JPH05201290A - Interior panel for vehicle - Google Patents

Abstract

PURPOSE:To provide better appearance by making a skin material into a sandwich structure for preventing hard foam molding raw material from being impregnating a high foaming magnification foam layer completely, and making the inmost skin layer permeable for throwing away gas generated by foaming to the high foaming magnification foam layer to eliminate the generation of irregularity in the outmost skin layer. CONSTITUTION:In a door trim 1 where hard foaming basic material 5 is integratedly-foamed at the back of a skin material 3, the skin material 3 is constituted of the outmost skin layer 13 which forms the outmost skin, a high foaming magnification foam layer 15 integratedly-formed at the back of the outmost skin layer 13, and a low foaming magnification foam layer 17 which is integratedly formed at the back of the high foaming magnification foam layer 15 and is not impregnated with the hard foam molding raw material of the hard foaming basic material 5 at the time of molding a panel, and passes only the gas generated by foaming.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in a vehicle interior panel having a high foaming ratio foam layer in which a hard foaming base material is integrally molded on the back surface of a skin material, and more particularly to a surface defect countermeasure. Is.

[0002]

2. Description of the Related Art Generally, a vehicle interior panel such as an automobile door trim is disclosed in, for example, Japanese Patent Laid-Open No. 63-99912, in which a back surface of a skin material such as polyvinyl chloride is made of hard urethane foam or the like. It is configured by integrally molding a rigid foam base material. Then, the skin material of such an interior panel has a two-layer structure of an outermost skin layer forming the outermost skin and a high expansion ratio foam layer integrally formed on the back surface of the outermost skin layer, thereby providing a feeling and the like. There are things that try to improve. Further, it has been conventionally practiced to form the high expansion ratio foam layer of the skin material having the two-layer structure by slush molding as disclosed in, for example, JP-A-61-100422.

[0003]

However, when molding a foam layer with a high expansion ratio as described above, uneven foaming may occur in the foam layer with a high expansion ratio unless the mold is heated uniformly.

That is, as shown in FIG. 7, after the outermost skin layer b constituting the outermost skin and the high expansion ratio foam layer c having the thickness L1 are laminated on the lower mold a to form the skin material d, As shown in FIG. 8, in a state where the upper mold e is clamped, a hard foam molding raw material f such as hard foam urethane is injected into the mold, and the hard foam molding raw material f is foam-cured to form a skin as shown in FIG. The hard foam substrate h is molded on the back surface of the material d.

At this time, a part of the hard foam molding raw material f is impregnated into the high foaming ratio foam layer c, but if the high foaming ratio foam layer c has foaming unevenness, the hard foam molding raw material f will be located at a high foaming ratio. Due to the large amount of the impregnated portion i, the thickness L′ 2 of the high expansion ratio foam layer c there is thinner than the thickness L′ 1 of the other portion. In the mold clamped state, the high foaming ratio foam layer c is wholly compressed by the upper mold e and becomes thin.

When the difference in thickness of the high expansion ratio foam layer c partially occurs, as shown in FIG. 9, when the molded interior panel j is released from the mold, the compression force by the upper mold e is released. As a result, the high expansion ratio foam layer c returns to the original thickness L1, but at the impregnated portion i, the hard foam molding material f is impregnated and hardened in the impregnated portion i, so that the restoration rate is small and the thickness is L2. Therefore, there is a problem that the thickness is smaller than the thickness L1 of the other portions, and as a result, the outermost skin layer b corresponding to the impregnated portion i is formed with the concave portion k and the appearance is deteriorated.

Therefore, as shown in FIG. 10, the outermost innermost layer m made of a solid layer is integrally formed as the third layer on the back surface of the high expansion ratio foam layer c, whereby the high expansion of the hard foam molding raw material f is achieved. It is conceivable to prevent the impregnation of the magnification foam layer c by the outermost endothelial layer m. However, in this case, the rigid foam molding raw material f that constitutes the rigid foam substrate h.
Of air generated due to the foaming of air is eliminated, and air pools n, n, ... Are generated on the back surface of the outermost endothelial layer m. Parts are generated, and the appearance becomes poor.

The present invention has been made in view of the above points, and it is an object of the present invention to make a hard foaming raw material highly foamable by making a skin material a sandwich structure and making an outermost endothelial layer breathable. The impregnation of the high-foaming ratio foam layer is reliably prevented, and the thickness of the high-foaming ratio foam layer is made substantially uniform throughout, and the gas generated due to foaming is released to the high-foaming ratio foam layer to the outermost skin layer. The purpose is to improve the appearance by eliminating the occurrence of unevenness.

[0009]

Means for Solving the Problems In order to achieve the above object, the solution means of the present invention is to provide an inner panel integrally formed with a hard foam base material on the back surface of a skin material, wherein the skin material is the outermost skin. Of the outermost skin layer, a high expansion ratio foam layer integrally formed on the back surface of the outermost skin layer, and the back surface of the high expansion ratio foam layer are integrally formed, and the hard foam substrate The low foaming ratio foam layer does not impregnate the rigid foaming raw material and allows only the gas generated by foaming to pass through.

[0010]

With the above structure, in the present invention, since the high expansion ratio foam layer of the skin material is covered with the low expansion ratio foam layer, when the hard foam substrate is formed on the back surface of the skin material, Impregnation of the foam molding raw material into the high expansion ratio foam layer is reliably prevented, so that the substantial thickness of the high expansion ratio foam layer is ensured uniformly throughout. Further, the gas generated by foaming during panel molding passes through the low expansion ratio foam layer and escapes to the high expansion ratio foam layer, so that air is not accumulated on the back surface of the low expansion ratio foam layer. Therefore, the outermost skin layer has no irregularities, and the appearance is improved.

[0011]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 2 shows an automobile door trim 1 as an interior panel for a vehicle according to an embodiment of the present invention. The door trim 1 has a hard foam base made of hard foam such as urethane foam on a back surface of a skin material 3. The material 5 is formed integrally. Then, the hard foam base material 5 of the door trim 1
One end of the resin fastener mounting seat 7 is inserted into a required portion of the door, and the fastener 9 is attached to the other end of the fastener mounting seat 7 so that the door trim 1 is assembled to the door inner panel 11 via the fastener 9. Has been done.

As shown in an enlarged detail in FIG. 1, the skin material 3 is provided with an outermost skin layer 13 which constitutes an outermost skin made of polyvinyl chloride or the like, and the outermost skin layer 13 has a predetermined shape by slush molding. Is molded into. A high expansion ratio foam layer 15 made of polyvinyl chloride or the like is integrally formed on the back surface of the outermost skin layer 13 by slush molding. Then, the expansion ratio of the high expansion ratio foam layer 15 is preferably set to 4.5 times or more as shown in the data showing the relationship between the expansion ratio and the hardness of the foam layer in FIG. In this way, the expansion ratio is set to 4.5 times or more because the foam layer has a hardness of C-side rubber hardness meter (Japanese Rubber Association standard 010 when the expansion ratio is less than 4.5 times).
This is because in 1), the soft feeling is insufficient when it exceeds 50 degrees.

Further, as a feature of the present invention, a low expansion ratio foam layer 17 made of polyvinyl chloride or the like is integrally formed on the back surface of the high expansion ratio foam layer 15 by slush molding, and the high expansion ratio foam layer 15 is formed. A three-layered skin material 3 having a three-layer structure sandwiched between the outermost skin layer 13 and the low expansion ratio foam layer 17 is molded.
The foaming ratio of the low foaming ratio foam layer 17 is set so as not to be impregnated with the hard foaming raw material of the hard foaming base material 5 at the time of panel molding and to allow only the gas generated by foaming to pass therethrough. It is preferably set to 0.5 to 4 times. In this way, the expansion ratio is set to 1.5 to 4 times because the gas generated due to foaming at the time of panel molding does not pass through the low expansion ratio foam layer 17 when the expansion ratio is less than 1.5 times, and the low expansion ratio is set. This is because, on the back surface of the magnification foam layer 17, air pools that cause the formation of protrusions are generated, while when it exceeds 4 times, the hard foam molding raw material is impregnated to form recesses.
Then, the low foaming ratio foam layer 17 of the skin material 3 having such a three-layer structure is integrally bonded to the hard foam base material 5 to form the door trim 1.

Next, a description will be given of the procedure for molding the door trim 1 in which the hard foam base material 5 is integrally molded on the back surface of the skin material 3 having the three-layer structure as described above.

First, as shown in FIG. 3, the skin material 3 having the above-mentioned three-layer structure is set on the lower mold 19 with the outermost skin layer 13 constituting the outermost skin facing down and formed into a predetermined shape by slush molding. To do.

Then, after injecting a hard foam molding raw material 23 such as a hard foam urethane on the low expansion ratio foam layer 17, as shown in FIG.
The hard foam molding raw material 23 is foamed and cured to obtain the door trim 1 in which the hard foam base material 5 is integrally molded on the back surface of the skin material 3 having a three-layer structure (see FIG. 5). At this time, the hard foam molding raw material 23 is blocked by the low expansion ratio foam layer 17 and does not impregnate the high expansion ratio foam layer 15, and the high expansion ratio foam layer 15 has a substantial thickness L1 as a whole. It In the mold clamped state of FIG. 4, the high foaming ratio foam layer 15 is entirely compressed by the upper mold 21 to have a thickness L'1.

Thereafter, as shown in FIG. 5, the upper mold 21 is separated from the lower mold 19 to remove the door trim 1. On this occasion,
The compressive force of the upper mold 21 is released, and the high expansion ratio foam layer 15 of the skin material 3 is restored to the original thickness L1 over the whole.

As described above, in the present embodiment, the impregnation of the high-foaming foaming raw material 23 into the high-foaming foaming layer 15 is reliably prevented by the low foaming-foaming foam layer 17. The high expansion ratio foam layer 15 is not impregnated, and after appearance of the mold, the appearance can be improved by eliminating the generation of recesses in the outermost skin layer 13 forming the outermost skin.

In the above embodiment, the gas generated by foaming during panel molding can be passed through the low expansion ratio foam layer 17 and escaped to the high expansion ratio foam layer 15. It is possible to reliably prevent air from being accumulated in the outermost skin layer 13.
It is possible to improve the appearance by eliminating the occurrence of convex portions.

In the above embodiment, the three-layer skin material 3 is formed by slush molding. However, the three-layer skin material 3 has a sheet forming the outermost skin on the front side and an intermediate sheet in the middle. A three-layer sheet in which a high-foaming foam sheet and a low-foaming foam sheet on the back side are laminated may be integrally formed into a predetermined shape by vacuum molding, press molding, or the like. The foam sheet and the low expansion ratio foam sheet are laminated with an adhesive that does not impair the air permeability. When the three-layered skin material 3 is formed by press molding, the outermost skin layer may have a fabric structure.

In the above embodiment, the case where the interior panel is the automobile door trim 1 has been described, but it may be an instrument panel or the like, and may be an interior panel other than the automobile.

[0023]

As described above, according to the present invention,
In a vehicle interior panel in which a hard foam base material is integrally formed on the back surface of a skin material, an outermost skin layer that constitutes the outermost skin of the skin material, and a high expansion ratio integrally formed on the back surface of the outermost skin layer. A foam layer and a low foaming ratio foam layer integrally molded on the back surface of the high foaming ratio foam layer, and the low foaming ratio foam layer is used as a hard foam molding raw material for the hard foam substrate during panel molding. It was configured not to be impregnated and to pass only the gas generated by foaming. Therefore, it is possible to reliably prevent the high foaming ratio foam layer from being impregnated with the hard foaming raw material composed of the hard foaming base material, and to secure a uniform thickness throughout the high foaming ratio foam layer, and at the time of panel molding. Gas generated by foaming can be released to the high expansion ratio foam layer through the low expansion ratio foam layer to eliminate air accumulation on the back surface of the low expansion ratio foam layer, and to improve the appearance by eliminating irregularities in the outermost skin layer. can do.

[Brief description of drawings]

FIG. 1 is an enlarged view of part A in FIG.

FIG. 2 is a vertical sectional side view of a door trim.

FIG. 3 is a process drawing of a die set of a skin material.

FIG. 4 is a process drawing of injecting a molding raw material into a mold.

FIG. 5 is a vertical sectional side view of the door trim after demolding.

FIG. 6 is a data diagram showing the relationship between foaming ratio and hardness of a foam layer.

FIG. 7 is a view corresponding to FIG. 3 of a conventional example.

FIG. 8 is a view corresponding to FIG. 4 of a conventional example.

FIG. 9 is a view corresponding to FIG. 5 of a conventional example.

FIG. 10 is an enlarged view of a conventional example in a B portion of FIG.

[Explanation of symbols]

 1 Door trim (interior panel) 3 Skin material 5 Hard foam base material 13 Outermost skin layer 15 High expansion ratio foam layer 17 Low expansion ratio foam layer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Internal reference number FI technical display location B29L 31:58 4F

Claims (1)

[Claims] 1. A vehicle interior panel in which a hard foam base material is integrally formed on the back surface of a skin material, wherein the skin material comprises an outermost skin layer forming an outermost skin and a back surface of the outermost skin layer. A high expansion ratio foam layer integrally molded, and a gas which is integrally molded on the back surface of the high expansion ratio foam layer and which is not impregnated with the hard foam molding raw material of the above-mentioned hard foam base material at the time of panel molding and is generated with foaming. An interior panel for a vehicle, characterized by comprising a low expansion ratio foam layer that allows only the air to pass through.