JPH03262615A - Manufacture of trim parts for automobile - Google Patents

Abstract

PURPOSE:To improve an external appearance of a product without generating creases on a skin material, by a method wherein after the skin material is heated, softened and vacuum-molded along a mold surface of a top force for mold press molding, at the time of mold press molding of a resin core material distributed and fed within a mold press molding tool, molding of the core material and unification of the core material and skin material are performed simultaneously. CONSTITUTION:A skin material 12 is positioned at an intermediate position between press molds 20, 30 and heated by a heater 50 up to a softened condition. Then the skin material 12 is vacuum-molded. Then a resin material 60 is distributed and fed to a fixed part on a mold surface 20a through a gate 23 of a bottom force 20. The top force 30 is lowered under a state where the skin material 12 is held by vacuum suction force and the resin material 60 is molded in the state of a desired curved surface form by fitting-in of the top and bottom forces 20, 30 and clamping-down. Along with molding of a resin core material 11 in the state of the desired curved surface form, the skin material 12 is pressed integrally with a surface side of the resin core material 11. Furthermore, an arbitrary pattern which is desirous of transferring to the surface of the skin material 12 can be engraved to a mold surface of the top force 30 by making use of a porous electroformed mold 33.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method of manufacturing interior parts for automobiles such as automobile door trims.

(Prior Art) Conventionally, the structure of automobile interior parts such as automobile door trims and rear corner trims, which are installed in automobile body panels, has been formed to have a desired curved shape, as shown in FIG. It is generally composed of a resin core material 1 and a skin material 2 laminated on the surface side of the resin core material 1.

As a molding method for the resin core material 1, the recent trend is that complex three-dimensional shapes are required, so a mold press molding method is used in which semi-molten resin is molded into a desired shape in a mold press mold. is frequently used.

In this case, in order to shorten the process, the resin core material 1
The skin material 2 is integrated with the resin core material 1 during molding.

To briefly explain this mold press method based on FIGS. 8 to 10, first, as shown in FIG. -It is set to be a curved surface.

When the upper and lower mold press molding molds 3.4 are in the open state, the skin material 2 is held at its periphery between the molds 3 and 4 by a clamp g type 5. In addition, a gate 6 for supplying semi-molten resin onto the mold surface is disposed inside the lower mold 3 for mold press forming, and as shown in FIG. 9, polyolefin resin, polyolefin composite A semi-molten resin material 7 such as resin is distributed and supplied onto the mold surface of the lower mold 3 .

After a predetermined amount of the resin material abrasive material 7 has been supplied, the upper mold 4 for mold press molding is lowered, and the resin material 7 is formed into a desired curved surface by the clamping of the mold press mold 1-lower mold 3.4. It is molded as a core material 1 having a shape, and a skin material 2 is integrated on the surface side of the core material 1 (see Fig. 10).
.

(Problems to be Solved by the Invention) As described above, in the conventional method of manufacturing interior parts by integrally pressing the resin core material 1 and the skin material 2 by mold press forming, the product appearance is determined by the appearance of the skin material 2. Although it is done,
Heat of resin material 7 (around 200℃) and press pressure (50~
80kg/cJ), if a decorative process such as a drawing pattern is applied to the surface of the skin material 2, the appearance pattern of the skin material 2 may be damaged due to drawing flow or the drawing pattern being deformed or flattened. It has been pointed out.

Furthermore, since the skin material 2 is not heated before molding, it is not expected to elongate as much, so wrinkles easily occur in areas with complex shapes, and areas with a high expansion rate are forcibly stretched. This results in further aggravation of appearance defects such as throttling flow.

In addition, with this molding method, it is difficult to form sharp highlight lines on the product surface, and in particular, thick skin materials such as foamed PVC sheets or resin sheets laminated with urethane foam are used as the skin material 2. In this case, it becomes almost difficult to form sharp highlight lines on the product surface.

The present invention has been made in view of the above circumstances, and the main feature of the present invention is to provide a method for manufacturing interior parts in which a skin material is simultaneously attached at the same time as molding a resin material by a mold press method. It is possible to maintain a beautiful surface appearance, and it is possible to reliably prevent wrinkles in the skin material in highly developed areas.
To provide a method for manufacturing an interior part M for an automobile which can emphasize sharp highlight lines and significantly improves the appearance design of the product.

(Means for Solving the Problems) In order to achieve the above object, the present invention provides an automated system comprising a resin core material molded into a desired shape and a skin material integrally attached to the surface side of the resin core material. In the manufacturing method for military interior parts, the skin material is formed by preheating and softening the non-porous skin material and then vacuum forming it along the mold surface of a mold press molding die equipped with a vacuum suction means. After distributing and supplying a predetermined amount of semi-molten resin material onto the mold surface of the lower mold for mold press forming, the preformed skin material L is held on the mold surface of the upper mold. In this state, the upper mold is lowered and the upper and lower mold press molding molds are clamped to mold the resin core material into the desired shape, and also to integrally adhere the skin material to the surface of the resin core material. Features (effects) characterized by comprising a step of integrating the core material and the skin material As is clear from the configuration in 1- below, the skin material is preheated and then vacuum formed, so mold press forming is performed. - It is possible to form a shape that is faithful to the surface of the upper mold, and it is possible to form a product of any shape beautifully, such as by emphasizing sharp highlight lines.

Furthermore, when a drawing pattern is engraved on the mold surface of the upper mold, the drawing pattern can be transferred to the surface of the skin material by vacuum suction force and press pressure, making the surface appearance of the skin material even better. It can be done.

(Example) Hereinafter, an example of the method for manufacturing an automobile interior part according to the present invention will be described in detail with reference to the attached drawing f1.

FIG. 1 is a cross-sectional view showing the structure of an automobile interior part manufactured according to the present invention, and FIGS. 2 to 6 are cross-sectional views showing the steps of the method of the present invention.

In FIG. 1, an automobile interior component 10 is generally composed of a resin core material 11 molded into a desired shape and a skin material 12 that is laminated and integrated on the surface side of the resin core material 11.

More specifically, the resin core 4-11 in L is filled with PP.
Resin such as resin or ABS resin (Original material is semi-molten,
It is distributed and supplied into a mold press mold having a required LIJ surface shape, and is molded into a complex four-sided shape using a mold press molding method.

As the skin material 12, materials with various specifications may be used depending on the purpose, such as a single PVC sheet, a foamed PVC sheet, a PVC sheet lined with polyolefin foam such as PEF, and a urethane pad. It may be a lined PVC sheet, an olefin sheet, etc., as long as it is non-air permeable so that it can be vacuum formed, as will be described later.

The surface of the skin material 12 has a beautiful appearance such as a drawing pattern, and sharp highlight lines are formed as shown in A shown in FIG.

The manufacturing process of the above automobile interior part 10 will be explained based on FIGS. 2 to 6.

FIG. 2 shows a mold assembly for the bottom shape of a mold press used in the method of the present invention.

In other words, Tokoro! It consists of a lower die 20 for mold press forming with a die surface of is configured to be able to be moved downward by a lifting device (not shown), and can be engaged and press-tightened while maintaining a predetermined clearance with respect to the lower die 20.

Furthermore, a gate 23 for supplying semi-molten resin from a nozzle 22 of an extrusion molding machine 21 to the mold surface -L is disposed in the lower mold 20 for mold press forming. On the other hand, the upper mold 30 has a vacuum suction hole 3 that communicates with a vacuum duct 31.
2 is opened, and the mold surface of this upper mold 30 is constituted by a porous electroforming mold 33 in order to provide a uniform vacuum suction force.

Next, the molding method will be explained in order (First, the peripheral edge of the skin material 12 is held by the clamp device 40, positioned at an intermediate position of the press molding die 20, 30, and as shown in FIG. 50, the skin material 12 is heated to a softened state.The heating conditions are set to appropriate conditions determined by the feed and thickness of the skin material 12.

Next, the upper mold 3 [] is lowered to a position where the peripheral portion of the upper mold 30 contacts the skin material 12, and a vacuum pump (not shown) connected to the vacuum duct 31 is activated. The skin material 12 is vacuum formed (see FIG. 4).

At this time, since the skin material 12 has been softened by heating in advance, it is vacuum-formed along the mold surface of the upper mold 30, but a uniform vacuum suction force is applied by the porous electroforming mold 33, and the skin material 12 is heated and softened in advance. The material 12 has good elongation and excellent moldability, and sharp highlight lines can be accurately produced.

Thereafter, as shown in FIG. 5, a semi-molten resin material 60 is first distributed and supplied through the gate 23 of the lower mold 20.

At this time, a predetermined amount of the resin material 60 is measured in advance by a measuring device (not shown), and this amount is passed from the nozzle 22 of the extrusion molding machine 21 to the gate 23 on the mold surface 20 of the lower mold 20.
It is distributed and supplied to predetermined locations on a.

After supplying the resin material 60, the upper mold 30 is moved to the skin material 12.
is lowered while being held by the vacuum suction force, and as shown in FIG. 6, the upper and lower mold press molding dies 20.30 are engaged and clamped to form the resin material 6C1 into a desired curved shape, and the resin material 6C1 is molded into a desired curved shape. The core material 11 is molded into a desired curved shape, and the skin material 12 is integrally pressed onto the surface side of the resin core material 11.

During this press integration, press pressure is applied to the skin material 12, and the skin material 12 is formed along the mold surface of the upper mold 30 by both the vacuum suction force and the press pressure, so that a clear It becomes possible to create shapes.

Furthermore, in this example, the shibori pattern was transferred to the surface layer 12 by using the porous electroforming mold 33, but the 1-mold 30
It is possible to engrave any pattern desired to be transferred onto the surface of the skin material 12 on the mold surface.

When the press integration is completed, the vacuum suction horn is released, the upper mold is raised, the mold is opened, and the product 10 is taken out from the lower mold 20, and the interior part 10 shown in FIG. can get.

In this way, according to the method developed by the present invention, the skin material 12 can be integrated into the core material 11 at the same time as the resin core material 11 is molded,
In addition to being superior in terms of performance, the surface layer 12 is vacuum-formed on the mold surface of the upper mold 30 before it is integrated with the push-piece, so it has good elongation and can easily follow high-development areas. Since it is possible to form a sharp shape and also to transfer the pattern engraved on the mold surface of the upper mold 30 to the surface of the skin material 12, the surface appearance of the skin material 12 becomes extremely beautiful.
This has the advantage of significantly improving the appearance and design of the product.

Next, examples of the method of the present invention will be described by illustrating specific molding conditions.

(Example 1) A PVC sheet or the like is used as a skin scar, and after heating it to 163° C. with a heater device, parting is performed along an upper die on which a shibori pattern is provided. In case 2, the molding conditions are a vacuum pressure of 760 mmHg and 1-0 seconds.

Thereafter, a semi-molten composite resin core material, which is a mixture of PP resin and wood powder filler in a ratio of 80 parts by weight and 20 parts by weight, is distributed and supplied to three locations on the mold surface "-1" of the lower mold.

After that, the upper mold is lowered while the skin shell is held by vacuum suction force, and the upper and lower molds are engaged and clamped to form the PP composite resin material into the required shape to obtain the PP composite resin core material. , a PvC sheet is integrated on the surface side of this composite resin core material. At this time, the press pressure was 75 kg/cJ and the press time was 40 seconds.

After that, the vacuum pump is stopped and the vacuum suction force is released, the upper mold is raised by 1-1, the mold is opened, and the product is removed from the mold to obtain the product. Clear highlight lines such as these are emphasized, there are no wrinkles, the product is molded into the desired shape, and the surface of the epidermis is clearly formed with a shibori pattern, making it possible to provide an extremely beautiful product.

(Example 2) A PVC sheet laminated with polyethylene foam on the back side is used as a skin scar. PVC sheet/thickness 0. 6 mm, polyethylene foam thickness 30 mm, and after heating and softening the PVC side to 165° C. using a heater device, a female bow is formed by vacuum forming. The vacuum forming conditions were the same as in Example 1.

Note that the same resin core key as in Example 1 is used.

The molded product had a good surface appearance as in Example 1, with a drawing pattern engraved on the surface of the skin, and the cushioning properties were E' due to the polyethylene foam.
% and can be molded into products with a good soft feel.

(Effects of the Invention) Salt 1 - As explained, according to the method of manufacturing automobile interior parts according to the method of the present invention, the skin material is heated and softened, and the skin material is vacuum-formed along the mold surface of the upper die for mold press forming. rear,
During mold press molding of the resin core material distributed and supplied into the mold press mold, the core material is formed and the core material and skin material are integrated at the same time, so the skin material has good elongation and high quality. The skin material follows the developed area, so there are no wrinkles in the skin material, and clear highlight lines can be emphasized in some corners, which improves the appearance of the product and improves vacuum forming. At the same time, it simultaneously transfers the shibori pattern etc. to the surface of the skin, so in addition to emphasizing the highlight lines, the surface appearance of the skin material can be made beautiful, and the appearance design of the product is significantly improved. have an effect.

[Brief explanation of drawings]

Fig. 1 is a cross-sectional view showing the structure of an interior part manufactured by the method of the present invention, Fig. 2 is a cross-sectional view showing an embodiment of a molding die device used in the method of the present invention, and Figs. 3 to 6. 7 is a sectional view showing the general structure of an interior component, and FIGS. 8 to 10 are sectional views showing a conventional method for manufacturing an interior component. be. 10...Automotive interior parts 11...Resin core material 12...Skin material 20...Mold press molding lower die 21...Extrusion molding block 23...Gate 30...Mold press molding 31... Vacuum duct 32... Vacuum suction hole 33... Porous electroforming mold 60... Mold on resin material

Claims (1)

[Claims] 1. A resin core material (11) molded into a desired shape, and a skin material (12) integrally attached to the surface side of the resin core material (11).
In the method for manufacturing automobile interior parts, the method comprises: an upper die for mold press forming (30 mm) equipped with a vacuum suction means;
), the non-breathable skin material (12) is preheated and softened, and then vacuum-formed to form the skin material (12).
After distributing and supplying a predetermined amount of semi-molten resin material (60) onto the mold surface of the lower mold (20) for mold press forming, the preformed skin material ( 12) is held on the mold surface of the upper mold (30), the upper mold (30) is lowered, and the upper and lower mold press molding molds (20, 30) are clamped to form the resin core material (11). ) is molded into a desired shape, and a skin material (12) is integrally bonded to the surface of the resin core material (11). Manufacturing method for interior parts. 2. The method of manufacturing an automobile interior part according to claim 1, wherein at least a part of the mold surface of the upper die for mold press forming (30) is constituted by a porous electroforming die (33). 3. A drawing pattern is engraved on the mold surface of the upper die (30) for mold press forming, so that the drawing pattern is transferred to the skin material (12) during vacuum forming of the skin material (12). The method for manufacturing an automobile interior part according to claim 1.