JPH02145338A - Interior material for vehicle and manufacture thereof - Google Patents

Abstract

PURPOSE:To integrally manufacture a vehicle interior material by in-molding a bracket, etc. with a skin sheet having a leather-embossed design, and then in-molding a duct, a box, etc. by foaming. CONSTITUTION:A skin sheet 12 exhibiting a predetermined shape and having a leather-embossed design on its surface is molded by a molding machine 30. Then, the sheet 12 is placed in a first mold device 32, a first attachment component 16 made of metal magnetic material is held in an upper mold 72 for composing the device 32 through a magnetic 80, and an intermediate unit 100 made of the sheet 12, a first foamed material 14 and the component 16 is formed. Thereafter, after the unit 100 is blasted, a second attachment component 20 is placed, and a molding is formed in a second foaming step. An interior material 10 obtains sufficient rigidity without using a core material.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a vehicle interior body and a method for manufacturing the same. A skin sheet body having an uneven pattern on the surface is molded, and then, in a first foaming step, brackets and the like are in-molded on this skin sheet body,
Furthermore, by in-molding the ducts, frames, etc. in the second foaming process, the entire interior body can be manufactured in one piece, and the vehicle interior body has a particularly excellent appearance and is lightweight, and its production. Regarding the method.

[Background of the Invention] In general, an uneven leather pattern is often formed on the outer surface of an interior body into which an automobile instrument panel or the like is incorporated. That is, by forming a leather pattern, a so-called leather grain pattern, on the surface of the synthetic resin sheet, the interior body itself is given a sense of luxury. In addition, in order to ensure a soft touch, a composite sheet body is used in which a foam sheet made of vinyl chloride resin is attached as a cushion layer to a leather sheet made of vinyl chloride resin.

Therefore, in order to manufacture this type of interior body,
Two methods are widely used: That is, as a first method, a skin sheet body having an uneven pattern formed on its surface is heated and softened, and then the skin sheet body is placed in one of the pressing molds constituting a molding device, and
A core material whose polymerization surface is coated with an adhesive is placed in the other pressing mold. Then, by clamping the respective pressing dies, the skin sheet body and the core material are integrally fixed and molded into a predetermined shape to obtain an interior body.

On the other hand, in the second method, the skin sheet is heated and softened, a molding device is configured, and the skin sheet is vacuum-sucked into a pattern made of a porous electroformed body to form an uneven pattern, and then an adhesive is applied. The inner body is molded by applying the same and pressing the core material disposed in the other mold onto the skin sheet body.

However, when manufacturing an interior body including, for example, an automobile instrument panel using each of the above-mentioned conventional methods, it is necessary to divide the interior body into two or three parts because the interior body is large and has a complicated shape. After forming the part,
Must be joined to each other. In this way, since a single interior body is divided into two or three parts and each part is formed individually, it has been pointed out that there are disadvantages in that the entire manufacturing operation becomes complicated and requires a lot of man-hours.

Moreover, when joining and integrating the respective divided parts, joining lines appear on the surface of the interior body, making it difficult to obtain a sense of unity as a whole, and in addition, steps, etc. are caused at the joint parts, which deteriorates the appearance. The shortcomings of inferiority are exposed. Furthermore, due to the bonding, the rigidity of the interior body as a whole is reduced, and there is also a high risk that squeaks or the like may be generated from the bonded portions when the vehicle is driven. In addition, a core material is used to reinforce the outer sheet body, which increases the weight of the interior body.

Furthermore, assembly parts such as ducts and boxes are attached to the interior body manufactured by the above-mentioned conventional technique by screws, which reduces creep resistance and complicates assembly work. As a result, the inconvenience has become apparent that it is not possible to obtain a luxurious feel as an automobile interior body, and furthermore, the efficiency of the entire manufacturing operation cannot be achieved.

[Object of the Invention] The present invention has been made to overcome the above-mentioned disadvantages. First, a skin sheet body is formed into a predetermined shape and an uneven pattern is formed on its surface. A first foam body in which a part of a first attachment part such as a bracket is embedded is formed in the sheet body in a first foaming process, and a second attachment part such as a duct or a frame is further buried in a second foaming process. By forming a partially buried second foam in the skin sheet body, for example, it becomes possible to manufacture an automobile interior body as a whole as a whole, giving it a luxurious appearance with no joints. In addition to being able to exhibit
To provide a vehicle interior body and its manufacturing method, which can easily reduce the weight of the entire interior body, and further reduce the manufacturing process and the assembly process of various attachment parts at once to enable efficient manufacturing work. With the goal.

[Means for Achieving the Object] In order to achieve the above object, the present invention provides a skin sheet body having an uneven pattern formed on its surface, and a part of a first attachment part formed on the back surface of the skin sheet body. and a second foam formed on the back surface of the skin sheet body and/or the first foam and in which a part of the second attachment part is embedded. It is characterized by

The present invention also includes a step of molding a skin sheet body that corresponds to the shape of an interior body and has an uneven pattern on its surface, and arranging a first attachment part at a desired position of the skin sheet body,
A first foam body is formed by burying a part of the attachment part.
a second foaming step of arranging a second attachment part and embedding a part of the second attachment part to form a second foam in the skin sheet body and/or the first foam body; It is characterized by consisting of a foaming process.

[Embodiments] Next, preferred embodiments of the vehicle interior body and the manufacturing method thereof according to the present invention will be described in detail in connection with an apparatus for carrying out the same, and with reference to the accompanying drawings. .

In FIG. 1a, reference numeral 10 indicates a vehicle interior body according to this embodiment. In this case, the interior body 10 has an instrument panel mounting part A located on the left side in the figure and exhibiting a curved shape, a handlebar mounting part B located below this mounting part A, and a handlebar mounting part B located approximately in the center. It is integrally formed with a storage box C that houses an air conditioner, etc., and a glove box D that is located at the lower right side and can be opened and closed freely.

As can be understood from FIG. 2d, the interior body 10 includes an outer skin sheet body 12 with a skin wrinkle pattern formed thereon, a first foam body 14 formed on the back side of this skin sheet body 12, and a first foam body 14 formed on the back side of this skin sheet body 12. 1 first fitting part 1 in-molded in foam 14
6, a second foam 18 formed to overlap the first foam 14 and/or the skin sheet body 12, and a second attachment part 20 in-molded on the second foam 18.
It basically consists of.

The skin sheet body 12 is essentially a composite sheet body made by laminating a leather sheet such as polyvinyl chloride and a polyolefin foam sheet, while the first and second foam bodies 14 and 18 are made of hard urethane foam. Made of resin.

As shown in FIG. 1, the first mounting part 16 is composed of a plurality of brackets 22 made of a magnetic metal material, for example, a steel plate material, and these brackets 22 perform a reinforcing function for the interior body 10. Further, as shown in FIG. 1C, the second attachment part 20 includes an instrument back box 24, a clock box 26, a side duct 28, etc., which are made of a resin material.

Next, an apparatus for manufacturing the inner body l opening will be explained. That is, as shown in FIG.
A molding device 30 for molding, a first mold device 32 for forming the first foam 14, and a second mold device 34 for forming the second foam 18. There is.

The molding device 30 has a base 36, and the base 36
Supports 38a to 38d are erected at each of the four corners.

A crown 40 is attached to the upper part of the pillars 38a to 38d, and the cylinder 4 attached to this crown 40
A mold ram 44 is suspended from a piston rod 42a extending vertically downward from the mold ram 44. The mold ram 44 is guided by supports 38a to 38d and can be raised and lowered freely.
A frame ram 46 is similarly guided by supports 38a to 38d and is disposed below the frame ram 46 so as to be movable up and down under the action of an actuator (not shown). Four gripping means 48 are attached to the frame ram 46 and are capable of gripping the corners of the flat skin sheet body 12. In this case, the gripping means 48 holds the skin sheet body 1 by pressing means (not shown) provided on the frame ram 46.
The gripping action of No. 2 is configured to be releasable.

Therefore, the lower mold 54 is mounted on the base 36, and the upper mold 56 is suspended from the mold ram 44. In this case, the lower mold 5
4. The upper mold 56 is made of a so-called porous electroformed body having a plurality of ventilation holes, and pressurized air is directed from the lower mold 54 to the upper mold 56, but not shown in the upper mold 56. A suction mechanism is connected. Further, a leather pattern, that is, a leather grain pattern is formed in advance on the surface of the upper mold 56.

As shown in FIG. 4, the first mold device 32 includes a base 58, on which a lower mold 60 provided with a suction mechanism (not shown) is placed, and a side mold 62a. , 62b are swingably supported on the base 58 via support shafts 64a, 64b. Spring members 66a and 66b engage with the lower portions of the side molds 62a and 62b to press the side molds 62a and 62b toward each other, while a cylinder 68a is swingably supported on the base 58; Piston rods 70a, 70b extending from the side molds 62a, 62b
Attach to.

An upper mold 72 is disposed above the lower mold 60 and the side molds 62a, 62b so as to be movable up and down, and a cavity 74 is defined by the upper mold 72, the lower mold 60, and the side molds 62a, 62b. , the cavity 74 communicates with a nozzle 78 via a passage 76 . The upper die 72 has a first attachment part 1.
A magnet 80 is attached to a predetermined position to attract and hold the first mold device 32, and a plurality of clamp means 82 are provided for clamping the first mold device 32. The clamping means 82 includes a cylinder 84, and one end of a swing arm 88 engages a piston rod 86 extending from the cylinder 84. A substantially central portion of the swing arm 88 is supported by a support pin 90, and a roller 92 is supported at the lower end thereof. Then, the roller 92 presses the inner wall surface of the cylindrical locking member 94 provided on each side mold 62a162b to clamp the first mold device 32.

Furthermore, the second mold device 34 is configured in substantially the same manner as the first mold device 32 described above, and the same components are given the same reference numerals and detailed explanation thereof will be omitted. . In this case, as shown in FIG.
A cavity 96 having a predetermined shape is defined within the upper mold 72a, and the shape of the upper mold 72a is selected in advance so that the second attachment part 20 is disposed within the cavity 96.

Although not shown, a blasting device is disposed between the first mold device 32 and the second mold device 34 in order to remove the mold release agent adhering to the intermediate, as described later. Furthermore, a trimming device is provided downstream of the second mold device 34.

The apparatus for carrying out the method for manufacturing a vehicle interior body according to the present embodiment is basically configured as described above, and its operation and effects will be explained next.

Therefore, the inner body 10 is actually manufactured according to the procedures shown in FIGS. This will be explained below. It should be noted that the cutting parts shown in FIGS. 2a to 2d and the cutting parts in the respective devices 30, 32i6 and 34 show states in which the interior body 10 is cut at different parts.

First, in the molding apparatus 30, the frame ram 46 and the mold ram 44 are placed at the positions shown in FIG. The four corners of the skin sheet body 12 are gripped. Next, the frame ram 46 is lowered along the struts 38a to 38d under the action of an actuator (not shown), and the skin sheet body 12 is engaged with the lower mold 54. Further, the piston rod 42a is displaced vertically downward under the driving action of the cylinder 42, and the mold ram 44 suspended thereon is similarly lowered under the guiding action of the struts 38a to 38d.

At this time, pressurized air is led from the lower mold 54 to the skin sheet body 12, and the skin sheet body 12 is attracted to the upper mold 56 under the action of a suction mechanism (not shown). In this way, the supply and suction of pressurized air to the lower mold 54 and the upper mold 56 can be easily achieved by employing, for example, the mold structure disclosed in Japanese Patent Application Laid-Open No. 61-272126. Therefore, the skin wrinkle pattern formed on the upper die 56 is transferred to the surface of the skin sheet body 12, and the skin wrinkle pattern formed on the upper die 56 is transferred to the surface of the skin sheet body 12.
2 is molded into a predetermined shape (see Fig. a).

After the molding work of the skin sheet body 12 is completed, the cylinder 4
2 through the piston rod 42a under the driving action of the mold ram 4.
4 is raised to separate the upper mold 56 from the lower mold 54, and at the same time, the frame ram 46 is raised under the driving action of a drive source (not shown) to remove the skin sheet body 12 held by the gripping means 48.
is removed from the lower mold 54 and upper mold 56. Further, the gripping action of the skin sheet body 12 is released under the action of a pressing means (not shown). At that time, the skin sheet body 12 is held between conveyance means (not shown), and the skin sheet body 1
2 is transferred from the molding device 30 to the first mold device 32 side.

In the first mold device 32, the upper mold 72 is raised, and a release agent is applied to the upper mold 72 in advance, and the bracket, which is the first mounting part 16, is attached to the magnet 80 implanted in a predetermined position. 22 is held by suction.

Here, the skin sheet body 12 conveyed from the molding device 30 is inverted 1806 so that the skin grain pattern side is directed downward, and is placed on the lower mold 60 and the side molds 62a and 62b,
The skin sheet body 12 is attracted to the lower mold 60 under the action of a suction mechanism (not shown).

Next, as shown in FIG. 5, after lowering the upper die 72, the cylinder 84 constituting the clamping means 82 is driven to displace the piston rod 86 outward. Therefore, the swinging arm 88 that engages with the piston rod 86 swings around the support bin 90, and the roller 92 moves toward the side mold 6.
The inner wall surfaces of the locking members 94 provided at 2a and 62b are pressed, thereby clamping the first mold device 32. At that time, as shown in FIG. 2a, the skin sheet body 1
The first attachment part 16 is then disposed at a predetermined location of 2.

Therefore, when a foamed resin solution, for example, a hard urethane foamed resin solution, is supplied from the nozzle 78 to the passage 76 of the first mold device 32, the cavity 74 is filled with this solution.

Then, the solution in the cavity 74 is heated to foam, thereby forming the first foam body 14 on the back side of the skin sheet body 12. Here, the upper mold 72 has a magnet 8
A first attachment part 16 is held through the first attachment part 16, and as shown in FIG. In this case, ribs 14a and mounting allowances 14b for positioning and mounting the second mounting component 20 are formed at predetermined portions of the first foam body 14.

Skin sheet body 12, first foam body 14, and first attachment part 16
After integrally forming the intermediate body 100 consisting of the following, the first mold device 32 is opened. That is, the clamping means 82
By driving the cylinder 84 constituting the piston rod 86 and displacing the piston rod 86 inward, the swing arm 88 is swing-displaced, and the roller 92 is disengaged from the locking member 94. Then, while displacing the upper mold 72 upward, the cylinders 68a and 68b provided on the base 58 are driven to move the respective side molds 62a1 under the displacement action of the piston rods 70a and 70b.
62b is oscillated in a direction away from each other against the elastic force of spring members 66a and 66b. Further, the suction mechanism provided in the lower mold 60 is deenergized, and the intermediate body 100 is released from the first mold device 32 via a conveying means (not shown).

In this case, as described above, the upper die 72 has the intermediate body 1
A mold release agent is applied in advance so that the intermediate body 100 can be easily released from the mold, and the mold release agent often adheres to the intermediate body 100. For this reason, the intermediate body 100 taken out from the first mold device i32 is transferred to a blasting device (not shown), and the first foam body 14 of the intermediate body 100 is subjected to a blasting process, thereby substantially forming the first foam body. The mold release agent adhering to 14 is removed.

Next, the intermediate body 100 after the blasting process is carried out in a second
Transfer to mold device 34. In the second mold device 34, similarly to the first mold device 32 described above, the upper mold 72a is previously displaced upward, and first, the lower mold 60 and the side molds 62a, 62
The intermediate body 100 is placed on b. And the intermediate 1
Second mounting parts 20 made of resin material, such as an instrument back box 24, a clock box 26, and a side duct 28, are mounted on the first foam body 14 of No. 00. That is, as shown in FIG. 2C, after placing the instrument back box 24, which is the second attachment part 20, on the rib 14a and attachment allowance 14b formed on the first foam body 14, the upper mold 72a is placed. is lowered to clamp the second mold device 34. Next, a hard urethane foam resin solution is injected into the cavity 96 from the nozzle 78 and heated, whereby the second foam 18 is integrally molded into the intermediate body 100, and the second foam 18 is molded integrally with the intermediate body 100. A portion of the second attachment part 20 is embedded in the second foam body 18. In this case, as shown in FIG. 5, it is preferable to provide a sealing member S on the instrument back box 24 or the like to prevent the solution from leaking to unnecessary parts. In addition,
Of course, the second attachment part 20 is accurately positioned by the rib 14a and the attachment allowance 14b.

Furthermore, similarly to the first mold device 32 described above, the second mold device 34 is opened to remove the skin sheet body 12 and the first foam body 1.
4. The molded body 102 integrally provided with the first attachment part 16, the second foam 18, and the second attachment part 20 is released from the mold. Next, this molded body 10 is cut through a trimming device (not shown).
By trimming the ends of 2 and a predetermined opening, the interior body 10 is manufactured.

In this case, according to this embodiment, first, the skin sheet body 12 having a predetermined shape and having a skin grain pattern on the surface portion is molded by the molding device 30.

Next, this skin sheet body 12 is placed on the first mold device 32, and the upper mold 7 constituting the first mold device 32 is placed.
2 holds the first attachment part 16 made of a metal magnetic material through a magnet 80, and a first foaming process produces an intermediate body consisting of the skin sheet body 12, the first foam 14, and the first attachment part 16. Form 100. Furthermore, the intermediate 10
After blasting the 0, it is transferred to the second mold device 34.
A second layer made of resin material is added to this intermediate body 100.
Mounting part 20 is placed and molded body 1 is formed by a second foaming process.
Form 02. Then, the molded body 102 is subjected to a trimming process to obtain the inner body 10.

In this way, when forming the first and second foam bodies 14.18, the first and second attachment parts 16.20 consisting of the bracket 22, various boxes 24.26, etc., which were conventionally assembled by screwing etc. It is integrally in-molded. Therefore, it is possible to eliminate the need for complicated work such as screw fastening work, which requires human labor. This simplifies the manufacturing process of the interior body 10 at once, and has the effect that efficiency and automation of the entire manufacturing work can be easily achieved.

Moreover, the first and second parts are substantially made of hard urethane foam without using a core material and without screwing.
The foam members 14 and 18 make it possible to ensure the rigidity of the entire interior body 10, thereby reducing the weight of the interior body 10 as a whole.

Furthermore, since the interior body 10 is manufactured in one piece instead of being formed separately as in the past, unpleasant noises are not generated from the joints when the car is running, and quieter running can be achieved. There are advantages. Moreover, there are no seams, steps, etc. on the surface of the interior body 100, and therefore, it is possible to provide the interior body IO with a luxurious and heavy feel.

[Effects of the Invention] As described above, according to the present invention, a skin sheet body that corresponds to the shape of a vehicle interior body and has a skin wrinkle pattern on its surface is formed, and then the skin sheet body is formed by a first foaming step. A first attachment part such as a bracket is in-molded on the skin sheet body, and a second attachment part such as a duct or a box is in-molded in a second foaming process, thereby integrally forming the vehicle interior body. Manufactured in

In this way, compared to the conventional method of fixing mounting parts such as brackets, ducts, and boxes with screws, the effect is that the entire manufacturing work can be carried out efficiently and automatically all at once. It will be done. In addition, unlike when the interior body is molded separately, there is no inconvenience that unpleasant noises are generated from each joint during driving, and since there are no seams or steps, the interior body has a heavy and luxurious feel as a whole. The advantage is that it can be manufactured. Also,
It becomes possible to ensure the desired rigidity by using the foam itself instead of the core material, and the weight of the entire interior body can be reduced.

Although the present invention has been described above with reference to preferred embodiments, the present invention is not limited to these embodiments.
Of course, various improvements and changes in design are possible without departing from the gist of the invention.

[Brief explanation of the drawing]

1A to C are perspective explanatory views of a vehicle interior body according to the present invention; FIGS. 2A to 2D are process explanatory diagrams for manufacturing the interior body; and FIG. 3 is an apparatus for manufacturing the interior body. 4 and 5 are enlarged explanatory diagrams of various devices shown in FIG. 3. 10...Interior body 12...Skin sheet body 14...Foam 16...Mounting part 18...Foam 20...Mounting part 3
0... Molding device 32.34... Mold device 100... Intermediate body 102... Molded body FIG-28.

Claims (12)

[Claims] (1) A skin sheet body with an uneven pattern formed on its surface; a first foam formed on the back surface of the skin sheet body and embedding a part of the first attachment component; Alternatively, a vehicle interior body characterized in that the first foam body is integrally formed with a second foam body in which a part of the second attachment part is buried. (2) The interior body for a vehicle according to claim 1, wherein the first attachment part is made of a metal magnetic material, and the second attachment part is made of a resin-based material. (3) In the interior body according to claim 1, the first and second
A vehicle interior body characterized in that the foam is made of hard urethane foam resin. (4) The interior body for a vehicle according to claim 1, wherein the skin sheet body is a composite sheet body formed by polymerizing a resin-based leather sheet and a polyolefin-based foam sheet. (5) forming a skin sheet body that corresponds to the shape of the interior body and has an uneven pattern on its surface, and arranging a first attachment part at a desired position of the skin sheet body, a first foaming step of embedding a part of the skin sheet body and/or the first foam body; and a first foaming step of disposing a second attachment part and burying a part of the second attachment part to form the skin sheet body and/or the first foam body. A method for manufacturing a vehicle interior body, comprising a second foaming step of forming a second foam on one foam. (6) The method according to claim 5, wherein after forming the first foam in the first foaming step, blasting is performed to remove the mold release agent adhering to the first foam. A method for manufacturing a vehicle interior body. (7) A method for manufacturing a vehicle interior body according to claim 5, wherein after forming the second foam in the second foaming step, a trimming process is performed. (8) In the method according to claim 5, the first attachment part is made of a metal magnetic material, and the first attachment part is attached via a magnet to an upper mold constituting a first mold device for forming the first foam. 1. A method for manufacturing a vehicle interior body, which comprises sucking and holding the skin sheet body on a lower die on which the skin sheet body is placed via suction means while holding the parts by suction. (9) A method for manufacturing a vehicle interior body according to claim 5, wherein the second attachment part is made of a resin material. (10) In the method according to claim 5, a vehicle is characterized in that a rib and/or a mounting allowance for positioning and mounting the second attachment part on the first foam body is integrally formed in the first foaming step. A method of manufacturing an inner body for a vehicle. (11) The method according to claim 5, wherein the first and second
A method for manufacturing a vehicle interior body, characterized in that the foam is made of a hard urethane foam resin. (12) A method for manufacturing a vehicle interior body according to claim 5, wherein the skin sheet body is a composite sheet body obtained by polymerizing a resin-based leather sheet and a polyolefin-based foam sheet.