KR100494231B1 - Laminated object and method thereof - Google Patents

Abstract

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated structure for use in automobile interior parts, vehicle interior panels, building wall materials, residential interior panels, and the like and a manufacturing method thereof. According to the present invention, the foamed resin member 20 having a light weight and shape retention, between the outer frame 30 and the outer frame 30 along the outer circumference of the foamed resin member 20 is laminated integrally on the inner surface side of the foamed resin member 20; It is provided with a connecting rib 40 to be connected and installed, there is a light weight and cost reduction effect, and also reduce the load of the molding die, the molding cycle is shortened.

Description

Laminated structure and method of manufacturing the same

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a laminated structure suitable for automobile interior parts, such as door trims, rear side trims, and luggage trims, or other vehicle interior parts or construction fields, residential building materials, walls, interior panels, and the like, and a method of manufacturing the same. .

For example, the configuration of the interior parts for automobiles will be described with reference to FIGS. 19 and 20 by exemplifying a door trim.

The door trim 1 is formed by laminating integrally the skin 3 having excellent surface appearance on the surface of the resin core 2 having the shape retention and adhesion to the vehicle body panel.

The resin core material (2) is made of a polypropylene-based resin mixed with talc, and the outer skin (3) itself has no shape retention, and synthetic resin sheets such as vinyl chloride sheet are used. In consideration of cotton, many elastomer sheets such as TPO (thermoplastic olefin) sheets tend to be used.

Next, a conventional example of the method of forming the door trim 1 will be described with reference to FIG. 21. First, the shaping mold 4 forming the door trim 1 includes a shaping mold 5 capable of moving a predetermined stroke, a lower mold 6 on the fixed side paired with the shaping mold 5, and a shaping mold 6 ) Is roughly constituted by an injection machine (7) connected to the.

In order to form the product shape of the door trim 1 when the molded upper mold 5 and the lower molded mold 6 are fastened, a cavity portion 5a is formed in the molded upper mold 5, and a core portion is formed in the molded lower mold 6. 6a is provided. A lifting cylinder 5b is connected to move the mold upper mold 5 in a predetermined stroke, and the mold lower mold 6 has a manifold 6b and a gate 6c serving as a passage for the molten resin from the injection molding machine 7. It is installed.

In addition, the guide post 6d is installed at four corners of the lower mold 6 in order to maintain an appropriate posture, and the molding die 5 corresponds to the guide post 6d. The bush 5c is provided.

Therefore, when the upper mold 3 and the lower mold 6 are open when the upper mold 3 and the lower mold 6 are opened, the product cavity between both molds when the mold upper mold 5 and the lower mold 6 are clamped. By injection filling the molten resin M from the injection machine 7 through the manifold 6b and the gate 6c, the resin core 2 is formed into the required curved shape and the skin on the surface of the resin core 2 is formed. (3) is integrally molded.

In FIG. 21, for convenience of description, the molten resin M is supplied to the mold surface of the core part 6a in an open state. In reality, the molten resin M is a mold upper mold 5 and a mold lower mold 6. After tightening, it is injected and filled into the cavity.

However, in the conventional door trim 1, since the projection area of the resin core material 2 is large, a drawback is pointed out that material cost is high and a product is weighted.

In addition, since the projected area of the resin core material 2 is large, the injection pressure must be set at the time of molding, and a mold structure capable of withstanding high injection pressure is required. It is also pointed out that the molding cycle is prolonged due to cooling and solidification.

In addition, since the skin 3 is based on a non-breathable synthetic resin sheet, it has been pointed out that the sound absorbing performance is poor and sound absorption against vehicle noise cannot be expected.

The present invention has been made in view of the above circumstances and can provide a laminated structure that can promote weight reduction and reduce cost with high rigidity, can lower molding mold cost, shorten molding cycle, and have sound absorption performance. An object of the present invention is to provide a laminated structure and a method of manufacturing the same, which are excellent in terms of safety, environment, and recycling.

MEANS TO SOLVE THE PROBLEM As a result of earnestly researching in order to solve the said subject, as a result of providing a shape retention to the foamed resin sheet conventionally used as a skin material, it also has a function as a core material, and the part which needs more rigidity, ie, the edge of a product, a panel, or a part The present invention has been completed by arranging a synthetic resin molded article having excellent rigidity in the mounting portion.

That is, the laminated structure according to the present invention is characterized in that it comprises a foamed resin member having a shape retention, and an outer peripheral frame made of a synthetic resin molded body integrally laminated on the back side of the foamed resin member to follow the outer circumferential shape of the product.

Herein, the laminated structure may include interior parts for automobiles such as door trims, rear parcel shelves, floor trims, luggage trims, trunk trims, rear side trims, or interior panels embedded in panels of vehicles other than automobiles. It can be applied to building wall materials or interior panels embedded in residential rooms.

The foamed resin member having the shape retention shape is formed into a desired shape by a molding mold when the shape is close to a flat shape, and the heating softening step is omitted. The mold is molded into a desired curved shape in the mold to maintain the shape. If the product shape includes a high opening ratio, the foamed resin sheet is heat-softened and a vacuum suction mechanism is placed on the molding die, and the vacuum suction mechanism exerts a vacuum suction force along the inner surface of the molding mold. You may have to.

As the foamed resin sheet, a material in which a foaming agent is added to a thermoplastic resin is used. The thermoplastic resin may consist of one type of thermoplastic resin or two or more types of thermoplastic resins. Preferably, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. Can be used.

As the blowing agent, organic foaming agents such as azo compounds, sulfohydrazide compounds, nitroso compounds and azide compounds, or inorganic foaming agents such as sodium bicarbonate can be used.

The foamed resin member obtained by molding the foamed resin sheet into a required shape after heat-softening treatment is preferably 2 to 10 times the foaming ratio in consideration of the balance between the weight and strength of the product. The cell diameter of the foamed resin member at this time is preferably in the range of 0.1 µm to 2 mm, and the thickness is preferably 0.5 to 30 mm, preferably 1 to 10 mm.

On the other hand, the thermoplastic resin material used as the outer peripheral frame can be appropriately selected from a wide range of thermoplastic resins. Usable preferably are polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, polyamide resin, acryl Nitrile / butadiene / styrene (ABS) resins, polycarbonate resins, and the like.

Moreover, you may mix various fillers in these thermoplastic resins. Fillers that can be used include inorganic fibers such as glass fibers and carbon fibers, talc, clay, silica, calcium carbonate and the like. Moreover, various additives, such as antioxidant, a ultraviolet absorber, a coloring agent, a flame retardant, and a low shrinkage agent, may be mix | blended.

In addition, the foamed resin member having the shape retention may be wound around the product frame along the edge of the product, and the part covered by the relative parts may be cut simultaneously by cutting the foamed resin member and the outer frame at the same time. good.

And according to the laminated structure according to the present invention, it comprises a foamed resin member having a shape retention and a peripheral frame made of a synthetic resin molded body is laminated on the back side of the foamed resin member, and also along the product border, the foamed resin member The conventional resin core material can be abolished by providing an outer frame made of a synthetic resin molded body at the edge of the product which provides the core function and requires more rigidity. Therefore, the weight of the product can be reduced by eliminating the resin core material having a very large projected area, and further, the resin material can be saved, thereby reducing the material cost.

In addition, the porous sound-absorbing function of the foamed resin member provides a laminated structure with excellent sound absorption performance, and when the polyolefin resin is used as the material of the foamed resin member and the outer frame, the separation process can be abolished by the all-olefin resin. This can simplify recycling.

In another embodiment of the present invention, the outer circumferential frame may have a flat shape, but preferably, if the cross-sectional shape is set to a rigid shape having a substantially L-shaped cross section, the product shape can be satisfactorily stored for a long time.

Moreover, as a preferable embodiment, it is preferable to provide the connecting rib extended in the longitudinal direction between the frames of the outer peripheral frame. The connecting ribs can be integrally formed when forming the outer frame in the molding die. Especially, when the L-shaped cross section and the reverse T-shaped rib shape are adopted so that the part contacting the back side of the foamed resin member is plate portion, the product surface Since wrinkles do not form on the surface, the appearance is good and the shape retention of the product can be improved.

The rib thickness of the connecting rib can be appropriately adjusted by adjusting the thickness of the rib, for example, by setting a portion where the external force is largely applied to the product and making the portion where the external force is relatively thin. Therefore, it is sufficient to use the minimum resin material required, which can contribute to the weight reduction and cost reduction of the product.

The clip mounting portion or the mounting portion for mounting various components may be integrally formed on the outer circumferential frame or the connecting rib. Moreover, the skin which improves the external appearance can also be laminated | stacked on the surface of foamed resin member. As the skin, a woven fabric, a nonwoven fabric, a knitted fabric, a sheet, a film, a foam, a mesh member, or the like can be used. Although the material which comprises these skins is not specifically limited, It is preferable to use the breathable material, such as a woven fabric, a nonwoven fabric, and a knitted fabric, in the sense of utilizing the sound absorption performance of a foamed resin member.

Still another laminated structure according to the present invention is characterized by including a laminated structure having the above-described structure and a synthetic resin molded body which is bonded to the laminated structure and integrally formed with the outer peripheral frame of the laminated structure.

The laminated structure may be applied to, for example, a two-tone type door trim having a different product appearance up and down. For example, a foamed resin member having a shape retention formed by molding a foamed resin sheet into a required shape on the surface of the upper door trim, and an outer frame on the rear side of the foamed resin member, and, if necessary, a connecting rib connected between the outer frame. A laminated structure of a synthetic resin molded body is used, and the lower door trim is composed of a synthetic resin molded body made of a synthetic resin in a panel form.

Therefore, the laminated structure such as the upper door trim can contribute to weight reduction because the core material function is given to the lightweight foamed resin member as compared with the conventional laminated structure, and the cost is reduced because the supply balance is small.

Subsequently, a method of manufacturing a laminated structure according to the present invention is a method of manufacturing a laminated structure having a foamed resin member having a shape retention, and an outer peripheral frame and connecting ribs laminated integrally on the back side of the foamed resin member. The process of setting the foamed resin sheet which sets the foamed resin sheet, which is the material of the foamed resin member, and molding the molding die so that the foamed resin sheet follows the cavity shape of the molding mold, thereby forming the foamed resin member into a desired shape. In addition, the injection molding of the molten resin in the cavity of the molding die, characterized in that it comprises an integrated process of the laminated structure to integrally laminate the outer peripheral frame and the connecting rib on the back side of the foamed resin member.

Here, the molding mold includes a mold which can be moved, a molding die positioned below the molding die, and an injection machine connected to the molding die, and the molten resin supplied from the injection mold is a manifold and a gate installed in the molding die. It is supplied on the mold surface of the mold lower mold through a resin passage such as the mold mold lowered to the bottom dead center to mold the mold mold and the mold mold, and the molten resin is injected and filled into the cavity at a predetermined injection pressure.

Therefore, the foamed resin sheet is formed along the shape of the molding die by the fastening of the molding die and the molding die, and the molten resin is injected and filled into the cavity to form the outer frame and the connecting rib so that the outer frame and the connecting rib of the foam resin member It is laminated on the back side.

In another embodiment of the method of the present invention, the injection molding and charging of the molten resin through a manifold, gate, or the like is performed before the molding die reaches the bottom dead center, and is melted in the cavity by the press pressure of the molding die during the mold clamping. The resin may be spread evenly to form the outer circumferential frame and the connecting rib.

In the case where the product shape is set to a three-dimensional shape, after the heat softening treatment is performed by a heater or the like in the previous step, the foamed resin sheet is set in the molding die.

In addition, by supplying the foamed resin sheet in a heat-softened state into the mold, and then molding the mold, the foamed resin sheet is formed into a desired shape, thereby obtaining a foamed resin member having a shape retention.

Therefore, the outer circumferential frame and the connecting ribs may be laminated on the back side of the lightweight foamed resin member having the shape retention. If the final product has a high opening ratio, the mold may be molded several times, and the molten resin may be injected in the final mold clamping step.

In the case where the product shape includes a high opening ratio portion, a vacuum suction mechanism may be arranged on the mold to form the foamed resin member into a desired shape with a vacuum suction force along the mold surface of the mold.

Therefore, according to the method of the present invention, since only the outer frame and connecting ribs are formed, compared to the conventional resin core material having a large projected area, the load of the molding die is less and the amount of resin is small, thus saving the material cost and the conventional resin core material. Compared with this, the cooling time is shorter, and the molding cycle of the product can be shortened.

Another embodiment of the method of the present invention is a method of manufacturing a two-tone type laminated structure, the step of setting a foamed resin sheet for setting a foamed resin sheet which is a material of the foamed resin member at a predetermined position in the molding mold, and a molding mold. Mold the foamed resin sheet so that the shape of the foamed resin sheet follows the cavity shape of the molding die, forming the foamed resin member into a desired shape, and supplying molten resin to the back side of the foamed resin member through the resin passage in the first injection molding machine. The process of forming a laminated structure by integrally stacking the frame and connecting ribs connected thereto on the back side of the foamed resin member, and injecting into the cavity of the area where the foamed resin sheet is not set through the molten resin through the resin passage in the second injection molding machine. And a step of integrating the laminated structure to integrate the synthetic resin molded body with the laminated structure by filling. The features.

Also in this method, when the product shape is relatively flat, the heating step can be omitted, but in the case where the product shape is a three-dimensional shape, the foamed resin sheet may be heat-softened, and then set to a necessary part in the molding die.

Another method of this method is to supply a molten resin for the outer frame and the connecting rib through a common resin passage, a branch resin passage in a single injection molding machine, and then to a synthetic resin molded body through a common resin passage and a branch resin passage in the same injection molding machine. The molten resin may be injection filled.

Therefore, since the two-tone type laminated structure can be molded in one step, the man-hour can be shortened. In addition, in the case of a one-cylinder type injection machine instead of a two-cylinder type injection machine, the device cost can be reduced.

Embodiments according to the laminated structure according to the present invention and a method for manufacturing the same will be described by illustrating a door trim for a vehicle and a method for manufacturing the same.

Figures 1 to 12a and 12b shows a first embodiment of the present invention, Figure 1 is an external view showing a first embodiment applying the laminated structure according to the present invention to the door trim, Figure 2 is shown in Figure 1 3A and 3B are sectional views showing the configuration of the edge portion of the door trim shown in FIG. 1. 4 is a perspective view showing a modification of the door trim shown in FIG. 1 showing the outer circumferential frame and the connecting rib from which the foamed resin member is removed, and FIGS. 5A and 5B illustrate the relationship between the connecting rib and the foamed resin member. 6 and 7 are diagrams for explaining the relationship between the outer circumferential frame, the connecting rib and the clip mounting portion. 8 to 10 are respective process views showing the first embodiment in which the method of the present invention is applied to a method for manufacturing a door trim, and FIGS. 11A and 11B, 12A and 12B are adjacent to the laminated structure according to the present invention. It is a figure for demonstrating the coupling structure of components.

A first embodiment of the present invention will be described with reference to FIGS. 1 to 12A and 12B.

First, in Figures 1 and 2, the door trim 10 for an automobile is a foamed resin member 20 having a shape retaining shape formed into a desired curved shape, and the door trim 10 on the rear side of the foamed resin member 20. The outer peripheral frame 30 made of a synthetic resin molded body is integrally laminated along the product border of the foamed resin member 20 is composed of a coupling rib 40 is integrally laminated and connected between the outer peripheral frame 30 is laminated integrally have.

More specifically, the entire surface or part of the product surface of the foamed resin member 20 may be laminated with a skin for imparting decorativeness. The door trim 10 is also equipped with various resin components such as an inside handle assembly 11, a power window switch assembly 12, a speaker grill 13, and a pocket assembly 14.

By the way, the foamed resin member 20 is heat-softened the foamed resin sheet to have a shape retention, and then hot-formed into a desired shape, for example, cold press molding into a molding mold having a desired mold surface. The foamed resin member 20 may be formed. In addition, in a flat part such as a lead part such as jack lead, the foamed resin sheet can be molded flat without heat softening treatment.

The foamed resin sheet is a configuration in which a foaming agent is added to a general-purpose thermoplastic resin, and the thermoplastic resin is polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin. , Ionomer-based resins, acrylonitrile / butadiene / styrene (ABS) resins, and the like, and as the blowing agent, organic foaming agents such as azodicarbonamide or inorganic foaming agents such as sodium bicarbonate can be used. In this embodiment, a foamed resin sheet in which sodium bicarbonate is appropriately added to a polypropylene resin is used. The expansion ratio of the foamed resin member 20 is set to 2 to 10 times, and the thickness is set to 0.5 to 30 mm, particularly 1 to 10 mm.

The outer circumference frame 30 is made of a general-purpose synthetic resin molded body, which is usually preferably used as a synthetic resin, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride type Resin, ionomer resin, polyamide resin, acrylonitrile / butadiene / styrene (ABS) resin, polycarbonate resin, etc. are appropriately selected. In this embodiment, polypropylene resin is used in consideration of the environmental surface and the recycle surface. have.

The outer circumferential frame 30 may contain a suitable filler such as inorganic fibers such as glass fibers and carbon fibers, and inorganic particles such as talc, clay, silica, and calcium carbonate in the thermoplastic resin.

As shown in FIG. 2, a connecting rib 40 is disposed between the outer circumferential frames 30 to compensate for the shape retention of the foamed resin member 20 and to secure good shape retention as the door trim 10. As the connecting ribs 40, the same material is used because of integrally molding with the outer circumferential frame 30.

In addition, although the outer circumferential frame 30 along the product outer periphery of the door trim 10 may be formed flat as shown in FIG. 3A, it is preferable to set the cross-sectional L-shape to enhance rigidity as shown in FIG. 3B.

As described above, the door trim 10 shown in FIGS. 1 to 3A and 3B has a foamed resin member 20 having a shape retention and an outer circumferential frame that is integrally stacked along the outer circumference of the product on the rear surface of the foamed resin member 20 ( 30), a resin that occupies the entire surface of the product as in the prior art because it is configured to connect the connecting rib 40 between the outer circumferential frame 30, if necessary, for the purpose of reinforcing the shape preservation of the product. The core material can be abolished, and the lightweight foamed resin member 20 can be used to reduce the weight of the product by 40% or more compared to the conventional example, and can greatly reduce the resin material, contributing to cost reduction. can do.

Since the foamed resin member 20 has a porous structure, the door trim 10 has excellent sound absorption performance, thereby reducing noise in a vehicle interior. In order to maintain the sound absorbing property of the foamed resin member 20, the skin layered on the surface of the foamed resin member 20 is preferably a sheet material having breathability such as woven fabric, nonwoven fabric, and knitted fabric. In addition, the skin may be a synthetic resin sheet, a synthetic resin film, a foam, a mesh member, etc., in addition to a breathable sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric.

In addition, the terminal processing of the foamed resin member 20, as can be seen in Figure 2, for example, the portion corresponding to the flange portion for mounting the inner seal (not shown) of the upper edge of the door trim 10, even if the cut portion is exposed Regardless, the lower edge of the door trim 10 is a prominent part, and the foamed resin member 20 is wound around the outer frame 30 to trim the appearance.

As such, the door trim 10 preserves the shape of the product as a foamed resin member 20 having a shape retaining shape, and a part that requires more rigidity such as a mounting portion or a body panel mounting portion of the product rim or other functional parts is By arranging the outer circumferential frame 30 and the connecting rib 40, desired rigidity is ensured.

Therefore, the lightweight and inexpensive door trim 10 may be provided, while the outer frame 30 may be particularly rigid when the outer frame 30 is mounted on the body panel 50, so the body panel ( It is preferable because a gap or the like does not occur between and 50).

Subsequently, as shown in FIG. 4, in which the foamed resin member 20 is removed to expose the outer circumferential frame 30 and the connecting rib 40, in this embodiment, the outer circumferential frame 30 is connected. The connecting ribs 40 extending in the longitudinal and horizontal directions are integrally formed.

5A and 5B, the connecting rib 40 preferably has a reinforcing structure capable of securing desired rigidity, and in this case, the plate portion 41 is formed of the foamed resin member 20. By contact with, it is possible to distribute the load by receiving the pressure applied during injection molding or press molding in a large area, and the marking along the rib 40 is not exposed on the surface of the product, so that the appearance of the product can be preserved satisfactorily.

FIG. 5A shows that the connecting rib 40 has an inverted T-shaped cross section with a plate portion 41 in contact with the foamed resin member 20, and the rib thickness is set to a thick rib 40a. A connecting rib 40 having an L-shape, and similarly, a plate portion 41 which can secure a large contact area with the foamed resin member 20 is formed.

In addition, as shown in FIG. 4, when forming the connecting ribs 40 extending in the longitudinal direction, for example, the inside handle assembly 11, the power window switch assembly 12, the speaker grill 13, the pocket assembly 14, and the like. The mounting portion 42 for mounting the functional parts of the coupling ribs 40 may be integrally formed.

As shown in FIG. 4, 42a is a mounting portion of the inside handle assembly 11, 42b is a mounting portion of the power window switch assembly 12, 42c is a mounting portion of the speaker grill 13, and 42d is a mounting portion of the pocket assembly 14. Represent each. The mounting portion 42b of the power window switch assembly 12 is preferably formed in a plate shape in terms of the feel of the product surface.

As shown in FIG. 7, a clip mounting portion 43 for mounting the clip 51 to be mounted on the vehicle body panel 50 may be integrally formed on the rear side of the connecting rib 40, as shown in FIG. 6. Likewise, the clip mounting portion 43 may be formed to extend inward from the outer circumferential frame 30.

Next, an embodiment of the manufacturing method of the vehicle door trim 10 will be described with reference to FIGS. 8 to 10. First, the shaping mold 60 used for shaping the door trim 10 includes a shaping mold 61 capable of moving in a predetermined stroke, a lower mold 62 on the fixed side paired with the shaping mold 61, and a shaping mold. It consists of the injection molding machine 63 connected to 62 substantially.

More specifically, the shaping die 61 is formed with a cavity portion 611 that matches the shape of the product, and is driven up and down by a predetermined stroke by a lifting cylinder 612 connected to the top surface of the shaping die 61. Further, at four corners of the molding die 61, a guide bush 613 made of a guide mechanism is provided.

On the other hand, the lower mold 62 is provided with a core portion 621 corresponding to the cavity portion 611 of the upper mold 61. In addition, a manifold 622 and a gate 623 are provided to supply molten resin to the mold surface of the core portion 621, and the injection machine 63 passes through the resin passages of the manifold 622 and the gate 623. The molten resin (M) supplied from the) is supplied to the upper surface of the core portion 621.

In addition, at four corners of the lower mold 62, a guide post 624 serving as a guide mechanism protrudes, and the guide post 624 is formed when the mold upper mold 61 and the lower mold 62 are fastened. By being guided in 613, the press posture of the shaping | molding die 61 can be hold | maintained appropriately.

As a first step of forming the door trim 10, the foamed resin sheet S, which is a material of the foamed resin member 20, is formed when the upper mold 61 and the lower mold 62 are opened. The upper mold 61 and the lower mold 62 are set in this embodiment. In this embodiment, as the foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumitomo Chemical Industries, trade name; Sumerera foamed PP sheet, foaming ratio = 3 times, thickness 2mm), and as shown in Fig. 9, in the state where the foamed resin sheet S is heat-softened to 130 DEG C by the heater device 64, the mold upper mold 61 and the mold lower mold ( 63) supplied into.

Subsequently, after the foaming resin sheet S is supplied into the mold upper mold 61 and the mold lower mold 62, the lifting cylinder 612 is driven to lower the mold upper mold 61 by a predetermined stroke, as shown in FIG. When the 61 is lowered to the bottom dead center and the mold upper mold 61 and the mold lower mold 62 are in the clamped state, the injection machine 63 passes through the manifold 622 and the gate 623 to the door trim 10. Molten resin (M) for molding the synthetic resin molded body of each mounting portion (42a) to (42d) of the outer peripheral frame (30) and the connecting rib (40), if necessary, the various functional parts (11) to (14). Is supplied.

This molten resin (M) is Sumitomo Noble AX568 (polypropylene made by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min), and talc is mixed at an appropriate ratio.

Therefore, in the mold clamping state by the mold upper mold 61 and the mold lower mold 62, the foamed resin sheet S becomes a shape corresponding to the shape of the cavity portion 611 of the mold upper mold 61, and the foamed resin member The 20 is molded into a desired shape, and the outer circumferential frame 30 and the connecting rib 40 on the inner surface side of the foamed resin member 20, and if necessary, the mounting portions 42a to 42d are integrally stacked.

As such, the molding of the foamed resin member 20, the outer circumferential frame 30, and the connecting rib 40 can be performed in one molding process, and in particular, the outer circumferential frame 30 and the connecting rib 40 are compared with the conventional resin core material. If necessary, since the supply amount of the molten resin M for molding only the mounting portions 42a to 42d of the functional parts 11 to 14 is sufficient, the amount of molten resin can be saved and the shaped mold 61 In addition, the load on the die and the molding die 62 can be reduced, and since the injection molding machine 63 has a small capacity, the injection molding machine 63 can be miniaturized. On the other hand, in the specification of laminating the skin on the surface of the foamed resin member 20, the sheet for skin may be laminated on one surface of the foamed resin sheet S in advance.

In the case where the foamed resin member 20 is formed from the foamed resin sheet S, as described above, after the heat softening treatment is performed at a predetermined temperature by the heater device 64, the upper mold 61 and the lower mold 62 are formed. In the case of fastening of the molten resin and the injection of the molten resin M, the desired shape may be obtained. However, when a complicated curved shape is required at a higher opening rate, a vacuum suction mechanism is placed on the mold 61 and the mold 61 is formed. ) And the lower mold 62 may be vacuum-formed by applying a vacuum suction force on the mold upper mold 61 before or during mold clamping.

Further, the molding die 61 may be controlled in two stages. That is, the first step of forming the foamed resin member 20 by press molding of the foamed resin sheet (S) by the mold fastening of the molding upper mold 61 and the lower mold 62 in the first step, and then the molding upper mold 61 ) And lowering the molding die (61) again by injection molding the foamed resin member 20 and the molten resin (M) pre-formed in the second molding process in the cavity to the outer peripheral frame 30 and the connecting rib 40 If necessary, the mounting portion 42 of the functional part may be integrally formed. In addition, the foamed resin member 20 used in the laminated structure of a simple shape such as jack lead may omit the preheating step of the foamed resin sheet S, and the foamed resin member 20 may be formed of a simple shaped mold 61 and It is only molded along the cavity shape of the molding die 62.

In the above-described forming method, after molding the mold upper mold 61 and the mold lower mold 62, the molten resin M is filled into the cavity at the injection pressure through the manifold 622 and the gate 623 in the injection molding machine 63. The injection molding method was adopted, but when the molten resin is supplied from the injection molding machine 63, the molten resin M is supplied into the cavity in advance before the molding die 61 reaches the bottom dead center, and then the molding die 61 is lowered. It is also possible to employ a stamping mold method of filling the molten resin into the product cavity at the press pressure at that time when lowered to the point. In addition, the use of a stamping mold method is advantageous when employing a large number of plate portions 41 in the connecting ribs 40.

In the above, the laminated structure according to the present invention and the method of manufacturing the door trim 10 and the manufacturing method thereof have been described. In addition to the door trim, for example, the trunk side trim 70 or the trunk lid as shown in FIGS. 11A and 11B. It may be applied to the trim 71.

Even in this case, the trunk side trim 70 and the trunk rear trim 71 are formed of the foamed resin member 20, the outer frame 30 and the connecting rib 40 along the outer circumference of the product, as shown in FIG. Consists of. In the case of a relatively simple shape such as the trunk side trim 70 or the trunk rear trim 71, since the shape of the product is preserved only by the shape of the foamed resin member 20 and the outer circumferential frame 30, the connecting rib 40 is It may be abolished.

And when the laminated structure according to the present invention is applied to the trunk side trim 70 or trunk rear trim 71 using a lightweight foamed resin member 20 and the resin core material is closed to the outer peripheral frame 30, if necessary Since the connecting rib 40 is made of a synthetic resin molded body, it is possible to reduce the weight and cost, and in particular, as shown in FIG. 11B, the rigid part in the joint portion of the trunk side trim 70 and the trunk rear trim 71 is hard. There is an advantage that the occurrence of a gap can be reliably prevented by combining both outer circumferential frames 30.

12A and 12B, in the case of joining the interior parts together, the joggling of the laminated structures 80 and 81 as shown in Fig. 12A and the laminated structure 82 shown in Fig. 12B are shown. Also in the case of planar engagement of (83), taking advantage of the high rigidity of the outer circumferential frame (30), a gap is hardly generated in the joining portion and a good appearance can be obtained in the joining portion.

Next, a second embodiment of the present invention will be described with reference to FIGS. 13 to 18. 13 and 14 illustrate a two-tone type automotive door trim 100 to which the laminated structure according to the present invention is applied. The door trim 100 includes an upper door trim 110 and a lower door trim 120 between the two. It is comprised so that product appearance may differ from the boundary line 130 in the.

That is, the upper door trim 110 is applied to the configuration of the laminated structure according to the present invention, the foamed resin member 20, the outer peripheral frame 30 along the product outer periphery on the back side of the foamed resin member 20, and Consists of a synthetic resin molded body integrating the connecting rib 40 connected between the outer peripheral frame (30).

Therefore, since the upper door trim 110 adopts the configuration of the door trim 10 of the first embodiment, the weight reduction and cost reduction with the shape retention can be achieved, and the sound absorption performance can be improved.

In addition, the lower door trim 120 is an injection molded product of a synthetic resin, and because it represents the product surface of the door trim 100, colorant is mixed and a speaker grill 121 and a pocket opening 122 are provided, and the upper door trim 110 is provided. A concave groove is formed to improve the appearance of the boundary along the boundary line 130 of the lower door trim 120 and the terminal of the foamed resin member 20 is accommodated in the concave groove to improve the appearance of the joint.

An embodiment of the manufacturing method of the two-tone type door trim 100 will be described with reference to FIGS. 15 to 17. In addition to the upper mold 61 and the lower mold 62, two injection molding machines 63a and 63b are connected to the forming mold 60 for molding the two-tone type door trim 100. The resin passages for supplying the molten resins M1 and M2 to the upper door trim 110 and the lower door trim 120 of the door trim 100 for the two injection molding machines 63a and 63b, respectively, are provided. Manifolds 622a, 622b and gates 623a, 623b are provided independently. Since other configurations apply mutatis mutandis to the configuration of the molding die 60 shown in FIG. 8, description thereof will be omitted here.

Next, a manufacturing method of the two-tone type door trim 100 will be described. First, the foamed resin sheet S, which is a material of the foamed resin member 20 in the upper door trim 110, is formed into the cavity 611 of the upper mold 61 and the core 621 of the lower mold 62. Heat softening treatment is performed on the upper half of the cavity partitioned by a heater (not shown).

Then, after setting the foamed resin sheet S, the lifting cylinder 612 of the mold upper die 61 is operated so that the mold upper die 61 is lowered by a predetermined stroke, and the mold upper die 61 and the lower mold 62 are fastened. The foamed resin sheet 20 is molded by forming the foamed resin sheet S into a shape according to a desired mold surface shape, and the upper door trim is formed through the manifold 622a and the gate 623a in the first injection molding machine 63a. The molten resin M1 is injection filled into the cavity in the upper door trim 110 to form the outer frame 30 and the connecting rib 40 in the 110.

At the same time, the molten resin M2 is injected and filled into the lower half of the cavity from the second injection machine 63b through the manifold 622b and the gate 623b to form the lower door trim 120 so that the lower door trim ( 120 is molded into the desired shape.

Therefore, FIG. 17 illustrates a state in which the foamed resin member 20 is removed from the upper door trim 110, and the molten resins M1 and M2 are respectively removed from the first injection machine 63a and the second injection machine 63b. By injection filling the cavity into the cavity, the outer frame 30 and the connecting rib 40 in the upper door trim 110 is molded into a desired shape, and the lower door trim 120 is integrally molded therewith.

When the two-tone type door trim 100 is manufactured as described above, two resin injection molding machines 63a and 63b are connected to the molding die 62, and the resin passages for the upper door trim 110 and the lower door trim 120 are respectively formed. By injection-filling the molten resin (M1), (M2) through the two-tone door trim 100 can be manufactured in the form of reduced airflow into a single molding mold (60).

In this manner, the material of the outer frame 30 and the connecting rib 40 and the material of the lower door trim 120 in the upper door trim 110 may be different, and the material may be appropriately changed according to each required item. Can be.

Subsequently, as illustrated in FIG. 18, the molten resins M1 and M2 branched to the upper door trim 110 and the lower door trim 120 may be supplied by one injection machine 63.

In this case, the branch manifolds 622d and 622e are branched from the main manifold 622c communicating with the injection molding machine 63, respectively, and the respective gates 623d and 623e are set, and the opening and closing are opened and closed. By installing a valve, the injection timing of the molten resin M1 supplied from the injection molding machine 63 toward the upper door trim 110 and the supply timing of the molten resin M2 to the lower door trim 120 are different from each other. The upper door trim 110 and the lower door trim 120 can be integrally formed through the same.

Therefore, in the case of using the single injection molding machine 63 shown in Fig. 18, it is necessary to make the supply timings of the molten resins M1 and M2 different, but the two injection molding machines 63a and 63b are connected to one injection molding machine 63. It can be substituted by, which can simplify the structure.

As described above, the laminated structure according to the present invention includes a foamed resin member having a lightweight and retaining shape, and an outer frame laminated integrally at a portion where rigidity such as an outer rim of the product is required on the back side of the foamed resin member, and, if necessary, In addition, since it is composed of connecting ribs, the conventional heavy weight resin core material can be abolished, and it is lightweight and inexpensive, and since it is a porous material, there is an effect of providing a laminated structure excellent in sound absorption performance.

In addition, according to the cavity shape of the molding mold, if the foamed resin member is molded into a desired shape and a step of forming the outer frame and the connecting rib on the back side of the foamed resin member is adopted, the projection surface of the outer frame or the connecting rib which is the resin molded body is adopted. Since the tablets are smaller, compared to the conventional resin core material, the load on the molding die is less, the cooling time can be shortened, the productivity can be increased, and the cost can be reduced a lot.

1 is a perspective view showing a first embodiment of a door trim to which the present invention is applied;

2 is a cross-sectional view taken along the line II-II in FIG. 1,

3A and 3B are views for explaining the relationship between the product rim and the junction of the vehicle body panel in the door trim shown in FIG.

Figure 4 is a perspective view showing a modification of the door trim shown in Figure 1 showing the door trim with the foamed resin member removed,

5A and 5B are sectional views showing the joint portion of the connecting rib and the foamed resin member in the door trim shown in FIG. 4;

Figure 6 is a rear view of the door trim showing the clip mounting portion integrally formed on the connecting rib in the door trim to which the laminated structure according to the present invention is applied,

7 is a cross-sectional view showing a structure in which the clip mounting portion is integrally formed on the outer circumferential frame in the door trim shown in FIG.

8 is a view for explaining a step of setting the foamed resin sheet in the method of manufacturing the door trim shown in FIG.

9 is a view for explaining a pre-heating process of the foamed resin sheet,

10 is a view for explaining the injection molding process of the door trim shown in FIG.

11A and 11B are an external view showing a state in which the laminated structure according to the present invention is applied to a trunk side trim and a trunk rear trim, respectively, and a sectional view of the joint portion;

Figure 12a is a cross-sectional view of the laminated structure and the adjacent parts in the state in accordance with the present invention,

12B is a cross-sectional view of the laminated structure and the adjacent parts in a planar coupling state according to the present invention;

Figure 13 is a perspective view showing a two-tone type door trim to which the laminated structure according to the present invention is applied,

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

FIG. 15 is a view for explaining a step of setting the foamed resin sheet in the method of manufacturing the two-tone type door trim shown in FIG. 13;

FIG. 16 is a view for explaining an injection molding process in the manufacturing method of the two-tone type door trim shown in FIG.

FIG. 17 is a plan view showing a state in which the foamed resin member of the upper door trim is removed in the two-tone type door trim shown in FIG. 13;

18 is a view for explaining another embodiment of the manufacturing method of the two-tone type door trim shown in FIG.

19 is a front view showing a conventional door trim,

20 is a sectional view taken along the line XX-XX in FIG. 19,

21 is a schematic diagram showing a conventional method for manufacturing a door trim.

[Description of the code]

10 door trim

11 Inside Handle Assembly

12 Power Window Switch Assembly

13 Speaker Grill

14 Pocket Assemblies

20 Foamed resin member

30 Outer frame

40 connecting ribs

40a thick rib

41 Plate

42 (42a to 42d) mounting section

43 Clip Mount

50 body panels

60 Molding Mold

61 Molding upper mold

611 cavity section

612 lifting cylinder

62 Molding die

621 core part

622 manifold

623 gate

63 injection machine

63a first injection machine

63b 2nd Injection Machine

64 Heater

70 trunk side trim

71 trunk rear trim

80,81,82,83 Laminated Structure

100 two-tone door trim

110 Upper door trim

120 lower door trim

130 boundary line

M, M1, M2 melt

S Foamed resin sheet

Claims (16)

It is characterized in that it comprises a foamed resin member 20 having a shape retention, and an outer frame 30 made of a synthetic resin molded body integrally laminated on the back side of the foamed resin member 20 and following the outer circumferential shape of the product 10. Laminated structure. The laminated structure according to claim 1, wherein the outer circumferential frame (30) is set in an L-shaped cross-section with enhanced rigidity. According to claim 1 or 2, The outer peripheral frame 30, characterized in that the connecting rib 40 is installed between the outer peripheral frame 30 to shape the foam resin member 20, characterized in that the Laminated structure. The laminated structure according to claim 3, wherein the connecting rib (40) has a rigid cross-sectional shape including a plate portion (41) which is in surface contact with the rear surface of the foamed resin member (20). The laminated structure according to claim 3, wherein the rib thickness of the connecting rib (40) is variably adjusted in accordance with the strength of the external force applied to the surface of the product (10). 4. The laminated structure according to claim 3, wherein the outer circumferential frame (30) or the connecting rib (40) is integrally formed with mounting parts (42) and (43) for mounting the functional parts. The laminated structure according to claim 1, wherein the surface of the foamed resin member (20) is laminated integrally with the skin. The laminated structure according to claim 1, wherein the foamed resin member (20) comprises a lightweight member having a shape retaining shape formed of a foamed resin sheet (S) into a required shape. The laminated structure 110 according to claim 1, and the synthetic resin molded body 120 is bonded to the laminated structure 110 and integrally molded with the outer peripheral frame 30 of the laminated structure 110, characterized in that it comprises a Laminated structure. In the manufacturing method of the laminated structure 10 having a foamed resin member 20 having a shape retention, the outer peripheral frame 30 and the connecting rib 40 to be integrally laminated on the back of the foamed resin member 20, A process of setting the foamed resin sheet (S) for setting the foamed resin sheet (S) which is a material of the foamed resin member (20) in the molding dies (61) and (62), The molds 61 and 62 are clamped so that the shape of the foamed resin sheet S conforms to the shape of the cavity C of the molds 61 and 62 so that the foamed resin member 20 is desired. In addition, the molten resin is injected and filled into the cavity C of the molding molds 61 and 62 to integrally stack the outer circumferential frame 30 and the connecting rib 40 on the back side of the foamed resin member 20. Method for producing a laminated structure, characterized in that it comprises a step of integration of the laminated structure (10). In the manufacturing method of the laminated structure 10 having a foamed resin member 20 having a shape retention, the outer peripheral frame 30 and the connecting rib 40 to be integrally laminated on the back of the foamed resin member 20, A process of setting the foamed resin sheet (S) for setting the foamed resin sheet (S) which is a material of the foamed resin member (20) in the molding dies (61) and (62), The molds 61 and 62 are clamped so that the shape of the foamed resin sheet S conforms to the shape of the cavity C of the molds 61 and 62 so that the foamed resin member 20 is desired. After injection molding, the molten resin is injected into the cavity C of the molding molds 61 and 62 before the mold clamping of the molding molds 61 and 62, and then the molding molds 61 and 62 are filled. Laminated structure characterized in that it comprises an integration process of the laminated structure 10 to integrally laminate the outer peripheral frame 30 and the connecting rib 40 on the back side of the foamed resin member 20 by the press pressure by the clamping of the Manufacturing method. A method of manufacturing the laminated structure according to claim 9, wherein the foamed resin sheet S, which is a material of the foamed resin member 20, is set at a predetermined position in the molding dies 61 and 62. Setting process, The molds 61 and 62 are clamped so that the shape of the foamed resin sheet S follows the shape of the cavity C of the molds 61 and 62 so that the foamed resin member 20 is desired. In addition to molding to form a molten resin (M1) to the back of the foamed resin member 20 via the resin passage from the first injection machine (63a) to foam the outer peripheral frame 30 and the connecting rib 40 installed therein Forming a laminated structure 110 by integrally stacking the back surface of the resin member 20; The synthetic resin molded body 120 is laminated with the laminated structure 110 by injection filling the molten resin M2 from the second injection molding machine 63b into the cavity C in a region where the foamed resin sheet S is not set. Method for producing a laminated structure, characterized in that it comprises an integration process of the laminated structure 100 to be integrated. A method of manufacturing the laminated structure according to claim 9, wherein the foamed resin sheet S, which is a material of the foamed resin member 20, is set at a predetermined position in the molding dies 61 and 62. Setting process, The molds 61 and 62 are clamped so that the shape of the foamed resin sheet S follows the shape of the cavity C of the molds 61 and 62 so that the foamed resin member 20 is desired. In addition, the molten resin (M1) is supplied to the rear surface of the foamed resin member (20) from the first injection machine (63a) through the resin passage before the mold clamping of the molding mold (61), (62) and then the molding mold ( 61 and 62 to form a laminated structure 110 by integrally stacking the outer peripheral frame 30 and the connecting rib 40 connected thereto with the press pressure on the rear surface of the foamed resin member 20. Fair, The molten resin M2 is supplied from the second injection molding machine 63b through the resin passage to the surface of the molding die 62 in the region where the foamed resin sheet S is not set, and the mold clamping of the molding molds 61 and 62 is performed. And a step of integrating the laminated structure (100) to integrate the synthetic resin molded body (120) with the laminated structure (110). The resin passage 622d for forming the outer circumferential frame 30 and the connecting rib 40 of the laminated structure 110 and the resin passage 622e for molding the synthetic resin molded body 120 according to claim 12 or 13. A method of manufacturing a laminated structure, characterized in that the molten resin (M1), (M2) is supplied from one injection molding machine (63) by branching in the resin passage (622c), respectively. The method according to claim 10, wherein the foamed resin sheet (S) is heat-softened by a preheating step prior to the setting step of the foamed resin sheet (S), and foamed when the molds (61) and (62) are molded. The resin sheet (S) is molded into a desired shape to form a foamed resin member (20) having a shape retention, and to laminate the outer peripheral frame (30) and the connecting rib (40) on the back side of the foamed resin member (20). Method for producing a laminated structure characterized in that. The mold surface of the molding mold 61 according to claim 10, wherein a vacuum suction mechanism is attached to the molding mold 61, and the foamed resin sheet S subjected to heat softening is molded when the molding molds 61 and 62 are clamped. And a step of vacuum forming the foamed resin member 20 into a desired shape by operating the vacuum suction mechanism when forming the shape according to the shape.