JPH0811145A - Interior part for car and production thereof - Google Patents

Abstract

PURPOSE:To differentiate the soft feeling of a skin material at every region by simple constitution and to enhance the cushioning capacity and appearance of an interior part for a car produced by integrating a resin core material and the skin material by press molding. CONSTITUTION:A three-layered structure constituted of a shin material 30 consisting of a skin layer 31, a thick-walled part 32a and a thin-walled part 32b, a foamed layer 32 set so as to be made partially different in thickness and a backing layer 33 having heat insulating properties is preliminarily molded into a required shape. The skin material 30 molded into the required shape is set to the molding surface of the lower mold of a press mold through a predetermined clearance to be integrated with a resin core material by press molding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile interior part such as an automobile door trim and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, the structure of automobile interior parts such as automobile door trims and rear corner trims that are installed in the body panels of automobiles will be described by exemplifying the automobile door trims shown in FIGS. The door trim 1 for a vehicle is formed by laminating a resin core material 2 formed so as to have a desired curved surface shape, and a skin material 3 which is integrated on the front surface side of the resin core material 2 and has decorative and cushioning properties. It is composed of a molded body.

As a method of molding the resin core material 2,
Recently, since a complicated three-dimensional shape is required for molding, a mold press molding method having excellent moldability tends to be used frequently.

In this case, the skin material 3 is integrated with the resin core material 2 at the time of mold press molding of the resin core material 2 for the purpose of shortening the process.

That is, as shown in FIG. 11, the skin material 3 is set in advance on the upper die 4 for mold press molding,
Lower the upper mold 4 for mold press molding to move the upper and lower molds 4,
While maintaining a predetermined clearance between them, the molten resin M is distributed and supplied onto the mold surface of the lower mold 5 for mold press molding, and then the upper and lower molds 4 and 5 are tightened by engaging pressure.
As shown in FIG. 12, the resin core material 2 is molded and press-molded, and the skin material 3 is integrated on the surface side of the resin core material 2 to mold the door trim 1 into a desired product shape.

[0006]

However, according to the conventional method of integrally press-molding the resin core material 2 and the skin material 3 by mold press molding to mold the interior parts for automobiles, the thickness of the skin material 3 is increased. The cushioning performance is almost constant throughout the whole, but the skin material 3 is based on a portion where softness is required, such as an armrest portion or a waist portion, which is easily touched by an occupant's body. When set to, there was a problem that excessive quality was caused in other parts, resulting in higher cost and weight.

Therefore, as shown in FIGS. 13 and 14, the contact member 6 and the armrest 7 are attached to the door trim 1.
It is usual to install other members such as to give a soft feeling, but there is a problem that the number of parts, the number of mounting steps, etc. increase and the cost of the product increases.

Further, in the mold press molding method, during molding, the skin material 3 is excessively stretched at a portion having a high expansion rate, the portion becomes thin, the cushioning performance is deteriorated, and the heat of the molten resin M is reduced. It has also been pointed out that the skin material 3 is susceptible to static damage and the surface of the product is uneven, resulting in deterioration of the appearance performance of the product.

The present invention has been made in view of the above circumstances, and is an interior part for an automobile in which a resin core material and a skin material are integrated by a mold press molding method and a method for manufacturing the same. Department, etc.
Cushioning properties can be enhanced only in the parts where a soft feeling is required, and the skin material is not stretched at the parts where the expansion rate is high during mold press molding. It is an object to provide an interior part and a manufacturing method thereof.

[0010]

To achieve the above object, the present invention provides a resin core material obtained by molding a molten resin into a required shape in a mold for molding, and a mold press for the resin core material. During molding, in an automobile interior part configured with a skin material integrated with this resin core material, the skin material includes a skin layer, a thick portion and a thin portion from the product surface side, and a partial deviation It is characterized in that it is composed of a foamed layer set in a flesh shape and a backing layer having a heat insulating property, and is composed of a laminated molded body which is molded in a required shape in advance.

A synthetic resin sheet such as a PVC sheet or a cloth sheet such as a cloth is preferable as the skin layer constituting a part of the above-mentioned skin material.

The foam layer is preferably a thermoplastic resin foam, such as PE foam or PP foam.

As the backing layer, a heat compression urethane is preferable because it can eliminate the thermal damage of the molten resin, and a raw urethane layer having a thickness of 8 to 10 mm is preferable.
Compressed to a thickness of about 5 mm.

Further, in the method for manufacturing an automobile interior part according to the present invention, a laminated sheet having a three-layer structure in which a skin layer, a foam layer and a backing layer are adhered to each other is preheated, and then the foam layer is provided with a thick portion and a thin portion. And a step of forming a skin material to be formed into a desired shape so that the skin material formed in the step is set on a mold surface of a lower mold for mold press molding through a predetermined clearance, and then mold press molding While lowering the upper mold, the molten resin is distributed and supplied between the lower mold and the backside of the skin material to form the resin core material into the required shape, and press integration that integrates the resin core material and the skin material And a process.

[0015]

As apparent from the above construction, the foam layer of the skin material is provided with a thick portion and a thin portion, respectively. It is possible to have different feelings, and it is not necessary to install another member such as an inscribed member or an armrest.

Further, since the skin material is molded into a product shape in advance, the skin material is not excessively stretched in the step of integrating the resin core material and the skin material during mold press molding, and the skin material is Since a backing layer such as a heat compression urethane is located on the resin core side of the material, thermal damage to the molten resin can be eliminated.

Further, in the manufacturing method according to the present invention,
It is only necessary to set the skin material consisting of the three-layer structure molded into the required shape on the lower mold for mold press molding, and the work of setting the skin material can be performed more easily than the conventional work of setting the skin material. .

[0018]

Embodiments of an automobile interior part and a method of manufacturing the same according to the present invention will be described below in detail with reference to the accompanying drawings.

FIG. 1 is an external view showing an automobile door trim which is an embodiment of an automobile interior part according to the present invention, FIG. 2 is a sectional view showing the structure of the automobile door trim, and FIGS. FIG. 8 is a cross-sectional view showing a method of manufacturing a vehicle door trim, and FIG. 8 is a cross-sectional view showing a configuration of another embodiment in which the vehicle interior component according to the present invention is applied to a vehicle door trim.

1 and 2, an automobile door trim 10 is generally composed of a resin core material 20 formed into a required shape and a skin material 30 laminated and integrated on the surface side of the resin core material 20. ing.

More specifically, the resin core material 20 is made of polypropylene resin mixed with talc, and is distributed and supplied in a molten state into a mold for press molding having a desired curved surface shape, followed by mold press molding. It is molded to have a complicated curved surface shape.

The skin material 30 is composed of a three-layer laminated molded body consisting of a skin layer 31, a foam layer 32 and a backing layer 33 from the product surface side. The skin layer 31 is
Although the cloth is used in the present embodiment, other cloth sheet, PVC sheet, or other synthetic resin sheet may be used, and the material thereof is not particularly limited as long as it is decorative and has a feeling of touch.

Next, polyethylene foam is used in this embodiment as the foam layer 32 located on the back side of the skin layer 31, and the waist portion 11 and the armrest portion 12 are used.
The thick part 32 is the part where the occupant's shoulders and waist are easily touched.
The thickness is a, and the portion that is not touched by the body of the occupant is formed as a thin portion 32b with a partially uneven thickness.

Further, a backing layer 33 having a heat insulating property is located on the back surface of the foam layer 32, and in this embodiment, heat compression urethane is used.

This heat-compressed urethane is obtained by compressing urethane foam having a thickness of 8 to 10 mm to a thickness of 1.5 mm, and even if the resin comes in contact with the resin at 200 to 210 ° C., its thermal insulation causes problems. If the plate is processed with a fixed plate, the urethane surface becomes smooth, and the fluidity of the resin during mold press molding, which will be described later, is not impaired.

As described above, the automobile door trim 10 according to the present invention comprises the three-layer structure of the skin layer 31, the foam layer 32 and the backing layer 33 as the skin material 30, and the resin core material 20 and the mold press. Before being integrated by molding, it is molded into a product shape in advance, and in particular, the foam layer 32
Has a partially uneven thickness so as to include the thick portion 32a and the thin portion 32b, and therefore, such as the waist portion 11 and the armrest portion 12 of the door trim 10 where cushioning properties are required and other portions. The difference in softness can be revealed between the parts and, and the number of parts and mounting man-hours can be greatly reduced compared to the conventional configuration in which a separate center contact member or a separate armrest is set, and it can be implemented at low cost. There are advantages.

Further, since the skin material 30 is molded in a required shape in advance, at the time of molding press molding with the resin core material 20, the skin material 30 is excessively stretched and thinned in a portion having a high curvature. Cushion performance does not deteriorate.

In addition, on the resin core material 20 side of the skin material 30, a backing layer 3 having excellent heat insulating property such as heat compression urethane.
Since 3 is located, the adverse effect of the resin heat of the molten resin can be eliminated, and since the urethane surface is smooth, the fluidity of the resin can be increased, so that there is no unevenness on the product surface, Moreover, the molding accuracy is also improved.

As described above, the automobile door trim 10 according to the present invention has various operational effects in terms of its structure. One embodiment of the method for manufacturing the automobile door trim 10 will be described with reference to FIGS. 3 to 7. Explained.

3 to 5 show a molding process of the skin material 30 having a three-layer structure, and FIGS. 6 to 7 show a mold press molding process of the resin core material 20 and the skin material 30, respectively. .

First, the molding process of the skin material 30 will be described with reference to FIGS. 3 to 5. First, as shown in FIG. 3, the skin layer 31 and the foam layer 3 which are the materials of the skin material 30.
2, the backing layer 33 is laminated in this order, and after forming a laminated sheet S in which three layers are bonded and fixed with an adhesive,
160 ~ 200 ℃ by heater device 40 such as warm air heater
Heat to.

After heat-softening the laminated sheet S, as shown in FIG. 4, a softened state is obtained between the cold press molding upper and lower molds 50 and 51 having substantially the same mold surface as the product shape by the above process. The peripheral edge of the laminated sheet S
Positioning is carried out while being held by the clamp device 52.

Thereafter, as shown in FIG. 5, the cold press molding upper die 51 is lowered to shape the skin material 30 into a product shape.

At this time, the foam layer 32 has the waist portion 1
1, a portion corresponding to the armrest portion 12 is a thick portion 32a
In addition, the general portion is formed with a partially uneven thickness so as to become the thin portion 32b.

The above is the process of forming the skin material 30.

The skin material 30 formed in this manner is shown in FIG.
As shown in FIG. 5, the lower mold 60 for mold press molding is set on the mold surface with a predetermined clearance (about 5 mm).

An upper mold press molding die 70 is located above the lower mold press molding die 60.
The door trim 10 has a mold surface that is substantially the same as the curved surface of the product, and is configured to be vertically movable by a predetermined stroke by an elevating device (not shown).

Further, an injection molding machine 80 for supplying the molten resin M, which is a material of the resin core material 20, onto the mold surface of the lower mold press molding die 60 is operated by the lower molding die 6 for mold press molding.
0, and the molten resin M flows through the injection molding machine 80 into the hot runner 61 and the gate 62 in the lower mold 60.
Through, and is supplied to predetermined positions on the mold surface of the lower mold 60.

Then, after the skin material 30 is set on the mold surface of the lower mold press molding die 60, the upper mold press molding die 70 descends to reach a predetermined clearance between the upper and lower dies 60, 70. The molten resin M is supplied into the cavity between the backing layer 33 of the skin material 30 and the mold surface of the lower mold 60, and further by the lowering operation of the upper mold 70,
The molten resin M is forcibly filled in the cavity, and after a predetermined cooling time, the resin core material 20 is molded and press-molded into a required shape, and the resin core material 20 and the skin material 30 are also formed.
And are integrated by pressing (see FIG. 7).

In the mold press molding step of the resin core material 20 and the skin material 30, as shown in FIG. 6, the skin material 30 molded into a required shape is placed on the mold surface of the lower mold press molding die 60. It only needs to be set, and as compared with the conventional setting work of fixing to the upper mold, the setting work of the skin material 30 can be remarkably simplified, and the set workability is improved.

Further, a backing layer 33 having a heat insulating property is located on the back surface of the skin material 30, so that the resin heat of the molten resin M does not reach the foamed layer 32 and the like, and the appearance performance of the product is deteriorated. There is no such thing, and good cushioning performance can be maintained, especially when using heat compression urethane,
The back surface of the backing layer 33 is a smooth surface, and there is an advantage that the resin flow of the molten resin M is good and the molding accuracy is improved.

In addition, in the conventional case, there is a problem that the skin material is excessively stretched and thinned at a portion having a high expansion rate, and the cushioning performance is deteriorated. However, in the method of the present invention, the skin material 30 is The skin material 30 is preliminarily molded into a required shape, and the skin material 30 is not excessively stretched at the time of mold press molding, and the skin material 30 can be prevented from being thinned.

Next, FIG. 8 shows a second embodiment in which the automobile interior part according to the present invention is applied to an automobile door trim as in the first embodiment. In the case of this embodiment, the skin material 3 is used.
0, the decorative member 34 is provided at a predetermined position on the surface side of the skin layer 31.
If the decorative member 34 is also integrally formed in the step of forming the skin material 30, the work process can be performed as compared with the conventional case where the decorative member is post-processed after the door trim is formed. There is an advantage that it can be simplified, and since a decorative effect can be expected by the decoration member 34, there is an advantage that the appearance quality is further improved.

[0044]

As described above, the present invention has the following special operational effects.

(1) An automobile interior part according to the present invention comprises:
The skin material is pre-formed into the required shape, and in particular, the foam layer is formed into a partially uneven thickness, so it is cheaper and simpler than the conventional configuration in which the center contact member and armrest are set separately. With the configuration, the softness of the interior parts can be made different for each part, and the product value can be inexpensively increased.

(2) The interior parts for automobiles according to the present invention are:
As the skin material, a three-layer structure including a skin layer, a foam layer, and a backing layer is formed in advance into a desired shape. Therefore, the skin material is excessively stretched during mold press molding with the resin core material. There is an effect that good cushioning performance can be maintained without thinning.

(3) The interior parts for automobiles according to the present invention are:
Since the backing layer has a heat insulating property, the backing layer has a heat insulating property. The adverse effect of the resin heat of the molten resin can be eliminated by this backing layer, there is no melting and crushing of the foam layer, there is no unevenness on the product appearance surface, no pocking etc., and the effect that a good product appearance can be maintained Have.

(4) According to the method of the present invention, a laminate having a three-layer structure consisting of a skin layer, a foam layer and a backing layer is molded into a required shape to form a skin material, and then a lower mold for mold press molding. Since the skin material is set on the upper side, the setting work can be simplified and the workability is improved as compared with the conventional work of setting the skin material on the upper mold.

[Brief description of drawings]

FIG. 1 is an external view showing an embodiment in which an automobile interior part according to the present invention is applied to an automobile door trim.

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

FIG. 3 is a cross-sectional view showing a step of preheating a skin material in the method of the present invention.

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

FIG. 5 is a cross-sectional view showing a press-molding process of a skin material in the method of the present invention.

FIG. 6 is a cross-sectional view showing a step of setting a skin material on a mold for mold press molding in the method of the present invention.

FIG. 7 is a sectional view showing a mold press molding step in the method of the present invention.

FIG. 8 is a cross-sectional view showing the configuration of another embodiment in which the automobile interior part according to the present invention is applied to an automobile door trim.

FIG. 9 is a perspective view showing a conventional automobile door trim.

FIG. 10 is a sectional view taken along line XX in FIG. 9;

FIG. 11 is a cross-sectional view showing a step of setting the skin material before the conventional mold press molding step.

FIG. 12 is a cross-sectional view showing a conventional mold press molding process.

FIG. 13 is a cross-sectional view showing a configuration of a conventional automobile door trim in which a contact member is installed.

FIG. 14 is a cross-sectional view showing the configuration of a conventional automobile door trim in which an armrest is installed.

[Explanation of symbols]

 10 Automotive Door Trim 20 Resin Core Material 30 Skin Material 31 Skin Layer 32 Foam Layer 33 Backing Layer 50,51 Cold Press Molding Mold 60 Mold Press Molding Lower Mold 70 Mold Press Molding Upper Mold

Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display area // B29K 105: 04 B29L 31:58

Claims (4)

[Claims] 1. A mold for mold press molding (60, 70)
A resin core material (20) formed by molding a molten resin (M) into a desired shape, and a skin material integrated with the resin core material (20) during mold press molding of the resin core material (20). (3
In the interior parts for automobiles, the skin material (30) comprises the skin layer (3) from the product surface side.
1), a thick portion (32a) and a thin portion (32b), respectively, each of which is composed of a partially uneven thickness foam layer (32) and a heat-insulating backing layer (33), and has a predetermined shape in advance. An interior part for an automobile, which is characterized by being formed of a molded laminate. 2. The automobile interior component according to claim 1, wherein the backing layer (33) is made of heat compression urethane. 3. The foam layer (32) is made of PE foam, PP.
The interior part for an automobile according to claim 1, wherein the interior part for an automobile is formed of a thermoplastic resin foam such as foam. 4. A resin core material (2) formed into a required shape.
0) and a skin material (30) adhered to the surface side of the resin core material (20), a method for manufacturing an interior part for an automobile, comprising a skin layer (31), a foam layer (32), Backing layer (3
After the preheating of the laminated sheet (S) having a three-layer structure to which 3) is adhered, a thick portion (32a) and a thin portion (3) are formed on the foam layer (32).
2b) and a step of forming a skin material into a desired shape, and the skin material (30) formed in the above step is placed on a mold surface of a lower mold (60) for mold press molding through a predetermined clearance. The upper mold for mold press molding (7
0) while lowering the lower mold (60) and the skin material (3
0) A press integrated that distributes and supplies the molten resin (M) between the back surface and the back surface to mold the resin core material (20) into a required shape, and integrates the resin core material (20) and the skin material (30). A method of manufacturing an interior part for an automobile, comprising: