JPH0464412A - Manufacture of interior automotive trim - Google Patents

Abstract

PURPOSE:To simplify the equipment of manufacture, while its producing process is remarkably shortened by molding integrally the pad member using flexible urethane foam as a base and the mold pad composed of semirigid urethane in the foam molding of the core member of rigid urethane. CONSTITUTION:The mold pad 16 with excellent shock-absorbing properties is integrally set between a pad member 13 and a rigid urethane-core member 12 in molding of rigid urethane-core member 12. Consequently, the soft feeling of a product is improved. The protrusion 23 provided on the bottom force 2 for foam molding is inserted into the setting hole 18 provided on the flange 17 of the mold pad 16, whereby the mold pad 16 is positioned at the suitable position of the mold. Consequently, when rigid urethane-core member 12 is molded, the fact that the mold pad 16 is pushed by the flow of resin and is shifted, does not occur. Moreover, since the front side of the mold pad 16 is covered with the pad member, a parting line is not formed on the edge of the periphery of the mold pad.

Description

[Detailed Description of the Invention] (Industrial Application Field) This invention relates to a method for manufacturing interior parts for automobiles such as automobile door trims, and in particular, weight reduction and a soft feel in the armrest portion are required. The present invention relates to a method of manufacturing an automobile interior part that has a good feel.

(Prior art) For example, various interior parts are installed in the interior of a car, and these interior parts require fiberboards, resin boards, etc. that have shape retention and rigidity for mounting on car body panels. It is generally known that it is a laminated structure consisting of a core material formed into a shape and a skin shell that is integrally attached to the surface side of the core material so as to provide cushioning properties and decorative properties.

By the way, when a navy blue board, a resin board, etc. are used as a core material, the weight tends to increase and it is not suitable for reducing the weight of the product.In addition, the moldability is not satisfactory and the core material has a complicated curved shape. The problem was that it could not be easily adapted to other products.

As a countermeasure to this problem, it has been proposed and implemented to promote weight reduction and improve moldability by using hard urethane reinforced with glass mat or the like.

FIG. 11 is a cross-sectional view showing the structure of an automobile door trim using hard urethane 8. This automobile door trim 1 consists of hard urethane
It is roughly composed of a shrine 2, a pad 3 made of polyurethane foam or the like laminated on the surface side of a hard urethane pad 2, and a skin material 4 covering the outer periphery thereof.

To briefly explain the manufacturing process of this automobile door trim 1, first, as shown in FIG. 12, a pad 3 and a hard urethane 8
After each of the glass mats to be layered inside the tube 2 is set, a hard urethane resin liquid is injected into the mold 5, and an upper mold for foam molding (not shown) is engaged with the lower mold 5 to integrate the band material 3. The hard urethane 2 is molded into the desired shape.

Next, as shown in FIG. 13, the hard urethane core 2 and the outer skin 4 produced in the above process are integrated using a crimping mold 7°8.

(Problem to be solved by the invention) In this way, in conventional interior parts, for example, the 11th
In the type of door L,1 shown in the figure, which uses a hard urethane core material 2 to promote weight reduction,
In addition to the cushioning properties of the padding material 3, is it possible to use a slush-molded skin as the skin material 4 to give a soft feel to the overall area?Especially in the armrest area where the passenger's elbow rests and the door waist area. Thus, in areas where relatively strong external forces act, the cushioning properties of the pad H3 and the skin material 4 are insufficient, and there is an urgent need to improve the kit properties of these areas.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide interior parts for automobiles using hard urethane which reduces weight and improves impact resistance. To provide a method for manufacturing an interior part for an automobile, which gives a soft feel to the part to which a large load is applied, and provides a good cushioning function.

(Means for Solving the Problems) In order to achieve the object described in -1-, the method for manufacturing automobile interior parts according to the present invention provides a foam molding method in which vacuum suction holes are provided at required locations. In the lower mold 1, high elongation film f
・The process of setting a mold made of 1 bag from 1 batch and molding this basoduki in the open air, pressurizing the mold into a thin shape and bringing it into close contact with the lower mold surface, and sealing the periphery with a metal flange. The supported mold pad is set on the upper side of the pad material in the thin-walled deaf, and the magnetic attraction between the magnet installed in the lower mold for foam molding and the flange of the mold pad holds the mold pad and lowers the pad material. The process involves positioning the mold pad in the proper position by fitting the protrusion of the mold into the setting hole of the flange, and inserting the glass mat from both sides of the band material set in the lower mold for foam molding and the mold pad. By laminating, further injecting hard urethane resin liquid, closing the upper mold for foam molding, and foaming and hardening the hard urethane resin liquid,
A step of molding a hard urethane core material and integrating the pad material, mold pad, and hard urethane core material, and a hard urethane pad and a skin pad that integrate the pad material produced in the above step and the mold pad. and a crimping step of integrating the crimping molds with a crimping mold.

(Operation) As is clear from the above configuration, according to the method of the present invention,
When molding hard urethane 8, pad material and hard urethane 8
A molded pad with good cushioning properties is integrated between the shrine and the shrine, which improves the soft feel of the product.

In addition, by fitting the protrusion provided on the lower mold for foam molding into the cell I hole provided on the flange of the mold pad, the mold pad can be positioned at an appropriate position in the mold. When molding urethane core material,
The mold pad is not pressed and displaced due to resin flow.

In addition, since the surface side of the mold pad is covered with a pad material, no parting line is formed around the periphery of the mold pad, and a good product appearance can be obtained.

(Example) Hereinafter, a method for manufacturing an automobile interior part according to the present invention will be described in detail with reference to the accompanying drawings.

1 and 2 are perspective views and sectional views showing the structure of an automobile door trim obtained by applying the method of the present invention, and FIGS. 3 to 10 are sectional views showing the manufacturing process of the automobile door trim. It is.

First, automobile door trim 1 obtained by applying the method of the present invention
0 will be explained based on FIGS. 1 and 2. This automobile door trim 10 includes a hard urethane core +412 with a glass mat 11 as an inner layer, and a pad material integrated on the surface side of the hard urethane core 12. 13, a molded pad 16 installed at a location where a large external force is applied from the occupant, and a skin cover 19 covering the outer periphery of these pads.

More specifically, in this embodiment, the pad material 13 is made of a laminate of a high elongation film 14 such as a polyurethane film and a sheet-like soft urethane foam 15,
The thickness of the urethane high elongation film 14 is 25 to 50μ, and the density of the soft urethane foam 15 is 0. 025~
0. 05 g/cm3, and its thickness is approximately 2 mm, and both are integrated in advance with an adhesive or by heat fusion.

Further, the mold pad 16 is made of semi-rigid urethane molded into a desired shape.A metal flange 17 is provided around the mold pad 16, and the mold pad 16 is supported by the flange 17. There is. Furthermore, a plurality of setting holes 18 are formed at predetermined locations on the metal flange 17, as will be described later.

Further, as the skin cover 19, one skin material is used in this embodiment, in which a slash skin layer 19a on the front side and a slash foam layer 19b on the back side are laminated by slash molding.

As configured as described above, the automobile door trim 10 obtained by the knob method of the present invention is made of hard urethane 8.
By using the moon 12, the weight can be significantly reduced and the impact resistance 14 can be improved.

In addition to the good surface feel and appearance of the skin abrasions 19 and pad material 13, the molded pad 16 significantly improves the soft feel of areas to which a relatively large external pressure from the occupant is applied.

Further, since the mold pad 16 is covered with the pad material 13 and the skin material 19, the parting of the peripheral edge of the mold pad 16 is not visible from the outside, which is also aesthetically pleasing.

Next, the manufacturing process of the automobile door trim 10 described in "1" will be sequentially explained.

FIG. 3 shows a foam molding lower mold 20 for molding the hard urethane core material 12 into a desired shape.
a, vacuum suction holes 21 are opened at predetermined locations, and magnets 22 for positioning the mold pad 16 at predetermined locations are embedded. Further, a protrusion 23 of about 0.5 to 1 mm is protruded from the surface of the magnet 22.

The structure of the lower mold 20 for foam molding used in the present invention is as follows: First, the pad material 13 is placed around the pad material 13 with the high elongation film 14 facing upward using a clamping device 24.
and set it on the upper surface of the lower mold 20.

Next, as shown in FIG. 4, air is evacuated from the vacuum suction holes 21 provided in the lower mold 20, and the foam material 13 is vacuum-formed along the mold surface 20a of the lower mold 20 for foam molding. . This and the thickness of Pad Tsuki 13 are 0.2-0.3 from 2■
It will be in a thin state of about 1.

Next, as shown in FIG. 5, a molded pad 16 is set on one side of the thin pad material 13.

Due to the magnetic attraction force between this and the flange 17 provided around the mold pad 16 and the Macnet 22 installed on the lower mold 20, the mold pad 16 is held in a predetermined position and is attached to the flange 17. By fitting the protrusion 23 formed on the upper surface of the mucknet 22 into the provided setting hole 18, the mold pad 16 can be accurately positioned to prevent it from slipping into the chin.

In this case, the protrusion 23 is covered with a thin pad 13, and since the pad 13 is extremely thin, the protrusion 23 can be easily fitted into the setting hole 18.

Next, as shown in FIG. 6, after laminating the glass mats 1, a hard urethane resin liquid 26 is injected into the lower mold 20 for foam molding from the nostle 25 of the foam molding machine, and a predetermined amount of hard urethane resin liquid 26 is injected into the lower mold 20 for foam molding. After injecting the urethane resin liquid 26, as shown in FIG. A foaming reaction of the urethane resin liquid 26 is performed.

In addition, since the high elongation film 14 acts as a barrier, the hard urethane resin liquid 26 does not seep into the soft urethane foam 15, and the soft urethane foam 1
5's rough 1-feel is not affected.

In this way, the hard urethane core material 12 in which the pad A13 and the molded pad 16 are integrated is molded into the desired shape.

In the molded product taken out from the upper and lower molds 20.27 for foam molding, the pad material 13 has been restored to its original thickness.
As shown in the figure, due to the thickness of Nono Sodogeki 13,
Not only the parting lines of the mold pawl throat 16 and the metal flange 17, but also the evidence of the center throat hole 18 do not appear on the product appearance, and an extremely good appearance can be obtained.

Thereafter, as shown in FIG. 9, the hard urethane core material 12 obtained by foam molding in the above process is set in the upper mold 30 for crimping, and one slash of the skin material is placed on the mold surface of the lower mold 31 for crimping. Position the skin layer 1.9 with the a side facing down, and apply adhesive to the Sula Soche foam layer 19b,
As shown in FIG. 10, the manufacturing of the automobile door trim 10 having the structure shown in FIG. 1 and shown in FIG.

Above, we have described an example in which the method of the present invention is applied to a method of manufacturing an automobile door trim 10. However, if it is an automobile interior part made of a laminated structure using a hard urethane core material 12, the application is particularly limited. It's not something you do.

(Effects of the Invention) As explained above, the method of manufacturing automatic military interior parts according to the present invention has the following special effects.

■The reason for the method of the present invention is that during foam molding of the hard urethane core material, the pad H based on soft urethane foam and the molded pad made of semi-hard urethane are integrated, so three types with different densities can be formed. Even though urethane is used, the foam molding process is only one step, so the manufacturing process can be significantly shortened, and the equipment is also simplified, resulting in a significant cost reduction.

■The method of the present invention is that the padding material and the molded pad are integrated during the foam molding of the hard urethane core H, so this molded pad allows the soft feel of the old temple part to be relatively pressure-free from the occupant. This has the effect of significantly increasing the commercial value of interior parts.

■The problem with the method of the present invention is that the surface of the mold pad that is inserted into the appropriate location is covered with the epidermis H of the pad material.・It has the effect of making the product appearance more desirable without exposing the cutout to the outside.

■The method of the present invention enables accurate positioning of the mold pad by fitting the setting hole provided in the flange around the mold pad to the protrusion of the mold during foam molding of the hard urethane core material. Furthermore, by preventing 1) γ misalignment of the mold pad during foam molding as much as possible, the effect of improving accuracy in foam molding is achieved.

[Brief explanation of the drawing]

Figure 1 is a perspective view showing the structure of an automobile door trim manufactured by applying the method of the present invention, and Figure 2 is 1l-Il in Figure 1.
Line sectional views, FIGS. 3 to 10 are sectional views showing the manufacturing lower punch of the automobile door door 1, and FIG. 11 is a sectional view showing the structure of the conventional automatic military door door 1, No. 12.13. The figures are cross-sectional views illustrating a conventional lower punch for manufacturing automobile door trims. 10... Automobile door trim 11... Glass mantle 12... Hard urethane core material 13... Pad material 14... High elongation fill 1. 15...Soft urethane foam 16...Mold pad 17...Metal flange 18...Cent hole 19...Skin hole 20...Lower mold for foam molding 21...Vacuum suction hole 22... ...Magnet 23...Protrusion 24...Clamp 25...Nosle 26...Hard urethane resin liquid 27...Soil mold for foam molding 30...Upper mold for crimping 31...Lower mold for crimping

Claims (1)

[Claims] 1. A pad material made of a foam sheet (15) with a high elongation film (14) on a lower mold for foam molding (20) with vacuum suction holes (21) opened at required locations. By setting (13) and vacuum forming this pad material (13),
While pressing the pad material (13) into a thin shape, the lower mold (20)
The mold pad (16) whose peripheral edge is supported by a metal flange (17) is set on top of the thin pad material (13) and placed in the lower mold for foam molding (20). The magnetic attraction force between the magnet (22) and the flange (17) of the mold pad (16) holds the mold pad (16), and the protrusion (20) of the lower mold (20)
23) into the setting hole (18) of the flange (17) to position the mold pad (16) at an appropriate position, and the pad material (23) set in the lower mold for foam molding (20) 13)
, and a glass mat (11) is laminated from above the mold pad (16), and a hard urethane resin liquid is further injected, the upper mold for foam molding (25) is closed, and the hard urethane resin liquid is foamed and hardened. By molding the hard urethane core material (12), the pad material (13),
Mold pad (16), and hard urethane core material (1
2), and a hard urethane core material (12) that integrates the pad material (13) produced in the above step and the molded pad (16).
) and a skin material (19) using a crimping die (30, 31).