JPS60166420A - Manufacture of interior material made of synthetic resin for automobile - Google Patents

Abstract

PURPOSE:To obtain the neat periphery, which is not corrugated, of an opening in an expansion molded shape by positioning a skin material along a swell-out section formed to an expansion die by a projection formed to a core material and expanding an expanded material. CONSTITUTION:Swell-out sections 5a, 5b are formed to the inner surface of a recessed die 5, on which a skin material 10 must be fast stuck, in an expansion die B while being made to correspond to sections to which openings 11, 12 are to be shaped. Positioning projections 8a, 8b surrounding the swell-out sections 5a, 5b are formed to a core material 8 in a projecting manner. The swell-out sections 5a, 5b and the positioning projections 8a, 8b have dimensional relationship of which they have clearances in size approximately the same as the thickness of the skin material 10 under the state in which the expansion die B is mold-clamped. When the core material 8, an expanded material 9 and the skin material 10 are set to a cavity 7 in the expansion die B by using such a core material 8 and the expansion die B, and mold-clamped and the expanded material is expanded, the expanded material sufficiently spreads to the skin materials 10 in the opening sections even when the blowing pressure of sections corresponding to the openings 11, 12 is small.

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention comprises a foam molded product in which a foam as a cushion body is interposed between a core material and a skin material, and the foam molded product has a The present invention relates to a method of manufacturing a synthetic resin interior material for an automobile in which an opening is formed.

(Prior Art) In synthetic resin interior materials for automobiles, such as instrument panels, a foam material is used as a cushion between a core material and a skin material, as shown in Japanese Utility Model Application Publication No. 55-110220. It is composed of an interposed foam molded product,
This foamed molded product is generally formed with openings for so-called hole parts such as side vent louvers, defroster grilles, console panels, etc.

The above-mentioned foam molded product has a core material, a skin material, and a foam member located between the two in the cavity of one foam mold.
After that, the foaming material is foamed in a closed foaming mold, and the foaming pressure of the foaming material causes the skin material to form a predetermined shape that closely follows the inner surface of the foaming mold.

By the way, the foaming pressure of the above-mentioned foam material may not necessarily be sufficiently distributed to every corner of the cavity, and especially when the shape is complex and the radius of curvature at the corner is small, the foaming pressure in this area tends to be insufficient. .

For this reason, if the opening is formed in a region where the foaming pressure is likely to be insufficient, wrinkles such as waving may occur at the edge of the formed opening, resulting in an unsightly parting line. When the hole member is installed in the opening, the so-called gap (the gap between the outer periphery of the hole member and the surrounding skin material) differs in the circumferential direction of the hole member, which also becomes unsightly. This could easily cause problems. In other words, when the mold is simply clamped, the portions of the skin material corresponding to the corners tend to be largely separated from the inner surface of the mold, and even if the skin material is flexible, the portions of the inner surface of the mold A considerable amount of foaming pressure is required to bring the skin material into close contact with the corners.

(Object of the Invention) The present invention has been made in consideration of the above-mentioned circumstances, and is designed so that, before foaming, the part of the skin material where the openings will be formed is made to fit almost tightly against the inner surface of the foaming mold. It is an object of the present invention to provide a method for producing a synthetic resin interior material for an automobile, which allows a foam molded product having a predetermined shape along the inner surface of a mold, that is, a product with neat parting lines and gaps.

(Structure of the Invention) In the present invention, the foaming mold and the core material cooperate with each other so that the skin material can be properly positioned on the foaming mold in the area where the opening is to be formed.

Specifically, a bulge is formed on the inner surface of the foaming mold on the side where the skin material is brought into close contact with the foaming pressure of the foaming material, corresponding to the position where the opening is formed, while a bulge is formed on the core material. In this case, a positioning protrusion is formed to surround the bulge.

Then, in the molded state, the skin material is positioned by the positioning protrusion so as to follow the bulge, and then the foam material is foamed.

With this configuration, even if the foaming pressure is low in the area where the opening is to be formed, the skin material is already aligned almost along the inner surface of the mold by the bulge and the positioning protrusion. Therefore, even with this small foaming pressure, the skin material is brought into close contact with the inner surface of the mold, and as a result, the area where the opening is to be formed is neatly finished into a predetermined shape.

(Example) In FIG. 1, A is an instrument panel as a synthetic resin interior material formed by the method of the present invention,
The skin material is located on the driver's side (indoor side), the core material is located on the back side, and the foam is located between the two.

The above-mentioned instrument panel is formed with openings to which various hole members are attached, and in this embodiment, the hole members include side vent louvers l located at both ends of the front surface, and a defroster extending slenderly at both ends of the upper surface. There is a grille 2, a hole cover 3 in the center of its upper surface, and a console panel 4 in the center of its front surface. An opening for mounting is formed.

The instrument panel is basically formed in a conventional manner. That is, as shown in FIG. 2, the cavity 7 of the foamed mold B, which is composed of a concave mold 5 and a convex mold 6, is filled with a core material 8 made of synthetic resin, a foamed material (the foamed material is a secondary foamed material, etc.), respectively. After sequentially setting the flexible skin material 10 (shown as a foamed foam 9 in the figure), the foam material is foamed in the closed foaming mold B to form a foam as shown in Figure m3. A foamed molded product C is formed. Then, openings 11 and 12 for attaching hole members may be formed at predetermined positions in the foam molded product C taken out from the foam mold B (FIGS. 3 and 4), as shown in FIG. In the figure, only the opening 11 corresponding to the hole cover 3 and the opening 12 corresponding to the console panel 4 are shown). After this, a hole member 3.4 corresponding to the opening LL12 may be attached to the opening 11.12 of the foamed molded product C, as shown in FIG. Note that this interrogation is generally carried out by locking claw pieces 3A and 4A protruding from the hole member 3.4 onto the back surface of the core member 8.

Here, in the present invention, in the foaming mold B, an opening 11.
bulges 5a, 5b corresponding to the portions where 12 are to be formed.
is formed. This one swollen portion 5a is connected to the hole member 3 (
The bulging portion 5b corresponds to the hole member 4 (
apertures 12), and corresponding apertures 11 respectively.
．． The shape corresponds to the shape of No. 12. That is,
The outer peripheral shape of the bulging portion 5a or 5b is the opening 11.12.
The dimensions are set so that they are all spaced at the same distance from the periphery in the circumferential direction.

On the other hand, the core material 8 is provided with positioning protrusions 8a and 8b that surround the bulged portion 5a or 5b (
The positioning protrusion 8a corresponds to the bulge 5a, and the positioning protrusion 8b
corresponds to the bulge 5b). This positioning protrusion 8a (
The same applies to the positioning protrusions 8a (8b), which may be scattered at large intervals as shown in FIG.
) may be shaped to extend in the circumferential direction of the opening 11 (12). Then, the bulging portions 5a, 5b and the positioning protrusion 8a
, 8b means that the foaming mold B is clamped and the skin material 1 is
The dimensional relationship is such that there is a gap of approximately the same size as the thickness of 0. Therefore, using such a core material 8 and foam mold B, after setting the core material 8, foam material, and skin material 10 in the cavity 7 of the foam mold B, when the mold is clamped, the bulging portion 5a, The skin material 10 is held between the mold 5b and the positioning protrusions 8a and 8b, and the skin material 10 is approximately positioned at a predetermined position along the inner surface of the concave mold 5 within the cavity 7. If the foam material is foamed in such a state, even if the foaming pressure in the portions corresponding to the openings 11 and 12 is low, the foam material will sufficiently spread over the skin material IO in these opening portions. As a result, wrinkles such as undulations do not occur in the portion corresponding to the opening 11.12, particularly in the vicinity of the opening edge of the opening 11.12. Therefore, when the hole member 3.4 etc. is located in the opening 11.12, all the so-called sight gaps are the same as shown in FIG. may be the same for the entire periphery of the hole member, and the size of the gap may be different for each hole member),
It will look good.

Note that it is preferable that the opposing surfaces of the bulging portions 5a, 5b and the positioning protrusions 8a, 8b be tapered. Further, the core material 8 made of a relatively hard material has an opening 11 in advance.
Although openings corresponding to 12 may be formed in advance, the openings 11 and 12 may be completely newly formed after the foamed molded article C is formed.

In the following two embodiments, an instrument panel has been described as an interior material made of synthetic resin, but the present invention can be similarly applied to interior materials such as door lining materials.

(Effects of the Invention) As is clear from the above description, the present invention makes it possible to make the parting line or the periphery of the opening formed in a foamed molded product neat and free from undulations, etc. Even if a hole member is attached to the hole member, the gap can be made the same, and a good appearance can be obtained. Furthermore, since the peripheral edge of the opening is always reinforced by the positioning protrusion of the core material, the peripheral edge of the opening will not be deformed even if it receives some external force when attaching the hole member.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing an instrument panel as an example of an automobile synthetic resin interior material formed by the method of the present invention. FIG. 2 is a cross-sectional view taken along the line XX in FIG. 1, showing a state in which the foaming material is foamed in the foaming mold. FIG. 3 is a sectional view of a portion corresponding to FIG. 2, showing an opening formed in a foam molded product formed by a foaming mold. FIG. 4 is a sectional view of a portion corresponding to FIG. 2, showing a state in which a hole member is attached to the foam molded product in which the opening shown in FIG. 3 is formed. FIGS. 5 and 6 are perspective views showing examples of positioning protrusions provided on the core material. A: Instrument panel (synthetic resin interior material) B: Foam mold C: Foam molded product 1, 2.3.4: Hall member 5: Concave mold 5a, 5 b: nll group: Convex mold 7: Cavity 8: Core Materials 8a, 8b: Positioning protrusion 9: Foam 10: Skin material 11.12: Opening Fig. 4 Fig. 5 Fig. 6

Claims (1)

[Claims] (1) The cavity of the foaming mold is filled with a core material, a flexible skin material, and a foaming material between the core material and the skin material, and the foaming material is foamed in the mold that is clamped. By doing so, a foamed molded product with a foam interposed between the core material and the skin material is formed, and then openings are formed partially in this foamed molded product to form a synthetic resin interior material for an automobile. In the manufacturing method, a bulge is formed on the inner surface of the foaming mold on the side where the skin material is brought into close contact with the foaming pressure of the foaming material, corresponding to a position where the opening is formed. , for the core material.
(ii) a positioning protrusion is formed to surround the bulge, and with the foaming mold clamped, the skin material is positioned along the bulge by the positioning protrusion;
A method for manufacturing a synthetic resin interior material for an automobile, comprising foaming the foaming material.