超臨界の不活性ガスを混入した発泡樹脂原料から、コアバッグによる射出発泡成形を行うことで形成される。   The foam 36 is a member constituting the surface of the panel member 30, for example, from a foamed resin raw material in which a chemical foaming agent or a supercritical inert gas is mixed with TPO (olefin-based elastomer) or styrene-based elastomer. It is formed by performing injection foam molding with a core bag.

前記発泡体３６は、突条部３４の先端３４ａがパネル部材３０の表面側に露出するように該突条部３４の周りを囲うように設けられる(図３参照)。また、発泡体３６は、突条部３４の周りが凹むように形成され、この発泡体凹部３６ａによって縫い目を構成する突条部３４によって発泡体３６の表面があたかも押し込んでいるように形成されている。ここで、発泡体３６では、発泡体凹部３６ａが突条部３４に近づくにつれてなだらかに湾曲するように沈み込み、発泡体凹部３６ａの下縁が突条部３４の面取り部分の下端より僅かに下側に揃うようになっている。また、実施例のパネル部材３０では、発泡体３６における発泡体凹部３６ａの上縁に連なる表面が突条部３４の先端３４ａより僅かに上方に位置している(図４または図５参照)。   The foam 36 is provided so as to surround the protrusion 34 so that the tip 34a of the protrusion 34 is exposed on the surface side of the panel member 30 (see FIG. 3). The foam 36 is formed so that the periphery of the protrusion 34 is recessed, and the foam 36 is formed so that the surface of the foam 36 is pushed in by the protrusion 34 constituting the seam by the foam recess 36a. Yes. Here, in the foam 36, the foam recess 36 a sinks so as to be gently curved as it approaches the protrusion 34, and the lower edge of the foam recess 36 a is slightly below the lower end of the chamfered portion of the protrusion 34. It comes to be aligned to the side. Moreover, in the panel member 30 of an Example, the surface which continues to the upper edge of the foam recessed part 36a in the foam 36 is located slightly above the front-end | tip 34a of the protrusion part 34 (refer FIG. 4 or FIG. 5).

次に、実施例に係る複層部材としてのパネル部材３０の製造方法について説明する。実施例では、基材３２の表面側に対応した成形面を有する第１成形型４０と、基材３２の裏面側に対応した第２成形型４２とを備える型設備による型成形によって、前記パネル部材３０が成形される(図６または図７参照)。第１成形型４０は、基材３２の表面に突設する突条部３４に合わせた凹溝部４０ａを有しており、凹溝部４０ａの閉塞端に突条部３４の先端３４ａに糸目模様を転写する凹凸が設けられている。また、第１成形型４０は、凹溝部４０ａの開口縁が第２成形型４２側に膨らむように形成されて、得られるパネル部材３０は、発泡体３６が突条部３４の周りで凹むように形成される。ここで、実施例の型設備は、第２成形型４２に対して第１成形型４０が進退移動するよう構成され、第１成形型４０が該第１成形型４０に設けられた凹溝部４０ａの延在方向(凹溝部４０ａの深さ方向)に沿って直線的に移動するようになっている。   Next, the manufacturing method of the panel member 30 as a multilayer member which concerns on an Example is demonstrated. In the embodiment, the panel is formed by molding by a mold facility including a first molding die 40 having a molding surface corresponding to the front surface side of the base material 32 and a second molding die 42 corresponding to the back surface side of the base material 32. The member 30 is molded (see FIG. 6 or 7). The first molding die 40 has a concave groove portion 40a that is aligned with the ridge portion 34 protruding from the surface of the substrate 32, and a thread pattern is formed on the tip end 34a of the ridge portion 34 at the closed end of the concave groove portion 40a. Irregularities to be transferred are provided. Further, the first molding die 40 is formed such that the opening edge of the concave groove portion 40 a swells toward the second molding die 42, and the obtained panel member 30 is such that the foam 36 is recessed around the protrusion 34. Formed. Here, the mold equipment of the embodiment is configured such that the first molding die 40 moves forward and backward relative to the second molding die 42, and the first molding die 40 is provided in the first molding die 40. It moves linearly along the extending direction (the depth direction of the groove 40a).

先ず、基材３２を成形する基材成形工程が行われる。図６(ａ)に示すように、第１成形型４０および第２成形型４２を最も近接させた状態になるよう型閉めすることで、突条部３４を含めた基材３２の外形形状と同じ第１のキャビティ４４が画成される。この第１のキャビティ４４に基材３２の素になる樹脂原料４５を注入する(図６(ｂ)参照)。そして、樹脂原料４５を第１のキャビティ４４内で硬化させることで、第１のキャビティ４４で基材３２が成形される(図６(ｃ)参照)。実施例の基材成形工程では、加熱により流動化した樹脂原料４５を圧力をかけつつ第１のキャビティ４４に対して注入する射出成形法によって基材３２が成形される。   First, a base material forming step for forming the base material 32 is performed. As shown in FIG. 6 (a), by closing the mold so that the first molding die 40 and the second molding die 42 are brought closest to each other, The same first cavity 44 is defined. A resin material 45 to be a base material of the base material 32 is injected into the first cavity 44 (see FIG. 6B). And the base material 32 is shape | molded by the 1st cavity 44 by hardening the resin raw material 45 in the 1st cavity 44 (refer FIG.6 (c)). In the base material molding step of the embodiment, the base material 32 is molded by an injection molding method in which the resin raw material 45 fluidized by heating is injected into the first cavity 44 while applying pressure.

次に、発泡樹脂原料４７(図７(ｂ)参照)を注入する発泡体一次成形工程が行われる。発泡体一次成形工程では、基材３２の突条部３４の一部が第１成形型４０の凹溝部４０ａに挿入された状態を保つように、第１成形型４０および第２成形型４２を突条部３４の突出方向に沿って相対的に離間する第１のコアバックを行う(図７(ａ)参照)。すなわち、型設備では、第１成形型４０を第２成形型４２から離すように突条部３４に沿って直線的に移動させることで、基材３２の表面と第１成形型４０の成形面との間に発泡体３６の厚みより小さい第２のキャビティ４６を画成する。ここで、突条部３４の２／３程度が凹溝部４０ａから抜け出る(突条部３４の１／３程度が凹溝部４０ａに残った状態)まで、第１成形型４０が第１のコアバックをするように設定され、凹溝部４０ａが該凹溝部４０ａに嵌り込んだ突条部３４によって塞がれている(図７(ａ)参照)。第１のコアバック量は、突条部３４の突出寸法の範囲内で発泡体３６の発泡倍率等に応じて適宜調節されるが、凹溝部４０ａが突条部３４で塞がれた状態を必ず維持するように設定される。   Next, a foam primary molding step for injecting the foamed resin raw material 47 (see FIG. 7B) is performed. In the foam primary molding step, the first molding die 40 and the second molding die 42 are kept so that a part of the protruding portion 34 of the base material 32 is inserted into the concave groove portion 40a of the first molding die 40. A first core back that is relatively spaced along the protruding direction of the protrusion 34 is performed (see FIG. 7A). That is, in the mold facility, the surface of the substrate 32 and the molding surface of the first molding die 40 are moved linearly along the protrusion 34 so as to separate the first molding die 40 from the second molding die 42. A second cavity 46 smaller than the thickness of the foam 36 is defined therebetween. Here, until about 2/3 of the protruding portion 34 comes out of the recessed groove portion 40a (a state in which about 1/3 of the protruding portion 34 remains in the recessed groove portion 40a), the first molding die 40 is the first core back. The concave groove portion 40a is closed by the protrusion 34 fitted in the concave groove portion 40a (see FIG. 7A). The first core back amount is appropriately adjusted in accordance with the expansion ratio of the foam 36 within the range of the projecting dimension of the protrusion 34, but the state where the groove 40a is blocked by the protrusion 34 is shown. It is set to be maintained.

第２のキャビティ４６に対して発泡体３６の素になる発泡樹脂原料４７を注入する(図７(ｂ)参照)。ここで、発泡樹脂原料４７は、第２のキャビティ４６を満たす量が充填され、発泡体一次成形工程では、基材３２や第１成形型４０に接触する発泡樹脂原料４７の表面にスキン層５０が形成されるまで当該状態が維持される(図７(ｃ)参照)。このように、発泡体一次成形工程では、第１のコアバックを行って第２のキャビティ４６を画成しても凹溝部４０ａを突条部３４で塞いでいるので、凹溝部４０ａに発泡樹脂原料４７が流入することがなく、突条部３４の先端３４ａが発泡体３６で被覆されるのを防止することができる。スキン層５０は、発泡体３６において発泡せずに気泡が形成されていない所謂ソリッド状の部分または発泡体３６において発泡が進行せずに内側と比べて見掛け密度が高い部分であって、発泡樹脂原料４７の発泡膨張に際して破れない厚み(例えば０．４ｍｍ〜０．５ｍｍ程度)に設定される。   A foamed resin raw material 47 that is a base of the foam 36 is injected into the second cavity 46 (see FIG. 7B). Here, the foamed resin raw material 47 is filled with an amount that fills the second cavity 46, and in the foam primary molding process, the skin layer 50 is formed on the surface of the foamed resin raw material 47 in contact with the substrate 32 and the first molding die 40. This state is maintained until is formed (see FIG. 7C). As described above, in the foam primary molding process, even if the first core back is performed to define the second cavity 46, the groove portion 40a is closed by the protruding portion 34. Therefore, the foamed resin is formed in the groove portion 40a. The raw material 47 does not flow in, and it is possible to prevent the tip 34 a of the protrusion 34 from being covered with the foam 36. The skin layer 50 is a so-called solid portion where no foam is formed in the foam 36 or a bubble is not formed, or a portion where the foam 36 does not progress in foaming and has a higher apparent density than the inside. It is set to a thickness (for example, about 0.4 mm to 0.5 mm) that does not break during the expansion of the raw material 47.

次に、発泡樹脂原料４７を発泡成形する発泡体二次成形工程が行われる。発泡体二次成形工程では、基材３２や第１成形型４０に接触する発泡樹脂原料４７の表面にスキン層５０が形成された段階で、第１成形型４０および第２成形型４２を突条部３４の突出方向に沿って相対的に離間する第２のコアバックを行う(図７(ｄ)参照)。すなわち、型設備では、第１成形型４０を第２成形型４２から離すように突条部３４に沿って直線的に移動されて、第２のキャビティ４６を広げた第３のキャビティ４８が画成され、これにより発泡樹脂原料４７を発泡膨張させて発泡体３６を成形する。第３のキャビティ４８は、第２のキャビティ４６より基材３２と第１成形型４０の成形面との間が離れており、最終的に得る発泡体３６の厚みに合わせて基材３２と第１成形型４０の成形面との間に画成される。第２のコアバック量は、突条部３４のほとんどが凹溝部４０ａから抜け出るまで第１成形型４０が第２成形型４２から離間移動するように設定されている。すなわち、実施例において、第２のコアバックは、突条部３４の一部が凹溝部４０ａに挿入された状態を保つように行われる。第２のコアバックを行っても、凹溝部４０ａの開口端が突条部３４の先端３４ａにおける対向する面が平行な部位(突条部３４の先端３４ａの面取り端部より僅かに根元側)に整合し、実施例では凹溝部４０ａが該凹溝部４０ａに嵌り込んだ突条部３４によって塞がれている。   Next, a foam secondary molding step of foam-molding the foamed resin material 47 is performed. In the foam secondary molding step, the first molding die 40 and the second molding die 42 are protruded when the skin layer 50 is formed on the surface of the foamed resin raw material 47 that contacts the base material 32 and the first molding die 40. A second core back relatively spaced along the protruding direction of the strip 34 is performed (see FIG. 7D). That is, in the mold facility, a third cavity 48 that is linearly moved along the protrusion 34 so as to separate the first mold 40 from the second mold 42 and widens the second cavity 46 is defined. Thus, the foamed resin material 47 is foamed and expanded to form the foam 36. The third cavity 48 is spaced apart from the base 32 and the molding surface of the first mold 40 from the second cavity 46, and the base 32 and the second base 48 are matched to the thickness of the foam 36 finally obtained. It is defined between the molding surface of one mold 40. The second core back amount is set so that the first molding die 40 moves away from the second molding die 42 until most of the protruding portion 34 comes out of the concave groove portion 40a. That is, in the embodiment, the second core back is performed so as to keep a state in which a part of the protrusion 34 is inserted into the concave groove 40a. Even when the second core back is performed, the opening end of the groove 40a is parallel to the opposite surface at the tip 34a of the ridge 34 (slightly root side from the chamfered end of the tip 34a of the ridge 34). In the embodiment, the concave groove portion 40a is closed by the ridge portion 34 fitted in the concave groove portion 40a.

前記発泡体二次成形工程では、第２のコアバックを行うことで、第２のキャビティ４６から拡開した第３のキャビティ４８において発泡樹脂原料４７の発泡膨張が許容され、スキン層５０を押し広げつつ第３のキャビティ４８で発泡体３６が発泡成形される(図７(ｄ)参照。そして、型設備を開いて、基材３２の表面側に発泡体３６が一体的に接合されたパネル部材３０が取り出される(図７(ｅ)参照)。   In the foam secondary molding process, by performing the second core back, the foamed resin raw material 47 is allowed to expand and expand in the third cavity 48 expanded from the second cavity 46, and the skin layer 50 is pressed. The foam 36 is foam-molded in the third cavity 48 while spreading (see FIG. 7D), and the mold facility is opened, and a panel in which the foam 36 is integrally bonded to the surface side of the base material 32. The member 30 is taken out (see FIG. 7 (e)).

このように、前述した製造方法によれば、第１成形型４０を順次コアバックするだけで、基材３２を成形し、この基材３２の表面側に発泡体３６を発泡成形することができる。すなわち、従来例で説明したように金型１１０,１１２,１１４の組み合わせを変えることなく、１組の成形型４０,４２だけで２層構造のパネル部材３０を簡単に成形することができる。従って、実施例の製造方法によれば、成形型４０,４２の必要数を最小限に抑え、成形する層に応じて成形型４０,４２を取り替えるための機構を省略することが可能で、型設備を簡易にすることができ、設備にかかるコストを低減することができる。また、成形型４０,４２の取り替え作業が必要ないので、製造効率がよい。   As described above, according to the manufacturing method described above, the base material 32 can be formed only by sequentially core-backing the first mold 40, and the foam 36 can be foam-molded on the surface side of the base material 32. . That is, as described in the conventional example, the panel member 30 having a two-layer structure can be easily formed with only one set of molds 40 and 42 without changing the combination of the molds 110, 112, and 114. Therefore, according to the manufacturing method of the embodiment, it is possible to minimize the necessary number of the molds 40 and 42 and to omit the mechanism for replacing the molds 40 and 42 according to the layer to be molded. Equipment can be simplified, and the cost of equipment can be reduced. Further, since the replacement work of the molds 40 and 42 is not necessary, the manufacturing efficiency is good.

実施例の製造方法では、基材成形工程で基材３２の突条部３４の先端３４ａに凹凸等の模様を形成しても、発泡体成形工程において突条部３４の先端３４ａから第１成形型４０が離れるように移動されて、該発泡成形工程で凹溝部４０ａの閉塞端と突条部３４の先端３４ａとが当接しない。このように、同じ組み合わせの成形型４０,４２をコアバックすることで基材３２および発泡体３６を成形しても、突条部３４の先端３４ａに第１成形型４０の成形面を突き当てる必要がなく、突条部３４の先端３４ａに凹凸等の模様を施しても当該模様が発泡体３６の成形に際して潰されたりすることを回避できる。すなわち、パネル部材３０は、突条部３４の先端３４ａにレーザー等によって模様を後加工することなく、１組の成形型４０,４２による一連の製造工程で簡単に模様を形成することができる。   In the manufacturing method of the embodiment, even if a pattern such as irregularities is formed on the tip 34a of the ridge 34 of the substrate 32 in the substrate molding process, the first molding is performed from the tip 34a of the ridge 34 in the foam molding process. When the mold 40 is moved away, the closed end of the groove 40a and the tip 34a of the protrusion 34 do not come into contact with each other in the foam molding process. Thus, even if the base 32 and the foam 36 are formed by core-backing the same combination of the molds 40 and 42, the molding surface of the first mold 40 is abutted against the tip 34 a of the protrusion 34. This is unnecessary, and even if a pattern such as irregularities is formed on the tip 34 a of the ridge 34, the pattern can be prevented from being crushed when the foam 36 is formed. That is, the panel member 30 can easily form a pattern in a series of manufacturing steps using a pair of forming dies 40 and 42 without post-processing the pattern on the tip 34a of the protrusion 34 with a laser or the like.

発泡体一次成形工程において、基材３２の突条部３４を形成する第１成形型４０の凹溝部４０ａが、第１のコアバックしても突条部３４で塞がれているので(図７(ｂ)参照)、発泡樹脂原料４７を第２のキャビティ４６に注入しても凹溝部４０ａへの該発泡樹脂原料４７の流入を防止することができる。また、発泡体二次成形工程において、凹溝部４０ａが、第２のコアバックしても突条部３４で塞がれているので(図７(ｄ)参照)、第２のキャビティ４６を第３のキャビティ４８に広げて発泡樹脂原料４７を発泡膨張させても凹溝部４０ａへの該発泡樹脂原料４７(発泡体３６)の流入を防止することができる。更に、発泡体二次成形工程では、発泡樹脂原料４７の表面にスキン層５０が形成された段階で第２のコアバックを行うことで、凹溝部４０ａおよび外方への発泡樹脂原料４７の漏出を防止しつつ発泡膨張させることができる。   In the foam primary molding step, the concave groove portion 40a of the first mold 40 that forms the ridge portion 34 of the base material 32 is blocked by the ridge portion 34 even when the first core is backed (see FIG. 7 (b)), even if the foamed resin material 47 is injected into the second cavity 46, the foamed resin material 47 can be prevented from flowing into the groove 40 a. Further, in the foam secondary molding step, since the concave groove portion 40a is blocked by the protruding portion 34 even when the second core is backed (see FIG. 7D), the second cavity 46 is formed in the second cavity 46. The foamed resin material 47 (foam 36) can be prevented from flowing into the concave groove portion 40a even if the expanded resin material 47 is expanded and expanded in the third cavity 48. Further, in the foam secondary molding process, the second core back is performed when the skin layer 50 is formed on the surface of the foamed resin raw material 47, so that the foamed resin raw material 47 leaks out to the groove 40a and outward. It is possible to expand and expand while preventing.

すなわち、突条部３４の先端３４ａを第１成形型４０の成形面に突き当てて封止しなくても、凹溝部４０ａに挿入された突条部３４自身または発泡樹脂原料４７の発泡に先立って形成されるスキン層５０によって、凹溝部４０ａへの発泡樹脂原料４７の流入を防止できる。このように、実施例の製造方法によれば、１組の成形型４０,４２のコアバックによって基材３２および該基材３２の表面側に発泡体３６を設けても、発泡体３６に先立って形成された基材３２の突条部３４が発泡体３６で覆われることなく、該突条部３４をパネル部材３０の表面に適切に臨ませることができる。従って、得られたパネル部材３０は、突条部３４の先端３４ａから発泡体３６を除去する等の仕上げを省略することができ、突条部３４を縫い目とする疑似ステッチの如き細かい模様にも対応可能である。そして、実施例の製造方法によれば、凹溝部４０ａに挿入された突条部３４自身または発泡樹脂原料４７の発泡に先立って形成されるスキン層５０によって、凹溝部４０ａへの発泡樹脂原料４７の流入を防止しているので、突条部３４の先端３４ａまたは発泡体３６の表面に凹凸等の模様を設けることができる。   That is, prior to foaming of the protrusion 34 itself or the foamed resin material 47 inserted into the concave groove 40a without sealing the tip 34a of the protrusion 34 against the molding surface of the first mold 40. The skin layer 50 thus formed can prevent the foamed resin raw material 47 from flowing into the concave groove portion 40a. As described above, according to the manufacturing method of the embodiment, even if the base material 32 and the foam body 36 are provided on the surface side of the base material 32 by the core back of the pair of molds 40 and 42, the foam body 36 is preceded. The protrusions 34 of the base member 32 formed in this way can be appropriately exposed to the surface of the panel member 30 without being covered with the foam 36. Therefore, the obtained panel member 30 can omit finishing such as removing the foam 36 from the tip 34a of the protrusion 34, and can be applied to a fine pattern such as a pseudo stitch having the protrusion 34 as a seam. It is possible. And according to the manufacturing method of an Example, the foamed resin raw material 47 to the concave groove part 40a is formed by the protrusion 34 itself inserted in the concave groove part 40a or the skin layer 50 formed prior to foaming of the foamed resin raw material 47. Therefore, a pattern such as unevenness can be provided on the tip 34a of the protrusion 34 or the surface of the foam 36.

(変更例)
前述した実施例の構成に限定されず、以下のように変更可能である。
(１)実施例では、インストルメントパネルの一部であるパネル部材を例に挙げたが、車両内装部材であれば、インストルメントパネル全体、グローブボックスのリッド、アームレスト、ドアトリム等に本願発明の製造方法が適用できる。
(２)基材としては、硬質な合成樹脂に限定されず、弾力性がある弾性体であってもよい。
(３)実施例では、パネル部材を２層構造としたが、基材を多層に形成したり、発泡体を多層に形成してもよい。例えば、第１の基材を成形した後にコアバックして第２の基材を成形し、この第２の基材の表面に発泡体を形成したり、発泡体を成形した後に発泡体の表面に別の合成樹脂層を成形してもよい。この場合、一番最初に成形される基材に設けられる突条部が各層の成形時に凹溝部を塞いでるのが好ましい。
(４)発泡樹脂原料の表面にスキン層が形成される前に、第２のコアバックを行ってもよい。この場合は、第２のコアバックを突条部で凹溝部を塞いだ状態を保つように行うのが望ましい。
(Change example)
The present invention is not limited to the configuration of the embodiment described above, and can be modified as follows.
(1) In the embodiment, the panel member which is a part of the instrument panel is taken as an example. However, if it is a vehicle interior member, the entire instrument panel, glove box lid, armrest, door trim, etc. The method is applicable .
(2) The substrate is not limited to a hard synthetic resin, and may be an elastic elastic body.
(3) In the embodiment, the panel member has a two-layer structure, but the base material may be formed in multiple layers, or the foam may be formed in multiple layers. For example, after forming the first base material, the core is backed to form the second base material, and the foam is formed on the surface of the second base material, or the foam surface is formed after the foam is formed. Another synthetic resin layer may be formed. In this case, it is preferable that the protrusion provided on the base material to be molded first closes the groove when molding each layer .
(4 ) A second core back may be performed before the skin layer is formed on the surface of the foamed resin material. In this case, it is desirable to perform the second core back so as to keep a state where the groove portion is closed by the protruding portion.

３２ 基材，３４ 突条部，３６ 発泡体，４０ 第１成形型，４０ａ 凹溝部，
４２ 第２成形型，４４ 第１のキャビティ，４５ 樹脂原料，
４６ 第２のキャビティ，４７ 発泡樹脂原料，４８ 第３のキャビティ 32 base material, 34 ridge part, 36 foam, 40 1st shaping | molding die, 40a concave groove part,
42 second mold, 44 first cavity, 45 resin raw material,
46 Second cavity, 47 Foam resin raw material, 48 Third cavity

Claims (4)

一面に突出すると共に互いに離間して所定ラインに沿って並ぶように形成された複数の突条部を有する基材と、この基材における突条部が設けられた一面を該突条部の先端部を除いて覆う発泡体とを備え、発泡体から露出する複数の突条部の先端部によって擬似的なステッチ模様を形成する車両内装部材の製造方法であって、
前記突条部の夫々に合わせて設けられて、閉塞端に該突条部の先端部に糸目模様を付ける凹凸が形成された凹溝部を有する第１成形型と、第２成形型との間に、前記基材の外形に合わせた第１のキャビティを画成し、
前記第１のキャビティに樹脂原料を注入することで、先端部に糸目模様が施された複数の突条部を形成した基材を成形し、
前記突条部における先端部側の一部を前記凹溝部に挿入して該突条部により凹溝部を塞いだ状態を保つように、第１成形型および第２成形型を該突条部の突出方向に沿って相対的に離間する第１のコアバックを行うことで、前記基材と第１成形型との間に第２のキャビティを画成し、
前記第２のキャビティに発泡樹脂原料を注入し、
前記突条部における先端部側の一部を前記凹溝部に挿入して該突条部により凹溝部を塞いだ状態を保つように、前記第１成形型および第２成形型を前記突条部の突出方向に沿って相対的に離間する第２のコアバックを行い、前記第２のキャビティを広げた第３のキャビティを画成することで、発泡樹脂原料を発泡膨張させて、突条部の先端部に施した糸目模様が露出するように該突条部の周りを囲うと共に前記基材の一面を覆って前記発泡体を成形するようにした
ことを特徴とする車両内装部材の製造方法。 A base material having a plurality of ridges formed so as to protrude on one surface and be spaced apart from each other and aligned along a predetermined line, and the one surface provided with the ridge portions on the base material at the tip of the ridge portion A vehicle interior member for forming a pseudo stitch pattern by the tip portions of a plurality of protrusions exposed from the foam .
Provided in accordance with the each of the protrusions, a first mold having a concave groove which irregularities are formed to give a fine line pattern at the tip portion of the protruding strip portion the closed end, between the second mold And defining a first cavity adapted to the outer shape of the substrate,
By injecting a resin raw material into the first cavity, a base material formed with a plurality of protrusions with a thread pattern on the tip is formed ,
A part of the tip side of the projecting portion so as to maintain the state of closing the concave groove portion by the projecting strip portion is inserted into the groove portion, a projecting streak portion first mold and a second mold By performing a first core back relatively spaced along the protruding direction, a second cavity is defined between the base material and the first mold,
Injecting a foamed resin material into the second cavity,
The first molding die and the second molding die are placed on the projecting portion so that a part of the projecting portion on the front end side is inserted into the recessed groove portion and the recessed groove portion is closed by the projecting portion. The second core back relatively spaced along the projecting direction of the first is performed, and the third cavity is defined by expanding the second cavity, so that the foamed resin material is expanded and expanded . A method for manufacturing a vehicle interior member, characterized in that the foam is formed so as to surround the ridge portion and to cover one surface of the base material so that the thread pattern applied to the tip portion of the base material is exposed. . 前記第１成形型において前記第２成形型側に膨らむように形成された前記凹溝部の開口縁によって、前記発泡体を前記突条部の周りで凹むように成形する請求項１記載の車両内装部材の製造方法。 2. The vehicle interior according to claim 1 , wherein the foam is molded so as to be recessed around the protruding portion by an opening edge of the concave groove portion formed so as to swell toward the second molding die in the first molding die. Manufacturing method of member. 前記第１成形型において前記第２成形型側に膨らむように形成された前記凹溝部の開口縁によって、前記基材の一面を前記突条部の周りで凹むように成形すると共に、該基材の根元部分および一面側の凹みに対応して凹むように形成された第２成形型によって、基材における前記一面と反対面を、該基材の根元部分および一面側の凹みに対応して膨らむように成形する請求項２記載の車両内装部材の製造方法。 In the first molding die, one surface of the base material is molded so as to be recessed around the ridge portion by the opening edge of the concave groove portion formed to swell toward the second molding die side, and the base material The second molding die formed so as to be recessed corresponding to the root portion of the substrate and the recess on the one surface side swells the surface opposite to the one surface in the substrate corresponding to the root portion of the substrate and the recess on the one surface side. The method for manufacturing a vehicle interior member according to claim 2 , wherein the vehicle interior member is molded as described above. 前記第２のコアバックは、前記発泡樹脂原料の表面にスキン層が形成された段階で行われる請求項１〜３の何れか一項に記載の車両内装部材の製造方法。The method for manufacturing a vehicle interior member according to any one of claims 1 to 3, wherein the second core back is performed when a skin layer is formed on a surface of the foamed resin raw material.
JP2011000778A 2011-01-05 2011-01-05 Method for manufacturing vehicle interior member Expired - Fee Related JP5714333B2 (en)

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