JPH0732523A - Interior member and production thereof - Google Patents

Abstract

PURPOSE:To closely and certainly weld a skin and a base material even in a case having a complicated outer shape and to effectively prevent the deformation of a surface part. CONSTITUTION:An interior member consists of a skin 12, a foam welded layer 14 and a base material 16 and the skin 12 has a skin layer 18 and the cushion layer 20 provided on the rear surface side of the skin layer 18 and welded to the foam welded layer 14.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior member in which a surface skin, resin beads and a base material are laminated, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, an interior member formed by laminating a foam layer on a skin has been widely used for vehicles. In recent years, it has been demanded to impart a soft feeling to this type of interior member in order to increase the quality of the interior member.
A "method for manufacturing a vehicle interior member" disclosed in Japanese Patent No. 344227 is known.

In this manufacturing method, a skin, a base material and expandable resin beads, each of which is made of an olefin resin, are prepared, and the foamable resin is provided in a predetermined gap formed between the skin and the base material. By supplying beads and supplying a heat medium from the ventilation holes of the base material, the expandable resin beads are foamed to form a foam layer, whereby the outer skin, the foam layer and the base material are welded together without a gap. ing.

[0004]

By the way, such an interior member is formed between the skin and the base material in relation to the complicated outer shape due to design requirements and the function required of the base material. The gap is not constant as a whole, and there are narrow gaps and portions where this gap changes rapidly. However, according to the above-mentioned conventional technique, a predetermined amount of expandable resin beads are supplied with a gap provided in consideration of the volume expansion after foaming. Therefore, the expandable resin beads are foamed by the heat medium. When filling the gap,
In many cases, it is not possible to effectively fill the narrow portion of the gap or the portion where the gap changes rapidly. For this reason, it has been pointed out that it is not possible to reliably fill the entire gap formed between the skin and the base material with the expandable resin beads, which causes defective filling of the expandable resin beads. Further, when the expandable resin beads supplied to the gap are foamed by the heat medium, the foam density becomes uneven in the portion where the gap is not constant, and as a result, wavy or uneven deformed portions are formed on the surface of the molded product. Will occur.

The present invention is intended to solve the above-mentioned problems, and even when it has a complicated outer shape, the skin and the base material can be reliably welded together without a gap, and the surface portion It is an object of the present invention to provide an interior member that can effectively prevent the deformation of the product and a method for manufacturing the interior member.

[0006]

In order to achieve the above object, the present invention provides a skin, a foam welding layer made of resin beads laminated on the back side of the skin, and a foam welding layer. A base material provided on the opposite side of the skin,
And a cushion layer provided on the back surface side of the skin layer and welded to the foam-welding layer.

Further, according to the present invention, a process of filling the pre-expanded resin beads into a predetermined gap between the base material and the skin, which are separated from each other via a molding die, without gap, and the pre-expanded resin beads are filled. By introducing a melting medium into the gap formed, the already-foamed resin beads are welded to each other to form a foam welding layer, and the outer skin and the base material are welded via the foam welding layer. And a process.

Further, it is preferable that the outer skin is provided with a cushion layer on the back surface side to which the resin beads are supplied.

Furthermore, the already expanded resin beads are
It is preferable to fill the predetermined gap in a state of being compressed and deformed in advance.

[0010]

In the above-mentioned interior member according to the present invention, since the outer skin has the cushion layer which is welded to the foam welding layer on the back surface side of the skin layer, unevenness or the like occurs on the welding surface portion of the foam welding layer. However, it is possible to effectively prevent the cushion layer from absorbing the uneven portion and causing the surface of the skin to be deformed.

Further, in the method of manufacturing the interior portion according to the present invention, the already expanded resin beads are used. Here, the already-expanded foam refers to one in which all the foaming steps of the resin beads have been completed, and does not include one that is newly foamed by the action of heating or the like. This is because if the resin beads filled in the mold with no gaps are re-foamed, the design surface will have conspicuous concavities and convexities and the soft feeling will not be obtained.

Therefore, according to the present invention, even if the predetermined gap formed between the base material and the surface skin has various shapes, the foamed resin beads can be filled into the gap without any gap. . Then, the already-expanded resin beads are welded to each other by the melting medium to form the foam-welding layer, so that the skin and the base material can be welded through the foam-welding layer without a gap.

At this time, if the pre-expanded resin beads are supplied to the gap between the base material and the skin in a state of being compressed and deformed in advance, the pre-expanded resin beads are formed when the foam welding layer is formed by the melting medium. Has been restored to its original size. This allows
The welding area between the resin beads is further increased, the welding strength is improved, and a strong interior body is obtained.

[0014]

EXAMPLES An interior member and a method of manufacturing the same according to the present invention will be described below with reference to the accompanying drawings.

In FIG. 1, reference numeral 10 indicates an interior member according to this embodiment. This interior member 10 has a skin 12
And a foam-welding layer 14 and a base material 16.
2, the foam welding layer 14 and the base material 16 are each made of an olefin resin, as described later.

The skin 12 is provided on the surface of a polyolefin resin skin 18 having a desired pattern or shape (hereinafter, referred to as a design) such as a grain pattern on the surface, and a back surface side of the skin layer 18, and is formed by welding a foam. The cushion layer 20 made of a polypropylene resin foam that is welded to the layer 14 is laminated to form a sheet.

The foam-welding layer 14 is formed by welding the already-foamed resin beads 22 made of polypropylene resin, and the base material 16 is made of a polyolefin resin or a material containing a talc material in the resin. In addition, the base material 16 has a plurality of through holes 24, 26 and 28 each having a predetermined diameter and at predetermined positions.

FIG. 2 shows a molding apparatus 30 according to the first embodiment for molding the interior member 10 constructed as described above.

The molding apparatus 30 is provided with a lower mold 32 and an upper mold 34, and a lower mold body 38 is provided on an upper portion of an outer frame 36 which constitutes the lower mold 32. Molding surface 40 on which a predetermined design is formed for molding the outer surface
Is provided. The lower mold body 38 has a plurality of ventilation holes 42.
This vent hole 42 communicates with a vacuum device (not shown) from a decompression chamber 44 formed in the outer frame 36 via a vent hole 46. As the lower mold body 38, an electroformed body or a cast member on which a design of a molded product is transferred can be used.
A resin molded product made of epoxy resin or the like or a portion corresponding to the molding surface 40 of this type of resin molded product may be provided with a plating layer having wear resistance.

In the decompression chamber 44, the molding surface 4 of the lower mold body 38 is formed.
A plurality of cooling passages 48 are arranged in contact with the surface opposite to 0. In order to reinforce the lower mold body 38, glass beads and metal beads may be mixed with an epoxy resin and a porous resin having air permeability may be provided in the decompression chamber 44 so as to cover the cooling passage 48.

An upper die main body 52 is provided below the outer frame 50 constituting the upper die 34. Inside the outer frame 50, partition plates 54 and 56 are used to provide a first surge tank 58 and a second surge tank 60. And are formed. The upper mold body 52 is provided with a molding surface 62 for molding the surface of the molded product on the base material side, a first through hole 64 for supplying the molten medium, a second through hole 66 for discharging the molten medium, and a resin. Third through hole 6 for beads supply
8 and a plurality are provided respectively.

As shown in FIG. 3, the first through-holes 64 and the second through-holes 66 are spaced apart from each other by a predetermined distance and are alternately provided. The third through-holes 68 have two large diameters. It is provided in. The first through hole 64 is the through hole 24 of the interior member 10.
The second through-hole 66 corresponds to the through-hole 26, and the third through-hole 68 corresponds to the through-hole 28, and each diameter has its function, that is, allows the molten medium to pass therethrough. It is sufficient that the function and the function of passing the resin beads 22 can be achieved, and it is possible to set all the diameters to the same size.

As shown in FIG. 2, the first surge tank 58
Communicates with a molten medium supply source (not shown), for example, a vapor supply source via a valve 70, and the second surge tank 6
0 communicates with a steam discharge unit (not shown) via a valve 72. The first surge tank 58 communicates with the first through hole 64 through the tubular first passage 74, while the second surge tank 60 receives the second through hole through the elongated tubular second passage 76. Connect to 66. Third through hole 68 of upper mold body 52
Is a long tubular third passage 7 extending to the outside of the outer frame 50.
Connect to 8.

A plurality of cooling passages 80 are arranged close to each other on the surface of the upper mold body 52 opposite to the molding surface 62. The cooling passages 80 should be covered with a porous resin like the cooling passages 48. Is also possible.

Next, the molding apparatus 30 having the above structure
A method of manufacturing the interior member 10 will be described.

The sheet-like skin 12 which is constructed by laminating the cushion layer 20 on the skin layer 18 in advance is the skin layer 1.
The design side (front surface side) of 8 is placed in contact with the molding surface 40 of the lower mold body 38, and the air in the decompression chamber 44 is sucked from the vent hole 46 under the action of a vacuum device (not shown). Therefore, the skin 12 is sucked through the plurality of ventilation holes 42 provided in the lower mold body 38, and the skin layer 18 is formed on the molding surface 40.
It is held by the lower mold body 38 so as to be familiar with.

On the other hand, the upper die 34 is arranged apart from the lower die 32, and the base 16 has the through holes 24, 26 and 28 in the upper die body 52 of the upper die 34. , And the second through hole 66 and the third through hole 68 are temporarily fixed. Then, the upper mold 34 is lowered, and the upper mold 34 and the lower mold 32 are clamped, whereby the skin 12 and the base material 16 are
A predetermined gap 82 is formed between and.

After the mold is clamped, the resin beads 22 which have already been foamed, that is, which have already been foamed, are discharged from the feeding device (not shown) to the third position.
It is supplied by being pressure-fed into the gap 82 from the third through hole 68 of the upper mold body 52 and the through hole 28 of the base material 16 through the passage 78. At this time, the already-expanded resin beads 22 are compressed and deformed in advance so that the diameter thereof is smaller than the diameter in the normal state, and in this state, the gap 82 is filled without any gap.

Next, when the valve 70 is opened and heated steam is supplied to the first surge tank 58 from a steam supply source (not shown), the steam is communicated with the first surge tank 58 by a plurality of first passages 74. Is passed through the first through hole 64 of the upper mold body 52 and the through hole 24 of the base material 16 into the gap 82. The vapor melts the surface of the pre-expanded resin beads 22 filled in the gap 82, and the pre-expanded resin beads 22 are mutually restored in a state where they are restored to their original size due to decompression. The foam welding layer 14 is formed by welding, and the heat of the steam melts the surfaces of the cushion layer 20 of the skin 12 and the base material 16 on the side of the foam welding layer 14, and the heat is applied through the foam welding layer 14. The skin 12 and the base material 16 are welded together without a gap (see FIG. 1).
reference).

The steam sent to the gap 82 is used for forming the foam-welding layer 14 and then passes through the through-hole 26 of the base material 16 and the second through-hole 66 of the upper mold body 52 through the second passage 76. The second surge tank 6 is sent to the second surge tank 60.
When 0 is filled with steam, the exhaust valve 72 is opened and the steam is discharged from the outer frame 50 to the outside.

After the skin 12, the foam-welding layer 14 and the base material 16 are welded, the valve 70 is closed to stop the supply of steam, and the cooling water is passed through the cooling passages 48 and 80. The product molded between the mold body 38 and the upper mold body 52, that is, the interior member 10, is cooled, and then the upper mold 34 is raised and the interior member 10 is taken out.

In this case, in the first embodiment, since the already expanded resin beads 22 are supplied to the gap 82 formed between the skin 12 and the base material 16, it is necessary to consider the volume expansion during foaming. There is no. Therefore, the already-expanded resin beads 22 can be filled into the gap 82 without any space, and in particular, the gap 8
Even if 2 has a narrow portion or a portion that changes abruptly, it is possible to reliably prevent the defective filling of the resin beads 22 in the gap 82. By using the already-expanded resin beads 22, the resin beads 22 are formed in the gap 82.
The reason is that the resin beads 22 can be filled in all the portions in the gap 82 without any gap, without foaming again. As a result, the interior member 10 having a complicated shape
Even in this case, it is possible to obtain the effect of enabling highly accurate manufacturing work without a gap.

Further, the pre-expanded resin beads 22 supplied to the gap 82 are filled in the gap 82 while being contracted by compression in advance. Then, the resin beads 22 are restored to their original size in the gap 82 and are welded by steam in a state of being pressed against each other, so that the welding area is considerably increased as compared with the conventional foamed resin beads, and the welding strength is increased. Is improved and a strong and lightweight interior member 10 is obtained. Moreover, the added value of softness will be added.

Furthermore, the interior member 10 according to this embodiment.
Then, the cushion layer 20 is provided between the skin layer 18 and the foam welding layer 14. Therefore, the resin beads 22
Even if a deformation such as unevenness occurs on the surface side of the foam-welded layer 14 due to the welding, the cushion layer 20 can absorb this deformation, and as a result, the skin layer 18 has an unnecessary deformed portion. Never. This has the advantage that molding defects can be effectively prevented and a high quality interior member 10 can be obtained efficiently.

In addition, the skin layer 18, the cushion layer 20,
By forming the foam-welding layer 14 and the base material 16 entirely from an olefin resin, there is an effect that they can be easily integrated by heat welding without using an adhesive and are excellent in recyclability.

Next, a method of manufacturing an interior member according to the second embodiment of the present invention will be described with reference to FIG. In this second embodiment, the same molding apparatus 30 as in the first embodiment is used, and the same components as those in FIG. 2 are designated by the same reference numerals and their detailed description will be omitted.

In the second embodiment, the upper mold 34 is relatively spaced apart from the lower mold 32, and the outer skin 12 is suction-held on the lower mold body 38 of the lower mold 32.
The foamed resin beads 22 are laminated on the cushion layer 20 side. This may be done using the third passage 78, or it may be done by feeding the resin beads 22 directly onto the skin 12 from between the upper mold 34 and the lower mold 32.

Therefore, after the base material 16 is temporarily fixed to the upper mold 34, the upper mold 34 is lowered and clamped, and thereafter,
The manufacturing work of the interior member 10 may be performed in the same manner as in the first embodiment.

In this case, in the second embodiment, the foamed resin beads 22 are formed with the upper mold 34 separated from the lower mold 32.
Is laminated on the skin 12, so that, for example, this skin 12
More than the amount of resin beads 22 filled in the gap 82 formed between the substrate 16 and the base material 16 (filling amount in the case of the first embodiment).
If the upper mold 34 and the lower mold 32 are clamped, the resin beads 22 are pressed against each other and the gap 8
Accommodated in 2. Therefore, the welding area between the resin beads 22 is further increased, and the strength of the entire interior member 10 can be further improved.

Next, a method of manufacturing the interior member according to the third embodiment will be described with reference to FIGS.

As shown in FIG. 5, the molding apparatus 100 for carrying out the manufacturing method according to the third embodiment has a lower mold 1
02 and an upper mold 104. The upper mold 104 is provided with a second surge tank 106 surrounding the upper mold body 52. As shown in FIGS. 6 and 7, this second surge tank 106 communicates with the gap 82 via a plurality of grooves 108 provided on the surface 12 side of the base material 16a. Note that the other configurations are the same as those of the molding apparatus 30 shown in FIG. 2, and the same components are designated by the same reference numerals, and detailed description thereof will be omitted.

In the manufacturing method according to the third embodiment, after the vapor sent from the first surge tank 58 to the gap 82 is used for manufacturing the interior member 10 by welding the resin beads 22 to each other. The groove 108 formed in the base material 16a
The second surge tank 106 is charged through the valve 7
It is discharged from 2 to the outside.

[0043]

According to the interior member and the method for manufacturing the same according to the present invention, the following effects can be obtained.

Since the back surface side of the skin layer has a cushion layer that is welded to the foam welding layer, even if irregularities or the like occur on the welding surface portion of the foam welding layer, the cushion layer will cover this irregular portion. It is possible to effectively prevent the occurrence of deformation on the surface of the epidermis by absorption. This makes it possible to efficiently obtain a high quality interior member.

Furthermore, in the method for manufacturing an interior part according to the present invention, since the resin beads that have already been foamed are supplied to the predetermined gap formed between the base material and the skin, the resin beads can be formed without any gap. It is possible to fill a predetermined gap.
Therefore, even if the gap has a complicated shape, it is possible to form the foam-welded layer without a gap in this gap.

At this time, if the pre-expanded resin beads are compressed and deformed in advance and supplied to the gap between the base material and the skin, the pre-expanded resin beads are formed when the foam-welding layer is formed by the melting medium. Weld to each other in a state of being restored to the original size. As a result, the welding area between the resin beads is further increased, the welding strength is improved, and a strong and lightweight interior body is obtained.

[Brief description of drawings]

FIG. 1 is a partially longitudinal explanatory view of an interior member according to an embodiment of the present invention.

FIG. 2 is a schematic vertical cross-sectional explanatory view of a molding apparatus used in the method for manufacturing an interior member according to the first embodiment of the present invention.

FIG. 3 is an explanatory plan view of an upper mold body that constitutes the molding apparatus.

FIG. 4 is an explanatory view of a molding apparatus for carrying out a method of manufacturing an interior member according to a second embodiment of the present invention.

FIG. 5 is a schematic vertical cross-sectional explanatory view of a molding apparatus for carrying out the method for manufacturing an interior member according to the third embodiment of the present invention.

FIG. 6 is an enlarged view of the base material of the interior member manufactured by the molding apparatus according to the third embodiment.

7 is a sectional view taken along line VII-VII in FIG.

[Explanation of symbols]

10 ... Interior member 12 ... Skin 14 ... Foam welding layer 16, 16a ...
Base material 18 ... Skin layer 20 ... Cushion layer 22 ... Resin beads 30 ... Molding device 32 ... Lower mold 34 ... Upper mold 38 ... Lower mold body 52 ... Upper mold body 58, 60 ... Surge tank 82 ... Gap 100 ... Molding device 102 … Lower mold 104… Upper mold 106… Surge tank

Claims (4)

[Claims] 1. A skin, a foam welding layer made of resin beads laminated on the back surface side of the skin, and a base material provided on the foam welding layer on the side opposite to the skin. In addition, the interior member includes an outer skin layer and a cushion layer provided on the back surface side of the outer skin layer and welded to the foam weld layer. 2. A process of filling pre-expanded resin beads into a predetermined gap between a base material and a skin, which are separated from each other by a molding die, and the gap filled with the pre-expanded resin beads. A step of welding the already foamed resin beads to each other to form a foam-welding layer by introducing a melting medium into the, and welding the skin and the base material via the foam-welding layer; A method for manufacturing an interior member, comprising: 3. The method for manufacturing an interior member according to claim 2, wherein the outer skin is provided with a cushion layer on the back surface side to which the resin beads are supplied. 4. The method of manufacturing an interior member according to claim 2, wherein the foamed resin beads are filled in the predetermined gap in a state of being compressed and deformed in advance.