JPH06312464A - Production of interior part for car - Google Patents

Abstract

PURPOSE:To efficiently perform the setting work of a skin material and to shorten a manufacturing process to reduce manufacturing cost in the production of an interior port for a car by the press bonding of a skin material due to powder slush molding and a molding core material. CONSTITUTION:A PP composite resin plate and a cushion material 12 such as nonwoven fabric are integrated by cold press molding to mold the core material 11 fitted with the cushion material 12 into a required shape and a low m.p. hot-melt film 15 is preliminarily laminated to the single surface of the cushion material 12. This low m.p. hot-melt film 15 is melted under heating to be set to a press bonding mold and a skin material 13 due to powder slush molding and the core material 11 fitted with the cushion material are integrated by utilizig the bonding strength of the low m.p. hot-melt film 15 to produce an interior part 10 for a car.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing automobile interior parts such as automobile door trims and instrument pads, and more particularly to a core material integrated with a cushion material and a skin material formed by powder slush molding. The present invention relates to a method for manufacturing an automobile interior part, which is obtained by crimping, by increasing the work efficiency in setting work of each material and shortening the process.

[0002]

2. Description of the Related Art Conventionally, powder slush molding has been frequently used as a manufacturing method for interior parts such as automobile door trims and instrument pads that are required to have a relatively good surface appearance and feel. Has been done.

This powder slush molding is one of the methods for molding a skin material. Usually, in order to manufacture interior parts, in addition to the powder slush molding step for the skin material, a step for molding a core material and a skin material. A step of integrating the core material with the core material is required.

For example, an automobile door trim 1 shown in FIG.
Has a structure in which the skin material 3 formed by powder slush molding is integrally formed on the surface of the core material 2, but normally, in order to absorb the variation in the thickness of the skin material 3, the space between the core material 2 and the skin material 3 is absorbed. The cushion material 4 is inserted.

A brief description will be made on a conventional method for manufacturing an automobile door trim 1. First, as shown in FIG. 9, a sheet of a thermoplastic resin plate, a thermoplastic composite resin plate or the like is used as a material of the core material 2. The material S is preheated and set in the softened state in the cold press molding lower die 5, and the cold press molding upper die 6 is set in the cushion material 4.

The upper and lower molds 5 for cold press molding
The sheet material S is formed into a desired shape by engaging pressure tightening 6 to form the core material 2, and the cushion material 4 is integrated on one side thereof.

After that, as shown in FIG. 10, the skin material 3 which is powder slush molded into a required shape in a separate step is set on the mold surface of the lower crimping die 7 and the upper crimping die 8 is set to the shape shown in FIG. Then, the core material 2 with the cushion material 4 formed in the required shape is set.

At this time, the adhesive 9 (two-component urethane adhesive) is previously applied to the inner surface of the skin material 3.

Then, the skin material 3 is integrated with the core material 2 via the cushion material 4 by the pressure bonding process of the pressure bonding upper and lower dies 7 and 8, and the molding of the automobile door trim 1 shown in FIG. 8 is completed.

[0010]

As described above, in the conventional method for manufacturing the automobile door trim 1, first, the cushion material 4 and the core material 2 are integrated by cold press molding, and then the cushion material 4 is formed. Upper and lower molds 7 and 8 for crimping the attached core material 2 and the powder slush molded skin material 3
However, since the adhesive 9 is applied to the powder slush-molded skin material 3 and dried through a heater, the skin material 3 is easily softened, and the lower die 7 for pressure bonding is used.
It becomes very difficult to set the sheet material on the sheet, and the defective displacement of the skin material 3 easily occurs, resulting in poor product yield.

Further, the number of steps such as the step of applying the adhesive 9 and the step of drying is large, resulting in an increase in product cost.

In addition, when the adhesive 9 is applied and dried,
There were problems such as the deterioration of the working environment and the cost of incidental equipment such as exhaust equipment.

The present invention has been made in view of the above circumstances, and improves workability by changing the bonding means between the powder slush-molded skin material and the core material with cushion material, and the process It is an object of the present invention to provide a method for manufacturing an automobile interior part, which is significantly shortened.

[0014]

In order to achieve the above-mentioned object, a method for manufacturing an automobile interior part according to the present invention comprises a thermoplastic resin plate or a thermoplastic composite resin plate having a low melting point after being preheated and softened. Cushion material laminated with hot melt film is laminated and cold press molding die is used to perform integral press molding to integrally mold the core material and cushion material, and the required shape for each of the upper and lower crimping die surfaces. After setting the slush-molded skin material and the core material with the cushion material in the state where the low-melting hot melt film was melted in the preheating step, the upper and lower molds for crimping are engaged and tightened to make the skin material and the cushion And a step of integrating the core material with a material by pressure bonding.

[0015]

As apparent from the above construction, the adhesion of the skin material and the core material with the cushion material is carried out after the low melting point hot melt film laminated on one side of the cushion material is heated and melted. Therefore, since the adhesive is not applied, dried and softened on the surface material as in the conventional case, the surface material can be easily set in the pressure bonding type and the adhesive application step and the drying step can be omitted.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a method for manufacturing an automobile interior part according to the present invention will be described in detail below with reference to the accompanying drawings.

1 and 2 are external views and sectional views showing an automobile door trim manufactured by applying the method of the present invention, FIGS. 3 to 6 are sectional views showing respective steps in the method of the present invention, and FIG. 7 is a book. It is sectional drawing which shows the structure of another Example of the door trim for motor vehicles manufactured by the method of invention.

First, referring to FIGS. 1 and 2, an automobile door trim 10 manufactured by the method of the present invention is formed into a desired curved shape, and a core material 11 having shape retention and rigidity for mounting on a vehicle body panel. The cushion material 12 is integrally attached to the surface side of the core material 11, and the skin material 13 is further laminated and integrated on the surface side.

More specifically, the core material 11 is obtained by extruding polypropylene resin with an appropriate amount of wood powder filler extruded into a sheet by a T-die extrusion molding machine, heat-softening the sheet-like material, and then performing cold press molding. It is shaped into a shape.

In this embodiment, the cushioning material 12 is made of polyester fiber non-woven fabric (weight of 100 to 150).
g / m ² ) is used, and the cushioning property is given to the product, and the cushioning material 12 has a function of absorbing the variation in the thickness of the skin material 13.

The skin material 13 is formed into a product shape by powder slush molding using a vinyl chloride resin powder as a raw material, and the slash skin layer 13 forming the surface of the product.
a and a slush foam layer 13 having an appropriate cushioning property
b is a two-layer structure and has a slush foam layer 1
As described above, the variation in the thickness of 3b is the cushion material 1
Absorbed by 2.

A feature of the method of the present invention is to provide a method of manufacturing the automobile door trim 10 having the above-described structure with good workability and in a short process.

That is, the method of the present invention will be described in detail with reference to FIGS. 3 and 4 show a molding process of the core material 12 in which the cushion material 12 is integrated.

That is, as shown in FIG. 3, PP, which is the material of the core material 11, is formed on the upper surface of the cold press molding lower die 20.
Set the composite resin plate S, but this PP composite resin plate S
Is preheated to 200 ° C. by a heater device (not shown), and an olefin hot melt film 14 (30 to 50 μm) is laminated on the surface facing the cushion material 12.

On the other hand, the cushion material 12 is set on the cold press molding upper die 21, and one surface of the cushion material 12 (a side surface opposite to the surface facing the core material 11).
Low melting point hot melt film 15 (30 to 50 μm)
m) is laminated. As the low melting point hot melt film 15, a polyester film having a melting point of 100 to 120 ° C., a polyamide film having a melting point of 90 to 110 ° C. or the like can be used.

In order to set the cushion material 12, set pins 22 are set along the peripheral edge of the cold press molding upper die 21.

When the setting of the PP composite resin plate S in the preheated and softened state and the cushion material 12 is completed in this way, the cold press molding upper die 21 is lowered, and as shown in FIG. 4, cold press molding is performed. By the upper and lower molds 20 and 21,
The core material 11 in which the cushion material 12 is integrated is press-molded into a required shape.

Next, FIGS. 5 and 6 show a press-bonding step of the skin material 13 formed in a separate step and the core material 11 with the cushion material 12 shown in FIG. 4, and firstly shown in FIG. As described above, while setting the skin material 13 formed in the required shape by powder slush molding on the mold surface of the lower die 30 for pressure bonding, with the slash skin layer 13a facing downward,
The core material 11 with the cushion material 12 is set on the set pin 32 of the upper die 31 for pressure bonding.

At this time, a plurality of suction / compression air holes 33 are formed in the lower die 30 for pressure bonding, and the suction / compression air holes 33 are formed.
Are configured so that they can be alternately switched and connected to the vacuum suction pump 35 and the blower 36 via the switching valve 34.

In the step of setting the skin material 13, the suction and pressure holes 33 are connected to the vacuum pump 35 so that the skin material 13 fits well to the mold surface of the lower crimping die 30 by the vacuum suction force. Held in.

Further, in the core material 11 with the cushion material 12 set in the upper die 31 for pressure bonding, the cushion material 1
The low melting point hot melt film 15 laminated on one side of No. 2 is set in a state of being heated and melted by a heating means such as a heater.

After that, the upper and lower molds 30 and 31 for crimping are engaged with each other, and the low melting point hot melt film 15 is adhered, whereby the skin material 13, the cushion material 12 and the core material 11 are integrated into one body. 1, the production of the automobile door trim 10 shown in FIG. 2 is completed.

In the crimping process shown in FIG. 6, the switching valve 34 is switched, the blower 36 is connected to the suction / compression air hole 33, and the compression / aerodynamic force is added from the suction / compression air hole 33, so that the core material 11 And the skin material 13 are integrated.

As described above, according to the method of the present invention, the core material 11 with the cushion material 12 and the skin material 13 are bonded to each other by heating the low melting point hot melt film 15 laminated on one surface of the cushion material 12 in advance. Since it is performed by melting, it is not a method of applying and drying an adhesive on the inner surface of the skin material 13 unlike the conventional method.
The lower mold 30 for crimping the skin material 13 does not soften
Is extremely easy to set, and the adhesive application process and drying process can be eliminated, helping to shorten the process and improving the deterioration of the work environment due to the use of an adhesive (urethane 2-liquid adhesive). In addition, various effects such as the need for exhaust equipment are eliminated.

FIG. 7 shows another embodiment of an automobile door trim 10 to which the method of the present invention is applied. In this embodiment, compressed urethane 16 is used as a cushion material.
In this embodiment as well, the low melting point hot melt film 15 is laminated on one surface of the compressed urethane 16 (the surface facing the skin material 13), which has the same effect as that of the above-mentioned embodiment, and is the same as that of the first embodiment. There is an advantage that the cushioning property is further improved as compared with the one.

[0036]

As described above, the method for manufacturing an automobile interior part according to the present invention has the following special operational effects.

(1) According to the method of the present invention, a low-melting-point hot melt film is laminated on one surface of the cushion material integrated with the core material, and in the pressure bonding step of the core material with cushion material and the skin material, By utilizing the adhesive strength of this low melting point hot melt film, the core material and the skin material are integrated, so that the adhesive is applied to the inner surface of the skin material and dried as in the conventional method. Since it is not carried out, the skin material can be easily handled, and the work of setting the skin material in the pressure-bonding die becomes very easy and the workability is significantly improved.

(2) According to the method of the present invention, the skin material and the core material are integrated by utilizing the adhesive force of the low melting point hot melt film laminated on one surface of the cushion material. The conventional adhesive coating process and drying process can be eliminated, the manufacturing process can be significantly shortened, and the defect rate such as the skin material set deviation can be reduced, and the manufacturing cost can be significantly reduced.

(3) According to the method of the present invention, since the low melting point hot melt film laminated on one surface of the cushioning material is used, the conventional adhesive can be eliminated and harmful organic solvent is scattered. There is an effect that the work environment can be favorably maintained such that it can be eliminated and exhaust equipment is not necessary, and that auxiliary equipment such as exhaust equipment can be abolished.

[Brief description of drawings]

FIG. 1 is a front view of an automobile door trim manufactured by applying the method of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a cross-sectional view showing a step of molding a core material in the method of the present invention, showing a step of setting a raw material in a press die.

FIG. 4 is a sectional view showing a core material forming step in the method of the present invention, showing a cold press forming step of the core material with a cushion material.

FIG. 5 is a sectional view showing a crimping step in the method of the present invention, showing a state in which the material is set in the crimping die.

FIG. 6 is a cross-sectional view showing a crimping step in the method of the present invention, showing the crimping step of the skin material and the core material.

FIG. 7 is a sectional view showing the structure of a second embodiment of an automobile door trim manufactured by applying the method of the present invention.

FIG. 8 is a cross-sectional view showing a configuration of a conventional automobile door trim.

FIG. 9 is a sectional view showing a molding process of a core material in a conventional automobile door trim.

FIG. 10 is a cross-sectional view showing a pressure bonding step of a skin material and a core material in a conventional automobile door trim.

[Explanation of symbols]

 10 Automotive Door Trim 11 Core Material 12 Cushion Material 13 Skin Material 13a Slash Skin Layer 13b Slash Foam Layer 14 Hot Melt Film 15 Low Melting Temperature Hot Melt Film 20 Lower Mold for Cold Press Molding 21 Upper Mold for Cold Press Molding 30 Lower Mold for Crimping 31 Upper die for crimping 33 Suction and compressed air hole

Continuation of the front page (51) Int.Cl. ⁵ Identification number Office reference number FI technical display location // B29L 9:00 4F 31:58 4F

Claims (1)

[Claims] 1. A mold for cold press molding, comprising stacking a cushioning material (12) obtained by laminating a low melting point hot melt film (15) after preheating and softening a thermoplastic resin plate or a thermoplastic composite resin plate ( 20 and 21) are integrally press-molded to form a core material (11) and a cushion material (1).
2) is integrally molded, a skin material (13) slush molded into a required shape on each mold surface of the upper and lower molds (30, 31) for pressure bonding, and a low melting point hot melt film (15) by a preheating process. After setting the core material (11, 12) with the cushion material in the state of being melted, the upper and lower molds (30, 31) for crimping are engaged and tightened to make the skin material (13) and the core material with the cushion material. And (11, 12) are pressure-bonded and integrated with each other, and a method for manufacturing an automobile interior part.