JPS6246629A - Manufacture of internal trim part or the like for automobile - Google Patents

Abstract

PURPOSE:To facilitate the welding between a core material and a skin and at the same time eliminate the scattering of positional relationship between both by a method wherein a separate core material is fixed onto a melt skin by pressure during the molding of a skin material, and an integrally molded part of the skin material with the core material is installed in a foaming mold. CONSTITUTION:Firstly, liquid or powder plastic raw material is charged in a molding tool 20 after the molding tool 20 is heated up to the predetermined temperature. Secondly, excess raw material is discharged from the molding tool so as to melt the raw material 30 by keeping on heating in order to forms a melt skin 31. A core material 40, which is engaged onto a mold 20a or an installation jig so as to face to the opening of the molding tool 20 in such a manner as shown in the attached figure, is fixed onto the molten skin 31 by pressure. The skin 31 is solidified by cooling the molding tool 2 while the core material being kept in the state to be fixed by pressure. Thirdly, said core material 40 and skin material 31 are integrally molded in the state that a soft foam is interposed between them so as to form a gap 60 between them. Finally, liquid foaming raw material is poured in the gap 60 between the core material 40 and the skin material 31 so as to integrally bond the core material with the skin material 31 by foam molding. Thus, an internal trim part having a cushioning foam beneath the skin material 31.

Description

[Detailed description of the invention] (Industrial field of application)
The present invention also relates to a manufacturing method for producing molded parts suitable for interior parts of automobiles such as console boxes, door trims, cabinets, and rests.

(Prior art) Conventionally, many of the above-mentioned automotive interior parts have been made of plastic skin material, especially a fake leather-like skin material mainly made of soft polyvinyl chloride resin (with an inner surface), as shown in Table 1■. It is integrated with a core material and a cushioning material such as plastic foam.

On the other hand, many of these inner bag parts usually have a three-dimensional surface, so in many cases the skin material is formed into a predetermined shape by vacuum forming etc. in advance, and then molded in a separate process. The core material is attached to the core material, or the skin material is placed in a foaming mold, and the core material is integrated onto the skin by injecting a foaming solution such as soft urethane foam after the molding.

(Problems to be Solved by the Invention) However, these methods require a step of manufacturing the skin material, core material, etc. in separate processes as described above, and then combining and integrating them. Many steps are required before it can be manufactured into a product, and the positional relationship between the components tends to vary when assembled.

On the other hand, in addition to the vacuum forming method mentioned above, there are injection molding methods, slush molding methods, etc. that are widely used as molding methods for plastic skin materials. Since the skin material can be shaped by suction, it is possible to mold the skin material with relatively simple molding equipment. However, on the other hand, the plastic sheet for molding must be manufactured in advance, and the plastic sheet is stretched during molding. It has the disadvantage that the iris pattern etc. applied on the top become diluted. .

Since the injection molding method press-fits molten resin into a predetermined mold cavity, the dimensional accuracy of the molded product (skin material), such as the thickness, is better than that of other methods.
Equipment investment for molds, molding equipment, etc. is large, and in the case of thin walls and large surface areas such as skin materials, the gap between the mold cavities is narrow, making it difficult for molten plastic to flow.
Large ones tend to be impossible to mold.

In the slush molding method, liquid or powder plastic raw materials are put into a heated mold and the skin material (film) is formed by melting the raw materials, so the transferability of patterns etc. on the mold surface etc. Although it is good, it has drawbacks such as the large temperature difference between heating and cooling the mold, which requires time and equipment, and the raw material is in liquid or powder form, making it difficult to handle. ing.

In this way, each skin material molding method has its advantages and disadvantages.

(A further means to solve the problem) By the way, as mentioned above, the slush molding method requires a lot of time for melting the plastic raw material and solidifying the molten skin, but when forming the skin, the raw material melts. The present inventor focused on this and completed the present invention.

The gist of the first invention is that in the process of forming the skin material by slush molding, the core material is pressed onto the skin material when the skin material is melted, and in this state, the skin material is cooled and solidified together with the core material. There is a method for obtaining a molded product with a core material.

The gist of the second invention is that, in addition to the process of producing a molded product with a core material according to the first invention, after demolding the molded product, the molded product is formed into a foaming mold, and a liquid foaming raw material is applied onto the skin material. Cast foaming,
The core material and the skin material are integrated.

(Function) As described above, the first invention is to press a separate core material onto the molten skin during molding of the skin material, that is, when the plastic raw material is melted to form a predetermined skin. Therefore, the core material is easily welded to the skin.

In this state, the skin is cooled and solidified, so that after cooling, the core material and the skin are integrated. That is, a skin material with a core material can be obtained depending on the molding time of the skin material, and the conventional process of combining and applying the core material after molding the skin material can be omitted. In this case, by composing the skin material with two or more layers and making at least one of the layers a foam, it is possible to manufacture an integrally molded product of the skin material and the core material with cushioning properties, and the product can be manufactured as is. It is also possible to do this.

On the other hand, the second invention is an integrally molded product of a cough skin material and a core material, that is, a product in which the positional relationship between the two is fixed, following the process of the first invention, so it is not necessary to use the conventional method. There is almost no variation in the positional relationship between the two, and the device can also be "At" using the core material.

(Example) Fig. 1 shows a door which is an example of the first invention) IJ-1
An example of 0 is shown.

The mold 20 is provided with a desired cavity surface 21, and is provided with a pipe 22 surrounding the cavity surface 21 through which a heating or cooling medium, such as oil, etc., flows.

First, this mold 20 is heated to a predetermined temperature, and then a liquid or ladle-shaped plastic raw material is put into it. This raw material 30 may be any type of thermoplastic resin as long as it is a thermoplastic resin, but a composition mainly composed of soft vinyl chloride (finger-resistant or soft vinyl chloride resin) is preferable due to its suitability as a skin material. You can add a certain amount of toner to it to color it, mix it with a foaming agent, or leave it hot.

Next, the excess raw material is removed from the mold by 4J)17, and the force [1
The heat is then applied to melt the raw material 30 and form a molten skin 31.

Note that if the input raw material 30 is in a predetermined amount to form the skin 31 and there is no need to discharge it, it is not necessary to discharge the raw material 1 at t and it. In addition, during heating, it is preferable to make the mold 1) () uniform in thickness by heating the mold 11'il+ or repeating it 1ti times to make the thickness of the melted skin uniform.
In the state of ゜, -, a predetermined core 140 that has been cut and formed in advance
(In the illustration, a core material for Tl-IJl) is crimped onto the molten skin 31-t. As the core material 4, a molded product of plastic or its foam, or various molded products such as hardboard or cardboard, or a combination thereof, can be selected as appropriate according to the target product and used. The material 40 is secured to the mold 20a facing the opening 1 part of the mold 20 as shown in the figure, or to a device jig, and is crimped onto the molten skin 31 inside the mold 20.

At this time, it is preferable to slightly embed 4 parts of the core material 4() into the skin 31.Also, the core material 110 is preliminarily filled with a primary foam, such as a continuous cell structure. Put a string-like material (not shown) such as soft polyurethane or tanfort on the prefecture name and press it onto the foam surface 1 (melted surface layer 1); ] Surface and melt (・]! Make sure to create a void between the surface and the skin.

Then, this core is cooled in the mold 2 [) while maintaining the crimped state of 10, and the skin 31j-solidifies;'i +4
- 1, then the skin; After that, the skin 31'p Fl, Sugazu J-.) is removed together with the core + A40 to obtain an integrally molded product.

In the above, it was explained that if the epidermis 1 is a single layer, there is one in the molded product, but the epidermis 1 is not limited to the funeral layer, and it can be used as shown in the second bij (b). Even so)
It's a small thing. That is, the first layer of the epidermis 31: 31a (
The outermost layer and Ieruj*) are not emitted in terms of formation and shape, and 14 Buu Zuna! layer, e.g. non-foamed soft j+:, +t
l・fL 'ff-, le (!11 fat l flash, toshi, 2nd
Layer: ILB; plastic layer 7 of the package V) 1, for example, 1 primary vinyl chloride resin layer 7-1,! [1<
, the formation of the epidermis 31 is repeated several times 2, and the final layer is folded, and the core +; JJ1 is formed on the layer 31b.
Pressing 10 is also good. Good job, (,・
- As in the example below, the surface of the molded product is non-standard, the back lf+
A molded product in which 1 is a foam layer is 111, and! )・、Touch 1
, 1ji (Please give me a molded product that is suitable for sex.)

Next, the second invention will be explained based on FIG.

(H, The skin material 31 molded as shown in (p) and the old core material 1i, 'S, le product are molded as shown in Ms 3 m. 31/”:
i:i:'', -t, 0-1-yabite, a character with i-face 41;i-shi';11!50-,509 i-':j, t
! -N))-6.1 Poly-ri like the bouquet! A liquid foam raw material (such as Notani 7 ohm) is cast onto the upper surface of the skin H131 and foamed to form a body. In this case,
The above-mentioned core material and the outer layer are interposed with a soft foam to form a core material 4.
-F gap 60 between 0 and skin material;) 1 in the shape j1ν, the core ÷, ] 40 old skin + dry skin material;) 1: liquid 1 (foaming prefecture Inject another layer 17, foam the core material, and glue the inner and outer skin side Ill together.
- Di i'1 foam relative 7) Ft, t fl, surface material 31 bottom:, blue λ', lJr',! ↓ iλ response body at6 -! j2 jHB product JJ -? ' J:, <, T
he i', u-1T, 52 in Z15.1m is injection of liquid foaming agent (,S), 3゜j, 2-9
, Actual 1i (In 11 examples: !Door 1 rim 11 cases a) 1 light j, 117) )Other instruments)
'+-Benerva... Do, Ni console box, Arm Mitsut, etc. skin +, 1 f] to the inside of the sleeve] 1) The same (Kanashi no 1') ro 1-Tobai Tocho There is no 0.

(Effect of the invention) Wood □・1℃1・, Ming is [hereinafter 1-YQ], skin material (
When forming (5 te go; 1, +71, +9 skin +1 -i'll-zu1 5S also ・D application, ka ・-1(゛L
Separately, the next day ['ku core jg, 1-epidermis to], and the 11th short name 7. The jet\ process is no longer necessary, resulting in labor savings. In addition, since the skin material is fixed when it is melted, its adhesion is strong, and it also has great secondary effects, such as making it easier to demold the skin material.

Furthermore, by making the skin material multi-layered, especially at least one of the layers is a foam layer, a molded product with an elastic skin material can be produced extremely easily, and a product suitable as an interior part for an automobile can be provided. It is. Furthermore, when the liquid foaming raw material of the second invention is further injected and foamed to form an integrally molded product with urethane foam, etc., the core material and the skin material are positioned relative to each other by partial fixation or the like. It is possible to produce an integrally foamed molded product with a constant shape without causing any misalignment with the skin material.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing an embodiment of the first invention;
A) and (B) are enlarged cross-sectional views of the joint between the core material and the skin material, FIG. 3 is a cross-sectional view showing the step of injecting liquid foam raw material in the second invention, and FIG. FIG. Figure 1 Figure 4

Claims (4)

[Claims] (1) Consisting of a step of forming a molten skin by putting the plastic raw material into a desired mold and heating the mold, a step of crimping a core material onto the molten skin, and a step of cooling the molten skin. A method for manufacturing automotive interior parts, etc., characterized by: (2) The method for producing interior parts for automobiles, etc. according to claim 1, wherein in the step of forming the molten skin, the skin is formed into a multilayer structure from two or more plastic raw materials. (3) Automotive interior parts, etc. according to claim 2, wherein at least one of the two or more plastic raw materials is a plastic raw material containing a foaming agent, and at least one layer of the multilayer structure is a foam layer. Production method. (4) A step of putting the plastic raw material into a desired mold and heating the mold to form a molten skin, a step of crimping the core material onto the molten skin, cooling and solidifying the molten skin, and forming the core material. It is characterized by comprising the steps of demolding the integrally formed product with the skin, mounting the integrally molded product in a foaming mold, and pouring a liquid foaming raw material into the mold and foaming the foaming raw material. A manufacturing method for automobile interior parts, etc.