JP3875541B2 - Molding method for vehicle interior parts - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for molding vehicle interior parts such as instrument panels, door trims, and consoles.
[0002]
[Prior art]
As one of the vehicle interior parts, for example, there is one shown in FIG. The vehicle interior product 1 includes a foam 2 and a covering 3. The foam 2 is formed by foaming polypropylene beads (hereinafter referred to as PP beads) and is formed in a rectangular parallelepiped shape. On the other hand, the covering 3 is made of a resin sheet and has a front wall portion 3a, a side wall portion 3b, and a back wall portion 3c that cover the peripheral portions of the front surface 2a, the side surface 2b, and the back surface 2c of the foam 2, respectively. is doing.
[0003]
Conventionally, when the interior product 1 is manufactured, a covering material 4 shown in FIG. 7 is first formed from a sheet material (not shown). The covering material 4 finally becomes the covering 3, and includes a front wall portion 4 a, a side wall portion 4 b formed around the front wall portion 4 a, and an annular protruding portion protruding outward from the side wall portion 4 b. 4c. The front wall portion 4a and the side wall portion 4b have substantially the same shape as the front wall portion 3b and the side wall portion 3c of the covering 3. After the covering material 4 is molded, it is mounted on a molding recess formed in one of a pair of molds (not shown). Next, the pair of molds are brought into contact with each other and clamped, and the space formed between the other mold and the covering material 4 is filled with pre-foamed PP beads. And PP beads are heated and the surface part is melted. Thereafter, when the PP beads whose surface is melted are cooled and solidified, the PP beads are fused together to form the foam 2, and the PP beads are fused to the covering material 4 to form the foam 2. The covering material 4 is fused. Thereby, the interior material 5 shown in FIG. 7 is manufactured. Thereafter, the adhesive 6 is applied to the protruding portion 4 c of the covering material 4 and the outer peripheral side portion of the back surface 2 c of the foam 2. And the protrusion part 4c is bend | folded to the foam 2 side as shown by the arrow in FIG. 7, and it adheres and fixes to the outer peripheral side part of the back surface 2c. As a result, the protruding portion 4c becomes the back wall portion 3c, and the covering material 4 becomes the covering 3, whereby the interior product 1 is manufactured.
[0004]
[Problems to be solved by the invention]
When the interior product 1 is manufactured as described above, that is, when the protruding portion 4c protruding outward is bent inward and bonded to the back surface 2c of the foam 2, thereby forming the back wall portion 3c as the protruding portion 4c. As shown in FIG. 8, an arc portion 3d is formed between the side wall portion 3b and the back wall portion 3c. As a result, when the interior part 1 is attached to the body of the vehicle, for example, the door panel 7, a wedge-shaped gap S is formed between the door panel 7 and the peripheral part of the interior part 1 (peripheral part of the back wall 3c). End up. For this reason, there existed a problem that the appearance of a door deteriorated. In addition, there is a problem that a lot of labor is required to bond the protruding portion 4c.
[0005]
[Means for Solving the Problems]
In order to solve the above problems, the present invention provides a foam obtained by fusing foamed polypropylene beads (hereinafter referred to as PP beads) together, and the peripheral edges of the surface, side and back of the foam. A molding method for molding an interior product for a vehicle including a sheet-like covering body having a front wall portion, a side wall portion, and a back wall portion covering each portion, corresponding to the surface and side surface of the covering body And a second molding surface for molding the back surface of the vehicle interior product on the surface opposite to the molding recess of the first mold. There a second mold which is formed is used, the first molding surface of the molding recess, covered with a front wall portion and side wall portions of the front and lateral walls and their respective same shapes of the covering body A mounting process for mounting a body material and a covering body mounted in the molding recess The filling recess filled with the foamed PP beads in the housing recess defined by the front wall portion and the side wall portion, and the housing recess filled with the first and second molds clamped And heating the PP beads so as to melt the surface portion thereof, fusing the PP beads together, and fusing the PP beads to the covering material. An end portion of the side wall portion on the opening side of the housing recess protrudes toward the inside of the housing recess and extends along the second molding surface when the first and second molds are clamped. An annular projecting portion that abuts is formed in advance.
In this case, after forming the sheet material into a molded body having the same front wall portion and side wall portion as the covering body material and having a concave wall portion extending annularly along the peripheral edge portion of the side wall portion, this forming is performed. the body bisected by cutting the central portion in the width direction of the recessed wall portion, one part having the above table and lateral walls are as the covering body material, followed by the side wall portions of said one portion It is desirable that the remaining portion of the concave wall portion is the protruding portion. The concave wall is preferably formed in a semicircular cross section.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be described below with reference to FIGS.
FIG. 1 shows an interior product 10 for a vehicle molded by the molding method according to the present invention. The interior product 10 includes a foam 20 and a covering 30.
[0007]
The foam 20 is formed by foaming PP beads, and is formed in a rectangular parallelepiped shape. Of course, the shape of the foam 20 is not limited to a rectangular parallelepiped shape, and various shapes are adopted corresponding to the shape of the interior article 10.
[0008]
On the other hand, the covering 30 is formed by molding a resin sheet, and the front wall portion 31 and the side wall portion 32 that respectively cover the surface 21 and the side surface 22 of the foam 20 and the peripheral edge of the back surface 23 of the foam 20. And a back wall portion 33 covering the portion. The front wall portion 31, the side wall portion 32, and the back wall portion 33 are fixed to the surface 21, the side surface 22, and the back surface 23 when the foam 20 is molded. The back wall portion 33 enters an annular recess 23 a formed on the outer peripheral portion of the back surface 23, and the width and depth of the recess 23 a are set to be the same as the width and thickness of the back wall portion 44. Therefore, the outer surface of the back wall portion 33 is flush with the back surface 23 of the foam 20, and the back surface of the interior article 10 is configured by the outer surface of the back wall portion 33 and the back surface of the foam body 23. The back wall portion 33 may protrude from the back surface 23 by the thickness of the back wall portion 33 in the same manner as the interior article 1 shown in FIG.
[0009]
When molding the vehicle interior article 10 having the above-described configuration, first, a covering material 40 shown in FIG. 4 is manufactured. The covering material 40 is to be the covering 30 and has a front wall portion 41, a side wall portion 42, and a protruding portion 43. The front wall part 41 and the side wall part 42 are formed in substantially the same shape as the front wall part 31 and the side wall part 32 of the covering 30, respectively. The projecting portion 43 is formed in an arc shape having a substantially quadrant cross section, and the center of curvature thereof is located on the extension of the outer surface of the side wall portion 42. Accordingly, the protruding portion 43 protrudes toward the inside of the rectangular parallelepiped accommodating recess 44 formed by the front wall portion 41 and the side wall portion 42.
[0010]
The covering material 40 is formed from a resin sheet material. In this case, the sheet material may be either a single layer or a plurality of layers, but in this embodiment, a three-layer sheet material 50 shown in FIG. 2 is used. The sheet material 50 includes a resin foam layer 51 and resin thin film layers 52 and 53 respectively fixed to both surfaces of the foam layer 51. The foam layer 51 is formed, for example, by foaming polypropylene (PP), and has a thickness of about 2 mm. The thin film layer 52 is made of, for example, thermoplastic olefin (TPO) and has a thickness of about 0.5 mm. The thin film layer 52 is made of PP, for example, and has a thickness of about 0.5 mm.
[0011]
The covering material 40 can be manufactured using the sheet material 50 as follows, for example. That is, when manufacturing the covering material 40, first, the formed body 70 is formed from the sheet material 50 using the vacuum forming die 60 shown in FIG. The vacuum forming die 60 has a material forming part 61 and a recessed part forming part 62 formed following one end of the material forming part 61. The material forming portion 61 has a surface 61a and a side surface 61b having the same shape as the inner surfaces (surfaces facing the accommodation recess 44) of the front wall portion 41 and the side wall portion 42 of the covering material 40, respectively. In other words, the material forming portion 61 has the same cross-sectional shape as the housing recess 44 of the covering material 40. On the outer peripheral surface of the recessed portion forming portion 62, a recessed portion 62a that extends annularly along the lower end portion of the side surface 61b in FIG. The recess 62 a has the same radius of curvature as the inner surface of the protrusion 43 of the covering material 40 (the surface facing the housing recess 44). The center of curvature of the recess 62a is located on the extension of the side surface 61b. Therefore, when the sheet material 50 is vacuum-formed using the vacuum forming die 60, the surface material has the front wall part 71 and the side wall part 72 having the same shape as the front wall part 41 and the side wall part 42 of the covering material 40, and the curvature radius and A molded body 70 having a semicircular concave wall portion 73 having the same center of curvature as the protruding portion 43 is molded.
[0012]
When the molded body 70 is molded, it is released from the vacuum mold 60. At this time, the concave wall portion 73 interferes with the wall surface defining the concave portion 62a. However, the concave wall portion 73 has a semicircular shape, and the center of curvature is located on the extension of the side surface 61b. 73 can be removed from the recess 62 a relatively easily, and the molded body 70 can be easily released from the vacuum mold 60. When the molded body 70 is released, the central portion in the width direction of the concave wall portion 73 is cut along the longitudinal direction (cut on the imaginary line in FIG. 3), and the molded body 70 is divided into two. The covering material 40 having the front wall portion 41, the side wall portion 42, and the protruding portion 43 is obtained by the portion on the material molding portion 61 side of the two cut portions, that is, the portion on the upper side from the imaginary line in FIG.
[0013]
Next, as shown in FIG. 4, the foam 20 is integrally formed with the covering material 40 using the paired first and second molds 80 </ b> A and 80 </ b> B. The first and second molds 80A and 80B are arranged facing left and right. The position of the first mold 80A is fixed. On the surface of the first mold 80aA facing the second mold 80B, a tapered hole 81 and a molding recess 82 following the tapered hole 81 are formed. The taper hole 81 has a smaller diameter as the distance from the second mold 80B increases. The end portion on the small diameter side is formed in the same shape as the opening of the molding recess 82. The molding concave portion 82 is for molding the front wall portion 31 and the side wall portion 32 of the covering 30, and has an inner surface (first molding surface) 82 a having the same shape as each outer surface of the front wall portion 31 and the side wall portion 32. Have. However, the depth of the molding recess 82 is deeper than the height of the covering 30 from the outer surface of the back wall portion 33 to the outer surface of the front wall portion 31. Therefore, when the covering material 40 is inserted into the molding recess 82 until the front wall portion 41 hits the bottom surface of the molding recess 82, the entire covering material 40 is accommodated in the molding recess 82. And the opening side edge part of the shaping | molding recessed part 82 is exposed to the 2nd metal mold | die 80B side.
[0014]
The second mold 80B is disposed so as to be movable toward and away from the first mold 80A in the left-right direction. A taper portion 83 and a short straight portion 84 following the tapered portion 83 are provided on the surface facing the first mold 80A. Is formed. The taper part 83 has the same taper degree as the taper hole part 81, and becomes smaller in diameter toward the first mold 80A side. The outer diameter of the tip end portion of the tapered portion 81, that is, the small diameter side end portion is the same as the inner diameter of the small diameter side end portion of the tapered hole portion 81. On the other hand, the straight portion 84 has the same cross-sectional shape as the molding recess 82, and the length in the left-right direction is set to be the same as the difference between the depth of the molding recess 81 and the height of the covering material 40. . Therefore, when the taper part 83 is fitted into the taper hole part 81, the first and second molds 80A and 80B are in a mold-clamping state. In this state, the leading end surface (second molding surface) 84 a of the straight portion 84 abuts against the end surface of the side wall portion 42 of the covering material 40 and also abuts against the protruding portion 43. As a result, the projecting portion 43 is bent so as to be substantially orthogonal to the side wall portion 43, and almost the entire surface of the projecting portion 43 facing the second mold 80B comes into contact with the distal end surface 84a. Further, in the state where the first and second molds 80A and 80B are clamped, the opening portion of the housing recess 44 is closed by the straight portion 84, and is sealed from the outside by the housing recess 44 and the front end surface 84a. A cavity C is formed.
[0015]
After the first and second molds 80A and 80B are clamped, the PP beads B previously foamed into the cavity C from the injection hole 85 formed in the second mold 80B are filled with a predetermined pressure. When filling is completed, the injection hole 85 is closed. Thereafter, heated steam is supplied into the cavity C from a steam passage (not shown) formed in the second mold 80B, and the surface portion (surface layer portion) of the PP beads B is heated and melted. Thereafter, the PP beads B are fused together by solidifying the surface portion of the melted PP beads B. Thereby, the foam 20 is shape | molded. In the foam 20, when the PP beads B are filled in the cavities C, the portions corresponding to the protruding portions 43 are not filled with the PP beads B, so that the portion is formed as a recess 23 a. Further, the covering material 40 is pressed against the inner surface (first molding surface) 82a of the molding recess 82 by the pressure accompanying the filling of the PP beads B, and the PP beads B and the protrusions 43 are pressed against the front end surface 84a of the straight portion 84. It is done. As a result, the covering material 40 is formed as the covering 30. Moreover, the foam 20 and the covering 30 are fixed to each other when the PP beads B are cooled. Thereby, the interior goods 1 are shape | molded.
[0016]
Here, of the inner surface 82a of the molding recess 82, the end portion on the opening side and the tip end surface 84a of the straight portion 84 are orthogonal to each other, and the side wall portion 42 and the protruding portion 43 of the covering material 40 are formed on these portions. It is pressed by the pressure of PP beads B. Moreover, since the covering material 40 is heated and softened by the heating steam supplied into the cavity C, the side wall portion 42 and the protruding portion 43 are pressed against the opening side end portion and the tip end surface 84a of the inner surface 82a, respectively. As a result, they are bent at right angles to each other. The state bent at a right angle is fixed by the PP beads B and the covering material 40 being cooled and solidified. As a result, an arc portion is not formed between the side wall portion 32 and the back wall portion 33 of the molded covering 30, and a bent portion 34 that is bent at a right angle is formed. Therefore, when the interior article 10 is attached to a vehicle body (not shown) such as a door panel, a wedge-shaped gap is not formed between the peripheral edge of the interior article 10 and the body. Therefore, the aesthetics of the door etc. to which the interior goods 10 were attached can be improved.
[0017]
In addition, this invention is not limited to said embodiment, It can change suitably.
For example, in the above embodiment, after the first and second molds 80A and 80B are clamped, PP is formed in the cavity C defined by the covering material 40 and the tip surface 84a of the second mold 80B. The beads B are filled, but the first and second molds 80A and 80B are clamped after the PP beads B are filled in the housing recess 44 surrounded by the front wall 41 and the side wall 42 of the covering material 40. May be. In that case, the first mold 80A is disposed with the molding recess 82 facing upward, while the second mold 80B is disposed above the first mold 8A so as to be movable in the vertical direction.
[0018]
【The invention's effect】
As described above, according to the present invention, the side wall portion and the back wall portion of the covering of the vehicle interior product are molded in a state of being bent at a right angle without forming an arc portion therebetween. be able to. Therefore, it is possible to prevent a wedge-shaped gap from being formed between the peripheral edge of the interior product and the vehicle body when the interior product is attached to the vehicle body, and to improve the appearance of the door to which the interior product is attached. Can be made. And the effect that the effort which adhere | attaches the back wall part of a coating | cover on a foam can be acquired.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an example of an interior product for a vehicle molded according to the present invention.
2 is an enlarged cross-sectional view of a sheet constituting the covering of the interior product shown in FIG.
3 is a cross-sectional view showing a state in which a molded body that is a precursor of a covering material that is a material of the covering of the interior product shown in FIG. 1 is being molded. FIG.
FIG. 4 is a cross-sectional view showing a state in which the first and second molds used in the molding method according to the present invention are opened.
FIG. 5 is a sectional view showing the first and second molds clamped together.
FIG. 6 is a cross-sectional view showing an example of a conventional vehicle interior product.
7 is a cross-sectional view showing a state in the middle of manufacturing the interior product shown in FIG. 6;
8 is an enlarged cross-sectional view showing a state in which the interior product shown in FIG. 6 is attached to a door panel.
[Explanation of symbols]
B PP Bead 10 Vehicle Interior 20 Foam 21 Surface 22 Side 23 Back 30 Cover 31 Front Wall 32 Side Wall 33 Back Wall 40 Cover Material 41 Front Wall 42 Side Wall 43 Protrusion 44 Housing Recess 50 Seat Material 70 Molded body 71 Front wall portion 72 Side wall portion 73 Concave wall portion 80A First mold 80B Second mold 82 Molding recess 82A Inner surface of molding recess (first molding surface)
84a Tip surface (second molding surface)

Claims (3)

A foam formed by fusing together foamed polypropylene beads (hereinafter referred to as PP beads), and a front wall portion, a side wall portion, and a back surface covering the peripheral portions of the front surface, side surface, and back surface of the foam body, respectively. A molding method for molding a vehicle interior product including a sheet-like covering having a wall portion,
The 1st metal mold | die in which the shaping | molding recessed part which has the 1st shaping | molding surface of the shape corresponding to the surface and side surface of the said covering body was formed, and the back surface of the said vehicle interior goods in the surface facing this shaping | molding recessed part of this 1st metal mold | die And a second mold on which a second molding surface for molding is formed,
The first molding surface of the molding recess, a mounting step of mounting the covering body material having a front wall portion and side wall portions of the front and lateral walls and their respective same shapes of the covering body,
A filling step of filling PP beads pre-foamed into an accommodation recess formed by a front wall portion and a side wall portion of the covering material attached to the molding recess;
In a state where the first and second molds are clamped, the PP beads filled in the housing recesses are heated to melt the surface portions thereof, and the PP beads are fused together. A fusion process for fusing the above-mentioned covering material to
An end of the side wall of the covering material on the opening side of the housing recess protrudes toward the inside of the housing recess, and the second molding is performed when the first and second molds are clamped. A method for forming an interior part for a vehicle, wherein an annular projecting part that abuts along the surface is formed in advance. After forming the sheet material into a molded body having the same front wall portion and side wall portion as the covering body material and having a concave wall portion extending annularly along the peripheral edge portion of the side wall portion, the molded body is bisecting cut at central portion in the width direction of the recessed wall portion, one part having the above table and lateral walls are as the covering body material, the concave wall subsequent to the sidewall portion of said one portion The method for molding an interior part for a vehicle according to claim 1, wherein the remaining part of the part is the protruding part.   The method for molding an interior part for a vehicle according to claim 2, wherein the concave wall part is formed in a semicircular cross section.

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