JPH0343069Y2 - - Google Patents

Description

[Detailed Description of the Invention] <<Field of the Invention>> This invention relates to improvements in interior parts for automobiles, such as rear parcel shelves and package trays.

《Prior art and its problems》 Normally, behind the rear seat of a passenger car, there is a luggage shelf, commonly known as a rear parcel shelf, on which luggage is placed.
As shown in the figure, a decorative skin material 2 such as a carpet is pasted on the surface of a core material 1 such as a polypropylene composite resin board (a board formed by adding wood flour as a filler to polypropylene), and the core material 2 is attached for reinforcement. Reinforcing metal fittings 3 are attached at appropriate positions on the lower surface of the material 1 in a horizontal manner. When attaching the reinforcing metal fittings 3, use a backing sheet 4 made of the same material as the core material 1, heat the core material 1 and the backing sheet 4 to a semi-molten state, and soften the reinforcing metal fittings 3. By sandwiching the core material 1 and the backing sheet 4 and applying pressure from both sides by press working, the reinforcing metal fitting 3 is embedded integrally as shown in FIG. 4b.

However, in the case of the rear parcel shelf having the above configuration, in order to increase the rigidity of the product, it is necessary to set the core material 1, which is relatively heavy, thick.
Furthermore, since the reinforcing metal fitting 3 such as a metal pipe is attached, the weight of the product is increased, and problems such as the plate thickness becoming extremely thick at the attachment part of the reinforcing metal fitting 3 have occurred. In particular, it has been pointed out that the opening/closing type rear parcel shelf is difficult to use due to the above-mentioned reasons.

Furthermore, due to the reinforcing metal fitting 3, the back side of the product protrudes, giving an unsightly appearance, and due to the difference in heat shrinkage rate between the reinforcing metal fitting 3 and the core material 1,
During long-term use, the ends of the reinforcing metal fittings 3 are exposed from the core material 1, resulting in an extremely unsightly appearance.
For this reason, decorative caps are usually fitted into the ends of the reinforcing metal fittings 3 to prevent the appearance from deteriorating, but this results in high costs and is not a practical solution.

In this way, conventional rear parcel shelves use relatively heavy composite resin boards and reinforcing metal fittings, making the product heavy and difficult to use. It has been pointed out that there are disadvantages such as a decrease in aesthetic appearance and an increase in costs.

《Purpose of the invention》 This invention was made in view of the above-mentioned problems.The purpose of this invention is to create an extremely high-quality material that can contribute to weight reduction and thinning, has a good appearance, and is expected to have sound absorption properties. Our goal is to provide practical automotive interior parts.

<<Structure and Effects of the Invention>> In order to achieve the above object, the present invention laminates composite resin sheets heated and softened to a semi-molten state in a sandwich pattern on the upper and lower surfaces of a hard resin foam molded into a desired shape. In addition, a skin material is placed on the side that will become the product surface, and compression molding is performed using a press mold with a desired press mold surface, and in an automobile interior part in which these are integrated, through-holes are formed at appropriate locations in the foam. is drilled, and the area around the through hole is formed thicker than other parts, so that the molten portions of the upper and lower composite resin sheets are forcibly introduced into this through hole during press molding. It is characterized in that the upper and lower composite resin sheets are connected through this through hole.

That is, the automobile interior parts according to the present invention are
The relatively heavy composite resin sheet is significantly reduced, reinforcing metal fittings are eliminated, and a relatively lightweight hard resin foam is used instead as the core, making it possible to reduce the weight of the product. In addition, it is possible to provide a product that is aesthetically pleasing without causing problems associated with reinforcing metal fittings.

Furthermore, in the case of the present invention, since through-holes are drilled at appropriate locations in the hard resin foam, composite resin sheets heated and softened to a semi-molten state are laminated on the upper and lower surfaces of the hard resin foam. When compressed using a press mold, the upper and lower composite resin sheets are connected through the through holes, and the bonding strength between the hard resin foam and the composite resin sheet can be made extremely strong.

Furthermore, by setting the plate thickness around the through-hole to be thick, the composite resin sheet near the through-hole can be easily introduced into the through-hole during press molding, making it possible to integrate the hard foam resin and the composite resin sheet. When press molding is performed to achieve this, the semi-molten composite resin flows smoothly into the through hole, and the upper and lower composite resin sheets are easily connected through the through hole.

<<Description of Embodiment>> Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

Fig. 1 is a partially cutaway perspective view showing a rear parcel shelf to which the present invention is applied, Fig. 2 is a perspective view showing a hard resin foam used in the present invention, and Fig. 3 is a hard resin foam during press molding. FIG. 3 is a cross-sectional view illustrating a bonded state between the composite resin sheet and the composite resin sheet.

In Figure 1, rear parcel shelf 10
consists of a hard resin foam 11, composite resin sheets 12, 12 located on the upper and lower sides of the foam 11, a skin material 13 attached to one surface of the composite resin sheet 12 on the front side, and a composite resin on the back side. A backing sheet 13' is attached to one side of the sheet. In addition,
It may be omitted depending on the specifications of this backing sheet 13'.

More specifically, the hard resin foam 11 is
In a mold (not shown), polyurethane,
A foaming liquid such as Styrofoam is injected, and the foaming liquid is foamed and hardened to form a desired shape. Furthermore, through holes 14 are bored at appropriate locations in this hard resin foam 11.
A convex portion 15 is formed around the convex portion 1.
5, the plate thickness around the through hole 14 is set to be thicker than the plate thickness in other parts. The composite resin sheet 12 is made by extruding a mixture of polypropylene and wood flour into a sheet using an extruder, heating and softening the sheet to a semi-molten state, and then plastically deforming it by press molding. As shown in , in this example, the hard resin foam 11 is plastically deformed along the surface shape. Next, the skin material 13 is a fabric skin material such as carpet or cloth material, and when the composite resin sheet 12 is in a slightly softened state, the fibers of the skin material 13 bite into the molten resin, causing the skin to tighten due to the so-called anchor effect. The material 13 is firmly joined to the composite resin sheet 12.

Next, the joining of the hard resin foam 11 and the composite resin sheet 12 will be explained based on FIG.
3', composite resin sheet 12, hard resin foam 11,
After the composite resin sheet 12 and the skin material 13 are stacked and placed in this order, and this positioning set is performed, the press upper mold 17 is lowered and the press lower mold 16 is lowered.
The rigid foam 11, the composite resin sheet 12, and the skin material 13 are integrated by fitting the press upper die 17. At this time, the composite resin sheet 12 is semi-melted by a heating means such as a heater (not shown). Since it has been heated and softened to a state, press mold 1
6, 17, the composite resin sheet 12
is plastically deformed along the mold surfaces of the upper and lower molds of the press, but at the same time it also penetrates into the through hole 14 formed in the hard resin foam 11, and through this through hole 14, the upper and lower composite resin sheets 12, 12 are concatenated.

At this time, since the plate thickness around the through hole 14 is set to be thicker than other parts, a larger pressurizing force is applied to the molten resin in the part indicated by A in FIG. , the molten resin in portion A easily flows into the through hole 14 as indicated by the arrow in the figure.

Generally, polypropylene resin has low polarity,
Adhesion to a mating member is extremely poor, and this tendency does not change even with composite polypropylene resins mixed with fillers. However, by drilling the through holes 14 at appropriate locations in the hard resin foam 11 in this way and setting the plate thickness around the through holes 14 thick,
Hard resin foam 11 Upper and lower composite resin sheets 12
can be easily connected, and the bonding strength between the hard resin foam 11 and the composite resin sheet 12 can be strengthened by the above structure.

In this way, in the rear parcel 10 according to the present invention, by using the hard resin foam 11 as the core, the thickness of the composite resin sheet 12 can be set thin, and reinforcing fittings such as metal pipes can be eliminated. This makes it possible to reduce the weight of the product,
It also eliminates conventional problems such as the reinforcing metal fittings protruding from the back of the product, and also eliminates deformation such as warping due to thermal deformation associated with the reinforcing metal fittings, and the difference in shrinkage rate between the reinforcing metal fittings and the composite resin sheet. All problems such as exposure of the reinforcing metal end can be completely solved.

Furthermore, the porous structure of the hard resin foam 12 improves sound absorption, contributing to quietness in the vehicle interior, making this an extremely practical idea.

In this embodiment, only the rear parcel shelf has been described, but there is no problem in applying the present invention to other interior parts such as a package tray, and the scope of application of the present invention is wide.

[Brief explanation of the drawing]

Fig. 1 is a partially cutaway perspective view showing a rear parcel shelf to which the present invention is applied, Fig. 2 is a perspective view showing a hard resin foam used in the present invention, and Fig. 3 is a hard resin foam and a composite resin sheet. FIGS. 4a and 4b are sectional views showing the structure of a conventional rear parcel shelf. 10...Rear parcel shelf, 11...Hard resin foam, 12...Composite resin sheet, 13...
Skin material, 14... Through hole, 15... Convex portion, 16...
...Press lower mold, 17...Press upper mold.

Claims (1)

[Scope of utility model registration request] Composite resin sheets heated and softened to a semi-molten state are laminated in a sandwich pattern on the upper and lower surfaces of the hard resin foam molded into the desired shape, and a skin material is placed on the side that will become the product surface to form the desired press mold surface. In an automobile interior part formed by compression molding using a press die equipped with a mold and integrated, through-holes are formed at appropriate locations in the foam, and the area around the through-hole is thicker than other areas. Due to the formed shape, the molten portions of the upper and lower composite resin sheets are forcibly introduced into this through hole during press molding, and the upper and lower composite resin sheets are connected through this through hole. Automotive interior parts.