JPH11115643A - Interior trim part for automobile and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent a resin core material, broken by the impact from the outside, from breaking through a cuticle material by forming the cuticle material of interior trim parts for an automobile by a piled body by a cloth for giving a high-class feeling, a backing sheet for restraining the shrinkage of the cloth and having a barrier function and a foaming layer. SOLUTION: A door trim 10 for an automobile is composed of upper/lower two divided bodies such as a trim upper 11 and a trim lower 12 and the trim upper 11 is formed by a piled structure body in which a cuticle material 30 is integrally pasted on the surface of a resin core material 20. The resin core material 20 is molded in a desired curved shape by extruding a polypropylene resin mixed a wood flour filler in a sheet shape by a T die extrusion molding machine and cold press molding this sheet original roll. While, the cuticle 30 is formed by a three layers piled body such as the cuticle material 31 for giving a high-class feeling, a backing sheet 32 having a barrier function for stopping a broken piece when the resin core material 20 is broken and a foaming layer 33 for giving a soft feeling.

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 suitable for an automobile door trim, rear corner trim, and the like, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Normally, various interior parts such as an automobile door trim and a rear corner trim are mounted in an automobile interior. The configuration of an automobile door trim will be described with reference to FIGS. And a surface material 3 integrally formed on a surface of a core material 2 formed into a desired curved surface shape. As materials of the core material 2 and the skin material 3, the molding requirements and cost of the door trim 1 are required. Various types are used in consideration of work processes and the like.

For example, a wood fiber board or a composite resin board such as a thermoplastic resin mixed with a filler such as wood flour is often used as the core material 2. As the skin material 3, a foam is formed on the resin sheet and the back of the resin sheet. A laminated sheet material lined with a foam layer such as PVC or polyethylene foam is often used.

[0004] Above all, in order to reduce costs and work processes,
A composite resin plate made of a polypropylene resin mixed with a wood powder filler is used as a material of the core material 2. As the skin material 3, a sheet material in which a foam layer such as a polyethylene foam is lined on the back surface of a PVC sheet is mainly used. And FIG.
As shown in FIG. 5, after the raw material of the core material 2 is preheat-softened,
The core material 2 is set in the mold of the cold press molding die 4 and the skin material 3 is supplied thereabove, and the core material 2 and the core material 2 and the skin material 3 are formed by clamping the cold press molding die 4. And press integration.

Further, as a recent tendency, the door trim 1 is formed of a divided body like a trim upper 1a and a trim lower 1b to give an external appearance accent, and particularly, the occupant's body is easy to touch. In order to give a sense of quality to a location that is easily noticeable, a cloth is often used as the skin material 3 of the trim upper 1a. As the core material 2 of the trim upper 1a,
In order to effectively absorb shock when a shock is applied to the vehicle from the side, a crushable type molding design in which the core material 2 breaks and absorbs the shock is currently used. .

[0006]

Conventionally, when a cloth is used as the skin material 3, a laminated sheet material in which a foam layer such as a polyurethane foam is laminated on the back of the cloth has been used. Due to poor elongation and large residual stress when molded, the laminated sheet of cloth and polyurethane foam is liable to peel off after molding. As a practical matter, when cloth is used as the skin material 3, the core is The fact is that the cloth is directly adhered directly to the material 2.

Accordingly, the trim upper 1 of the door trim 1
When an external impact is applied to a, the core material 2 breaks,
At this time, there is a problem that a crushable type core cannot be set as the core material because there is a fear that an edge generated by the breakage breaks through the cloth to form a sharp edge structure and damage an occupant.

The present invention has been made in view of such circumstances, and in an automobile interior part formed by press-integrating an impact-absorbing resin core material and a skin material using a cloth, an impact from the outside is provided. It is an object of the present invention to provide an automotive interior part which does not break through the skin material even when the resin core material breaks when the resin core material breaks and prevents the skin material from peeling, wrinkling, deformation and the like, and a method of manufacturing the same.

[0009]

In order to achieve the above-mentioned object, the present invention relates to an interior part for automobiles, comprising a surface material of a resin core material press-formed into a curved surface and a skin material pressed and integrated. The skin material is composed of a three-layer laminate consisting of a cloth that gives a sense of quality from the product surface side, a backing sheet that has a barrier function while suppressing shrinkage of the cloth, and a foam layer that provides cushioning to the product. It is characterized by having.

[0010] Here, as interior parts, the present invention can be applied to door trims, rear corner trims, and the like in which a part of an occupant's body is easy to touch. Further, a laminated structure of a resin core material and a skin material may be employed over the entire interior part, but a trim upper is provided with a resin core material and a skin material such as an upper and lower split door trim. The trim lower may be made of an injection molded body of a synthetic resin.

Further, as the resin core material, a thermoplastic resin mixed with a filler is preferable because it can be press-integrated with the skin material, is inexpensive and has good moldability. Polypropylene resin mixed with T
A composite resin plate extruded in a sheet shape by a die extruder is suitable, but a thermoplastic resin plate or the like in which a filler is not mixed can also be used.

On the other hand, the skin material is a three-layer structure in which a cloth, a backing sheet, and a foam layer are laminated from the product surface side. The backing sheet is a PVC sheet, and the foam layer is a polyethylene foam, a polypropylene foam, or the like. Polyolefin foams are preferred.

Further, in order to enhance the function of the backing sheet for suppressing the shrinkage of the cloth, it is preferable to increase the thickness of the backing sheet at the portion where the expansion rate is high during press molding. A laminated sheet material in which a plurality of sheets are stacked and provided with a step may be used, but a gradually changing sheet in which the thickness of the backing sheet is gradually changed is preferable. Further, not only the backing sheet but also the thickness of the foamed layer in the high expansion rate portion may be increased.

Next, a method for manufacturing an automobile interior part according to the present invention is directed to an automobile interior part comprising a resin core material surface and a skin material comprising a three-layer laminate of a cloth, a backing sheet, and a foam layer are integrated. In the manufacturing method of, the resin core material in the preheated softened state is set in the mold of the cold press molding die, the skin material is positioned thereabove, and the heater device is put in from the foam layer side of the skin material, It is characterized in that the resin core material and the skin material are press-integrated into a required shape by clamping the cold press molding die after heating and softening to a predetermined temperature.

The heating condition of the skin material is appropriately set depending on the cloth specifications, the formed shape and the expansion rate of the formed product, but in consideration of the tact and the like, about 60 to 80 ° C. is appropriate. It is desirable to heat from the back side, that is, from the foam layer side, in consideration of the hair fall of the cloth surface and the like.

In the heating method, a heater device may be set only for a part to be deformed, a heater balance (temperature is changed depending on a part) may be adjusted, and only a necessary part may be heated. The masking member may be inserted into a portion that does not require the masking member.

As is apparent from the above configuration, the backing sheet having a barrier function on the back surface of the cloth and the laminated sheet material in which a foamed layer having a cushioning property is laminated on the back surface are employed as the structure of the skin material. When added, even if the resin core material breaks, the backing sheet prevents the edge portion from projecting toward the indoor side by the barrier function, so that a sharp edge at the time of side collision can be eliminated. Further, by setting the thickness of the backing sheet to be large at the high expansion rate portion during press molding, the backing sheet is not thinly stretched at the high expansion rate portion, and a good barrier function can be obtained.

Further, according to the manufacturing method of the present invention, the skin material is heated, so that the elongation of the cloth is improved and the residual stress of the cloth is reduced, so that shrinkage after molding is suppressed,
Product defects such as wrinkles and defects such as peeling of the skin material are eliminated.

In addition, by limiting the heating portion of the skin material, the backing sheet does not become thinner, and the barrier function of the backing sheet can be effectively utilized.

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of an automobile interior part and a method of manufacturing the same according to the present invention will be described in detail with reference to the accompanying drawings.

1 to 8 show a first embodiment of the present invention. FIG. 1 is a front view showing a door trim for an automobile to which the present invention is applied, and FIG. 2 is a sectional view showing the structure of the door trim for the automobile. , FIGS. 3 and 4 are cross-sectional views showing a molding process of the trim upper in the automotive door trim, FIG. 5 is a graph showing heating-tensile characteristics of the skin material, and FIGS. 6 and 7 are graphs of the skin material of the trim upper. FIG.
FIG. 4 is an explanatory view showing a modified embodiment of a molding process of the trim upper.

9 to 12 show a second embodiment of the present invention. FIG. 9 is a sectional view of a door trim, and FIG.
Is a perspective view showing an embodiment of a skin material used for the door trim, and FIGS. 11 and 12 are sectional views showing a molding process of the door trim.

First, a first embodiment of the present invention will be described with reference to FIGS. As shown in FIGS. 1 and 2, the door trim 10 for an automobile is composed of a vertically upper and lower divided body of a trim upper 11 and a trim lower 12. The commercial value of the trim upper 11 and the trim lower 12 is given by an accent effect in appearance. Is increasing.

More specifically, the trim upper 11 is formed of a laminated structure in which a skin material 30 is integrally adhered to the surface of the resin core material 20.
T with polypropylene resin mixed with wood powder filler
The sheet is extruded into a sheet by a die extruder, and the sheet is cold-pressed to form a curved surface as shown.

The trim lower 12 is made of an injection-molded product of PP resin, and has a door pocket 13 and a speaker grill 14.
Are integrally formed, and the joining structure between the trim upper 11 and the trim lower 12 is formed by projecting ultrasonic pegs 15 on the back side at predetermined intervals along the upper edge of the trim lower 12, and A mounting hole 16 is opened in the trim upper 11 correspondingly, and after inserting the ultrasonic peg 15 into the mounting hole 16, the tip of the ultrasonic peg 15 is ultrasonically caulked, so that the trim upper 11 and the trim lower 12 are fixedly joined.

The present invention is characterized by the structure of the door trim 10, particularly the trim upper 11, which has no appearance defects such as deformation and wrinkles, and has no problems such as peeling of the skin material 30, and has side collisions. The feature is that sharp edges are not formed even when a shock is applied from the side, and occupant safety is enhanced.

For this purpose, the structure of the skin material 30 includes a skin material 31 that can give a high-grade appearance, a backing sheet 32 having a barrier function of blocking fragments when the resin core material 20 breaks, and a soft feeling. In this embodiment, a PVC sheet is used as the backing sheet 32, and a polyolefin foam such as polyethylene foam or polypropylene foam is used as the foam layer 33 in the present embodiment. Can be used.

As the backing sheet 32, a PVC sheet is 0.5 mm thick, and a sheet having a thickness of 1.0 mm is used as a foam sheet 33.

Next, the trim upper 11 is made of the resin core material 2.
0 and the skin material 30 are integrally press-formed by cold press molding as described later. However, as described above, when a side collision occurs due to the backing sheet 32 of the skin material 30, an external force is applied to the trim upper 11 and the resin core material 20 is formed. Breaks,
Debris is prevented from protruding into the vehicle interior from the backing sheet 32, and sharp edges at the time of side collision can be effectively prevented, which is very preferable in terms of safety.

Next, FIGS. 3 and 4 show the trim upper 11.
In this molding step, a cold press molding die 40 is used as shown in FIG.

The cold press mold 40 comprises a cold press upper mold 41 having a desired mold surface shape and a cold press mold lower mold 42 having a corresponding mold surface shape which is almost the same. The upper and lower dies 41 and 42 can be opened and closed with each other.
3 allows a predetermined stroke up and down movement.

Then, as shown in FIG.
When the mold 42 is in the mold open state, the periphery of the resin core material 20 is held by the clamp device 44, softened by a preheating device (not shown), supplied into the mold, and the periphery of the skin material 30 is placed above the mold. It is held by the clamp device 45 and is also supplied into the mold. Further, the movable heater device 50 is put into the mold, and the back side of the skin material 30, that is, the foam sheet 33 side is maintained at 60 to 80 ° C. Heat and soften.

Thereafter, as shown in FIG. 4, the upper and lower dies 41 and 42 are clamped by the operation of the lifting / lowering cylinder 43 to form the resin core material 20 into a required shape, and the resin core material 2 is formed.
The surface material 30 is integrally attached to the surface of the trim 0, and the molding of the trim upper 11 is completed. In addition, the skin material 30 of the resin core material 20
A hot-melt film is preliminarily laminated on the opposing side surfaces, and the skin material 30 is previously formed so that air does not remain between the resin core material 20 and the skin material 30 during cold press molding. Needle hole processing is applied.

As described above, the skin material 30 is heated by the heater 50.
5, the elongation of the entire skin material 30 is improved, residual stress is reduced, and problems such as generation of wrinkles after molding and peeling of the skin material 30 are effectively solved, as is apparent from the graph of FIG. it can.

The heating direction of the skin material 30 by the heater 50 is preferably performed from the back side, that is, from the foam sheet 33 side in consideration of the hair falling of the cloth 31, but is not limited to this. In this case, the heater 50 may be set only in a part to be deformed, or the heater balance (change of the temperature depending on the part) may be adjusted, and the temperature may be raised to the above-mentioned temperature only in the necessary part. Therefore, it is possible to form the trim upper 11 without wrinkles or deformation and without peeling the skin material 30.

FIGS. 6 and 7 show a modification of the skin material 30. When attention is paid to the expansion rate of the trim upper 11 at the time of press molding, the armrest portion 17 is a high expansion rate portion a. The degree of elongation of the skin material 30 is required as compared with the part b.

Accordingly, when the skin material 30 is extended, the backing sheet 32 is elongated and thinned, thereby deteriorating the barrier function and generating a sharp edge. As shown in FIG. 6, the thickening sheet 32a is laminated on the backing sheet 32 for the high expansion rate portion a, and a sharp edge countermeasure is performed using the stepped skin material 30.

As shown in FIG. 7, the thickness of the backing sheet 32 is large in the high expansion rate portion a, and
The thickness of the backing sheet 32 is not set so large, and the thickness of the backing sheet 32 is gradually changed.
May be adjusted, which is preferable because a smooth feeling on the product surface can be obtained.

Next, FIG. 8 shows a modification of the heating step in the method of the present invention.
For example, if the masking member 51 is inserted into the skin material 30 at the high expansion rate portion so that heat from the heater device 50 is not transmitted, the backing sheet 32 in the high expansion rate portion a becomes thin after molding. It has a good barrier function and prevents sharp edges as much as possible. It should be noted that the same cushioning performance may be ensured even in the high expansion rate part a and the general part b by changing the thickness of the foam sheet 33.

Next, FIGS. 9 to 12 show a second embodiment of the present invention. As shown in FIG. 9, the door trim 10 is common to the trim upper 11 and the trim lower 12 only in the appearance. The resin core material 20 is used.

That is, the resin core material 20 is an integral product common to the trim upper 11 and the trim lower 12, and a polypropylene resin mixed with wood powder is extruded into a sheet shape by a T-die extruder, and the sheet material is heated and softened. By performing cold press molding thereafter, the resin core material 20 is formed into a curved surface shape as shown in the drawing, and at the time of cold press molding of the resin core material 20, the skin material 30 is integrally adhered. The skin material 30a in the trim upper 11 has a three-layer structure. That is, the backing sheet 32 has a three-layer structure in which the backing sheet 32 and the foam sheet 33 are laminated on the back surface. The skin material 30b of the trim lower 12 has a two-layer structure of the backing sheet 32 and the foam sheet 33 instead of the cloth 31. P as 32
The surface of the VC sheet is made of a material having an enhanced design such as a squeezed pattern.

A wood grain groove 21 is provided in the resin core material 20 along the boundary between the trim upper 11 and the trim lower 12. Part skin material 30b
Is accommodated.

As shown in FIG. 10, the end of the upper skin material 30a and the end of the lower skin material 30b may be sewn to the wire 35, but the cloth 31 in the upper skin material 30a is simply used. May be simply cut along the joining portion 34.

Then, similarly as shown in FIGS. 11 and 12, the resin core material 20 and the skin material 30 are formed by cold press molding.
Are press-integrated, but as described above,
When the movable heater device 50 is put into the foam sheet 33 side and the resin core material 2 and the skin material 30 are molded in a state where the heating and softening treatment is performed, a door trim for an automobile which can prevent a sharp edge at the time of a side collision can be provided. 10 can be easily formed.

In this embodiment, two kinds of skin materials 3 are used.
There is an advantage that the attaching process of Oa and 30b is only one process, and the working process can be greatly shortened.

[0046]

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

(1) According to the first aspect of the present invention, a three-layer laminated sheet material in which a backing sheet and a foam sheet are laminated on the back surface of a cloth is used as a structure of a skin material that is press-integrated with a resin core material. Because of the configuration,
Even if the resin core material breaks when an impact load is applied to the interior components, the foam layer absorbs the impact and the debris is blocked by the backing sheet, so it does not break through to the indoor side and reliably prevents sharp edges And has an effect of being excellent in safety.

(2) According to the second aspect of the present invention, since the thickness of the backing sheet at the high expansion rate portion at the time of press molding is set to be large, the backing sheet can be made thin at the time of press molding. Therefore, a desired barrier function can be obtained, which is effective in preventing sharp edges.

(3) According to the third aspect of the invention, since the thickness change between the thickened portion and the general portion of the backing sheet is gradually changed, no step is formed in the molded product and the appearance is reduced. In addition, it has the effect of improving the feeling of touch.

(4) According to the fourth aspect of the invention, when the resin core material and the skin material are subjected to cold press molding, the skin material is previously subjected to a heat treatment to reduce residual stress and to reduce wrinkles after molding. It is possible to reliably prevent defects such as generation and deformation or peeling of the skin material, and to improve the molding accuracy of the interior parts.

(5) According to the fifth aspect of the invention, when the resin core material and the skin material are integrated by cold press molding, the skin material is heated in advance. Since the adjustment is performed, the thickness of the backing sheet can be kept almost constant without adjusting the thickness of the backing sheet, and it is possible to easily and at low cost to mold a molded article with sharp edge measures. Has an effect.

[Brief description of the drawings]

FIG. 1 is a front view showing a first embodiment of an automobile door trim to which an automobile interior part according to the present invention is applied.

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

FIG. 3 is a cross-sectional view showing a molding process of a trim upper in the door trim shown in FIG. 1 and showing a material setting process.

FIG. 4 is a sectional view showing a cold press forming step of a trim upper in the door trim shown in FIG. 1;

FIG. 5 is a graph showing heating-tensile characteristics of a skin material used for a trim upper in the door trim shown in FIG. 1;

FIG. 6 is an explanatory view showing a modification of a skin material used for a trim upper in the door trim shown in FIG. 1;

FIG. 7 is an explanatory view showing a modification of a skin material used for a trim upper in the door trim shown in FIG. 1;

FIG. 8 is an explanatory view showing a modification of a heating step before press forming of the trim upper in the door trim shown in FIG. 1;

FIG. 9 is a sectional view of an automobile door trim showing a second embodiment of the present invention.

FIG. 10 is a perspective view showing an embodiment of a skin material used for the automobile door trim shown in FIG. 9;

11 is a cross-sectional view showing a cold press forming step of the automobile door trim shown in FIG. 9 and showing a material setting step.

FIG. 12 is a cross-sectional view showing a cold press forming step of the automobile door trim shown in FIG. 9;

FIG. 13 is a front view of a conventional automobile door trim.

FIG. 14 is a sectional view taken along line XIV-XIV in FIG. 13;

FIG. 15 is an explanatory diagram showing an outline of a conventional cold press forming process of an automobile door trim.

FIG. 16 is a cross-sectional view showing a conventional upper and lower two-parting type door trim.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Car door trim 11 Trim upper 12 Trim lower 20 Resin core material 30 Skin material 31 Cross 32 Backing sheet 33 Foam layer 30a Upper part skin material 30b Lower part skin material 40 Cold press molding die 41 Upper die 42 Lower die 43 Lifting cylinder 44, 45 Clamping device 50 Heater device 51 Masking member

Claims (5)

[Claims] 1. An interior part for automobiles comprising a skin material (30) press-integrated on the surface side of a resin core material (20) press-formed into a curved shape, wherein the skin material (30) is a product surface thereof. A cloth (31) that gives a sense of quality from the side, and a backing sheet (32) that suppresses shrinkage of the cloth (31) and has a barrier function
And a foamed layer (33) for imparting cushioning properties to the product. 2. The automotive interior part according to claim 1, wherein the backing sheet (32) has an increased thickness at a portion having a high expansion rate during press molding. 3. The vehicle interior part according to claim 2, wherein a change in thickness of the backing sheet (32) is gradually changed. 4. A cloth (3) is formed on the surface of the resin core material (20).
1) A method of manufacturing an interior part for an automobile, comprising a skin material (30) formed of a three-layer laminate of a backing sheet (32) and a foam layer (33), comprising: a mold for a cold press molding die (40); A resin core material (20) in a preheated and softened state is set in a mold, a skin material (30) is positioned above the core material, and a heater device (50) is placed from the foam layer (30) side of the skin material (30). After being charged and heat-softened to a predetermined temperature, the cold press molding die (40) is clamped to integrate the resin core material (20) and the skin material (30) into a required shape. Manufacturing method of interior parts for automobiles. 5. A skin material (3) by a heater device (50).
5. The vehicle according to claim 4, wherein when heating 0), a masking member (51) is interposed in a portion having a high expansion rate to suppress softening of the skin material (30) in the high expansion rate portion. Manufacturing method of interior parts.