JPH0788020B2 - Manufacturing method of automobile interior parts - Google Patents

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 an automobile interior part using a low-cost and lightweight cellulosic low density mat as a base material.

[0002]

2. Description of the Related Art Conventionally, an interior part mounted on the inner surface of a trunk lid panel (hereinafter referred to as a trunk lid trim) has a base material having an appropriate shape retention property and a skin which is integrally attached to the surface of the base material. It is composed of a laminated structure with materials,
As the base material, an inexpensive and lightweight cellulose-based low density mat, for example, Carubo (manufactured by Tojo Paper Co., Ltd.) has been widely used recently.

A method of manufacturing a trunk lid trim when a cellulosic low density mat is used as a base material will be described with reference to FIGS. 6 and 7. As shown in the chart of FIG. A trunk lid trim is manufactured by preheating the original fabric of the density mat, heating and softening it, and then polymerizing it with a non-woven fabric as a skin material and press-integrating.

At this time, as shown in FIG. 7, after heat-softening the raw fabric 1 and the skin material 2 are set on the cold press lower mold 3, the cold press upper mold 4 is lowered to press the upper and lower molds. The actual situation is that the trunk lid trim in which the base material 1 and the skin material 2 are integrated is formed by the mold clamping of 3 and 4.

[0005]

However, the substrate 1
The cellulosic low-density mat used as is inexpensive and lightweight, but has a limit in moldability.

Therefore, although it is effective for a product having a relatively simple shape, it is not applicable to a deep-drawing product, and it is pointed out that the degree of freedom in molding is greatly restricted.

Further, the low density cellulose mat is prone to cracks due to variations in materials, errors in heating temperature, variations in the set state, etc., and many defects occur, and repair work is performed every time defects occur. Is a major factor that reduces the product yield.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a moldability in a method of manufacturing an automobile interior part using a cellulosic low density mat as a base material. It is intended to provide a method for manufacturing an automobile interior part having sufficient rigidity, improving the molding flexibility of the product, reducing defects and dramatically improving the product yield.

[0009]

In order to achieve the above object, the present invention provides a substrate formed into a required shape by thermoforming a raw material made of a cellulosic low density mat impregnated with a thermoplastic resin. In a method for manufacturing an automobile interior part comprising a material and a skin material press-integrated on the surface side of the base material, the raw material is composed of at least two or more thin sheets, and a press metal is used. When setting the material in the mold, in the high expansion rate part of the press mold,
A reinforcing sheet made of a resin material that is compatible with the base resin of the base material is inserted, and by press molding, the original sheets are laminated and integrated with the reinforcing sheet embedded in the specified location to form a base material of a specified thickness. It is characterized by doing.

[0010]

As is clear from the above construction, at least 2
By forming a plurality of thin sheets by superimposing them on each other, slippage between the thin sheets is promoted, the mold surface of the press die is easily followed, and the formability is improved.

Further, in the high expansion rate portion of the press die,
Since the reinforcing sheet is interposed between the original fabrics and even if the original fabric is cracked, the reinforcing sheet fills the cracks, so that the rigidity is enhanced.

The reinforcing sheet embedded in the base material does not affect the appearance because the skin material is attached to the front surface side of the base material.

[0013]

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

FIG. 1 is a perspective view showing a trunk lid trim manufactured by the method of the present invention, FIG. 2 is a cross-sectional view of an essential part showing the structure of the trunk lid trim, and FIGS. 3 to 5 show each step of the method of the present invention. FIG.

First, referring to FIGS. 1 and 2, a trunk lid trim 10 comprises a base material 11 made of a cellulosic low density mat which is moderate in weight and has a proper shape retention property, and a surface side of the base material 11. And a skin material 12 integrally attached to the trunk lid trim 10. A reinforcing sheet 13 is embedded in a base material 11 at a high expansion rate portion of the trunk lid trim 10, and a fixing means such as a clip is used. Attached to the trunk lid panel 20.

More specifically, the base material 11 is a cellulosic low-density mat (area density 700 to 1500 g / m ² ) formed into a sheet by a wet papermaking method, and for example, the trade name "Karubo" (Jujou). Pulp / olefin resin manufactured by Paper Manufacturing Co., Ltd .; a mat formed by molding a composite resin material having a mixing ratio of 35/65 into a sheet shape is preferable.

The skin material 3 is preferably a non-woven fabric made of synthetic fiber which is compatible with the resin used as the base of the base material 11, in consideration of the adhesiveness to the base material 11. When "Carub" is used, a non-woven fabric containing polyolefin resin fibers in at least a part thereof is suitable.

Next, each step of the method of the present invention will be described with reference to FIGS.

First, as for the substrate 11, the raw material M of the cellulosic low density mat is characterized in that at least two thin sheets are used.

That is, in this embodiment, four thin original sheets M
Are heated and softened by the heater 30, as shown in FIG. At this time, the temperature of the heater 30 is adjusted to 200 to 230 ° C.

Then, as shown in FIG. 4, when the heat-softened raw fabric M is set in the cold press molding lower die 40, the reinforcing sheet 13 is embedded in the base material 11, especially in the deep-drawn portion. The reinforcing sheet 13 is inserted between the original fabrics M of the high expansion rate portion.

Next, in a state in which the original fabric M of the base material 11, the reinforcing sheet 13, and the skin material 12 are set between the cold press molding lower mold 40 and the cold press molding upper mold 41, as shown in FIG. As shown, cold press upper mold 4
1 is lowered and a proper press pressure is applied to integrate the four original fabrics M in a state where the reinforcing sheet 13 is embedded therein to form the base material 11 having a required shape and the base material 11
The skin material 12 is press-integrated on the surface side of the.

At this time, since the original fabric M of the base material 11 is not a single sheet but a plurality of thin sheets, the mutual original fabrics M slide into each other and follow the mold surface shapes of the upper and lower press dies 40 and 41. And exhibits excellent moldability.

Further, since the reinforcing sheet 13 is inserted at the portion where the base material 11 is likely to crack, as described above, even if the original fabric M is cracked, the reinforcing sheet will crack. Since it penetrates and fills this crack, the rigidity of this portion is strengthened, defects and repair work can be significantly reduced, and the product yield is dramatically improved.

Since the reinforcing sheet 13 is a resin material compatible with the base resin of the base material 11, in this embodiment, the polyolefin resin in consideration of the adhesiveness to the base material 11, Although a polyolefin resin sheet is used in this embodiment, an olefin resin sheet reinforced with glass fiber may be used if it is desired to further strengthen the rigidity partially.

In the present embodiment, the four substrates M are integrated to form the base material 11, but at least two or more sheets may be formed. In the present invention, the number of the sheets M is limited. is not.

[0027]

As described above, according to the method of the present invention, the following special operational effects are obtained.

(1) Since the raw material of the substrate is composed of at least two thin sheets, the individual thin sheets slide into each other during press molding and easily follow the die surface of the press die. This has the effect of significantly improving the formability of the material.

(2) Since a reinforcing sheet is inserted between the webs corresponding to the high expansion rate portion of the press die, even if a crack occurs, it can be reinforced with the reinforcing sheet. Since sufficient rigidity can be secured, the defect rate is greatly reduced,
Rework work can also be reduced, improving yield,
It has the effect of dramatically improving production efficiency.

[Brief description of drawings]

FIG. 1 is an overall perspective view showing a trunk lid trim manufactured by 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 one step of the method of the present invention, showing a step of heating a raw material substrate.

FIG. 4 is a cross-sectional view showing one step of the method of the present invention, showing a step of setting a material in a press die.

FIG. 5 is a cross-sectional view showing one step of the method of the present invention, showing a step of press-integrating a base material and a skin material.

FIG. 6 is a chart showing a manufacturing process of a conventional interior part.

FIG. 7 is a sectional view showing a conventional press-molding process for an interior component.

[Explanation of symbols]

 10 Trunk lid trim 11 Base material 12 Skin material 13 Reinforcement sheet 20 Trunk lid panel 30 Heater 40 Lower mold for cold press molding 41 Upper mold for cold press molding M Original fabric

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Claims (1)

[Claims] 1. A base material (11) formed into a required shape by cold pressing a raw material (M) made of a cellulosic low density mat impregnated with a thermoplastic resin, and the base material (11). A skin material (1
2) In the method of manufacturing an automobile interior part, the raw material (M) is composed of at least two thin sheets, and is pressed when setting the material in a press die (40). A reinforcing sheet (13) made of a resin material compatible with the base resin of the base material (11) is inserted between the raw fabrics (M) in the high development rate portion of the mold (40), and press-molded. , Reinforcement sheet in place (13)
A method for manufacturing an automobile interior part, comprising: stacking and integrating raw fabrics (M) in a state of being embedded to form a base material (11) having a predetermined thickness.