JPH0520263B2 - - Google Patents

Description

[Detailed Description of the Invention] <<Field of the Invention>> The present invention relates to automobile interior parts such as automobile door trims, rear side trims, and rear parcel shelves, which are press-molded integrally with a skin material and a core material. The present invention relates to a method for manufacturing interior parts for automobiles.

≪Prior art and its problems≫ For example, automobile interior parts such as automobile door trims, rear side trims, and rear parcel shells have a rigid core material and are attached to the surface of this core material, and have decorative or good properties. A laminated structure with a skin material that gives a surface feel is common, and conventionally, a core material such as a thermoplastic resin board or a thermoplastic composite resin board is heated and softened, and a skin material such as a nonwoven fabric or resin sheet is made. By cold-pressing the layered material on the surface of the core material, an interior component having a desired shape was obtained.

By the way, recently, in order to shorten the manufacturing man-hours of these interior parts, for example,
A method as disclosed in the above publication has also been proposed.

As shown in Fig. 5, an interior/exterior sheet 1 is first set on a lower mold 3 for pressing, and then a block-shaped thermoplastic resin material 2 such as polyolefin resin is placed from above, and then pressed. The upper die 4 for press is lowered as shown in FIG. 6, and the upper and lower press dies 3 and 4 are engaged and tightened to stretch the block-shaped thermoplastic resin material 2, as shown in FIG. Then, the interior/exterior sheet 1 and the thermoplastic resin material 2 are integrated and molded into a desired shape.

In order to ensure the adhesion between the polyolefin resin, which usually has poor adhesion, and the interior/exterior sheet 1, the back side of the interior/exterior sheet 1 has a fibrous surface 1.
A fibrous material such as a non-woven fabric is laminated so as to be b'.

However, although this method can certainly reduce the number of manufacturing steps, it is only possible to use resin sheets such as PVC sheets as the material for the interior and exterior sheets 1. For example, cloth that gives a soft feel,
When a porous material such as a carpet or non-woven fabric is used as the skin material, excessive press pressure will cause the molten resin to seep out from the fiber gaps of the skin material to the surface side, resulting in poor appearance.

Therefore, this method has the drawback that only non-breathable materials can be used as the skin material, and there are significant restrictions in terms of material quality.

Furthermore, in order to press-form a block-shaped thermoplastic resin material into a sheet shape, excessive press pressure and high temperatures are required.As a result, the molten resin penetrates into the fibers, and strong adhesion can be expected due to the anchor effect. Since the molten resin enters into the fiber gaps of the fibrous material, irregularities are created on the surface side of the interior/exterior sheet 1, which impairs the surface appearance and also has disadvantages such as not having a good surface feel. There is.

≪Object of the Invention≫ This invention has been made in view of the above-mentioned circumstances, and an object of the present invention is to provide a manufacturing method for automobile interior parts in which a core material and a skin material are integrated by press molding. In addition to reducing the number of man-hours, it also increases the flexibility in material selection, such as allowing the use of soft-feeling porous cloth, carpet, non-woven fabric sheets, etc. as the skin material, and also eliminates surface irregularities. , good product appearance,
An object of the present invention is to provide a method for manufacturing interior parts for automobiles that provides a product feel.

<<Structure and Effects of the Invention>> In order to achieve the above object, the present invention includes extruding a semi-molten resin material to be extruded as a core material from an extrusion molding machine directly onto the mold surface of a lower mold for cold press, and A skin material with a heat-sealable hot melt film laminated on the back side of the core material is positioned and set on the mold surface of the upper mold for cold pressing, with the hot melt film surface facing downward, and then cold pressing is performed. By tightening the upper and lower press molds, the core material and the skin material are integrated, and the hot melt film prevents the molten resin material from seeping into the skin material side. do.

That is, according to the method of the present invention, if a skin material is set in an upper die for cold press, and a semi-molten resin material is extruded as a core material directly into the lower die for cold press from an extrusion molding machine, the upper and lower cold press molds can be formed. Since the molded product can be easily formed by pressing the mold, it is easier to mold than the conventional method of heating and softening the raw material made of resin plate or composite resin plate separately and setting it in the predetermined position of the lower mold for pressing. , the number of manufacturing steps can be significantly reduced.

Furthermore, as shown in Japanese Patent Publication No. 61-32142, instead of bonding the skin material and the core material by the anchor effect, the skin material and the core material are bonded by the thermal adhesive properties of hot melt film. Therefore, no unevenness is formed on the skin material side of the core material, so the product surface can be kept smooth.
It has the advantage of providing a product that has a good appearance and a good feel.

Furthermore, the barrier function of the hot melt film prevents the semi-molten resin from seeping out onto the surface of the product, making it ideal for fabric sheets such as cloth, carpet, etc.
A porous base material such as a non-woven fabric can also be used as the skin material, which has the advantage of dramatically increasing the degree of freedom in selecting the material for the skin material, as well as a resin sheet.

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

Fig. 1 is an explanatory diagram showing the overall configuration of the apparatus used in the method of the present invention, Figs. 2 and 3 are sectional views showing each step of the method of the present invention, and Fig. 4 is an automobile molded by the method of the present invention. FIG.

In FIG. 1, the apparatus used in the method of the present invention is roughly composed of an extrusion molding machine 10, a movable die mechanism 20, and a press device 40. First, the extrusion molding machine 10 sends the raw materials to a hopper 11 that supplies pellet-shaped thermoplastic resin material and filler such as wood flour if desired, a single screw screw 12 that heats and melts these raw materials, and a movable die mechanism 20. It is composed of a breaker plate 13.

Next, the movable die mechanism 20
0, the molten resin reaches the breaker plate 1.
3 to the sheet supply die 24 through the first to third supply pipes 21, 22, 23.

Further, the sheet supply die 24 and the third supply pipe 23 are fixed to the upper surface of a movable base 25, and the movable base 25 is configured to be movable in the direction of the arrow in FIG. 1 relative to the table 26. , for example, in this embodiment, fixed table 2
A servo motor 27 is attached to 6, and a feed ball screw 28 is connected to the axis of the servo motor 27. A nut 29 that fits into the ball screw 28 is attached to the lower surface of the movable base 25 via a bracket 30.

Therefore, by the rotational drive of the servo motor 27,
Due to the feed screw mechanism of the ball screw 28 and nut 29, the movable base 25 can move forward and backward in the direction of the arrow by a stroke amount corresponding to the rotation speed and direction of rotation of the servo motor 27, and accordingly, the sheet feeding die 24 also moves forward and backward. Let's do it.

Following the forward and backward movements of the sheet supplying die 24, the first supply pipe 21 and the second supply pipe 22 each perform a link operation along a plane perpendicular to the plane of the paper. 1
The breaker plate 13 is provided with connecting hinge portions indicated by reference numerals 31 to 33 in the figure, and by linking with the first supply pipe 21 and the second supply pipe 22, the breaker plate 13 The structure is such that molten resin is constantly introduced into the sheet supplying die 24.

The sheet feeding die 24 is a wide die usually called a T die, and the molten resin is slightly cooled in this die 24, and a semi-softened sheet material is extruded from the tip.

Although not shown, the movable base 25 is configured to move forward and backward smoothly and reliably by a guide member provided on the fixed table 26.

Next, a press device 40 is provided adjacent to the fixed table 26 supporting the movable die mechanism 20. 41
and an upper mold 42 for cold press having almost the same mold surface 42a, and this upper mold 42 for cold press can be raised and lowered relative to the lower mold 41 by a lifting device such as a hydraulic cylinder 43. It is configured.

As described above, as the sheet feeding die 24 of the movable die mechanism 20 moves forward and backward, the die 24 moves from the position indicated by the dashed line in FIG. Perform forward and backward movement to the position shown.

In this embodiment, a ball screw mechanism using a servo motor 27 and a feeding ball screw 28 was adopted as the driving mechanism for the sheet feeding die 24, but a hydraulic cylinder was directly connected to the sheet feeding die 24 to perform forward and backward operations. You may also do this.

Next, an embodiment in which the method of the present invention is applied to a door trim manufacturing method will be described using FIGS. 2 and 3.

First, as shown in FIG. 2, the skin material 50 is positioned and set along the mold surface of the upper mold 42 for cold pressing. This skin material 50 has a hot melt film 51 laminated on the back surface thereof, and is set in the upper die 42 for pressing so that the hot melt film 51 is located on the lower side. The hot melt film 51 must be made of a resin that can be thermally bonded to a core material, which will be described later. For example, when using polyolefin resin such as polypropylene, polyethylene, or PP composite as the core material, use polypropylene film or nylon-polypropylene laminate film, and when using ABS resin as the core material, use urethane resin. Use film, urethane, nylon, polyester film, etc.

And, like this, the upper die 42 for cold press
With the skin material 50 set on the mold surface of the cold press lower mold 41, molten resin is introduced into the sheet supplying die 24 from the extruder plate 13 of the extrusion molding machine 10 through each supply number 21 to 23. is slightly cooled in this die 24 and extruded as a semi-softened sheet. In this case, the sheet feeding die 24 is moved forward and backward from the position shown by the dashed line in FIG. 2 to the position shown in the solid line by a feeding mechanism not shown in FIG. Supplied in sheet form.

Next, as shown in FIG. 3, the cold press upper mold 42 is lowered by the operation of the hydraulic cylinder 43, and the upper and lower cold press molds 41 and 42 are clamped, thereby simultaneously forming the core material 52 and forming the skin material 5.
0 and a core material 52 are bonded together via a hot melt film 51.

At this time, in this embodiment, the semi-molten resin material that is the raw material for the core material 52 is extruded into a sheet shape, but a normal die is used instead of the sheet feeding die 24 to extrude the semi-molten resin material that will become the core material. The molten resin may be placed in the form of a block on the upper surface of the lower die 41 for cold pressing. However, compared to extruding into a sheet, it is necessary to raise the press pressure and mold temperature slightly, and when extruding into a sheet, molding can be performed at lower pressure and at a lower temperature than when extruding into a block.

After that, after a predetermined cooling period, the hydraulic cylinder 4
3, the cold press upper pole 42 is raised, and the molded product is taken out from the cold press lower mold to obtain the door trim shown in FIG. 4.

According to the present invention, as shown in FIG. 2, the resin material is extruded directly onto the upper surface of the cold press lower die 41 from the extrusion molding machine through the sheet feeding die 24. The process of setting the original fabric can be omitted, and the number of manufacturing steps can be significantly shortened.

Furthermore, since the hot melt film 51 laminated on the back side of the skin material 50 is made of a material that can be heat-sealed to the core material 52, the skin material 50 and the core material 52 shown in FIG. When integrally molded with the hot melt film 51, the skin material 50 and the core material 52 can be firmly bonded to each other by the heat fusion action of the hot melt film 51, and in particular, the anchor material 50 and the core material 52 are bonded by heat fusion rather than an anchor effect. The surface of the product becomes smooth without the unevenness that accompanies it, and the surface feel is also good.

Moreover, since the hot melt film 51 acts as a barrier function, the core material 52 is
It is possible to reliably prevent the problem of the semi-molten resin on the side seeping into the skin material 50 side, and it is also possible to create a soft feel by using a porous fabric sheet such as cloth, carpet, or non-woven fabric as the skin material 50, for example. , there is an advantage that the material of the skin material 50 can be selected freely.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram showing the overall configuration of the apparatus used in the method of the present invention, FIGS. 2 and 3 are process diagrams showing the manufacturing process of a door trim, which is an embodiment of the method of the present invention, and FIG. 5 to 7 are cross-sectional views showing the door trim formed by the same process, and FIGS. 5 to 7 show conventional examples. FIGS. It is a sectional view showing a product molded by a molding method. 10...Extrusion molding machine, 11...Hopper, 12
... Single shaft screw, 13 ... Plaker plate, 20 ... Movable die mechanism, 21 to 23 ... Supply pipe, 24 ... Sheet supply die, 25 ... Movable base, 26 ... Fixed table, 27 ... ... Servo motor, 28 ... Ball screw for feeding, 29 ... Nut, 30 ... Bracket, 31 to 33 ... Connection hinge section, 40 ... Press device, 41 ... Lower mold for cold press, 42 ... Cold press Upper mold for use, 43... Hydraulic cylinder, 50... Skin material, 5
1... Hot melt film, 52... Core material.

Claims (1)

[Claims] 1 An extrusion molding machine extrudes the semi-molten resin material extruded as a core material directly onto the mold surface of the lower mold for cold press, and a hot melt film that can be heat-sealed to this core material is placed on the back side. The laminated skin material is positioned and set on the mold surface of the upper mold for cold pressing, with the above-mentioned hot melt film surface positioned on the lower side, and the core material and the skin material are bonded by pressing the upper and lower molds for cold pressing. 1. A method of manufacturing an interior part for an automobile, characterized in that the hot melt film prevents the molten resin material from seeping into the skin material side.