JPH02153708A - Method for mounting part and structure therefor - Google Patents

Abstract

PURPOSE:To much more securely mount a part and as well as to simplify production process by a method wherein the positioning site of the part is formed integrally at the formation of a first foamable resin layer onto a skin sheet and, after that, the part is seated and fixed to said site and finally a second foamable resin layer is formed so as to bury at least a part of the part. CONSTITUTION:Embossed pattern imitating leather or the like is applied onto the outer surface of a skin sheet S. Positioning ribs 12a and 12b for seating an interior part 14 at the predetermined position are formed inadvance in a primary foamed layer 12. In this case, the skin sheet S is formed in the predetermined shape with a mold and the like. On the other hand, the primary foamed layer 12 is foam-molded with a mold similarly to the skin sheet formed as mentioned above. After that, an interior part 14 is seated on the primary foamed layer 12 in such a manner as being positioned by positioning ribs 12a and 12b. In this case, the interior part 14 has a projected piece 14a, which is positioned to be hollow to the primary foamed layer 12. Under the state as mentioned above, by properly pouring foaming urethane, a secondary foamed layer 16 is formed to the interior part 14 and its projected piece 14a.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for attaching parts and a structure thereof, and more particularly, to a method for arranging said parts in a primary foaming process when manufacturing interior parts. A method for attaching a component, in which a positioning part is formed, the part is accurately positioned and held through this positioning part, and the part is in-molded by a secondary foaming process to arrange an interior part, and the method thereof Regarding structure.

[Background of the Invention] When attaching parts (for example, a passage duct for cooling and heating air, a case for mounting an air conditioner) to a skin sheet formed in a predetermined shape in a vehicle instrument panel, conventionally, screws, etc. Recently, an in-mold structure has been adopted as an alternative to the one using a tightening member.

As shown in Japanese Patent Laid-Open No. 62-292421, which has already been filed by the present applicant, the in-mold molding structure of this interior component is such that a skin sheet is placed in a mold, and a foamed resin sheet is placed in the skin sheet. The end of the interior component is placed above the mold, and the end of the interior component is attached to one of the molds consisting of an upper mold and a lower mold, and the mold is heated to foam the foamable resin sheet to form a part of the interior component. It is embedded in a foamable resin sheet.

This in-mold molding structure has the following advantages in comparison with conventional component mounting methods and structures.

■ Manufacturing process is simplified.

■ It is possible to suppress manufacturing costs.

■ There is no need for fastening members such as screws, and there is no creaking noise caused by screws.

However, in this type of in-mold molding structure, if the shape of the interior component is complicated, it becomes difficult to hold the interior component in a predetermined position with respect to the mold. As a result, it has been pointed out that the interior parts may be misaligned, resulting in inconveniences such as the finished product being unable to be shipped from the warehouse.

[Object of the Invention] The present invention has been made in order to overcome the above-mentioned disadvantages, and includes forming a first foam layer that forms a positioning part of a component with respect to a skin sheet, and The structure is such that after positioning the part, it is in-molded with the second foam layer, thereby eliminating the need for tightening members such as screws as mounting members for the part, and also reducing the squeak noise caused by the screws. To provide a method and structure for attaching parts, which can eliminate the occurrence of such occurrences, enable more reliable attachment of the parts, simplify the manufacturing process, and suppress manufacturing costs.

[Means for Achieving the Object] In order to achieve the above object, the present invention, when forming the first foamable resin layer on the skin sheet, integrally molds the positioning portion of the component, and then The method is characterized in that the component is placed and fixed in the positioning portion, and a second foamable resin layer is further formed to bury at least a portion of the component.

Further, the present invention provides a synthetic resin sheet as a skin sheet,
A first foamable resin layer formed on the synthetic resin sheet and forming a positioning part of the component, and embedding at least a part of the component to be placed at a predetermined position by the positioning part of the first foamable resin layer. It is characterized in that it is integrally constituted with a second foamable resin layer.

[Embodiments] Next, preferred embodiments will be described in detail with reference to the accompanying drawings, together with a method for attaching parts and a structure thereof according to the present invention.

FIG. 1 shows a sectional view of an instrument panel for an automobile or the like according to this embodiment. Here, reference numeral 10 indicates an instrument panel, which includes a skin sheet S made of vinyl chloride or the like, a primary foam layer 12 made of a foamable resin, and interior parts 14 (for example, ducts for passage of cold and hot air, air conditioning machine mounting case) and a secondary foam layer 1 made of foamable resin.
It basically consists of 6. The outer surface of the cover sheet S is preferably provided with a grain pattern of leather or the like. Also,
Positioning ribs 12a and 12b for placing the interior component 14 in a predetermined position are formed in advance on the primary foam layer 12. In this case, the skin sheet S is molded into a predetermined shape using a mold or the like, while the primary foam layer 1
2 is formed by foam molding the skin sheet S formed in this manner using a mold (not shown) in the same manner. Then, the interior parts 14 have the positioning ribs 12a, 1
2b is placed on the primary foam layer 12 to be positioned.

In this case, as can be easily understood from the figure, interior parts 1
4 has a protruding piece 14a, and this protruding piece 14a is positioned so as to be hollow with respect to the primary foam layer 12.

Therefore, foamed urethane is preferably injected into the interior component 14 and its protrusion 14a, and the secondary foamed layer 16
is formed.

As a result, the foam has a two-layer structure, and the protruding pieces 14a
A secondary foam layer 16 is formed to surround the foam layer. Therefore, the main body of the interior component 14 is sandwiched between the first foam layer 12 and the second foam layer 16, while the protruding piece 14a
is held substantially only by the secondary foam layer 16.

Next, a mold for manufacturing the instrument panel 10 will be explained.

FIG. 2 shows a state in which the skin sheet S made of vinyl chloride or the like is placed on a mold in order to form a primary foam layer 12 made of a foamable resin on the skin sheet S. Reference numeral 20 indicates a primary foaming mold, which includes a lower mold 22 having a concave cross section, an upper mold 24 having a convex cross section, a foamable resin injection member 26, and a locking mechanism 28.30. It consists essentially of: The lower mold 22 includes a base 23, and the lower mold 2
Arm locking portions 32.34 constituting a locking mechanism 28.30, which will be described later, are protrudingly provided on both sides of the locking device 20. On the other hand, the upper mold 24 includes a base 25, and drive cylinders 36.38 constituting a locking mechanism 28.30 are attached to both ends of the base 25. Furthermore, said drive cylinder 36.3
A piston rod 36a138a extending from the end of the locking mechanism 28.30 is engaged with one end of an arm portion 40.42 constituting the locking mechanism 28.30. Further, on both sides of the upper mold 240,
A support block 44.46 is provided, and a pivot shaft 48.50 for supporting the arm portion 40.42 is attached to the support block 44.46. And the arm portion 40
．． Engagement rollers 40a and 42a are provided at the other end of 42.

By operating the drive cylinder 36.38, the arm portion 40.42 swings, and the engaging roller 40 of the arm portion 40.42 engages the locking portion 32.34 on the side of the lower die 22.
a, 42a can be engaged or disengaged. As a result, the lower mold 22 and the upper mold 2
4 is locked or unlocked. Further, a foamable resin injection member 26 is provided at one end of the base 25 of the upper mold 24, and a nozzle portion 26a penetrates the base 25 and enters the upper mold 24. The tip of the nozzle portion 26a is arranged so as to communicate with a cavity to be described later.

Therefore, when the primary foaming mold 20 is locked by the locking mechanism 28.30 via the skin sheet S,
A positioning rib 12a between the lower mold 22 and the upper mold 24
, 12b is defined to form the primary foam layer 12. This is because the upper mold 24 has recesses 27a and 27 corresponding to the positioning ribs 12a and 12b.
This is because b is formed.

Next, as shown in FIG.
This shows the state set to 2. Said secondary foaming mold 52
has the same structure as the primary foaming mold 20 for forming the primary foaming layer 12. That is, the lower mold 54, the upper mold 56, the foamable resin injection member 58, and the locking mechanism 60.
62. The functions achieved by each of these components are the same as those of the primary foaming mold 20, and detailed description thereof will be omitted.

Note that a cavity 59 for forming the second foam layer 16 is defined in the upper mold 56 . The cavity 59
The nozzle portion 58a of the foamable resin injection member 58 is configured to face the nozzle portion 58a.

The apparatus for implementing the component attachment method according to this embodiment is basically constructed as described above, and the manufacturing process and effects thereof will be explained next.

In the primary mold 20, first, the already molded skin sheet S is placed on the lower mold 22, and then the upper mold 24 is brought into contact with the lower mold 22, and the base 25 of the upper mold 24 is actuate the drive cylinders 36 and 38 of the piston rod 36a.
, 38a. As a result, the arm portion 40.4
2 swings around the rotation axis 48.50, and the locking portion 32.3
4, the engagement rollers 40a, 42 of the arm portion 40.42.
The locking of the lower mold 22 and the upper mold 24 is achieved by the locking of the lower mold 22 and the upper mold 24. At this time, as described above, a cavity 27 for forming the primary foam layer 12 having positioning ribs 12a, 12b is defined between the lower mold 22 and the upper mold 24.

Next, foamable resin is injected into the cavity 27 from the foamable resin injection member 26 to form the first foamed layer 12. Then, the lock mechanisms 28, 30 are activated to unlock the mold 20, and the skin sheet S on which the primary foam layer 12 is formed is taken out.

Next, the skin sheet S is placed on the lower mold 54 of the secondary foaming mold 52, and the interior component 14 is placed in alignment with the positioning ribs 12a and 12b formed on the primary foaming layer 12. (See Figure 3).

Then, the upper mold 56 is brought into contact with the lower mold 54, and the lower mold 54 and the upper mold 56 are locked by the lock mechanisms 60 and 62. After that, a foamable resin for forming the second foamed layer 16 is injected from the foamable resin injection member 58. As a result, the second foam layer 1
6 is formed. Then, the completed product as the instrument panel 10 is taken out from the secondary foaming mold 52 and sent to the next assembly line.

Instrument panel 1 manufactured by the corresponding process
The interior component 14 of No. 0 is arranged at a predetermined position by the positioning ribs 12a and 12b formed on the first foam layer 12, and is integrally covered by the second foam layer 16, so that no misalignment of the interior component occurs. A high-quality instrument panel 10 can be obtained in which this is prevented as much as possible.

Next, FIG. 4 shows another embodiment of the method of attaching parts and its structure according to the present invention. In FIG. 4a, reference numeral 70 indicates an instrument panel, and the instrument panel 70 includes a skin sheet S made of vinyl chloride or the like, a primary foam layer 72, an interior component 74, and a seal made of an elastic material. It basically consists of a member 76 and a secondary foam layer 78. The primary foam layer 72 has an interior component 7
A step portion 72a and a rib 72b for positioning 4 are formed. Further, the interior component 74 has an end portion 74a and a flat plate portion 74b formed to fit the step portion 72a and rib 72b of the primary foam layer 72. Then, the end portion 74a of the interior component 74 and the stepped portion 72 of the primary foam layer 72
A sealing member 76 made of an elastic body is interposed between the
Further, a second foam layer 78 is formed on the step portion 72a. Further, a seal member 76 is interposed between the rib 72b of the primary foam layer 72 and the flat plate portion 74b of the interior component 74, and a seal member 76 is provided near the rib 72b so as to cover the tip of the flat plate portion 74b. A secondary foam layer 78 is formed.

Incidentally, the instrument panel 70 having such a structure is manufactured through the same steps as in the above-described embodiment. That is, the seal member 76 is interposed between the step portion 72a and the rib 72b formed by the first foaming process, and the end portion 74a and flat plate portion 74b of the interior component 74 are placed and held between molds (not shown).

Then, foamable resin is injected from the foamable resin injection part, and the end portion 74a, the flat plate portion 74b, and the rib 72 of the interior component 74 are injected.
A second foam layer 78 is formed near b and fixed (fourth
(see figure). At this time, since a sealing member 76 made of an elastic body is interposed between the end 74a of the interior component 74 and the step 72a of the primary foam layer 72, the seal member 76 is made of an elastic material. When the foamed resin is injected, leakage of the foamed resin from between the end portion 74a and the stepped portion 72a is prevented.

On the other hand, the flat plate portion 74b of the interior component 74 and the primary foam layer 72
A sealing member 76 is attached to the rib 72b as a positioning part.
is interposed between the ribs 72b and the interior component 74, thereby preventing leakage of the foamed resin embedding the engagement portion between the rib 72b and the interior component 74. Therefore, after the completion of the secondary foaming process, the secondary foam layer 78
There is no need to perform a finishing process or the like to remove unnecessary parts.

Further, since the interior component 74 is supported via the seal member 76 made of an elastic body, distortion due to external stress is absorbed by the seal member 76. Therefore, even if there is vibration during driving after the product is completed, especially after it is installed in an automobile, the generation of squeaks is prevented.

[Effects of the Invention] As described above, the present invention comprises a synthetic resin sheet as a skin sheet and a foamed resin body laminated to this sheet, and the foamed resin body has parts positioning parts. It has a first foamed layer to be formed and a second foamed layer in which a component to be placed is embedded by the positioning portion of the first foamed layer. Therefore, even if the shape of the component is complicated, the component can be more securely attached without shifting from a predetermined position, and the manufacturing process can be simplified. Moreover, since a sealing member made of an elastic body is interposed between the component and the positioning portion of the primary foam layer, leakage of the foamable resin during the foaming process can be prevented. Therefore, there is an advantage that a high quality product can be obtained.

Furthermore, since the interior parts are installed using a sealing member made of foamed resin and an elastic material without using tightening members such as screws, the generation of squeaks and other noises caused by tightening members such as screws is prevented. I can do it.

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 present invention.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view showing the mounting structure of parts according to the present invention, FIG. 2 is a diagram illustrating the step of forming a primary foam layer in the manufacturing process shown in FIG. 1, and FIG. 1 is a diagram illustrating the step of forming a secondary foam layer in the manufacturing process of FIG. 1. FIGS. 4a and 4b are longitudinal sectional views illustrating another embodiment of the present invention. DESCRIPTION OF SYMBOLS 10... Instrument panel 12... Primary foam layer 12a, 12b... Positioning rib 14... Interior parts 16... Secondary foam layer 27.59... Cavity 70... - Instrument panel 72... Primary foam layer 72a... Step portion 72b
... Rib 74 ... Interior parts 76 ...
Seal member 78...Second foam layer FfG, 2 1z FIG, 3

Claims (7)

[Claims] (1) When forming the first foamable resin layer on the skin sheet, the positioning portion of the component is integrally molded, the component is then placed and fixed on the positioning portion, and at least one of the component is 1. A method for attaching parts using a foam, the method comprising forming a second foamable resin layer to embed the parts. (2) A method of attaching a component according to claim 1, wherein a sealing member is provided in advance on the component to be fixed to the positioning portion formed in the first foamable resin layer. (3) In the method according to claim 2, the sealing member
A method for attaching parts, characterized in that when a foamable resin layer is foamed, a part of the foam is prevented from leaking. (4) A method for attaching parts according to any one of claims 1 to 3, characterized in that the first foamable resin layer and/or the second foamable resin layer are urethane foam. (5) A synthetic resin sheet as a skin sheet, a first foamable resin layer formed on the synthetic resin sheet and forming a positioning part of the component, and a predetermined positioning part of the first foamable resin layer. A component mounting structure characterized in that the component mounting structure is integrally formed with a second foamable resin layer in which at least a portion of the component to be placed in the position is buried. (6) The component mounting structure according to claim 5, wherein a sealing member is interposed between the component and the positioning portion of the first foamable resin layer. (7) A component mounting structure according to claim 6, wherein the sealing member is made of an elastic body.