JP7112891B2 - METHOD FOR MANUFACTURING PADDED VEHICLE INTERIOR - Google Patents

Description

The present invention relates to a method of manufacturing a padded vehicle interior, such as an automobile instrument panel.

For example, some automotive interior parts such as instrument panels and glove boxes have pads integrally laminated on a hard core material. The pad has a soft skin with a design surface and an elastic foam material provided on the back surface. In a vehicle interior product with a pad, the core material provides the necessary strength, the skin improves the decorativeness, and the foam material improves the tactile sensation and reduces the impact in the event of an accident.

Patent Literature 1 below discloses a method of manufacturing an instrument panel with a pad (vehicle interior part). Briefly, first, a preformed skin and core material are placed in a lower mold and an upper mold, respectively. A ridge is formed in advance at the joint portion of the core material with the skin, and when the upper mold and the lower mold are matched and the ridge is brought into close contact with the skin for sealing, the gap between the core material and the skin is formed. A filling space is formed in By filling the filling space with the foaming raw material while foaming, the pad composed of the skin and the foaming material is integrally laminated on the core material.

In the method of manufacturing an instrument panel with a pad disclosed in Patent Document 1, the projections provided on the core material are brought into close contact with the skin, thereby preventing the foaming material from leaking out of the filling space. However, when the foaming raw material is filled, the air in the filling space and the gas generated from the foaming raw material cannot escape from the filling space to the outside, causing voids (air pockets) in the manufactured instrument panel. Therefore, the product value of the instrument panel is impaired.

Patent Document 2 below discloses a method for manufacturing an instrument panel with a pad as in Patent Document 1. In the method disclosed in Patent Document 2, a large number of small gas vent grooves are provided in a portion of the core material that is in close contact with the skin over substantially the entire circumference of the filling space to communicate the inside and outside of the filling space. As a result, the air in the filling space and the gas generated from the foaming material can escape from the filling space to the outside when the foaming material is filled, thereby suppressing the formation of voids in the manufactured instrument panel.

Japanese Patent Publication No. 4-15091 (Fig. 5) Japanese Patent Application Laid-Open No. 6-344358 (Figs. 1, 2, 5)

When manufacturing an instrument panel with a pad by the manufacturing method of Patent Document 2, it is possible to suppress the generation of voids, but it is necessary to prevent only the gas from leaking from the filling space through the gas vent groove and the foaming raw material to leak. In order to achieve this, it was necessary to finely adjust the width, depth and length of the gas vent grooves, the distance between the adjacent gas vent grooves, and the like. However, it has been difficult to achieve both the prevention of void generation and the prevention of leakage of the foaming raw material from the gas vent grooves. If the foaming raw material does not leak from the gas vent groove or if the leaking amount is reduced, the formation of voids cannot be avoided. Therefore, in order not to cause voids, a certain amount of the foaming raw material had to leak from the filling space.

The foam material that leaked out of the filling space flowed from the outer edge of the many gas vent grooves, and solidified foam material burrs adhered to the core material and skin, degrading the appearance of the instrument panel. As a result, the post-treatment for removing the adhering burrs has become complicated.

In order to solve the above-mentioned problems, the present invention fills a filling space between a core material and a skin with a foaming raw material from an injection port while foaming, so that a pad containing the skin and the foam material is the core material. In the method of manufacturing a padded vehicle interior part that is integrally laminated thereon, an escape passage is formed between the core material and the outer skin at a location away from the injection port at the peripheral edge of the filling space. are connected to the outside of the filling space, and a guide portion is formed outside the filling space so as to continue to the escape passage. In the step of foaming and filling the foaming raw material, air in the filling space is released from the release passage, and part of the foaming raw material leaks out and is guided to the guide portion.

According to the above configuration, by providing an escape passage at a location away from the injection port, the air in the filling space that has been cornered by the filling of the foaming raw material gathers and escapes from the filling space, so that the generation of voids can be suppressed. can. In addition, this escape passage can concentrate the leaking portion of the foaming raw material. Furthermore, the leaked foaming raw material can be guided to a desired position by the guide portion formed in continuation with the escape passage. As a result, it is possible to limit the adhesion position of the burrs of the foaming material caused by the solidification of the leaked foaming raw material to a position that is not visible or that can be easily removed. Therefore, it is possible to omit or simplify the burr removal process that is performed as a post-treatment after manufacturing the vehicle interior trim with pads.

Preferably, the guide part penetrates the core material, and part of the foaming material leaking from the escape passage in the step of filling the foaming material with the foaming material flows to the back side of the core material through the guide part. be guided.
According to the above configuration, around the filling space, there is no room for escape of the leaked foaming raw material, such as the end of the core material, and there is a place where it is not desired to generate burrs of the foaming material for reasons such as conspicuousness. , the foam raw material can be guided to the back side of the core material by the guide part penetrating the core material. Therefore, it is possible to increase the degree of freedom in selecting the installation positions of the escape passage and the guide portion.

Preferably, the vehicle interior trim is an instrument panel.

ADVANTAGE OF THE INVENTION According to this invention, the void is not produced in the vehicle interior goods with a pad, and the burr removal process performed after manufacture of the vehicle interior goods with a pad can be abbreviate|omitted or simplified.

1 is a perspective view showing a padded instrument panel manufactured by a manufacturing method according to an embodiment of the present invention and having been post-processed; FIG. FIG. 4 is an enlarged plan view of the main part of the instrument panel, showing the right part in the vehicle width direction; (A) An enlarged view of circle portion III in FIGS. 1 and 2, showing a guide portion of the instrument panel. (B) is a perspective view showing a guide rib that constitutes the same guide portion. Fig. 3 (A ) along the IV-IV line. (A) It is the figure which expanded the circular part V of FIG.1 and FIG.2, Comprising: The guide part as a modification of the same instrument panel is shown. (B) is a perspective view showing guide ribs and through-holes forming the same guide portion. Fig. 5 (A ) along the VI-VI line.

An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 shows a schematic configuration of a padded instrument panel 1 (padded vehicle interior part) as a product. The instrument panel 1 has a core member 10 extending in the left-right direction, and a pad 20 covering a predetermined region of the core member 10 and laminated integrally with the core member 10 . The pad 20 has an outer skin 30 whose surface is a design surface, and a foam material 40 provided in a state sandwiched between the outer skin 30 and the core material 10 on the back side thereof.

The core material 10 is formed by molding a hard thermoplastic resin such as a composite resin containing polypropylene as a base material and talc or ABS resin by injection molding or the like. An opening 11 is formed for installing equipment. The core member 10 has a first covered area 12a and a second covered area 12b covered with the pads 20 on the left and right sides of the opening 11 in the vehicle width direction.

In the core member 10, an injection part 13 having a plurality of injection holes 13a is provided near the center of the upper edge of the opening 11. As shown in FIG. A first runner forming portion 14 extends into the first covering region 12a from the inlet 13a, and a second runner forming portion 15 extends into the second covering region 12b.

The first and second covering regions 12a and 12b are defined by sealing ribs 16 shown in FIG. 3(B). The sealing rib 16 is formed integrally with the core member 10 . In this sealing rib 16, the top of the sealing rib 16 is V-shaped as shown in FIG. A notched groove 16a is formed.

As will be described later, by covering the first and second covered regions 12a and 12b defined by the sealing ribs 16 with the skin 30, a filling space 50 is formed in the second covered region 12b as shown in FIG. Although not shown, a filling space 50 is also formed in the first covering region 12a. The filling space 50 is filled with the foaming raw material. Further, by covering the groove portion 16a of the sealing rib 16 with the skin 30, the escape passage 60 is formed by the skin 30 and the groove portion 16a. This escape passage 60 allows the air in the filling space 50 to escape and part of the foaming material in the filling space 50 to leak out during the process of filling the foaming material.

As shown in FIG. 3B, two guide ribs 17, 17 are provided in parallel on the opposite side of the sealing rib 16 from the filling space 50 so as to sandwich the groove 16a therebetween. It extends towards the edge of the core material 10 . The guide ribs 17 are formed integrally with the core member 10 . The proximal ends of the guide ribs 17 intersect the sealing ribs 16, and intersect substantially perpendicularly in this embodiment. The top of the proximal end of the guide rib 17 is flush with the top of the sealing rib 16 . The protrusion height of the guide rib 17 from the surface 10a of the core member 10 gradually decreases from the base end to the tip end, and the protrusion height is constant from the halfway point 17a near the sealing rib 16. - 特許庁

As shown in FIGS. 3A and 4, the guide ribs 17, 17 are covered with the skin 30, so that the space surrounded by the skin peripheral edge 30a, the surface 10a of the core material 10, and the guide ribs 17, 17 becomes the guide portion. 70. The guide portion 70 is connected to the escape passage 60, and guides the foaming material leaking from the filling space 50 toward the tip of the guide rib 17 in the process of filling the foaming material, as will be described later.

As shown in FIG. 2, other guide ribs 17, 17 are also provided at a position close to the left side in the vehicle width direction with respect to the guide ribs 17, 17 of the circular portion III, and are similar to the guide ribs 17 of the circular portion III. A guide portion 70 is formed by covering the core material 10 with the outer skin 30, and an escape passage 60 connected to the guide portion 70 is formed.

The skin 30 is made of polyvinyl chloride, thermoplastic urethane, thermoplastic olefin, or the like, and is formed by powder slush molding, hot press molding, vacuum molding, or the like depending on the material.
As shown in FIG. 1 , the skin 30 has a shape corresponding to the first covering area 12 a and the second covering area 12 b of the core material 10 . Specifically, the skin 30 has a first region 32a corresponding to the first covering region 12a and a second region 32b corresponding to the second covering region 12b. The first region 32a and the second region 32b are formed slightly larger than the first covering region 12a and the second covering region 12b of the core material 10, respectively. The outer skin 30 also has a runner cover region 33 having a shape corresponding to the injection portion 13 , the first runner forming portion 14 and the second runner forming portion 15 of the core material 10 .

A method of manufacturing a padded instrument panel using the core material and the skin having the above structure will be described.
As shown in FIG. 4, the core member 10 and the outer skin 30 are set in the mold 80 with the instrument panel 1 turned upside down from when it was attached to the vehicle body. The skin 30 is set on the lower mold 81 and fixed by vacuum suction through suction holes (not shown) provided in the lower mold 81 . The core material 10 is set in the upper mold 82, and the inlet 13a of the core material 10 shown in FIG.

The lower mold 81 is aligned with the upper mold 82, and the sealing ribs 16 of the core material 10 are brought into close contact with the outer skin 30 for sealing. At this time, the core material 10 and the skin 30 are arranged facing each other in the cavity of the mold 80, and the filling space 50 is formed therebetween. Specifically, between the first covering region 12a of the core material 10 and the first region 32a of the skin 30, and between the second covering region 12b of the core material 10 and the second region 32b of the skin 30, filling A space 50 is formed.

When the upper die 82 and the lower die 81 are matched, the escape passage 60 is formed by the groove portion 16a of the sealing rib 16 of the core material 10 and the skin 30, and the guide portion 70 is formed on the surface of the core material 10. 10a, guide ribs 17, 17, and skin peripheral edge 30a.
The filling space 50 is also formed between the injection portion 13, the first runner-constituting portion 14, and the second runner-constituting portion 15 of the core material 10 shown in FIG. Thereby, the first runner 4 is formed on the first runner forming portion 14 and the second runner 5 is formed on the second runner forming portion 15 .

Next, a foaming raw material is injected into the filling space 50 and foamed to form a foamed material.
The foam raw material is foamed and solidified to form the elastic foam material 40 . As a foaming raw material, for example, a two-liquid mixing type urethane foam raw material is injected into the inlet 13 a of the core material 10 through a gate (not shown) in the upper mold 82 of the mold 80 . The foaming raw material is branched from the inlet 13 a and directly supplied to the first runner 4 and the second runner 5 . The foaming material supplied to the first runner 4 fills the filling space 50 of the first covering area 12a, and the foaming material supplied to the second runner 5 fills the filling space 50 of the second covering area 12b.

The foaming raw material is filled into the filling space 50 while foaming. At that time, the air in the filling space 50 and the gas generated from the foaming raw material are forced into a position away from the injection port 15 in the filling space 50 by the filled foaming raw material, and finally escape as shown in FIG. It escapes to the outside of the filling space 50 through the passage 60 . When the filling space 50 is filled with the foaming raw material, excess foaming raw material leaks out through the escape passage 60 . Injection of the foaming material is stopped when a sufficient amount has leaked out to suppress the formation of voids. As shown in FIG. 4 , the foaming raw material leaking out of the filling space 50 flows through the guide portion 70 toward the edge of the core material 10 and stays inside the guide portion 70 and the portion beyond the tip of the guide rib 17 .

The foam raw material is foamed and solidified in the filling space 50 to form the foam material 40 . The foam material 40 is integrated with the core material 10 and the skin 30 due to the adhesiveness of the foam material during foaming. That is, the pad 20 composed of the skin 30 and the foam material 10 is laminated on the core material 10 . The foaming raw material leaking out of the filling space 50 is also foamed and solidified, and burrs 40 a of the foaming material 40 adhere to the inside of the guide portion 70 and the tips of the guide ribs 17 .

After foam molding is completed, the manufactured instrument panel 1 with pad is removed from the mold 80 .
As a post-treatment, the outer peripheral edge portion 30a of the sealing rib 16 in the skin 30 shown in FIGS. 3A and 4 is excised. At this time, the burrs 40a of the foam material 40 are also removed. If the sticking position of the burr 40a is in a place that is not visible to the human eye, the removing process of the burr 40a may be omitted. At this time, the injection portion 13 of the core material 10, the runner cover region 33 of the outer skin 30, and the foam material 40 of the injection portion 13 and the first and second runners 4 and 5 shown in FIG. 1 are removed.

According to the above-described embodiment, by providing the escape passage 60 at a location away from the injection port 13a, the air in the filling space 50 confined by the filling of the foaming raw material is collectively released to the outside. Thereby, the generation of voids in the pad 20 can be suppressed.
In addition, the escape passage 60 can concentrate the leaking portion of the foaming raw material, and the guide part 70 formed continuously with the escape passage 60 can guide the leaked foaming raw material to a desired position. In other words, it is possible to restrict the attachment position of the burr 40a of the foaming material 40 caused by solidification of the leaked foaming raw material, for example, it is possible to restrict the burr 40a to an out-of-sight position or an easy-to-remove position. Therefore, it is possible to omit or simplify the burr removal process that is performed as a post-treatment after manufacturing the vehicle interior product 1 with pads.

Next, modified examples of the present invention will be described. In addition, regarding the following modifications, only the configurations different from the above embodiment will be described, and the same components will be denoted by the same reference numerals, and descriptions thereof will be omitted.

Circle V in FIGS. 1 and 2 and FIGS. 5 and 6 show a variant of the invention. In this modified example, the location where the foaming raw material leaking out of the filling space is guided by the guide portion is different from that in the above-described embodiment.

As shown in FIG. 5B, a U-shaped guide rib 18 in plan view is provided integrally with the core member 10 on the opposite side of the sealing rib 16 from the filling space 50 . surrounds a groove 16a formed in the . The guide rib 18 has side wall portions 18a, 18a extending parallel to each other with the groove portion 16a interposed therebetween, and a facing wall portion 18b connecting the tip end portions of the side wall portions 18a and facing the groove portion 16a.

As shown in FIGS. 5A and 5B, a through hole 19 penetrating through the core member 10 is formed in the surface 10a of the core member 10 surrounded by the guide ribs 18 and the sealing ribs 16. As shown in FIGS. As shown in FIGS. 5A and 6, the guide rib 18 is covered with the skin 30 to form the guide portion 70A. The guide portion 70</b>A is composed of a space surrounded by the skin peripheral portion 30 a , the guide ribs 18 and the sealing ribs 16 , and the through holes 19 . The guide portion 70A continues to an escape passage 60 formed by the skin 30 and the groove portion 16a of the sealing rib 16. As shown in FIG.

In the step of filling the foaming raw material, after the foaming raw material fills the filling space 50, excess foaming raw material leaking out from the escape passage 60 flows through the guide portion 70A as shown in FIG. , toward the back surface 10b opposite to the skin 30 side. As a result, burrs 40a of the foam material 40 formed by solidifying the foam raw material adhere to the back surface 10b of the core material 10 .

According to the modified example described above, the burr 40 a can be generated on the back surface 10 b of the core material 10 by guiding the foam material to the back surface of the core material 10 . Therefore, around the filling space 50, there is no room for the leaked foaming material to escape, such as the end of the core material 10, and the foam material is not placed on the surface 10a of the core material 10 for reasons such as being visible to people. The escape passage 60 and the guide portion 70A can be provided even at a location where the burr 40a is not desired. Therefore, it is possible to increase the degree of freedom in selecting the installation positions of the escape passage 60 and the guide portion 70A.

The present invention is not limited to the above-described embodiments, and various aspects are possible without departing from the gist of the present invention. The present invention is not limited to instrument panels, but can be applied to the manufacture of vehicle interior parts having pads, such as glove boxes.
In the above-described embodiment, the molding space, the relief passage and the guide portion on the side of the second covering region 12b on the right side in the vehicle width direction of the core material of the instrument panel have been described. A guide is provided.
In the above-described embodiment, as shown in FIG. 2, the escape passage and the guide portion are provided at three locations on the one covering region 12b side of the instrument panel. The installation positions of the escape passage and the guide portion are not limited to the above embodiment.

INDUSTRIAL APPLICABILITY The present invention can be applied to manufacture of vehicle interior parts having pads such as instrument panels.

1 Instrument panel (vehicle interior parts)
REFERENCE SIGNS LIST 10 core material 10a core material surface 10b core material back surface 13a inlet 16 sealing rib 16a groove 17 guide rib 18 guide rib 19 through hole 20 pad 30 skin 30a skin periphery 30a
40 Foam material 40a Burr of foam material 50 Filling space 60 Relief passage 70, 70A Guide part 80 Mold 81 Lower mold (mold)
82 upper die (mold)

Claims (4)

A pad-equipped vehicle in which a pad containing the skin and the foam material is integrally laminated on the core material by filling the filling space between the core material and the skin with foaming raw material through an injection port. In a method for manufacturing an interior product,
The filling space is defined by a sealing rib integrally formed with the core material,
A relief passage formed between the core material and the outer skin continues at a portion away from the injection port in the peripheral edge portion of the filling space, and the relief passage is formed by notching the top portion of the sealing rib to the inside. is formed by a groove extending outwardly from and the skin covering the groove, and communicates with the outside of the filling space and the outside of the sealing rib ,
A guide portion is formed so as to be connected to the escape passage outside the filling space outside the sealing rib ,
A vehicle interior part with a pad, characterized in that, in the step of foaming and filling the foaming raw material, the air in the filling space is released from the escape passage and part of the foaming raw material leaks out and is guided to the guide portion. manufacturing method. The guide portion includes at least the sealing rib around the groove portion, and a pair of guide portions provided integrally with the core member so as to sandwich the groove portion outside the sealing rib and extending in a direction away from the sealing rib. guide ribs, the surface of the core material between the pair of guide ribs, and the skin covering the sealing ribs and the guide ribs. A method of manufacturing a padded vehicle interior trim. The guide part penetrates the core material, and in the step of filling the foam material with the foam material, part of the foam material leaking from the escape passage is prevented from flowing to the back side of the core material through the guide part. 3. A method of manufacturing a vehicle interior trim with a pad according to claim 1 or 2 . 4. The method for producing a padded vehicle interior part according to any one of claims 1 to 3, wherein the vehicle interior part is an instrument panel.

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