JP6549489B2 - Vehicle interior parts - Google Patents

Description

  The present invention relates to a vehicle interior product in which a pad made of a skin and a foamed resin layer is integrally formed on the surface of a base material.

  Patent Document 1 discloses an interior part for a vehicle in which a pad formed of a skin having a first and a second skin member adjacent to each other and a foamed resin layer is integrally formed on the surface of a base material. In this vehicle interior part, the extending portion is integrally extended on the back side along the adjacent edge at the adjacent edge of the first and second skin members, and the extending portions of both the skin members are It is sewn on the exposed surface configuration portion of the first skin member in a state of being overlapped from the back side.

Japanese Examined Patent Publication 7-45128

  By the way, in the interior part for vehicles like the above-mentioned patent documents 1, the pressure seal which pressure-contacts to the above-mentioned substrate by the pressure of the above-mentioned foaming resin layer in the state where it was pinched by the above-mentioned foaming resin layer and a substrate May form part. In such a case, if the end of the seamed portion of both skin members is located at the pressure-sealed portion forming portion, the extension portions of both skin members overlap each other at the seamed portion of both skin members, thereby enhancing the rigidity of the skin. When forming the foamed resin layer by injecting the foamed resin raw material between the skin and the base material, the foaming pressure of the foamed resin raw material acts on the end portion of the stitched portion of both the skin members. Also, there is a possibility that the end of the seamed portion of both the skin members does not press against the base material, and the sealability between the press-contact seal portion of the skin and the base material can not be secured.

  This invention is made in view of this point, The place made as the objective is to ensure the sealing performance between the press-contacting seal part of outer_skin | epidermis, and a base material.

  In order to solve the above-mentioned object, the present invention sets a position corresponding to a pressure-sealed portion at adjacent edges of both skin members as an extension portion non-formation portion, and a tape material so as to straddle the extension portion non-formation portion Is adhered to both the skin members.

  Specifically, the present invention is directed to an interior part for a vehicle in which a pad formed of a skin having a first and a second skin member adjacent to each other and a foamed resin layer is integrally formed on the surface of a substrate, The following solutions were taken.

  That is, according to the present invention, at the end edge of the skin, a pressure contact seal portion is formed which is in pressure contact with the base material by the pressure of the foam resin layer while being sandwiched between the foam resin layer and the base material. At the portions other than the end portions in the adjacent edges of the first and second skin members, the extension is integrally extended on the back side along the adjacent edges, and the extension at the adjacent edges of the both skin members is extended The non-protruding portion is located at the pressure-sealed portion forming portion, and the extending portions of the first and second skin members are sewn together by a suture thread, and the first and second skin members are The tape material straddles the extending portions of both the skin members in the middle in the longitudinal direction, and is folded back at the longitudinal ends thereof so that the portions where the extending portions are not formed at the adjacent edges of the both skin members are on both sides It is characterized in that it is pasted so as to straddle.

  According to the present invention, since the extension portion is not formed at the position corresponding to the pressure-sealed portion at the adjacent edge portion of both the skin members, the portion is easily deformed, so that the foamed resin material is injected between the skin and the base material. When forming a foamed resin layer, the said location can be reliably pressure-contacted by the base material with the foaming pressure of the foamed resin raw material. Therefore, the sealability between the press-contacting seal portion of the skin and the base can be more reliably ensured.

  Moreover, since the tape material was stuck on both skin members so that the extension part non-formation location of both skin members might be straddled on the front and back sides, the foamed resin layer is injected by injecting the foamed resin raw material between the skin and the base material. In the formation of the above, the leakage of the foamed resin raw material from between the extension non-formed portions of the adjacent edges of the two skin members is prevented.

It is a perspective view of an instrument panel as an interior product for vehicles concerning an embodiment of the present invention. It is a perspective view of the 1st and 2nd skin member. It is the III section enlarged view of FIG. It is sectional drawing in the IV-IV line of FIG. It is sectional drawing in the VV line | wire of FIG. It is a perspective view around a bending part crossing point in the adjoining edge of the 1st and 2nd skin member. It is the arrow line view which looked at the edge part in the adjacent edge of the 1st and 2nd skin member from the arrow VII direction of FIG. In the manufacturing method of an instrument panel, it is a manufacturing-process figure which shows the process of shape | molding a skin material. It is a perspective view of the 1st and 2nd outer skin member in the state where the extension part adhered. It is a manufacturing-process figure which shows the process of stitching | suture mutually in the preparation state which overlap | superposed the 1st and 2nd skin member in the manufacturing method of an instrument panel. It is a perspective view of the 1st and 2nd outer skin member in the preparation state of FIG. It is a manufacturing-process figure which shows the process of cutting off an extension part in the manufacturing method of an instrument panel. It is a manufacturing-process figure which shows the process of forming a stitch pattern in the manufacturing method of an instrument panel. It is a manufacturing-process figure which shows the process of affixing a tape material to a 1st and 2nd skin member in the manufacturing method of an instrument panel. In the manufacturing method of an instrument panel, it is a manufacturing-process figure which shows the process of setting a skin material to a lower mold | type and setting a base material to an upper mold | type. It is a manufacturing-process figure which shows the process of shape | molding an instrument panel in the manufacturing method of an instrument panel.

  Hereinafter, embodiments of the present invention will be described based on the drawings.

  1 to 7 show an instrument panel 1 as a vehicle interior according to an embodiment of the present invention of a right-handed vehicle. In this instrument panel 1, a resin pad 5 is integrally formed partially on the surface of a resin base material 3. A meter hood portion 7 is formed on the right side of the instrument panel 1 in the vehicle width direction, and the pad 5 is provided substantially over the entire vehicle body front end portion of the instrument panel 1 except the meter hood portion 7 . Accordingly, the base material 3 is exposed at the vehicle body front end portion of the instrument panel 1 and the meter hood portion 7. Further, on the left front side of the vehicle body in the pad 5 formation region of the instrument panel 1, a rectangular hinge portion 9 and a rupture planned portion 11 having a shape in which two Y-shapes are horizontally connected and symmetrically connected in the vehicle width direction The air bag door 12 is partitioned. The base material 3 is formed by injection molding of a resin material such as fiber-filled polypropylene (PP), acrylonitrile-butadiene-styrene (ABS) resin, or Noryl (registered trademark).

  The base material 3 extends substantially flatly toward the rear of the vehicle body from the entire width at the rear end of the front surface portion 13 and extends substantially in a substantially flat shape in the vehicle width direction at the front end portion of the vehicle body. And a general surface portion 15 which is bent in a letter shape. An outer peripheral groove portion 17 recessed on the back side is formed on the front end full width of the general surface portion 15 and the full width at both ends in the vehicle width direction. Further, a lateral groove portion 18 recessed on the back side is formed shallower than the outer peripheral groove portion 17 slightly forward of the bending portion of the general surface portion 15 in the vehicle body. The lateral groove portion 18 is formed in a trapezoidal shape in cross section so that the side wall portion thereof is inclined outward toward the open side. Further, on the general surface portion 15 slightly inward in the vehicle width direction from the portion of the outer circumferential groove portion 17 extending in the vehicle longitudinal direction, the inclined portions 19 are formed along both vehicle width direction end edges. It is done. The inclined portion 19 is located outside the air bag door 12 corresponding portion of the base 3. Further, a rear side projecting wall 21 (see FIGS. 15 and 16) projecting to the rear side is integrally formed over the entire length at the vehicle body rear end edge of the general surface portion 15, and the tip of the rear side projecting wall 21 The plate-like flange portion 23 (see FIGS. 15 and 16) is integrally extended to the outside along the entire length. A protrusion seal portion (not shown) is continuously and integrally projected on the surface of the flange portion 23 on the pad 5 side. In addition, the mounting wall portion 25 protrudes to the back side with the plate surface in the vehicle width direction between the rear end portions of the front surface portion 13 in the vehicle width direction and the full width of both the general surface portion 15 and the flange portion 23 in the vehicle width direction. Are integrally formed, and a plurality of attachment holes 27 for attaching a side panel (not shown) constituting the side portion of the instrument panel 1 to the attachment wall 25 are formed through in the vicinity of the tip of the attachment wall 25. ing. In addition, a resin injection port 29 (see FIGS. 15 and 16) is formed in the general surface portion 15.

  The pad 5 is composed of a skin 31 and a foam resin layer 33 formed by filling a foam resin material R (described later) between the skin 31 and the base 3.

  The skin 31 is divided into two in the longitudinal direction of the vehicle body at locations corresponding to the lateral grooves 18 of the general surface 15 of the base material 3, and the first skin member 35 on the vehicle front side and the second one on the vehicle rear side A skin member 37 is provided. These skin members 35 and 37 are molded by slush molding using an elastomer resin material such as thermoplastic urethane (TPU) or a resin material such as polyvinyl chloride (PVC). An abutting seal portion 39 is formed at the vehicle body rear end edge of the skin 31. The abutting seal portion 39 abuts on the ridge seal portion of the flange portion 23 of the base material 3 and seals the abutting portion. On the other hand, the foamed resin layer 33 is sandwiched between the foamed resin layer 33 and the side wall portion 17 a of the outer peripheral groove portion 17 of the base 3 at the vehicle body front end edge and the vehicle width direction both end edges of the skin 31. The pressure seal portion 41 is formed so as to be in pressure contact with the side wall portion 17 a of the substrate 3 by the pressure of

  The first skin member 35 has a flat surface portion 35a extending substantially flat in the vehicle width direction and exposed, and a side surface portion 35b integrally projecting toward the rear side at both ends in the vehicle width direction of the flat surface portion 35a. It has a three-dimensional appearance. A bent portion 35c is formed in a straight line at the boundary between the flat surface portion 35a and the side surface portion 35b, and the bent portion 35c is an adjacent edge portion of the first skin member 35 with the second skin member 37. And intersect. Further, a bent portion 35d is formed at the middle of the protruding direction of the side surface portion 35b so that the tip end side is positioned inward in the vehicle width direction than the base end side, and the side portion 35b on the tip end side than the bent portion 35d is It corresponds to the pressure seal part 41. At the adjacent edge of the first skin member 35 excluding the side surface portion 35b on the tip end side of the bent portion 35d, a protrusion 35e as an extending portion is continuously and integrally along the adjacent edge. It is protrusively installed. That is, the ridge 35e is formed on the portion of the adjacent edge of the first skin member 35 excluding the both longitudinal end portions, and the portion where the ridge 35e is not formed on the adjacent edge of the first skin member 35 is It is located at the location where the pressure seal part 41 is formed. The protruding length of the protruding portion 35e is the outer side in the vehicle width direction of the portion corresponding to the inclined portion 19 of the base material 3 and the inner side in the vehicle width direction of the inclined portion 19 corresponding portion of the base 3 It is set shorter than. That is, the protruding length of the protruding portion 35 e is set to be shorter than the other portions at the portion including the intersection of the bent portion 35 c at the adjacent edge portion of the first skin member 35. Further, the projection length L1 of the projection 35e on the outer side in the vehicle width direction of the base 3 corresponding to the inclined portion 19 is the shortest and is set to 2 mm. The vehicle width direction of the base 3 corresponding to the inclined portion 19 The projection length L2 of the projection 35e at the inner side is the longest and is set to 10 mm. Further, the protruding length of the protruding portion 35 e is gradually longer inward in the vehicle width direction at a portion corresponding to the inclined portion 19 of the base material 3. Further, in the vicinity of the inner side of the adjacent edge of the first skin member 35, a curved portion 35f which curves so as to expand to the back side excludes the side surface portion 35b on the tip side of the bent portion 35d of the adjacent edge. It is formed along the entire length, and a stitch pattern 43 made of sewing thread is formed on the curved portion 35f by sewing over the entire length. As described above, since the inclined portion 19 of the base material 3 is located outside the air bag door 12 corresponding portion of the base material 3, the adjacent edge of the first skin member 35 in the vicinity of the air bag door 12 is The projection length of the projection 35e in the part is the above-mentioned L2. A plurality of thin portions 35g are formed spaced apart from each other at the portion corresponding to the portion to be fractured 11 of the flat surface portion 35a. Further, the front extension surface portion 35h is integrally extended over the entire front end width of the flat surface portion 35a so as to be inclined outward toward the rear side, and constitutes the pressure contact seal portion 41. Further, as shown in FIGS. 6 and 7, an embossed pattern is formed over the entire surface of the flat surface portion 35a, the side surface portion 35b proximal to the bending portion 35d, and the bending portion 35d.

  The second skin member 37 also has a flat surface portion 37a extending substantially flat in the vehicle width direction, and side surface portions 37b integrally projecting toward the rear side at both ends in the vehicle width direction of the flat surface portion 37a. It has an appearance shape. At the boundary between the flat surface portion 37a and the side surface portion 37b, a bent portion 37c is formed in the same straight line as the bent portion 35c of the first skin member 35, and the bent portion 37c is a second skin It intersects the adjacent edge of the member 37 with the first skin member 35. Further, a bent portion 37d is formed in the protruding direction midway portion of the side surface portion 37b so that the tip end side is positioned inward in the vehicle width direction than the base end side, and the side portion 37b on the tip end side than the bent portion 37d is It corresponds to the pressure contact seal portion 41. The flat surface portions 35a and 37a of the first and second skin members 35 and 37 are flush with each other, and the side portions 35b and 37b of the first and second skin members 35 and 37 are flush with each other. At the adjacent edge of the second skin member 37 excluding the side surface portion 37b on the tip end side of the bent portion 37d, a ridge portion 37e as an extending portion is continuously and integrally along the adjacent edge. It is protrusively installed. That is, the ridge 37e is formed on the adjacent edge of the second skin member 37 except for both longitudinal ends, and the portion where the ridge 37e is not formed on the adjacent edge of the second skin 37 is: It is located at the location where the pressure seal part 41 is formed. The projection length of the projection 37e is set equal to the projection 35e of the first skin member 35 over the entire length. That is, the protruding length of the protruding portion 37e is also set shorter at the portion including the bent portion 37c intersection portion at the adjacent edge portion of the second skin member 37 than the other portions. Further, in the vicinity of the inner side of the adjacent edge of the second skin member 37, a curved portion 37f which curves so as to expand to the back side excludes the side surface portion 37b on the tip side with respect to the bent portion 37d of the adjacent edge. It is formed along the entire length, and in the curved portion 37f, a stitch pattern 45 made of sewing thread is formed by sewing over the entire length. In addition, a rear side projecting surface portion 37g integrally projecting toward the rear side is integrally formed with the rear end full width of the flat surface portion 37a of the second skin member 37, and the tip of the rear side projecting surface portion 37g is The contact seal portion 39 is integrally extended to the outside. Moreover, although it shows only in FIG.6 and FIG.7, in the surface of the side surface part 37b of the proximal end side rather than the said flat surface part 37a and the bending part 37d, and the surface of the bending part 37d, a crimp pattern is formed over the whole. .

  The outer side surfaces of the ridges 35e and 37e of the two skin members 35 and 37 are in contact with each other in the longitudinal direction of the vehicle body over the entire length. The proximal ends of the ridges 35e and 37e of the two skin members 35 and 37 are sewn together with the suture thread 47 over the entire length. On the other hand, both longitudinal end portions at adjacent edges of the two skin members 35 and 37, that is, the portions where the protrusions 35e and 37e are not formed are opposed to each other with a minute interval D (see FIG. 7). Further, on both the skin members 35, 37, the tape material 49 straddles the ridges 35e, 37e of the skin members 35, 37 in the middle in the longitudinal direction and stitch patterns 43, 45 of the two skin members 35, 37. Is covered from the back side, and is folded back at both longitudinal direction end portions where the ridges 35e and 37e are not formed at the adjacent edges of the two skin members 35 and 37 (the side portions 35b on the tip side of the bent portions 35d and 37d) , 37b) are pasted so as to straddle both the front and back sides.

  The foamed resin layer 33 is a urethane foam or the like, and has, for example, a semi-rigid structure in which the independent foaming and the communication foaming are distributed in about half. In the foamed resin layer 33, concave grooves 33a are formed to correspond to the ridges 35e, 37e of the first and second skin members 35, 37, and the concave grooves 33a include the first and second grooves. The ridges 35 e and 37 e of the second skin members 35 and 37 are inserted in a state of being covered by the tape material 49.

  8 to 16 show a method of manufacturing the instrument panel 1 configured as described above.

  At the time of manufacture, the base 3, the skin 31, and the mold 101 shown in FIGS. 15 and 16 are prepared. The forming die 101 includes a first die 103 which is a lower die and a second die 105 which is an upper die, and the second die 105 is provided with an injection head 107 and the first die 103. The slide core 109 is slidably provided by the expansion and contraction operation of the fluid pressure cylinder 111. In FIGS. 15 and 16, reference numeral 105a denotes an insertion hole into which the injection head 107 is inserted, and reference numeral 113 denotes a cavity. Moreover, illustration of the curved parts 35f and 37f of the outer skin 31 is omitted in FIGS.

  Here, the process of manufacturing the skin 31 will be described. In order to manufacture the skin 31, first, as shown in FIG. 8, with the slush mold 201, the first and second skin members 35, 37 and the ridges at the end edges of both the skin members 35, 37 A single surface material 55 is formed which constitutes the positioning extension 51 attached to the portion corresponding to the tips 35e and 37e via the second thin portion 59 (described later) and the unnecessary portion 53 (described later). Do. The extension portion 51 corresponds to a portion of the end edges of both the skin members 35 and 37 corresponding to the tips of the protruding portions 35e and 37e, in which the protruding length of the protruding portions 35e and 37e is shorter than L2. It adheres only to the part that In FIG. 2, the extension 51 is shown by a phantom line.

  In the slush mold 201, a molding surface 203 for molding a three-dimensional surface of the first and second skin members 35 and 37 is formed. On the molding surface 203, a first convex streak portion 205 having a triangular shape in cross section for forming a thin portion corresponds to the outer peripheral edge of the first and second skin members 35, 37 in a state where the extension portion 51 is attached. And the second ridge portion 207 having a triangular cross section for forming a thin portion is a boundary between the first and second skin members 35 and 37 and the extension portion 51, that is, a second thin portion. It is formed to correspond to the portion 59 (described later). In addition, a plurality of recessed portions 209 having a rectangular shape in plan view are formed to be spaced apart from each other at a location corresponding to the middle of the extension direction of the extension 51 attached to the first skin member 35 in the molding surface 203. There is. On the other hand, a plurality of convex portions 211 having a rectangular shape in plan view are integrally spaced apart from each other at a position corresponding to the middle of the extension direction of the extension 51 attached to the second skin member 37 in the molding surface 203. It is protrusively installed. Further, on the molding surface 203, the curved portions 35f of the first and second skin members 35, 37 and the bulged portion 213 for molding are formed.

  Next, the procedure for forming the surface material 55 using the slush mold 201 will be described.

  First, the slush mold 201 is heated by a heater (not shown), and a raw material storage box (not shown) containing powder resin raw materials such as TPU and PVC with the molding surface facing downward. Set from below. Then, the slush mold 201 and the raw material storage box are inverted, and the powder resin raw material in the raw material storage box is attached to the molding surface 203 of the slush mold 201. As a result, the powdered resin raw material adhering to the molding surface 203 starts to heat and melt due to the mold temperature. Thereafter, the slush mold 201 and the raw material storage box are inverted to return to the original posture, and the excess powder resin raw material is dropped into the raw material storage box. Then, the slush mold 201 is removed from the raw material storage box and heated again by the heater. As a result, the unmelted powder resin raw material attached to the molding surface 203 is completely melted, and a molten resin layer is formed. Thereafter, the slush mold 201 is cooled by blowing air. Thereby, the molten resin layer is cured, and a skin material 55 having a three-dimensional appearance shape corresponding to the appearance shape of the pad 5 is formed. A first thin portion 57 as a to-be-tearable portion is formed at a position corresponding to the first ridge portion 205 of the formed skin member 55, and the second ridge of the skin member 55 is formed. In a portion corresponding to the portion 207, a second thin portion 59 as a breakable portion which can be torn is formed. In addition, curved portions 35 f and 37 f are formed at locations corresponding to the bulging portions 213 of the surface material 55. Further, the fitting convex portion 61 is formed at a portion corresponding to the concave portion 209 of the formed skin material 55, and the fitting concave portion 63 is formed at a portion corresponding to the convex portion 211 of the formed skin material 55. It is done.

  Thereafter, the surface material 55 is peeled off from the molding surface 203, and the unnecessary portion 53 is pulled to tear off (break) the first thin portion 57, thereby cutting out the unnecessary portion 53 outside the first thin portion 57, as shown in FIG. Thus, the first and second skin members 35, 37 with the extension portion 51 attached via the second thin portion 59 are obtained. The fitting protrusion 61 is formed on the surface of the extension 51 attached to the first skin member 35, and the fitting recess 63 is formed on the surface of the extension 51 attached to the second skin member 37. It is formed. As described above, the unnecessary part 53 can be removed simply by pulling it, and since it is not necessary to specify the broken part, the breaking work becomes easy. In addition, since the equipment for breakage is unnecessary, the manufacturing cost can be reduced.

  Next, as shown in FIGS. 10 and 11, the surfaces of the first and second skin members 35 and 37 abut on each other, and the fitting convex portion 61 and the fitting concave portion 63 are fitted to each other The extension portions 51 of the two skin members 35 and 37 are fixed to each other by overlapping each other. In this state (preparation state), the two skin members 35 and 37 deform each other in a three-dimensional appearance so that the end edges on the extension 51 adhering side overlap each other over the entire length. As described above, since the two skin members 35 and 37 can be positioned only by fitting the fitting convex portion 61 and the fitting recess 63, compared with the case where the two skin members 35 and 37 are temporarily fixed by fasteners or the like, Positioning work becomes easy. Then, in this state, the end edge on the extension portion 51 side of both the skin members 35 and 37 is brought into contact with the ruler 301 as a guide portion of the sewing machine, and both the skin members 35 and 37 are the pressing plate 303 of the sewing machine and the needle plate The sewing machine is operated to move the sewing needle 307 up and down in a state of being sandwiched between the two. Thereby, a certain distance L (= L2) is located inside the second thin portion 59 of both the skin members 35, 37 and between the edge of the two skin members 35, 37 on the side where the extension portion 51 is attached. The two skin members 35 and 37 are sewn together with the suture thread 47 at the suture line LN which keeps In this manner, the suture line LN can be positioned simply by bringing the end edge on the extension 51 side of both the skin members 35 and 37 into contact with the ruler 301 of the sewing machine, and marking the suture line LN of the skin members 35 and 37 Since no work is required, the suturing work is easy.

  Next, as shown in FIG. 12, a portion inside the above-mentioned suture line LN in both the skin members 35 and 37 is developed so as to be flush with one another, and a three-dimensional original external appearance shape corresponding to the appearance shape of the pad 5 While making the other skin member 35, 37 project outside the above-mentioned suture line LN on the back side of the spread part, pull the extension part 51 in this state and tear off the second thin part 59 (break it). Thus, the extension portion 51 is cut off from both of the skin members 35 and 37. As a result, protrusions 35e and 37e, which are portions outside the suture line LN, are formed on the back side of the spread portion. As described above, it is possible to cut only by pulling the extension portion 51, and since it is not necessary to specify the break point, the break work becomes easy. In addition, since the equipment for breakage is unnecessary, the manufacturing cost can be reduced.

  Thereafter, as shown in FIG. 13, the two skin members 35, 37 are sandwiched between the presser plate 401 and the needle plate 403, and the curved portions 35f, 37f of the two skin members 35, 37 are presser plates of the double needle sewing machine. The sewing machine is operated in a state corresponding to the slit 401 a of the needle plate 401 and the slit 403 a of the needle plate 403 to move the sewing needle 405 up and down, thereby forming the stitch pattern 43, 45 is formed over the entire length.

  Thereafter, as shown in FIG. 14, the tape material 49 is applied to both the skin members 35 and 37 so as to straddle the projecting portions (protrusions 35 e and 37 e) of the skin members 35 and 37 at mid portions in the longitudinal direction. , 37 stitch patterns 43 and 45 are covered from the back side, and are folded back at both ends in the longitudinal direction to form non-stitched portions (protruded portions not formed with the ridges 35e and 37e) at adjacent edges of the two skin members 35 and 37. Paste it so that it straddles on both sides. Thereby, the skin 31 in which the above-mentioned tape material 49 is stuck on both skin members 35 and 37 is obtained.

  Next, how to manufacture the instrument panel 1 will be described.

  First, as shown in FIG. 15, in a state in which the second mold 105 is raised and the mold 101 is opened, the fluid pressure cylinder 111 is extended and the slide core 109 is advanced, and then the skin 31 is removed. Set to type 103. Thus, the terminal on the vehicle body front side of the skin 31 abuts on the tip of the slide core 109 and is held by the tip of the slide core 109 so as not to fall outward. In this state, the skin 31 is brought into close contact with the first mold 103 by the negative pressure from the vacuum suction hole (not shown). Meanwhile, the base 3 is set in the second mold 105. At that time, the base material holding device (not shown) holds the base material 3 so as not to drop from the second mold 105. In this state, the resin injection port 29 of the base 3 is in communication with the injection head 107.

  Next, as shown in FIG. 16, the fluid pressure cylinder 111 is contracted to retract the slide core 109, and the second mold 105 is lowered obliquely from above to close the mold 101. As a result, the end on the vehicle body front side of the skin 31 and the end on both sides in the vehicle width direction, that is, the pressure seal portion 41 is in contact with the outer side wall portion 17 a of the outer peripheral groove portion 17 of the substrate 3. On the other hand, the rear end of the skin 31 abuts on the ridge seal portion of the flange portion 23 of the base 3 so that the ridge seal portion bites into the skin 31 and seals the contact portion.

  Thereafter, in the mold closed state, the foamed resin raw material (not shown) is injected from the injection head 107 through the resin injection port 29 of the base 3 between the base 3 in the cavity 113 and the skin 31. The foam resin raw material foams and the foaming pressure causes the front edge of the cover 31 and both edges in the vehicle width direction, that is, the pressure seal portion 41 to be in pressure contact with the side wall portion 17a of the outer peripheral groove portion 17 of the substrate 3 The pressure contact point is sealed. At this time, the projection 37e is not formed at a position corresponding to the pressure-contacting seal portion 41 at the adjacent edge of the two skin members 35 and 37, and the portion is easily deformed. Thus, the substrate 3 can be reliably pressure-welded. Therefore, the sealability between the pressure-contacting seal portion 41 of the skin 31 and the substrate 3 can be ensured more reliably. Further, at this time, since the tape material 49 is attached to both the skin members 35, 37 so as to straddle the non-protrusions of the ridges 35e, 37e of both the skin members 35, 37 on both sides. , 37 are prevented from leaking between the non-formed portions of the projections 35e, 37e on the adjacent edges. Further, the curved portions 35f and 37f and the stitch pattern 43 are not formed on the side surface portions 35b and 37b on the tip end side of the bent portions 35d and 37d of both the skin members 35 and 37, that is, the pressure seal portion 41 formation portion. The sealability between the press-contacting seal portion 41 and the base material 3 is easily secured. Furthermore, since the stitch patterns 43 and 45 are covered by the tape material 49 from the back side, leakage of the foamed resin material from the sewing holes of the stitch patterns 43 and 45 is also prevented.

  After that, the foamed resin raw material is foamed and hardened, and the instrument panel 1 in which the pad 5 composed of the skin 31 and the foamed resin layer 33 is integrally formed on the surface of the base 3 is obtained.

  Therefore, according to the above-described embodiment, the portions of the outer skin members 35 and 37 outside the sutured portions constitute the ridges 35 e and 37 e and do not press against the exposed surface structure portions of the skin members 35 and 37 from the back side. It is possible to prevent the surface component from bulging and deteriorating the appearance.

  In addition, since the ridges 35e and 37e are formed short at the intersections of the bending parts 35c and 37c and are easily bent, bending is performed at the intersections of the bending parts 35c and 37c at the adjacent edge portions of the skin members 35 and 37. Thus, the stress generated thereby is reduced, and the exposed surface constituting portion around the intersection of the bent portions 35c and 37c at the adjacent edge portions of the skin members 35 and 37 is prevented from being deformed by the stress to deteriorate the appearance appearance.

  In addition, since the ridges 35e and 37e are formed long in the vehicle width direction inside of the portion corresponding to the inclined portion 19 of the base material 3 of each of the skin members 35 and 37, the ridges 35e The 35 e and 37 e do not easily come off, and the detachment of the skin members 35 and 37 from the foamed resin layer 33 is prevented.

  Further, since the ridges 35e and 37e are formed long at the adjacent edge in the vicinity of the air bag door 12, the detachment of the skin members 35 and 37 from the foamed resin layer 33 due to the opening operation of the air bag door 12 is prevented. Ru.

  In addition, since the projection length of the ridge portions 35e and 37e is set to 2 mm or more, the suture strength is enhanced as compared with the case where it is set to less than 2 mm, but the projection length of the projection portions 35e and 37e is 10 mm Since it is set as follows, compared with the case where it is longer than 10 mm, the foamed resin raw material is easily spread in the cavity 113 when the foamed resin layer 33 is formed.

  Further, since the stitch patterns 43 and 45 are formed by sewing, the handmade feeling and the luxury feeling are enhanced.

  Although the first and second skin members 35 and 37 are formed by slush molding in the above embodiment, they may be formed by vacuum molding.

  In the above embodiment, the stitch patterns 43 and 45 are formed on both the first and second skin members 35 and 37, but are formed on only one of the first and second skin members 35 and 37. They may or may not be formed.

  Further, in the above embodiment, the protruding portions 35e and 37e are extended on the adjacent edge of the first skin member 35 so as to protrude to the back side, but instead of these protruding portions 35e and 37e, flat surface portions An extension may be provided to extend to the back side so as to overlap with 35a.

  Moreover, in the said embodiment, although the press-contacting seal part 41 was formed in the vehicle width direction both-ends edge of the outer_skin | epidermis 31, you may form only in one edge.

  INDUSTRIAL APPLICABILITY The present invention is useful as a vehicle interior product in which a pad made of a skin and a foamed resin layer is integrally formed on the surface of a base material.

Reference Signs List 1 instrument panel 3 base material 5 pad 31 skin 33 foam resin layer 35 first skin member 35 e ridge portion (extension portion)
37 second skin member 37 e ridge (extension)
41 pressure seal portion 47 suture thread 49 tape material

Claims (1)

A pad (5) consisting of a skin (31) having first and second skin members (35, 37) adjacent to each other and a foamed resin layer (33) is integrally formed on the surface of the substrate (3) Vehicle interiors,
The edge of the skin (31) is pressed against the substrate (3) by the pressure of the foamed resin layer (33) while being sandwiched between the foamed resin layer (33) and the substrate (3) A pressure seal portion (41) is formed;
At the portions other than the end portions at the adjacent edges of the first and second skin members (35, 37), extending portions (35e, 37e) integrally extend on the back side along the adjacent edges. And the extended portion (35e, 37e) non-formation location at the adjacent edge of the two skin members (35, 37) is located at the pressure seal location (41) formation location,
The extensions (35e, 37e) of the first and second skin members (35, 37) are sewn together with a suture (47),
In the first and second skin members (35, 37), the tape material (49) straddles the extending portions (35e, 37e) of both the skin members (35, 37) in the middle in the longitudinal direction, And it is characterized in that it is folded back at its longitudinal end and straddles on the front and back sides the extension (35e, 37e) non-formed location at the adjacent edge of the two skin members (35, 37). Interior goods for vehicles.

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