JPH01160603A - Core structure of automotive interior trim - Google Patents

Abstract

PURPOSE:To contrive to simplify remarkably a production process by a method in which simultaneously with the hot press molding of a molding core member, the functional parts such as a bracket is integrally stuck to the core member by molding a prepreg. CONSTITUTION:For instance, in the manufacture of the door trim of an automobile, a sheetlike prepreg P is set on the prescribed position of the bottom force 15 for hot press-molding. A wood fiber-mat M impregnated with thermosetting- synthetic resin which is the stock of a molding core member 11 is placed on said prepreg. The top and bottom forces 15, 17 for the hot press are connected. While the wood fiber mat M is molded into a curved surface-shape as a molding core member 11, a projected portion 18 penetrates the mat M, and then the prepreg P is molded into the shape of a required bracket 13 by connecting a recessed portion 16 to the projected portion 18, and is fixed firmly to the molding core 11. After a support plate 14 has been provided so as to cover the opening over the bracket 13. A skin member 12 is integrally stuck onto the surface-side of the molding core member 11.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of the Invention) The present invention relates to a core material structure of an automobile interior part suitable for an automobile door trim or the like.

(Prior art and its problems) For example, a conventional automobile door trim will be explained based on FIG. 9. The automobile door trim 1 has appropriate rigidity,
It is composed of a molded core material 2 molded into a desired shape, and a skin material 3 that is attached to the surface side of the molded core material 2 and provides cushioning properties and design properties.

In order to attach this automobile door trim 1 to a vehicle body panel (not shown), a metal or rigid synthetic resin clip attachment bracket 4 is fixed to a predetermined location on the surface of the molded core material 2 with rivets 5 or the like. ing.

Although not shown, in addition to the clip bracket 4, reinforcing ribs, mounting bosses for tightening screws, and the like are similarly riveted to the surface of the molded core material 2.

As described above, the molded core material 2 of the conventional automobile door trim 1 includes a bracket for attaching a clip and a rib.

Since the functional parts such as bosses are fixed with rivets or screws, the process of molding these functional parts and attaching them to the molded core material is lengthy, resulting in a significant cost increase. It had been.

Further, when these functional components are set at multiple locations, problems such as incorrect attachment occur, and management of these functional components is also troublesome.

In addition, since this type of functional component is fixed by the rivet 5, depending on the installation, the head 5a of the rivet 5 may form a convex portion on the surface of the skin material 3, resulting in a problem that degrades the external design of the product. .

(Object of the Invention) This invention was made in view of the above-mentioned circumstances, and the object of the present invention is not only to form a molded core material by a hot press molding process but also to form a bracket.

By molding functional parts such as reinforcing ribs and fixing them to the core material at the same time, we can expect a significant cost reduction by simplifying the manufacturing process.Moreover, we are developing automotive interior parts that will not have a negative impact on the product appearance. The purpose is to provide a core material structure.

(Structure and Effects of the Invention) In order to achieve the above object, the core material structure of the automobile interior parts according to the present invention is obtained by hot press molding a wood fiber mat impregnated with a thermosetting resin into a desired shape. The molded core material and the prepreg inserted in advance into the hot press mold are integrally molded into a desired bracket shape, rib shape, etc. during hot press molding of the molded core material,
The molded core material is also characterized in that it is comprised of a functional component that is integrally fixed to a predetermined location on the back surface of the molded core material.

That is, according to the above configuration, prepreg (collectively referred to as BMCI block molding compound J, SMCr sheet molding compound) is used for functional parts such as clip brackets and reinforcing ribs that are fixed to predetermined locations on the back surface of the molded core material. This prepreg is molded and integrally fixed with the core material at the same time as the hot press molding of the core material, so it is possible to mold the functional parts separately from the molding of the core material as in the past. Since the man-hours required to attach molded functional parts to the core material can be omitted,
The manufacturing process is greatly simplified, and the number of man-hours required to manage these functional parts is also eliminated, which has the advantage of being expected to significantly reduce costs.

In addition, this prepreg is inserted into the hot press mold in advance and fixed at a predetermined location on the back side of the molded core material, so it does not have any adverse effect on the surface side of the core material, that is, the product surface, and unlike conventional Problems such as the head of the rivet appearing as a protrusion on the surface of the product can be effectively solved, and the appearance performance can also be significantly improved.

(Description of Embodiments) Hereinafter, embodiments in which the present invention is applied to a core material structure of an automobile door trim will be described in detail with reference to the accompanying drawings.

Figure 1 is a sectional view of an automobile door trim, Figures 2 to 4 are process diagrams showing the manufacturing process of the same door trim, and Figures 5 to 8 are diagrams showing other embodiments of the present invention. FIG.

In FIG. 1, an automobile door trim 10 includes a molded core material 11 that is molded into a required curved shape to form the product shape of the door trim and has an appropriate rigidity;
The molded core material 11 is formed by hot press molding a wood fiber mat impregnated with a thermosetting resin. In addition to being molded into a shape, the skin material 1
2 has a structure in which a cushioning material 12b such as polyurethane foam or polyolefin foam that imparts cushioning properties is laminated on the skin sheet 12aI, such as a PVC sheet that is rich in surface hardness and design.

Furthermore, the characteristic part of the present invention is that in order to attach this automobile door trim 10 to a vehicle body panel (not shown), a clip attachment bracket 13 fixed to the back side of the molded core material 11 is made of SMC (seal molding compound). ) and other prepregs are used.

That is, by molding this prepreg into the shape of a bracket 13 during hot press molding of the molded core material 11 and integrally fixing the bracket 13 to the back side of the molded core material 11, it is possible to mold the core material separately as in the conventional method. Compared to the conventional method, which required a bracket molding process and a bracket mounting process, significant cost reductions can be expected by shortening the process.

Furthermore, during hot press molding, this bracket 13
Because the molded core material 11 and the prepreg are firmly bonded and suspended by the thermosetting resin impregnated into both, the conventionally used rivets can be eliminated, and the rivet heads do not have a negative effect on the product surface. This allows the product to maintain its beautiful appearance.

Note that the reference number 14 in FIG. 1 indicates a support plate that covers the upper opening of the bracket 13 to keep the surface of the product smooth.

Next, the manufacturing process of the above automobile door trim 10 will be explained based on FIGS. 2 to 4.

For convenience of explanation, only the main parts, that is, the parts where prepreg is used, will be explained.

First, as shown in FIG. 2, the lower mold 15 for hot press molding
A sheet-like prepreg P, commonly called SMC, is set in the holder. At this setting location, a recess 16 of a predetermined shape is formed in the lower mold 15 so that the prepreg P is molded into a bracket shape. And on the upper side there is a molded core material 11.
A wood fiber mat M impregnated with thermosetting synthetic resin, which is the material of

The thermosetting resin to be impregnated into this fiber mat M is as follows:
It may be appropriately selected from polyester resin, epoxy resin, phenol resin, melamine resin, etc. An upper mold 17 for hot press molding is located above the lower mold 15 for hot press molding so as to be movable up and down with respect to the lower mold 15.
Also in this upper mold 17 for hot press molding, the recess 16
A convex portion 18 corresponding to this is formed.

When the setting of the prepreg P and the wood fiber mat M is completed, an elevating mechanism (not shown) is activated, and the upper mold 17 for hot press molding is lowered, and the upper and lower molds 15 and 17 for hot press molding are engaged. (See Figure 3).

Through this mold engagement, the wood fiber mat M is molded into the required curved shape as the molded core material 11, and
Since the fiber mat M does not have enough extensibility to conform to the shape of the convex portions 18 formed on the upper mold 17, the convex portions 18 penetrate through the mat M, and due to the engagement between the concave portions 16 and the convex portions 18, The prepreg P is molded into the desired shape of the bracket 13, and the thermosetting resin impregnated into the mat M and the prepreg P is cured at the joint between the mat M and the prepreg P, so that the brackets 1 to 13 are bonded to the molded core material 11. It is firmly fixed.

After the molded core material 11 and the bracket 13 are integrated in this way, as shown in FIG.
After installing the support plate 14 so as to cover the opening above the molded core material 11, the skin material 12 is integrally attached to the surface side of the molded core material 11, thereby producing the automobile door trim 10 shown in FIG.

As described above, according to the present invention, the bracket 13 can be formed and the bracket 13 fixed to the core material 11 at the same time as the molded core material 11 is molded by hot press molding in step -, which greatly shortens the manufacturing process. In addition, it is possible to reliably prevent defects such as erroneous attachment of brackets that conventionally occur, and the management of parts such as brackets can be abolished, so a significant cost reduction can be expected.

Next, another embodiment of the core material structure according to the present invention will be described based on FIGS. 5 to 8.

The one shown in FIG. 5 has a screw fastening boss 19 integrally fixed to the back surface of the molding core material 11, and as shown in the drawing, a substantially W-shaped recess is formed on the mold surface of the lower mold 15 for hot press molding. 20 is formed, and a block-shaped prepreg P called BMO (block molding compound) is charged in advance into this recess, and a thermosetting synthetic resin that will be the material of the molding core material is impregnated from the upper side. Set the wood fiber mat M.

Then, the upper mold 17 for hot press molding is operated by a lifting mechanism (not shown) to engage and tighten the upper and lower molds 15.17 for hot press molding, thereby molding the molding core material 11 into a desired shape. A screw tightening boss 19 having the shape shown in the drawing is integrally fixed to a predetermined location on the back surface of the screw.

In this example as well, prepreg P is used as in the previous example,
Since the boss 19 for screw tightening can be molded at the same time as the molded core material 11 and this boss 19 can be integrally fixed to the core material 11, there is no need to separately attach the boss 19 to the core material as in the conventional method. This can be eliminated, resulting in a significant cost reduction due to the shortening of the process, and improvements in design can be expected as the heads of rivets, etc. do not have a negative impact on the surface side.

Next, the one shown in FIG. 6 has through holes 2 on the molded core material 11 side.
1 is provided to further strengthen the bonding strength between the boss 19 and the molded core material 11. In addition, in FIG. In order to prevent flow from occurring and reducing the bonding strength between the molding core material 11 and the boss 19, a resin flow prevention protrusion 22 is provided on the outer periphery of the recess 20 of the lower mold 15 for hot press molding, and the prepreg P is crisped. A specific example of preventing protrusion is shown.

Similarly, in place of the bracket 13 for attaching the clip and the boss 19 for tightening screws, reinforcing ribs 23 are provided on the back side of the molded core material 11 in the same manner as in the embodiment described above, as shown in FIG. Conventionally, when a wood fiber mat is used as the molding core material 11, it is impossible to provide reinforcing ribs during molding, and the strength of the core material is not necessarily satisfactory. By fixing the prepreg P integrally as reinforcing ribs 23 during molding of the core material 11, it has become possible to roughly increase the strength of the molded core material 11.

As described above, according to the present invention, functional parts such as brackets for attaching clips, bosses for tightening screws, reinforcing ribs, etc. can be formed using prepregs such as SMC and BMC at the same time as press-molding the core material. Because it is molded and integrated with the core material, it is suitable for manufacturing core materials for various interior parts such as door trims.
This is an invention of extremely high practical value, as it can significantly shorten the manufacturing process, reliably prevent the wrong attachment of these functional parts, and maintain a beautiful product appearance.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing an example in which the core material structure of the present invention is applied to an automobile door trim, FIGS. 2 to 4 are process diagrams showing the manufacturing process of the automobile door trim, and FIGS. FIG. 8 is a sectional view showing another embodiment of the present invention, and FIG. 9 is a sectional view showing a conventional automobile door trim. 10... Automobile door trim 11... Molding core material 12... Skin material 13... Bracket 15... Lower mold for hot press molding 16. 20... Recessed portion 17... For hot press molding Upper mold 18...Protrusion 19...Boss for screw tightening 22...Protrusion 23 for preventing resin flow...Reinforcement rib

Claims (1)

[Claims] (1) A molded core material made by hot press molding a wood fiber mat impregnated with a thermosetting resin into a desired shape, and a prepreg inserted in advance into a mold for hot press molding. An automobile interior part comprising a functional part that is integrally molded into a desired bracket shape or rib shape during press molding and is integrally fixed to a predetermined position on the back surface of the molded core material. Core structure.