JP2009083411A - Interior component for automobile and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an interior component which is lightweight, achieves a cost reduction and enables simplification of an outer circumferential terminal treatment work, and to provide its manufacturing method. <P>SOLUTION: A door trim main body 20 comprises a lightweight foamed resin base material 21 having shape retainability, a resin rib 22 integrated on its inner surface and having a reinforcing function and a decorative material 23 laminated on the surface of the foamed resin base material 21. A hot melt seal 24 for bonding the foamed resin base material 21 and the decorative material 23 to each other is preliminarily laminated on the decorative material 23 side, and the foamed resin base material 21 is shaped into a predetermined shape and is integrated with the decorative material 23 by deep-forming a heat-softened foamed resin sheet S by clamping upper and lower shaping molds 41 and 42. Then the door trim main body 23 is removed from the mold, the hot-melt sheet 24A on the reverse side of a margin 26 to roll-in of the decorative material 23 is heat-melted and the margin 26 to roll-in is rolled in on the reverse side of the foamed resin base material 21. By this the terminal treatment work is simplified. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to automobile interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and manufacturing methods thereof. The present invention relates to an automotive interior part that can be easily and inexpensively processed along the terminal, and a method of manufacturing the same.

  For example, the configuration of automobile interior parts will be described with reference to FIGS. 19 and 20 exemplifying door trims. The door trim 1 has a shape retaining property and a mounting rigidity to a vehicle body panel, and is formed by laminating and integrating a skin 3 excellent in surface appearance on the surface of a resin core material 2 that extends over almost the entire product surface. Yes. The resin core material 2 is made of a polypropylene resin mixed with talc, and the skin 3 does not have shape retention itself, and the back surface of the synthetic resin sheet such as a vinyl chloride sheet is made of polyethylene foam or the like. A laminated sheet material in which a cushion material is laminated is used, and recently, an elastomer sheet such as a thermoplastic olefin (hereinafter referred to as TPO) sheet tends to be frequently used in consideration of environmental aspects and recycling aspects.

  Next, a conventional example of the method for forming the door trim 1 will be described with reference to FIG. First, a molding die 4 that molds the door trim 1 is connected to a molding upper die 5 that can move up and down by a predetermined stroke, a molding lower die 6 that forms a pair with the molding upper die 5, and a molding lower die 6. It is generally composed of the injection machine 7. When the upper and lower molds 5 and 6 are clamped, a cavity portion 5a is formed in the molded upper mold 5 and a core section 6a is provided in the molded lower mold 6 in order to shape the product shape of the door trim 1. Yes. Further, in order to move the molding upper die 5 up and down by a predetermined stroke, an elevating cylinder 5b is connected, and the molding lower die 6 is provided with a manifold 6b and a gate 6c that serve as a passage for molten resin from the injection machine 7. . Further, in order to maintain an appropriate posture, the upper molding die 5 that moves up and down is provided with guide posts 6d at the four corners of the lower molding die 6, and the molding upper die 5 has guides corresponding to the guide posts 6d. A bush 5c is provided.

  Therefore, when the molding upper and lower molds 5 and 6 are in the mold open state, either the skin 3 is set in the mold, and then either immediately before or after the molding upper and lower molds 5 and 6 are clamped The molten resin M is injected and filled from the injection machine 7 through the manifold 6b and the gate 6c into the product cavity between the molds at the timing, thereby forming the resin core material 2 into a required curved shape and the resin core material 2 The skin 3 is integrally formed on the surface (see, for example, Patent Document 1). In FIG. 21, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6 a in an open state, but actually, the molten resin M is injected into the cavity after the mold upper and lower molds 5 and 6 are clamped. It may be filled.

  Furthermore, as shown in FIG. 22, the processing of the product outer peripheral terminal of the door trim 1 is performed by simultaneously press-molding the skin 3 on the surface of the core material 2 and then performing a cutting process with a mold blade in the mold or after molding. The piercing cut process is performed in a separate process. Further, as shown in FIG. 23, after the core material 2 is press-molded, the skin 3 is integrated in a separate process by vacuum pressure bonding, press pressure bonding, or the like, and then the terminal 3a of the skin 3 is wound around the back surface side of the core material 2. Processing is also conventionally performed.

Japanese Patent Laid-Open No. 10-138268 (second page, FIGS. 3 and 4)

  However, in the conventional door trim 1, since the projected area of the resin core material 2 is large, there are problems that the material cost is high and the product is heavy. In addition, since the projected area of the resin core material 2 is large, it is necessary to set the injection pressure at the time of molding high, and a mold structure that can withstand the high injection pressure is required, and the production cost of the mold is increased, In addition, since a large amount of molten resin is cooled and solidified, the molding cycle becomes longer, which is a major factor for reducing productivity.

  Further, at the outer periphery of the door trim 1, as shown in FIG. 22, when the outer skin simultaneous press molding is performed, it is difficult to treat the outer periphery, and the mouth of the foam layer in the outer skin 3 of the laminated sheet material specification is exposed to the outside. In addition to the disadvantage that the appearance is poor and the appearance performance is lowered, as shown in FIG. 23, the method of winding the skin 3 in a separate process requires a large number of man-hours and an inevitable increase in cost.

  The present invention has been made in view of such circumstances, and can provide an automotive interior part that can promote weight reduction, can achieve high rigidity, and can reduce costs, and in particular, can enhance the appearance of a product outer peripheral terminal portion. Another object of the present invention is to provide an automobile interior part and a method for manufacturing the same that can easily perform terminal processing operations.

  As a result of earnest research, the present inventors have given the function as a core material by imparting shape retention to the foamed resin sheet that has been used conventionally as the skin, and more. High rigidity is required at places where rigidity is required, i.e. it can be closely contacted with the peripheral part of the product, the panel, the mating part with the mating part, or a part where a certain clearance is secured, or where a part is attached and where a load is applied By placing resin ribs, the weight of the product is reduced compared to the conventional resin core material with a large projected area, and the terminal of the outer periphery of the product is eliminated by eliminating the adhesive application and drying process. It has been found that processing can be performed easily and quickly, and the present invention has been completed.

  That is, the interior part for automobiles according to the present invention is a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a resin rib having a predetermined pattern shape that is integrated on the back surface of the foamed resin base material. And a laminated structure composed of a decorative material affixed to the surface of the foamed resin substrate as a whole or a part of the automobile interior part, the peripheral end portion of the laminated structure is foamed An adhesive provided on either the back surface of the above-mentioned winding paper or the back surface of the foamed resin base material to be joined to the decorative material by forming the trim cut and removing the resin base material. By applying a heat-melting process, the winding white of the decorating material is bonded and fixed.

  Next, a method for manufacturing an automotive interior part according to the present invention includes a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a predetermined pattern shape that is integrated on the back surface of the foamed resin base material. In the manufacturing method of interior parts for automobiles, in which the laminated structure composed of the resin rib and the decorative material affixed to the surface of the foamed resin base material is employed in whole or in part, the laminated structure is When the mold upper and lower molds are opened, a foam resin sheet that has been heat-softened, and a material setting step for setting the decorative resin provided with an adhesive on the foam resin sheet facing surface side in the molded upper and lower molds, The upper and lower molds are clamped and the foamed resin base material is press-molded into a desired curved shape along the cavity shape of the molding die, and any timing immediately before or after the upper and lower molds are clamped Molded lower mold groove After the molten resin is injected and filled, a molding process of the laminated structure in which the resin rib is integrated on the back side of the foamed resin base material to form the laminated structure, and the molded upper and lower molds are opened, and then the laminated structure Then, the adhesive provided on the back surface of the encasement of the decorative material extending around the periphery of the foamed resin base material is heated and melted, and the encasement white is placed on the back side of the foam resin base material. It is manufactured by the process which consists of a winding process process of the decorating material to wind-in and adhere.

  Here, the interior parts for automobiles can be applied to door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and the like. And, if the foamed resin base material that is lightweight and has shape retention properties is close to a flat shape, the heat softening step is omitted and it is molded into a desired shape by a molding die, but it is applied to a three-dimensional product. In this case, after the foamed resin sheet is heat-softened, the foamed resin sheet is molded into a required curved shape in a molding die, and the shape is maintained. Here, “shape retention” refers to having rigidity enough to retain the shape when the mold is removed after molding, even without a reinforcing material such as a rib. Also, if the product shape includes a high expansion ratio part, after the foamed resin sheet is heat-softened, a vacuum suction mechanism is provided in the molding die and the foamed resin sheet is vacuumed along the inner surface of the molding die. A suction force may be applied.

  As the foamed resin sheet, a material obtained by adding a foaming agent to a thermoplastic resin is used. The thermoplastic resin may be 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, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / Styrene (ABS) resin or the like can be used. As the foaming agent, an organic foaming agent such as an azo compound, a sulfohydrazide compound, a nitroso compound or an azide compound, or an inorganic foaming agent such as sodium bicarbonate can be used. The foamed resin base material obtained by heat-softening the foamed resin sheet and molded into a required shape preferably has a foaming ratio of 2 to 10 times in consideration of the balance between the weight and strength of the product. The cell diameter of the foamed resin base material at that time is preferably in the range of 0.1 μm to 2.0 mm, and the thickness is 0.5 to 30 mm, preferably 1 to 10 mm.

  On the other hand, the thermoplastic resin material used as the resin rib can be appropriately selected from a wide range of thermoplastic resins. Usually, those that can be preferably used include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, Acrylonitrile / butadiene / styrene (ABS) resin can be used. Moreover, you may mix various fillers in these thermoplastic resins. Examples of the filler that can be used include inorganic fibers such as glass fiber and carbon fiber, inorganic particles such as talc, clay, silica, and calcium carbonate. Moreover, various additives, such as antioxidant, a ultraviolet absorber, a coloring agent, a flame retardant, and a low shrinkage agent, may be mix | blended.

  Furthermore, in order to improve the appearance design, a decorative material is integrated on the surface of the foamed resin base material. As the decorating material, thermoplastic resin sheets such as TPO, thermoplastic urethane (TPU), and polyvinyl chloride (PVC), or fabric sheets such as woven fabric, non-woven fabric, and knitted fabric can be used. Further, a foam sheet such as polyurethane foam, polyethylene foam, polypropylene foam or the like can be laminated and integrated as a cushion layer on the back surface of the fabric sheet such as thermoplastic resin sheet, woven fabric, nonwoven fabric, knitted fabric or the like. In addition, if TPO sheet or polyethylene foam is used as the material of the decorating material and olefin resin is used as the material of the foamed resin base material or resin rib, all materials can be unified into the olefin resin and recycled. Above preferred.

  In the interior part for automobiles according to the present invention, a decorative material having decorating properties is laminated on the front surface side of the foamed resin base material having shape retention, and a resin rib for reinforcing rigidity is laminated on the back surface side. Therefore, the conventional resin core material can be abolished. Therefore, it is possible to reduce the weight of the product by eliminating the conventional resin core material having a very large projected area. Further, since the resin material can be saved, the material cost can be reduced at the same time.

  Next, the method for manufacturing a laminated structure in an automobile interior part according to the present invention includes a material setting step, a laminated structure forming step, and a decorating material winding process step. First, as a material setting step, when the upper and lower molds are in an open state, a sheet-shaped raw material such as a foamed resin base material and a decorating material is put into the upper and lower molds. The foamed resin sheet, which is the material of the foamed resin base material, is put in a state of being heat-softened by a heater device. Moreover, the adhesive agent is provided in the opposing surface side of the foamed resin sheet in a decorating material. As the adhesive, for example, a hot melt sheet (low melting point resin sheet such as a polyethylene sheet), a hot melt web, or the like is used. And it sets in a shaping | molding upper / lower mold in the state which accumulated the decorating material on the one surface of the foamed resin sheet heat-softened.

  Then, the foamed resin sheet is molded into a desired curved shape along the cavity shape of the molding die by clamping the upper and lower molds, and the foamed resin base material is obtained, and the foamed resin sheet is superposed on one side of the foamed resin sheet The decorating material is integrated on the surface side of the foamed resin base material by the adhesive function of the adhesive. Furthermore, in order to form a winding sheet at the peripheral portion of the decorating material, a trim cut process is performed on the surplus foamed resin base material along the outer periphery of the product. A shear block (made of a synthetic resin material such as polyamide resin, fluororesin or polyacetal resin, or a relatively soft light metal material such as aluminum or zinc) is arranged along the outer periphery of the cavity portion of the lower mold, and The surplus foamed resin base material is trim-cut and removed by the shearing action between the shear block and the inner wall surface of the molding upper mold. As the clearance at that time, a reference value of 0.4 to 0.5 mm is set, and the thickness of this reference value depends on the thickness of the decorating material. Then, the resin rib having a reinforcing function is formed on the back surface of the foamed resin base material by injection-filling the molten resin into the groove portion of the molding lower mold at any timing immediately before or after the mold clamping of the molding upper and lower molds. By being integrated along a predetermined pattern shape, a laminated structure in which the foamed resin base material, the decorating material, and the resin rib are integrated is formed into a required shape.

  Furthermore, as a process for winding up the decorative material, if the molding process of the laminated structure is completed, after opening the molding upper and lower molds, the laminated structure is removed from the molding die, If the back surface of the encasement of the decorative material extending outward along the periphery is heat-softened, the adhesive of this part is heated and melted, so that the entrainment is made to the back of the foamed resin base material. If the wrapping treatment is performed on the side, the wrapping shiro can be firmly bonded and fixed without applying or drying the adhesive.

  The molding die used in the method of the present invention is composed of a molding upper and lower mold and an injection machine connected to the molding lower mold. The molding upper die can move up and down by a predetermined stroke, and the molding lower die is formed with resin passages such as a manifold and a gate that serve as a passage for the molten resin supplied from the injection machine. Specifically, the molten resin is supplied into a groove formed in the mold surface of the lower mold. In addition, the above-described shear block is disposed on the outer periphery of the cavity of the lower mold. The molded upper mold is lowered to the bottom dead center, and the molded resin sheet is drawn into a required shape by clamping the molded upper and lower molds to obtain a foamed resin base material. Further, the molten resin is injected and filled into the groove portion provided on the mold surface of the molded lower mold at a predetermined injection pressure, but may be performed before mold clamping as the injection timing of the molten resin.

  Therefore, according to the method of the present invention, it is only necessary to mold the resin rib as compared with the conventional resin core material having a large projected area. Therefore, the injection pressure can be set lower than the conventional one, and the load on the molding die is reduced. In addition, the resin material can be saved and the cooling time can be shortened as compared with the conventional resin core material, so that the product molding cycle can be shortened. Furthermore, for the terminal portion along the outer periphery of the product of the laminated structure, after the laminated structure is removed from the molding die, the adhesive provided in advance on the back surface of the decorating material is heated and melted, and then the foam resin Since the winding process may be performed on the back surface side of the base material, the application process and the drying process of the adhesive to the winding paper can be abolished, so that the terminal processing operation of the decorating material can be performed easily and inexpensively. In addition, since the process of volatilizing and removing the solvent of the adhesive is not required, it is possible to maintain a favorable working environment, eliminate the need for exhaust equipment, and reduce the total equipment cost. Furthermore, by the shear action between the shear block and the inner wall surface of the molding upper mold, the trim cut processing of the foamed resin sheet can be performed, and the trim cut processing of the foam resin base material and the decorating material can be performed in the same pressing process. it can.

  Next, in a preferred embodiment of the present invention, a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a resin having a predetermined pattern shape that is integrated on the back surface of the foamed resin base material In a method for manufacturing an interior part for an automobile, in which a laminated structure composed of a rib and a decorative material affixed to the surface of the foamed resin base material is employed in whole or in part, the laminated structure is molded When the upper and lower molds are opened, the foam resin sheet with adhesive on both sides is heated and softened, and the decorative material is stacked on the surface side of the mold and set in the upper and lower molds. The mold is clamped and the foamed resin substrate is press-molded into the desired curved shape along the cavity shape of the molding die, and molded either before or after clamping the upper and lower molds. Melted in the groove of the lower mold By injecting and filling the fat, the molding process of the laminated structure in which the resin rib is integrated on the back side of the foamed resin base material to form the laminated structure, and the upper and lower molds are opened, and then the laminated structure is removed. Mold and heat the corresponding part of the foamed resin base material corresponding to the decorative material entrainment white to heat and melt the adhesive, and then apply the decorative material encasement white to the back side of the foam resin base material. It is manufactured by the process which consists of a winding process process of the decorating material which winds and adheres to.

  Furthermore, after the laminated structure is molded, the upper and lower molds are opened, the laminated structure is removed from the molding die, and an adhesive is provided on the back side of the foamed resin substrate. If the adhesive of the part is melt | dissolved by heat-processing the location to which the enrollment white of decorating material respond | corresponds, the entrainment white of decorating material can be firmly adhere | attached and fixed.

  Therefore, according to this embodiment, since the adhesive provided in advance in the foamed resin sheet is used as an adhesive medium for fixing the encasement of the decorating material, the application process of the adhesive to the entrainment and the drying process Can be abolished, and a large exhaust facility can be dispensed with, so that the terminal processing work of the decorating material can be performed easily and inexpensively.

  As described above, the automobile interior part according to the present invention is required to have rigidity such as a foamed resin base material that is lightweight and has shape retention, the back surface of the foamed resin base material, and the outer peripheral edge of the product. Because it is composed of resin ribs that are laminated and integrated on the part and a decorative material that is laminated on the surface of the foamed resin base material, the conventional heavy resin core material can be abolished. Since it is a porous material, it has an effect of excellent sound absorption performance.

  Furthermore, according to the method for manufacturing an automotive interior part according to the present invention, the foamed resin base material is molded into a required shape along the cavity shape of the molding die, and at the same time, the resin rib is formed on the back surface side of the foamed resin base material. Since the projected area of the resin rib, which is a resin molded body, is small, the load applied to the molding die is less than that of the conventional resin core material, and the cooling time can be shortened. Since it can be increased, the working efficiency can be increased, and in addition, there is an effect that a significant cost reduction can be brought about.

  Moreover, according to the manufacturing method of the interior part for automobiles according to the present invention, the terminal treatment method of the decorating material in the laminated structure is the adhesive provided on the back surface of either the decorating material or the foamed resin base material. After the heat treatment is performed and melted, it is only necessary to wind the decorating material roll on the back side of the foamed resin base material. Can be performed easily and inexpensively, and the terminal processing of the decorating material can be performed easily, and a large exhaust system is not required, so that the equipment cost can be reduced.

  DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments of a method for manufacturing an interior component for automobile according to the present invention will be described in detail with reference to the accompanying drawings. It should be noted that the gist of the present invention is as described in the claims, and the contents of the embodiments described below are merely examples of the present invention.

  1 to 12 show a first embodiment of the present invention. FIG. 1 is a front view showing a door trim to which the present invention is applied. FIG. 2 is a sectional view showing the structure of the door trim. FIG. 4 is an explanatory view showing the pattern shape of the resin rib, FIG. 4 is a cross-sectional view showing the configuration of the terminal processing portion in the door trim, and FIGS. 5 and 6 show a molding die used in the method for manufacturing the automobile door trim. FIG. 5 is an overall view of the molding die, FIG. 6 is a cross-sectional view showing the cavity outer periphery of the molding die, and FIGS. 7 to 12 show each step in the manufacturing method of the automotive door trim. FIG. 8 is an explanatory view showing the in-mold setting process of the decorating material and the foamed resin sheet, FIGS. 9 and 10 are explanatory views showing the press molding process of the foamed resin base material, and FIG. 11 is an explanatory view showing a resin rib molding process Figure 12 is an explanatory diagram showing a winding process of the decorative material in the door trim.

  1 and 2, an automotive door trim 10 is configured by attaching various functional parts to a door trim main body 20 formed into a desired curved surface shape. Specifically, an inside handle escutcheon 30 is attached to the inscribed portion of the door trim main body 20, and an armrest 31 swelled by an occupant who bulges indoors rests on the elbow in the middle of the door trim main body 20. A pull handle unit 32 and a power window switch escutcheon 33 are attached to the upper surface of the armrest 31, and a door pocket 34 that can accommodate equipment is provided below the armrest 31. A speaker grill 35 is attached to the door trim main body 20 or separately.

  As shown in FIG. 2, the door trim main body 20 is molded into a desired curved surface shape, and has a foamed resin base material 21 having a shape retaining property, and a resin rib integrated with the back surface side of the foamed resin base material 21. 22 and a decorating material 23 having a decorating function that is molded on the surface side of the foamed resin base material 21. The foamed resin base material 21 is subjected to heat softening treatment of the foamed resin sheet so as to have shape retention, and then thermoformed into a required shape, for example, cold press molded with a molding die having a desired mold surface. About the expansion | deployment rate part, you may shape the foamed resin base material 21 using vacuum forming together.

  The foamed resin sheet has a structure in which a foaming agent is added to a general-purpose thermoplastic resin. The thermoplastic resin includes a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a chloride resin. Vinyl resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. can be used. As the foaming agent, organic foaming agents such as azodicarbonamide and bicarbonate An inorganic foaming agent such as sodium can be used. In this embodiment, a foamed resin sheet in which sodium bicarbonate is appropriately added as a foaming agent to a polypropylene resin is used. The expansion ratio of the foamed resin base material 21 is set to 2 to 10 times, and the thickness is set to a range of 0.5 to 30 mm, particularly 1 to 10 mm.

  Next, the resin ribs 22 are disposed on the back surface side of the foamed resin base material 21 and, in particular, are set in a predetermined pattern extending in an intersecting manner as shown in FIG. In addition, as for this pattern, arbitrary pattern shapes may be selected if it is cross shape, such as a vertical and horizontal direction, an oblique direction, or a combination thereof. The resin rib 22 is made of a general-purpose synthetic resin molded body, and as a synthetic resin that can be preferably used normally, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin, A polyamide resin, a polyacetal resin, a polycarbonate resin, an ionomer resin, an acrylonitrile / butadiene / styrene (ABS) resin, or the like may be selected as appropriate. Is used. The resin rib 22 is appropriately mixed with a filler such as inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica, and calcium carbonate in the thermoplastic resin. May be.

  As described above, the door trim main body 20 in the door trim 10 shown in FIGS. 1 to 3 includes a foamed resin base material 21 having shape retention, a resin rib 22 integrated on the back surface of the foamed resin base material 21, and a decoration. In addition to using the lightweight foamed resin base material 21, the resin core material occupied over the entire surface of the product can be abolished. The resin rib 22 has a bone-like shape, and a portion to which a load is applied, for example, a portion excluding the clip seat, the upper surface of the waist portion, the upper surface of the armrest portion, etc. has a thinning structure. Compared to the above, the weight can be reduced by 40% or more, and the resin material can be greatly saved, thereby contributing to the cost reduction.

  Furthermore, since the foamed resin base material 21 has a porous structure, the door trim main body 20 is excellent in sound absorbing performance and can reduce noise in the passenger compartment. Moreover, in order to maintain the sound absorption property of the foamed resin base material 21, the decorating material 23 laminated in advance on the surface of the foamed resin base material 21 or integrated and laminated at the time of molding is a woven fabric or a non-woven fabric. A sheet material having air permeability such as a knitted fabric is preferable. The decorative material 23 may be a synthetic resin sheet such as a PVC sheet or a TPO sheet, a synthetic resin film, a foam, a net, or a fabric sheet, a synthetic sheet, in addition to a breathable sheet such as a woven fabric, a nonwoven fabric, or a knitted fabric. A laminated sheet material in which a cushion layer such as polyethylene foam or polyurethane foam is lined on the back surface of the resin sheet can also be used. In this embodiment, a laminated sheet material with a polyethylene foam 23b lined on the back surface of the TPO 23a is used as the decorative material 23, and a hot melt sheet 24 such as polyethylene resin is laminated on the entire back surface. . The hot melt sheet 24 is necessary for ensuring adhesion to the foamed resin base material 21, but may be an adhesive medium such as a hot melt web. And, it is a feature of the present invention that the adhesive medium typified by the hot melt sheet 24 is effectively used when the terminal treatment of the decorating material 23 is performed.

  Next, the outer peripheral terminal structure of the door trim body 20 in the door trim 10 will be described with reference to FIG. That is, in the door trim main body 20, the resin ribs 22 having a predetermined pattern shape for reinforcing rigidity are integrated on the back surface of the lightweight foamed resin base material 21 having shape retention as described above, and the surface of the foamed resin base material 21. The decorative material 23 having decorating properties is laminated and integrated. Further, a vertical wall portion 25 is formed in a stepped flange shape to make the product appear unity along the outer peripheral portion of the door trim body 20, and the decorative material 23 is wound around the outer peripheral terminal portion. The white 26 is wound around the back side of the foamed resin base material 21. At this time, the winding sheet 26 of the decorating material 23 is firmly bonded and fixed to the back surface side of the foamed resin base material 21 by effectively using the adhesiveness of the hot melt sheet 24 previously laminated on the back surface. Can do. Therefore, since the cut end of the foamed resin base material 21 is not exposed, the appearance appearance can be maintained satisfactorily. Moreover, although it mentions later, since an adhesive agent is not required separately, a terminal processing operation can be performed simply and inexpensively.

  Next, the outline of the manufacturing method of the door trim 10 including the terminal processing step of the outer peripheral terminal portion of the door trim main body 20 will be described first with reference to FIG. In FIG. 5, a molding die 40 used for molding the door trim 10 includes a molding upper mold 41 that can move up and down by a predetermined stroke, a molding lower mold 42 that is paired with the molding upper mold 41, and a molding lower mold 42. And an injection machine 43 connected to the main body.

  More specifically, the molding upper die 41 has a cavity portion 411 that matches the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 412 connected to the upper surface of the molding upper die 41. In addition, guide bushes 413 serving as a guide mechanism are provided at the four corners of the molding upper die 41. On the other hand, the molding lower die 42 is provided with a core portion 421 corresponding to the cavity portion 411 of the molding upper die 41. In addition, a manifold 422 and a gate 423 are provided to supply the molten resin to the mold surface of the core portion 421. The molten resin M supplied from the injection machine 43 via the manifold 422 and the gate 423 is the core portion. Supplied into a groove 424 formed on the upper surface of 421. In addition, guide posts 425 that serve as a guide mechanism protrude from the four corners of the molded lower mold 42, and the guide posts 425 are guided into the guide bush 413 when the molded upper and lower molds 41 and 42 are clamped. As a result, the pressing posture of the molding upper die 41 can be properly maintained. The molding lower mold 42 is provided with a set frame 44 for setting the material, and the set frame 44 moves up and down in conjunction with the vertical movement of the molding upper mold 41.

  Next, FIG. 6 shows a portion corresponding to the outer peripheral end portion of the door trim main body 20 in the molding die 40, and the shear block 50 is arranged along the outer periphery of the core portion 421 of the molded lower die 42. The shear block 50 is set so as to ensure an appropriate shear clearance with the inner wall surface of the molding upper die 41. In particular, in the present invention, as the material of the shear block 50, polyamide resin, fluorine It is characterized by using as a raw material a resin material such as resin or polyacetal resin, or a soft light metal such as aluminum or zinc. In this embodiment, the shear clearance indicated by the symbol d in FIG. 6 is set with a reference value of 0.4 to 0.5 mm. In this embodiment, as the decorating material 23, the TPO 23a and the polyethylene foam 23b are used. A laminated sheet material having a thickness of 3.5 mm is used. For this reason, in this embodiment, the shear clearance d is set in the range of 0.4 to 0.5 mm described above. In particular, since a resin material or a light metal material is used as the material for the shear block 50, variations in shear clearance during trim cut of the foamed resin sheet can be absorbed. The shear block 50 can be easily attached and fixed to the molded lower mold 42 by inserting the screws 52 into the screw holes 51 and tightening and fixing them in the screw holes of the molded lower mold 42. . Further, the shear clearance d is set between the corner portion 53 of the shear block 50 and the inner wall surface of the molding upper die 41.

  In this embodiment, the decorating material 23 having a thickness of about 3.5 mm is used. However, the dimension of the shear clearance d can be varied according to the material and thickness of the decorating material 23. In particular, when a soft material is set in the shear block 50 as in the present embodiment, it can be handled with a relatively rough accuracy of about a reference value ± 0.2 mm.

  Next, each step in the method for manufacturing the door trim 10 will be described with reference to FIGS. First, as shown in FIG. 7, the foamed resin sheet S is heat-softened to a high temperature of 160 to 220 ° C. by the heater device 60. As the foamed resin sheet S, a polypropylene foam sheet (manufactured by Sumika Plustech, trade name: Sumiceller foam PP sheet, expansion ratio = 3 times, thickness 3 mm) is used. Subsequently, as shown in FIG. 8, the decorative material 23 and the above-described heat-softened foamed resin sheet S are put into the mold when the upper and lower molds 41 and 42 are in the mold open state. Specifically, the decorating material 23 is preferably held by a set pin (not shown) in the molding upper die 41 or by a vacuum suction force by a vacuum suction mechanism attached to the molding upper die 41. It may be placed on the upper surface of S. At this time, the hot melt sheet 24 laminated on the back surface of the decorating material 23 faces the foamed resin sheet S. On the other hand, the foamed resin sheet S may be placed on the upper surface of the set frame 44 that is provided around the outer periphery of the core portion 421 at a predetermined distance.

  Thereafter, the elevating cylinder 412 of the molding upper die 41 is operated, the molding upper die 41 is lowered by a predetermined stroke, and the molding upper and lower dies 41 and 42 are clamped as shown in FIG. The foamed resin base material 21 is molded into a required shape. At this time, since the hot melt sheet 24 is laminated on the back surface of the decorating material 23, the hot melt sheet 24 is heated and melted by the remaining heat of the foamed resin sheet S, and the foamed resin base material 21 has a required shape. At the time of press molding, the decorative material 23 acts as a hot melt sheet 24 as an adhesive medium by this applied pressure, so that both are firmly bonded and integrated.

  And in the outer peripheral terminal part of the door trim main body 20, as shown in FIG. 10, the end material Sa of the foamed resin sheet S is cut and removed by the shearing action between the shear block 50 and the inner wall surface of the molding upper die 41. The trim cut process is performed in the same process as the press molding. Further, as described above, since the shear block 50 is made of a resin material or a light metal material, the shear clearance d between the corner portion 53 of the shear block 50 and the inner wall surface of the molding upper die 41 is a reference. Since an error of about ± 0.2 mm can be absorbed, the end material Sa of the foamed resin sheet S can be surely cut and removed, and the decorating material 23 is not cut by mistake, and an accurate cutting process is performed. It is. In this embodiment, due to the shearing action between the shear block 50 and the inner wall surface of the molding upper die 41, the end material is cut at the same time as the molding, and the winding scissors 26 are formed at the same time. As in the case of push cutting with a cutting blade, the winding scissors 26 may be formed by another means.

  Next, after molding the foamed resin base material 21, as shown in FIG. 11, the molten resin M is injected and filled into the groove portion 424 of the molding lower mold 42 from the injection machine 43 through the manifold 422 and the gate 423, and the resin rib 22 Is integrated into a predetermined location on the back surface of the foamed resin base material 21 to complete the molding of the door trim body 20. As the molten resin M, a composite resin material in which a filler such as talc is mixed in an appropriate ratio using Sumitomo Noblen BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 min) is used.

  Thereafter, the upper mold 41 is lifted to open the mold, and then the door trim main body 20 is removed from the molding die 40. First, as shown in FIG. About the winding white 26 of the decorating material 23 extending outward, the hot melt sheet 24A laminated on the back side thereof is subjected to a heat treatment such as hot air blowing to be heated and melted to a predetermined temperature. After the treatment, the wrapping white 26 is bent to the back side of the foamed resin base material 21, and the wrapping white 26 is smoothly wound using the adhesive force of the hot melt sheet 24A effectively. To complete the terminal process. This eliminates the need for conventional adhesive application and drying processes, eliminates the need for adhesives, saves material costs, and eliminates troublesome processes such as adhesive application and drying. As a result, a large exhaust system for discharging the organic solvent of the adhesive to the outside is not necessary, and the equipment cost can be reduced.

  In the first embodiment, the molding step of the foamed resin base material 21 and the injection filling step of the resin rib 22 are performed using the molding upper and lower molds 41 and 42 described above. After the foamed resin base material 21 and the resin rib 22 are molded, both may be crimped by a crimping die. Further, in the first embodiment, the method of the present invention is applied to the door trim body 20 in the integrated door trim 10, but the present invention can also be applied to a door trim upper in a vertically divided door trim.

  FIGS. 13 to 18 show a second embodiment of the present invention, and a description of the same parts as those in the first embodiment will be omitted. In the first embodiment, the hot melt sheet 24 is laminated on the back side of the decorating material 23 in advance, but in the second embodiment, the hot melt sheet 24 is a foamed resin sheet S that is a material of the foamed resin base material 21. Are integrated on both sides. Therefore, as shown in FIG. 13, the winding white 26 of the decorating material 23 is wound on the back side of the foamed resin base material 21, but it is the back side of the foamed resin base material 21 that provides adhesion. A hot melt sheet 24 laminated on the side is used. That is, the hot-melt sheet 24a on the front surface side of the foamed resin base material 21 contributes to the adhesion between the foamed resin base material 21 and the decorating material 23, and the hot-melt sheet 24b on the back surface side of the foamed resin base material 21 is It functions in order to adhere the winding white 26 of the decorating material 23. Instead of the hot melt sheet 24, a conventional adhesive medium such as a hot melt web can be used.

  Hereafter, each process of the manufacturing method of the door trim 10 in 2nd Example is demonstrated in detail along FIG. 14 thru | or FIG. As shown in FIG. 14, the foamed resin sheet S is heated and softened to a predetermined temperature by the heater device 60, and hot melt sheets 24a and 24b such as polyethylene sheets are laminated on the front and back surfaces of the foamed resin sheet S, respectively. Yes. Next, as shown in FIG. 15, when the molded upper and lower molds 41 and 42 are in the mold open state, the foamed resin sheet S that has been heat-softened in the preheating step is put into the molded upper and lower molds 41 and 42. Then, the decorating material 23 may be placed on the upper surface of the foamed resin sheet S, or the decorating material 23 may be held on the mold surface of the molding upper die 41, and the material is set at a predetermined position.

  Further, as shown in FIG. 16, the foamed resin sheet 21 is molded into a required shape by drawing the foamed resin sheet S with a predetermined press pressure by clamping the upper and lower molds 41 and 42, and foaming is performed. The decorating material 23 is integrated by causing the hot melt sheet 24a laminated on one surface of the resin base material 21 to function as an adhesive medium. As shown in FIG. 17, since the shear block 50 is provided on the outer periphery of the cavity portion of the molding lower die 42, the corner portion 53 of the shear block 50 and the molding upper die 41 are formed when the foamed resin base material 21 is molded. The surplus end material Sa can be trimmed by setting the mold clearance between the inner wall surface and the inner wall surface to an appropriate value. Therefore, since the end material Sa of the foamed resin base material 21 can be removed, the winding white 26 of the decorating material 23 can be secured at the same time as molding.

  Then, after molding the door trim main body 20, the mold upper and lower molds 41 and 42 are opened, and then the door trim main body 20 is removed from the mold, and before the roll-in operation of the winding 26 of the decorating material 23 as shown in FIG. The hot melt sheet 24b laminated on the back surface side of the foamed resin base material 21 is heated and melted, and then the winding sheet 26 is rolled in. The hot melt sheet 24b functions as an adhesive medium and is firmly bonded and fixed. Then, terminal processing can be easily performed. Also in this second embodiment, the conventional adhesive can be abolished, and the application process and the drying process of the adhesive are not required, so that productivity can be improved and the exhaust system for organic solvent, etc. There is an effect that equipment costs can be reduced.

  In the first and second embodiments described above, the present invention is applied to the method of manufacturing the door trim main body 20 in the automobile door trim 10. However, the method of the present invention can be applied to the door trim upper in the upper and lower split type door trim. In addition, as interior parts other than the door trim 10, the present invention can be applied to general interior parts for automobiles such as a rear parcel shelf, a floor trim, a trunk trim, a luggage trim, a roof trim, and a rear side trim.

It is a front view which shows the door trim for motor vehicles to which this invention is applied. It is the II-II sectional view taken on the line in FIG. It is a front view which shows the pattern shape of the resin rib which abbreviate | omitted the foamed resin base material in the door trim for motor vehicles shown in FIG. It is the IV-IV sectional view taken on the line in FIG. FIG. 2 is an overall view showing a molding die used in the method for manufacturing the automobile door trim shown in FIG. 1. It is sectional drawing which shows the cavity outer peripheral part of the shaping die shown in FIG. It is explanatory drawing which shows the preheating process of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process to the shaping die of the decorating material and a foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material in the manufacturing method of the door trim for motor vehicles shown in FIG. It is sectional drawing which shows the trim cut process of the foamed resin base material in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material and resin rib in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the terminal process process of the door trim main body in the manufacturing method of the door trim for motor vehicles shown in FIG. It is sectional drawing which shows the structure of the terminal part of the door trim for motor vehicles in 2nd Example of this invention. It is explanatory drawing which shows the pre-heating process of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process in the shaping die of the decorating material and a foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the trim cut process of the foamed resin base material in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the terminal process process of the door trim main body in the manufacturing method of the door trim for motor vehicles shown in FIG. It is a front view which shows the conventional door trim for motor vehicles. FIG. 20 is a sectional view taken along line XX-XX in FIG. 19. It is a schematic diagram which shows the shaping die which shape | molds the conventional door trim. It is explanatory drawing which shows the prior art example of the terminal part in the door trim for motor vehicles by press molding. It is explanatory drawing which shows the prior art example of the terminal part in the door trim for motor vehicle of a skin-wrapping type.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Automotive door trim 20 Door trim main body 21 Foamed resin base material 22 Resin rib 23 Decorating material 24 Hot melt sheet 25 Vertical wall part 26 Roll-in white 40 Molding die 41 Molding upper mold 42 Molding lower mold 43 Injection machine 50 Shear block 60 Heater device S Foamed resin sheet M Molten resin

Claims (3)

A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21), In the automotive interior part (10) formed by adopting the laminated structure (20) composed of the decorative material (23) attached to the surface of the foamed resin base material (21) in whole or in part,
In the peripheral end portion of the laminated structure (20), the foaming resin base material (21) is trim-cut and removed, so that a winding sheet (26) of the decorating material (23) is formed. Incorporation of the decorating material (23) is performed by subjecting the adhesive (24) provided on either the back surface of the wrapping white (26) or the back surface of the foamed resin base material (21) to be joined thereto to heat melting treatment. An interior part for an automobile, wherein the white (26) is bonded and fixed. A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21), In a method for manufacturing an interior part (10) for an automobile, in which a laminated structure (20) composed of a decorating material (23) attached to the surface of a foamed resin substrate (21) is employed in whole or in part. ,
The laminated structure (20) includes a foamed resin sheet (S) that has been heat-softened when the molded upper and lower molds (41, 42) are opened, and an adhesive (24) on the opposite side of the foamed resin sheet (S). A material setting step of superposing the provided decorating material (23) and setting it in the upper and lower molds (41, 42);
The upper and lower molds (41, 42) are clamped, and the foamed resin base material (21) is press-molded into a desired curved shape along the cavity shape of the molding die (40). 42) The molten resin (M) is injected and filled into the groove (424) of the molded lower mold (42) at any timing immediately before or after the mold clamping of 42). Forming the laminated structure (20) by integrating the resin rib (22) on the back surface side and forming the laminated structure (20);
After the mold upper and lower molds (41, 42) are opened, the laminated structure (20) is demolded, and then the decorative material (23) is wound around the periphery of the foamed resin base material (21). Winding of the decorating material (23) which heat-melts the adhesive (24A) provided on the back surface of (26), and winds the roll (26) onto the back surface side of the foamed resin base material (21). Processing process,
A method of manufacturing an interior part for an automobile, which is manufactured by a process comprising: A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21), In a method for manufacturing an interior part (10) for an automobile, in which a laminated structure (20) composed of a decorating material (23) attached to the surface of a foamed resin substrate (21) is employed in whole or in part. ,
The laminated structure (20) has a foamed resin sheet (S) provided with adhesives (24a, 24b) on both sides at the time of mold opening of the molded upper and lower molds (41, 42), and the surface side A material setting step in which the decorating material (23) is superimposed on the molding upper and lower molds (41, 42);
The upper and lower molds (41, 42) are clamped, and the foamed resin base material (21) is press-molded into a desired curved shape along the cavity shape of the molding die (40). 42) The molten resin (M) is injected and filled into the groove (424) of the molded lower mold (42) at any timing immediately before or after the mold clamping of 42). Forming the laminated structure (20) by integrating the resin rib (22) on the back side, and forming the laminated structure (20);
After the mold upper and lower molds (41, 42) are opened, the laminated structure (20) is removed from the mold, and the foamed resin base material (21) corresponding to the winding sheet (26) of the decorating material (23) is supported. After the part is heat-treated and the adhesive (24b) is heated and melted, the decoration white (26) of the decorating material (23) is wound on the back side of the foamed resin base material (21) and bonded. A winding process of the material (23);
A method of manufacturing an interior part for an automobile, which is manufactured by a process comprising:

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