JPH0234011Y2 - - Google Patents

Description

[Detailed Description of the Invention] This invention relates to an apparatus for manufacturing foam door trims for vehicles such as automobiles. More specifically, the present invention relates to a manufacturing apparatus capable of manufacturing a foamed door trim for a vehicle by foaming a foamed synthetic resin material while preventing deformation of a core material.

Foamed door trims are often used for doors of vehicles such as automobiles, especially for luxury models. This is a synthetic resin core material whose surface (inside the vehicle interior) is coated with a foamed synthetic resin (foamed urethane, etc.), and a cross section of one example is shown in FIG. 1 is a core material molded from a synthetic resin board containing cellulose, and has a complicatedly curved cross-sectional shape (the U-shaped part that protrudes to the right in the figure corresponds to the armrest part of the door);
Its surface is coated with a foamed synthetic resin 2 such as foamed urethane having a required thickness.

To manufacture this foamed door trim, a foamed synthetic resin material 2 is applied to the surface of a synthetic resin core material 1 that has been previously molded into a desired shape (by heat compression molding, etc.), and this is then molded using a pressing mold and a receiving mold. A foamed resin is placed on the receiving mold of a foaming mold as the receiving mold side, a pressing mold is placed on the mold, the mold is closed, and the foamed resin material is foamed by means such as heating to form a foamed synthetic resin 2 on the surface of the core material.
This results in the formation of a layer of

However, the core material 1 warps due to heat compression molding, and when the core material 1 is set in a foaming mold and the foaming process is performed, the thickness of the foamed synthetic resin 2 becomes uneven, especially when the foamed resin is If an attempt is made to reduce the wall thickness, some portions will be left without a foamed resin layer, resulting in a defective door trim. The peripheral edge of the door trim is the part that is attached to the door panel with clips, etc., so the foamed resin layer must be thin and accurate in shape and size. It is difficult to reduce the thickness, and the shape is often irregular.

Therefore, when it is required to make the foamed resin layer thinner at the peripheral edge of the door trim, a metal plate 3 such as a steel plate is applied to the peripheral edge of the core material 1 and fastened with rivets 4 before foaming. A method is being taken. FIG. 2 shows a cross section of the door trim formed by foam molding in this manner. However, such a method is not preferable because the use of the metal plate 3 increases cost and weight.

The present invention solves the above-mentioned conventional problems, straightens the door trim core material that has been distorted during molding to a flat state, and performs a foaming process. This was done with the aim of not only making it possible to realize the same design, but also making it possible to accurately measure dimensions when attaching to a mating component. In other words, the present invention is
In the manufacturing apparatus for manufacturing foam door trim by foaming a foam resin in a foam mold as described above,
The gist is that a permanent magnet is fixed on the side of the cap that is fitted into the clip hole in the peripheral edge of the core material, facing the pressing mold, and a magnetic body is attached to the portion of the pressing mold that faces the cap. Hereinafter, the configuration of the present invention will be explained based on the embodiments shown in the drawings.

FIG. 3 is a schematic plan view of the synthetic resin core material 1, and as shown in the figure, a large number of clip holes 5, 5, . . . are provided at the peripheral edge of the core material 1. After the door trim is completed, when assembling it to the vehicle body, clips are fitted into the clip holes 5, 5, . . . to attach it to the door panel.
5, . . . are bored simultaneously with the molding of the core material 1. As described above, before applying the foamed resin material to the core material 1 and inserting it into the foaming mold for foaming, the clip holes 5 are
Put the cap on. This is to prevent the foamed resin material from entering the clip hole 5 and to secure a space for inserting the clip during assembly. In the present invention, a permanent magnet is fixed on the upper surface of the cap (the side facing the pressing mold when inserted into the foaming mold) that is fitted into the clip hole 5 on the periphery of the core material 1. .

FIG. 4 is an external perspective view of the cap, and FIG. 5 is a sectional view taken along line AA in FIG. 4. The cap 6 is made of a soft material such as synthetic rubber or soft synthetic resin, and has a fitting part 7 that fits into the clip hole 5 of the core material 1 and a top part 8 that are integrally formed, and a permanent magnet is attached to the upper surface of the top part 8. 9 is embedded and fixed. Inset part 7
By pushing the foam material into the clip hole 5 and closing it as shown in FIG. 5, the foam material is prevented from entering the clip hole 5.

Figure 6 shows a state in which the cap 6 is fitted into the clip hole 5 as described above, and the core material 1 coated with a foamed resin material is set in a foam mold consisting of a press mold and a receiving mold to perform foaming. FIG. A magnetic material 12 such as a steel plate or a permanent magnet plate, which is attracted to the permanent magnet 9 of the cap 6, is placed in a recess 11 of the pressing die 10 of the foam molding die for escape of the cap 6.
Install it.

To carry out the foaming process, first, the core material 1 is set in the receiving mold 13 with the foaming material side down (receiving mold side), then the pressing mold 10 is closed and the foamed resin 2 is foamed by heating or the like. In this case, the permanent magnet 9 of the cap 6 is fitted into the clip hole 5 on the peripheral edge of the core material 1 as described above.
is attracted to the magnetic body 12 on the mold side, and the position of the peripheral edge of the core material 1 is reliably fixed, so even if the pre-formed core material 1 is deformed, the mounting surface of the core material 1 will be fixed. It forms a flat plane. After the foam molding process has been completed, the door trim is removed from the mold (Figure 7 shows a cross section of the main part of the door trim in this state), the cap 6 is removed, and the door trim is assembled to the door panel using clips. .

In the example shown in FIG. 4, the insertion part 7 of the cap 6 has a Daruma-type shape, but this corresponds to the shape of the clip hole 5 of the core material 1, and the clip hole 5 is different from other caps. If it has a shape (for example, circular), it may be of a shape corresponding to the shape.

The device for producing foam door trim for vehicles of the present invention is constructed as described above, and includes a permanent magnet fixed to the cap that fits into the clip hole in the peripheral edge of the core material, and a magnetic material attached to the press of the foam mold. Since the foamed material is foamed by firmly fixing the peripheral edge of the core material by suction with the core material, even if the pre-formed core material is deformed, such deformation can be corrected. Therefore, it is possible to prevent the door trim from being defective due to variations in the thickness of the foamed resin layer, or from assembly failures due to deformation, and to minimize the thickness of the peripheral foamed resin layer. becomes possible.

[Brief explanation of the drawing]

Figure 1 is a sectional view showing an example of foam door trim.
Fig. 2 is a sectional view of main parts showing another example, Fig. 3 is a schematic plan view of a foamed door trim core material, Fig. 4 is an external perspective view showing one embodiment of a cap used in the present invention, and Fig. 4 is a schematic plan view of a foamed door trim core material. 5 is a sectional view taken along the line A-A in FIG. 4, and FIG. 6 is a sectional view showing the foam molding process using the apparatus of the present invention.
FIG. 7 is a sectional view of the main part of the door trim after foam molding. 1... core material, 2... foamed synthetic resin, 3... steel plate, 4... rivet, 5... clip hole, 6...
Cap, 7... Inset part, 8... Top, 9... Permanent magnet, 10... Embossing die, 11... Recess, 12...
Magnetic material, 13...Receiving mold.

Claims (1)

[Scope of utility model registration request] A vehicle in which a foamed synthetic resin material is applied to a synthetic resin core material, the foamed synthetic resin material is inserted as the receiving mold side between the pressing mold and the receiving mold, and the foamed resin is foamed to produce a foamed door trim. In the manufacturing device for foamed door trims, a permanent magnet is fixed on the side of the cap that is fitted into the clip hole in the peripheral edge of the core material, facing the pressing die, and a magnetic body is attached to a portion of the pressing mold facing the cap. A manufacturing device for foam door trim for vehicles, which is characterized by: