JPH0237847B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing automobile interior materials such as door trims, and particularly relates to a method for manufacturing interior materials for automobiles such as door trims, and in particular, when the decorative surface has different materials depending on the part, it is possible to integrally mold the materials simultaneously in a mold. The present invention relates to a method of manufacturing an interior material for an automobile.

Recently, interior parts such as automobile door trims are required to have good design appearance performance.
For example, this can be combined with fabric and vinyl chloride,
Use a combination of carpet and fabric, or the recently developed spray skin layer (urethane elastomer, etc. is applied to the mold surface and cured to form a skin) with decorative fabric or vinyl chloride carpet, etc. I'm starting to see more things.

As for the assembly method of such interior parts, if the decorative surface is a combination of different materials,
For example, as shown in Fig. 1, an upper part 1 having a decorative skin such as cloth and a lower part 2 having a spray skin skin are made separately, and then assembled together with a core material 3 in the main assembly process. Alternatively, as shown in FIG. 2, the lower part 2 and the board core material 3 are integrated in advance, and the upper part 1 is combined therewith.

However, in this manufacturing method,
In order to manufacture parts with different decorative surfaces in separate processes and then assemble them together in the main assembly process later, a foam mold must be provided for each, and the number of steps required for joining them increases. Therefore, the cost of interior parts that integrate different decorative skins has become high.

The present invention has been made in view of the conventional drawbacks, and even if the interior parts have different skins, one
The present invention provides a method for manufacturing an automobile interior material that can be molded integrally with a core material by simultaneous foaming in one foaming mold.

Hereinafter, one embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 3 shows the structure of a foam molding die in which the present invention is applied to the manufacture of door trims.

This mold consists of a lower mold 11 and an upper mold 12,
The mold surface 11a of the lower mold 11 is for forming the outer surface of the molded product, and the mold surface 12a of the upper mold 12 is equipped with a core material, which will be described later, and is engaged onto the lower mold 11. A clearance, or cavity, is formed during this process.

A second mold 13 made of silicon rubber, metal, or the like is buried and fixed at an appropriate position of the lower mold, and forms a mold surface 13a continuous with the mold surface 11a of the lower mold 11, and Lower mold 1
A protruding portion 14 is formed at the joint portion between the mold surface 11a of the first mold and the mold surface 13a of the second mold 13, and a different boundary line, which will be described later, is provided with this protruding portion 14 as a boundary.

Next, the upper and lower molds 11, 1 configured as above are constructed.
The molding order using the mold 2 and the second mold 13 will be explained.

(1) First, with the second mold 13 removed from the lower mold 11, apply a urethane resin elastomer paint (two-component resin) on the mold surface 13a,
Due to the hardening, a skin 20 is formed on the mold surface 13a.
(see Figure 4a).

(2) On the other hand, in parallel with this, vacuum forming or the like is performed in advance on the mold surface 11a of the lower mold 11 to form a skin shape, such as ABS resin or PVC on the skin, such as cloth.
A decorative skin material 21 made of a skin material packed with a resin sealant, an ABS sheet, or a PVC sheet is set on the mold surface 11a. Further, the joining edge of the skin material 21 and the second mold 13 is formed in a shape corresponding to the protruding portion 14 protruding from the edge of the second mold 13 (see FIG. 4b). ).

(3) In addition, in parallel with the setting work of this skin material 21, a core material 22 made of a press molded body such as a composite resin plate containing wood powder is set on the mold surface 12a of the upper mold 12 and fixed to the mold surface 12a. (Fig. 4c)
reference). Note that a sealing material 23 made of, for example, slab urethane, fibrous cushioning material, etc. is set in advance on the lower surface of the core material 22 along the above-mentioned protrusion 14.

(4) Next, after completing such setting work, a second mold with the hardened spray skin skin 20 formed on the mold surface 3 is set on the lower mold, and then the joint edge of the skin material 21 is poked. shape part 1
The setting work is completed by superimposing it on top of 4.

(5) Next, if the urethane foaming resin liquid is injected onto the lower mold 11 and the second mold 13, and the upper mold 12 is immediately engaged in this state, the foaming resin liquid will be injected into both the molds 11, 12 and within the cavity formed between the second mold 13 and the upper mold 12, and the foam layer 24 integrally joins the skin material 21, the spray skin skin 20, and the core material 22. (See Figure 5).

Note that when the upper mold 12 is engaged, the sealing material 23 is pressed onto the protrusion 14,
The bonded area between the skin material 21 and the spray skin skin 20 is compressed, thereby preventing the resin from leaking from this area, and it is possible to effectively prevent the foamed resin from staining the surface of the molded product. Become.

FIG. 6 shows a door trim 30 formed through the above-described molding process. That is, in this case, the armrest protruding portion 30 is formed along the shape of the mold surface 11a of the lower mold and the mold surface 13a of the second mold 13.
It is composed of upper and lower epidermis 31 and 32 with a as a boundary. Moreover, the above-mentioned protrusion 14 is provided at the joining edge.
A linear groove 14' corresponding to the area will be formed, but by attaching a decorative band such as a bead to this part in a later process, the asymmetric shape of the bonded part or the inside of the groove will be changed. The asymmetric shape caused by the leaked foam resin can be effectively concealed.

As explained above, in the method of manufacturing an automobile interior material according to the present invention, conventionally, parts are assembled according to the shape of each skin in the subassembly process as shown in FIGS. 1 and 2. The process of assembling the whole thing in the main assembly process is omitted, and each part is integrally molded in a single molding process, which greatly simplifies manufacturing. Since this structure does not require any structure, it has advantages such as an extremely simple structure.

Therefore, the present invention is extremely effective as a method for forming skins of different materials on the same surface.

[Brief explanation of drawings]

Figures 1 and 2 are exploded perspective views showing the assembly structure of conventional automobile interior materials, Figure 3 is a sectional view of a mold to which the present invention is applied, and Figures 4 and 5 are views of the same mold. FIG. 6 is an explanatory cross-sectional view showing the molding order used, and FIG. 6 is a completed perspective view of a door trim to which the present invention is applied. 11...Lower mold, 12...Upper mold, 13...Second mold, 11a, 12a, 13a...Mold surface, 14...
Projection (junction edge), 20... Spray skin epidermis,
21... Skin material, 22... Core material, 23... Sealing material, 24... Foaming layer.

Claims (1)

[Claims] 1 The skin material is set on the mold surface of the lower mold, the core material is fixed on the mold surface of the upper mold, and both molds are engaged, and the foamed resin injected in advance into the cavity formed between the two molds is In a method in which a foam layer is formed between the core material and the skin material by foaming a liquid, and the core material and the skin material are integrated by the foam layer, an appropriate portion of the lower mold is coated with the foam layer. A second mold is provided which is removable and whose mold surface is continuous with the lower mold, and when the second mold is removed from the lower mold, a skin made of a spray skin layer is formed on the mold surface. , and in other parts of the lower mold, a skin material made of a material different from the spray skin skin, which has a cutout along the mold surface shape of the second mold, is set, and then the second mold is placed on the lower mold. While attaching the spray skin and overlapping the joint edges of the above-mentioned spray skin skin and skin material,
A sealing material along the joining edge is set in advance on the lower surface of the core material fixed to the upper mold, and when the upper mold is joined to the lower molding, the sealing material presses the joining edge and the outer surface of the core material is pressed. and a method for manufacturing an automobile interior material, characterized by sealing the overlapping portion of the skin material.