JPH06182795A - Interior component for automobile and manufacture thereof - Google Patents

Abstract

PURPOSE:To smoothly match to a skin material and to reduce in thickness and weight compressed urethane and resin core material in an interior component for an automobile formed of the resin core material integrated with the urethane by press molding and the skin material by powder slush molding and a method for manufacturing the same. CONSTITUTION:After a glass mat 12 is adhered to polyurethane foam F, it is hot press molded to conform to a shape of a resin core material 11, compressed urethane 13 integrated with the mat 12 and molded in a predetermined shape is set in a press molding upper mold 40, integrated at the time of press molding of the material 11 thereby to accurately shape the urethane 13 with rigidity of the mat 12 and to match it to a skin material 14.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to automobile interior parts such as automobile door trims and instrument pads, and a method for manufacturing the same, and more particularly to a resin core material integrated with compressed urethane and a skin material formed by powder slush molding. The present invention relates to an interior part for automobiles, in which the shape retention of compressed urethane is improved and the fitting with a skin material is good, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, powder slush molding has been frequently used as a manufacturing method for interior parts such as automobile door trims and instrument pads that are required to have a relatively good surface appearance and feel. Has been done.

This powder slush molding is one of the methods for molding a skin material. Usually, in order to manufacture interior parts, in addition to the powder slush molding step for the skin material, a step for molding a core material and a skin material. A step of integrating the core material with the core material is required.

For example, an automobile door trim 1 shown in FIG. 11 has a structure in which a skin material 3 formed by powder slush molding is integrally formed on the surface of a resin core material 2.
Resin core material 2 and skin material 3 in order to absorb the variation in wall thickness of
Compressed urethane 4 is inserted between the and.

The resin core material 2 and the compressed urethane 4 are integrated before the surface material 3 is pressure bonded.

Further, in order to enhance decorativeness, the door trim 1 is provided with a middle contact skin material 5 such as a cloth having a different color and feel from the skin material 3, and the middle contact skin material 5 is provided.
The peripheral edge end is press-fitted into the wood graining groove portion 1a formed in the door trim 1, and the intermediate contact skin material 5 is end-treated.

Next, a brief description will be made on a conventional method for manufacturing an automobile door trim 1. First, as shown in FIG. 12, the resin core material 2 is molded into a required shape by upper and lower molds 6 and 7 for mold press molding. , This resin core material 2
And the compressed urethane 4 are integrated in the molds 6 and 7.

A gate 6a is formed in the lower mold 6 for mold press molding, and a semi-molten resin material supplied from an injection molding machine (not shown) is used for the gate 6a.
Is distributed and supplied onto the mold surface of the lower mold 6.

FIG. 13 shows the resin core 2 and the compressed urethane 4 integrated with each other. At this time, the wood-grooving groove 1a is also formed.

Although not shown, the door trim 1 is obtained by crimping and fixing a resin core material 2 in which a compressed urethane 4 is integrated and a skin material 3 which is molded in a required product shape in advance by a crimping die with an adhesive. After that, the intermediate contact skin material 5 may be attached to a predetermined position on the surface of the door trim 1.

[0011]

As described above, conventionally, when the resin core material 2 and the compressed urethane 4 are integrated by the mold press molding method, the moldability is excellent and the thickness can be reduced. However, it is difficult to form the shape of the compressed urethane 4, and for example, as shown in an enlarged view in FIG. 13, in the groove portion 1a for wood grain, the thickness of the compressed urethane 4 becomes thin at the corner portion of the groove portion 1a. It has been pointed out that the groove portion 1a is opened, and the appearance of the middle contact skin material 5 is conspicuous, and the end of the middle contact skin material 5 is easily peeled off.

The present invention has been made in view of the above circumstances, and an object of the present invention is to use a resin core material integrated with compressed urethane and a powder slush molding which has a good surface appearance and surface feel. Automobiles that can accurately shape the shape of compressed urethane in automobile interior parts by pressure-bonding with skin materials and their manufacturing methods, improve appearance design, and contribute to thinner and lighter products It is an object to provide an interior part for automobile and a manufacturing method thereof.

[0013]

In order to achieve the above object, the present invention provides a resin core material molded into a required shape in a mold for press molding, and an integrated resin core material during molding. In an automobile interior part comprising a compressed urethane and a skin material attached to the surface side of the compressed urethane, a glass mat is adhered and fixed to the surface of the compressed urethane facing the resin core material, and the same as the resin core material. It is preformed into a shape, and the shape of the compressed urethane is retained by the glass mat.

Further, the above-mentioned method for manufacturing automobile interior parts comprises a step of molding a compressed urethane with a glass mat, which comprises forming a glass mat on one surface of a polyurethane foam and then thermocompressing the glass mat into a desired shape with a press die, and a mold press. While the preformed compression urethane with glass mat is set on the mold surface of the upper mold, the semi-molten resin, which is the material of the resin core material, is distributed and supplied to the mold surface of the lower mold for molding press. The molding process of the resin core material with compression urethane that engages the upper and lower molds for compression, and the resin core material with compression urethane and the skin material are set on the mold surface of the upper and lower molds for crimping, and the upper and lower molds for crimping are set. The step of crimping and unifying the resin core material with compressed urethane and the skin material by the engagement pressure tightening.

[0015]

As apparent from the above structure, the compressed urethane integrated with the resin core material by the mold press molding is
Prior to mold press molding, the glass mat is thermocompressed into the required shape with the glass mat adhered to one surface thereof, so that the shape retention function of the glass mat allows the compressed urethane to be precisely shaped.

Further, since the glass mat suppresses the semi-molten resin material, which is the material of the resin core, from entering the compressed urethane side, the amount of the molten resin impregnated in the compressed urethane can be reduced and the glass mat reinforcing function can be achieved. Thereby, the rigidity of the resin core material is further enhanced.

[0017]

Embodiments of an automobile interior part and a method of manufacturing the same according to the present invention will be described below in detail with reference to the accompanying drawings.

1 and 2 show an embodiment in which the present invention is applied to an automobile door trim. FIG. 1 is a front view showing the door trim, and FIG. 2 is a sectional view showing the structure of the automobile door trim.

3 to 8 are process diagrams showing an embodiment in which the method of the present invention is applied to a method for manufacturing an automobile door trim, and FIGS. 9 and 10 show an automobile interior part according to the present invention applied to a door trim. It is a front view and a sectional view showing a modification.

First, referring to FIGS. 1 and 2, a vehicle door trim 10 includes a resin core material 11, a compressed urethane 13 having a glass mat 12 bonded to the back surface thereof, and a skin material laminated and integrated on the front surface side thereof. It is composed of 14 and.

More specifically, the resin core material 11 is molded into a desired curved shape by molding press molding a polypropylene resin (or a polypropylene composite resin mixed with talc).
At the time of the mold press molding, the compressed urethane 13 to which the glass mat 12 is adhesively fixed is integrated.

The door trim 10 is manufactured by crimping and fixing the skin material 14 preformed in the product shape to the resin core material 11 in which the compressed urethane 13 is integrated via the glass mat 12. As the skin material 14, powder slush molding using a vinyl chloride resin powder is used, and it is composed of a two-layer structure of a slush skin layer 14a and a slush foam layer 14b. The urethane 13 is configured to absorb the elasticity.

By the way, a feature of the present invention is that a glass mat 12 adhered and fixed to urethane foam is thermoformed in advance according to the shape of the resin core material 11, and the preformed glass mat 12 is provided. The compressed urethane 13 is integrated with the resin core material 11 by mold press molding.

[0024] Then, a cloth 20 such as a cloth at the middle contact portion is attached to the surface of the door trim 10 to enhance the decorativeness by the accent effect of the skin material 14 and the middle contact surface material 20. The peripheral edge 20 of the skin material 20 in the middle part
The a is press-fitted into the wood-grooving groove 15 formed in the door trim 10 to end-process the middle contact skin material 20.

At this time, since the compressed urethane 13 is thermocompression-molded with the glass mat 12 adhered thereto, as shown in the enlarged view of FIG. When the peripheral edge end 20a of the middle contact skin material 20 is press-fitted into the wood-groove groove portion 15 after the ejection, the terminal 20a does not stand out to the outside. Is very good, and the conventional problem that the terminal 20a is peeled off can be effectively solved.

As described above, in the automobile interior parts according to the present invention, the polyurethane foam to which the glass mat 12 is adhered is thermocompression-molded in conformity with the shape of the resin core material 11, and the compressed urethane having a desired shape is formed. 13 to the glass mat 12
The rigidity of enables accurate shape formation, and at the time of mold press molding of the resin core material 11, after integrating the resin core material 11 and the compression urethane 13 with the glass mat 12,
The cover material 4 is covered by a pressure-bonding step to form the door trim 10. The rigidity of the glass mat 12 allows the compressed urethane 13 to be accurately shaped, so that the fitting property with the cover material 14 is good. It is possible to provide the door trim 10 that is good in appearance and feel.

Next, a manufacturing process of the automobile door trim 10 will be described with reference to FIGS.

Incidentally, FIGS. 3 to 8 show the skin material 20 of the contact portion.
It is a manufacturing process of the door trim 10 before mounting.

First, as shown in FIG. 3, an adhesive 30 is applied to one surface of a normal polyurethane foam F (density 0.02 to 0.05 g / cm ³ , thickness 5 to 10 mm), and then the glass mat 12 is applied. The adhesive 30 is set on the coated surface and is set in the hot press molding upper and lower molds 31 and 32, and as shown in FIG. 4, the hot press molding upper and lower molds 3 are formed.
Tighten 1, 32 engagement pressure, mold temperature 200 ℃ × 60 seconds,
Thermocompression molding is performed to mold the compressed urethane 13 laminated with the glass mat 12 into a desired shape (shape corresponding to the shape of the resin core material 11). At this time, the thickness of the compressed urethane 13 is compressed to 1/2 to 1/4 of the original fabric.

As the glass mat 12, a continuous strand mat having a basis weight of 150 to 450 g / m ² is used in this embodiment.

Next, as shown in FIG. 5, the compression urethane 13 with the glass mat 12 molded in the above step is set on the mold surface of the upper mold 40 in the mold press molding upper mold 40. At this time, the surface fastener 41 is installed along the side surface of the upper mold 40 to set the compressed urethane 13.

When the work of setting the compressed urethane 13 having the glass mat 12 and formed into the required shape on the upper die 40 for mold press molding is completed, the upper die 40 is lowered by the operation of the elevating device (not shown). When the clearance between the die and the lower die 50 for mold press molding reaches a predetermined dimension, the semi-molten resin material M, which is the material of the resin core material 11, is distributed and supplied onto the die surface of the lower die 50. .

As a mechanism for supplying the semi-molten resin M, the semi-molten resin M supplied from an injection molding machine (not shown) connected to the lower mold 50 is passed through the gate 51 onto the mold surface of the lower mold 50. It is distributed and supplied.

After that, as shown in FIG. 6, the resin core material 11 is molded into a required shape by engaging and pressing the upper and lower molds 40, 50 for molding press molding, and the compressed urethane 13 is inserted through the glass mat 12. Integrated with the resin core material 11.

At this time, the compressed urethane 13 is not crushed in the finely shaped portions such as the wood-grooving groove portion 15 even by the pressing pressure at the time of mold press molding, and the accurate shape of the compressed urethane 13 is obtained by the rigidity of the glass mat 12. It is possible to put it out.

Further, since the glass mat 12 suppresses the semi-molten resin M from entering the compressed urethane 13 side as much as possible, the amount of the semi-molten resin M impregnated into the compressed urethane 13 can be reduced, and the cushion of the compressed urethane 13 can be reduced. Since the thickness of the compressed urethane 13 can be set thin without impairing the property, the product can be made thin and lightweight, and the glass mat 12 is impregnated with the semi-molten resin, so that the resin core The rigidity of the material 11 is this glass mat 12
Will significantly enhance its rigidity.

Next, as shown in FIG. 7, the lower die 6 for pressure bonding is used.
The skin material 14 is set on the mold surface of 0, and the compression urethane 13 molded in the above step is formed on the mold surface of the upper crimping mold 70.
The resin core material 11 integrated with the glass mat 12 is set.

At this time, the suction / compressed air hole 61 is formed in the lower die 60 for crimping, and after the skin material 14 is set,
Immediately, the suction / compression air hole 61 and the vacuum suction means are connected, and the skin material 14 is held in close contact with the surface of the lower die 60 for pressure bonding by the vacuum suction force. Then, after applying the adhesive 62 to the slush foam layer 14b side of the skin material 14, as shown in FIG. 8, the crimping upper mold 70 descends and the crimping upper and lower molds 60, 70 are engaged and clamped. , Pressure bonding urethane 13
The skin material 14 is satisfactorily pressure-bonded and integrated with the resin core material 11 integrated through the glass mat 12.

At this time, the suction / compression air hole 61 formed in the lower mold 60 is connected to the blower, and the skin material 14 is satisfactorily joined by the pressure aerodynamic force.

After the resin core material 11, the glass mat 12, the compression urethane 13 and the skin material 14 are integrated by the above steps, the middle contact skin material 20 is attached to the automobile as shown in FIGS. The manufacture of the door trim 10 is completed.

Further, according to the method of the present invention, since the glass mat 12 has an excellent function of retaining the shape of the compressed urethane 13, and the fine shape such as the groove portion 15 for wood grain is precisely formed, it is possible to form the same with the skin material 14. Good adhesion, good touch, and improved design.

Compared with the case where sheet-like compressed urethane is integrated during mold press molding of the resin core material 11,
Both the plate thickness of the compressed urethane 13 and the plate thickness of the resin core material 11 can be reduced, which is advantageous in that it can contribute to the reduction in product thickness and weight.

Next, as shown in FIGS. 9 and 10, when the recess 16 is formed in the door trim 10 and the finisher 17 is fitted and fixed in the recess 16, compression is caused by the shape retention of the glass mat 12. Since the shape of the urethane 13 is sharply formed at the corner portion of the recess 16, when the finisher 17 is mounted,
There is no generation of scratches on the peripheral portion of the finisher 17, the mounting accuracy is improved, and the mounting with a good appearance is possible.

[0044]

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

(1) An automobile interior part according to the present invention comprises:
After bonding the glass mat and polyurethane foam,
Since the compressed urethane with glass mat is molded into a desired shape by thermocompression molding, the compressed urethane with glass mat is integrated during mold press molding of the resin core material, and then pressure-bonded to the skin material, the glass Due to the shape retention function of the mat, compressed urethane can be accurately shaped according to the shape of the product, and when attaching the skin material, air pockets etc. do not occur and the surface feel is good and In particular, since the shape of the groove for wood grain used for the end treatment of the inscribed part skin material can be made sharp, the end treatment of the inscribed part skin material can be finished well and the end of the inscribed part skin material can be peeled off. It has various effects that can be surely prevented.

(2) According to the method for manufacturing an automobile interior part according to the present invention, a polyurethane foam having a glass mat adhered thereto is molded into a desired shape by thermal compression molding, and then integrated with a resin core material by a mold press molding method. Since it is a process that does not allow the semi-molten resin to invade the compressed urethane side by the glass mat, the thickness of the compressed urethane can be reduced and the compressed urethane is molded into the required shape. Since the fluidity is smooth and the structure is reinforced with a glass mat,
The thickness of the resin core material can be reduced.

Therefore, since the thickness of the compressed urethane and the resin core material can be reduced, it is possible to greatly contribute to the reduction of the thickness and weight of the interior parts.

[Brief description of drawings]

FIG. 1 is a front view showing a vehicle door trim that is an embodiment of the present invention.

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

FIG. 3 is a cross-sectional view showing one step of the method of the present invention, showing a state in which a glass mat and a polyurethane foam are set in a hot press molding die.

FIG. 4 is a cross-sectional view showing one step of the method of the present invention and showing a molding step of compressed urethane.

FIG. 5 is a cross-sectional view showing one step of the method of the present invention, showing a state where compressed urethane is set in a mold for mold press molding.

FIG. 6 is a cross-sectional view showing one step of the method of the present invention and showing a mold press molding step of integrating a resin core material and compressed urethane.

FIG. 7 is a cross-sectional view showing one step of the method of the present invention, showing a state in which a skin material and a resin core material are set in a crimping die.

FIG. 8 is a cross-sectional view showing one step of the method of the present invention, showing a step of pressure-bonding a skin material to a resin core material.

FIG. 9 is a front view of a vehicle door trim showing another embodiment of the present invention.

10 is a sectional view taken along line XX in FIG.

FIG. 11 is a cross-sectional view showing a configuration of a conventional automobile door trim.

FIG. 12 is a cross-sectional view showing a conventional resin core material molding process.

FIG. 13 is a cross-sectional view showing a conventional example of a resin core material in which compressed urethane is integrated.

[Explanation of symbols]

 10 Automotive Door Trim 11 Resin Core Material 12 Glass Mat 13 Compressed Urethane 14 Skin Material 14a Slash Skin Layer 14b Slush Foam Layer 15 Wood Grain Groove 16 Recess 17 Finisher 20 Middle Contact Skin Material 31 Hot Press Molding Lower Mold 32 Hot Press Molding Upper mold 40 Mold press molding upper mold 41 Surface fastener 50 Mold press molding lower mold 51 Gate 60 Crimping lower mold 61 Suction and compressed air hole 70 Crimping upper mold F Polyurethane foam M Semi-molten resin material

Claims (3)

[Claims] 1. A mold for molding press molding (40, 5)
0), a resin core material (11) molded into a required shape, a compressed urethane (13) that is integrated when the resin core material (11) is molded, and a skin attached to the surface side Material (1
In the interior part for an automobile consisting of 4), a glass mat (12) is adhered and fixed to the surface of the compressed urethane (13) facing the resin core material (11), and the same shape as the resin core material (11) is spared. An interior part for an automobile, which is molded and in which the shape of the compressed urethane (13) is retained by the glass mat (12). 2. The glass mat (12) is composed of a continuous strand mat and has a basis weight of 1
50-450 g / m ² It is characterized by the above-mentioned.
Interior parts for automobiles described. 3. A glass mold (12) is bonded to one surface of a polyurethane foam (F), and then a press die (31,
32) a step of forming a compression urethane with a glass mat (12, 13) which is hot-pressed into a desired shape by a step 32), and a compression urethane with a glass mat (12, 13) is set, while a semi-molten resin (M) which is a material of the resin core material (11) is formed on the mold surface of the mold press molding lower mold (50).
Is distributed and supplied to upper and lower molds (40, 5) for mold press molding.
Resin core material with compression urethane (1)
1, 12 and 13), and a resin core material (11, 12, 13) with compression urethane and a skin material (14) are set on the mold surfaces of the upper and lower molds (60, 70) for crimping, respectively. , Crimping upper and lower dies (60, 7
0) A process for integrally crimping a resin core material (11, 12, 13) with a compressed urethane and a skin material (14) by engaging and tightening (0), and manufacturing an interior part for an automobile. Method.