JP2004262119A - Car interior component, its production method, and mold - Google Patents

Car interior component, its production method, and mold Download PDF

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Publication number
JP2004262119A
JP2004262119A JP2003055639A JP2003055639A JP2004262119A JP 2004262119 A JP2004262119 A JP 2004262119A JP 2003055639 A JP2003055639 A JP 2003055639A JP 2003055639 A JP2003055639 A JP 2003055639A JP 2004262119 A JP2004262119 A JP 2004262119A
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foamed resin
base material
molding die
laminated
resin
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JP4133451B2 (en
Inventor
Tetsuyuki Ota
哲行 大田
Masahiko Hara
正彦 原
Nobuaki Seki
伸明 関
Tatsufumi Ono
樹史 大野
Hiroyuki Aizawa
洋行 相澤
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Kasai Kogyo Co Ltd
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Kasai Kogyo Co Ltd
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  • Injection Moulding Of Plastics Or The Like (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To reduce weight and costs and to improve the appearance and strength of a product end part in a car interior component and its production method. <P>SOLUTION: An interior component (door trim upper) 20 is composed of a foamed resin substrate 21 which is lightweight and has shape holding properties, a resin rib 22 laminated/integrated on the inner surface side of the substrate 21, and a decorative material 23 laminated on the surface of the substrate 21. By eliminating a conventional heavy resin core material, the weight and costs of the interior component 20 are reduced. In the peripheral end part, a thin wall hinge part 24 is formed in the substrate 21, and a winding margin 25 set up in the peripheral part of the hinge part 24 with the hinge part 24 made a folding base point is wound on the inner surface side of the substrate 21 and fixed to improve the appearance and strength of the peripheral part. By cutting the substrate 21 in the margin 25, the flexibility of the margin 25 can be used. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
この発明は、ドアトリム、リヤパーセルシェルフ、フロアトリム、トランクトリム、リヤサイドトリム等の自動車用内装部品及びその製造方法並びに成形金型に係り、特に、軽量でかつ外周端末部の見栄え並びに機械強度に優れ、しかも、簡単かつ廉価に製作できる自動車用内装部品及びその製造方法並びに成形金型に関する。
【０００２】
【従来の技術】
例えば、自動車用内装部品の構成をドアトリムを例示して図２０，図２１を基に説明する。ドアトリム１は、保形性及び車体パネルへの取付剛性を備え、製品面のほぼ全面にゆきわたっている樹脂芯材２の表面に、表面外観に優れた表皮３を積層一体化して構成されている。
【０００３】
上記樹脂芯材２としては、タルクを混入したポリプロピレン系樹脂を素材としており、また、表皮３は、それ自体保形性を備えておらず、塩ビシート等の合成樹脂シート裏面にポリエチレンフォーム等のクッション材が積層された積層シート材料が使用され、最近では、環境面やリサイクル面を考慮して、ＴＰＯ（サーモプラスチックオレフィン）シート等のエラストマーシートが多用される傾向にある。
【０００４】
次に、上記ドアトリム１の成形方法における従来例について図２２を基に説明する。まず、ドアトリム１を成形する成形金型４は、所定ストローク上下動可能な成形上型５と、成形上型５と対をなす固定側の成形下型６と、成形下型６と接続される射出機７とから大略構成されている。
【０００５】
そして、成形上下型５，６を型締めした際、ドアトリム１の製品形状を形造るために成形上型５にはキャビティ部５ａが形成され、成形下型６にはコア部６ａが設けられている。上記成形上型５を所定ストローク上下動作させるために、昇降シリンダ５ｂが連結され、成形下型６には射出機７からの溶融樹脂の通路となるマニホールド６ｂ、ゲート６ｃが設けられている。
【０００６】
また、上下動作する成形上型５は、適正姿勢を維持させるために、成形下型６の４隅部にガイドポスト６ｄが設けられ、このガイドポスト６ｄに対応して成形上型５にはガイドブッシュ５ｃが設けられている。
【０００７】
従って、成形上下型５，６が型開き状態にあるとき、表皮３を金型内にセットし、その後、成形上下型５，６を型締めする直前か、または型締めした後のいずれかのタイミングで両金型間の製品キャビティ内に射出機７からマニホールド６ｂ、ゲート６ｃを通じて溶融樹脂Ｍを射出充填することにより、樹脂芯材２を所要の曲面形状に成形するとともに、樹脂芯材２の表面に表皮３を一体成形している（例えば、特許文献１参照。）。
【０００８】
尚、図２２では、説明の便宜上、コア部６ａの型面にオープン状態で溶融樹脂Ｍが供給されているが、実際は、溶融樹脂Ｍは成形上下型５，６の型締め後にキャビティ内に射出充填されても良い。
【０００９】
更に、ドアトリム１の製品の外周端末の処理については、図２３に示すように、芯材２の表面に表皮３を同時プレス成形した後、型内の型刃、あるいは成形後、別工程でピアスカット処理が行なわれている。
【００１０】
また、図２４に示すように、芯材２のプレス成形後、表皮３を別工程で真空圧着、プレス圧着等により一体化した後、表皮３の端末３ａを芯材２の裏面側に巻込み処理することも従来から行なわれている。
【００１１】
【特許文献１】
特開平１０−１３８２６８号公報 （第２頁、図３、図４）
【００１２】
【発明が解決しようとする課題】
しかしながら、従来のドアトリム１においては、樹脂芯材２の投影面積が大きいため、材料コストが高く、かつ製品が重量化するという問題点が指摘されている。
【００１３】
また、樹脂芯材２の投影面積が大きいことから、成形時における射出圧を高く設定せざるを得ず、高い射出圧に耐え得る金型構造が必要となり、金型の作製費用も嵩み、しかも、大量の溶融樹脂を冷却固化させるため、成形サイクルが長期化し、生産性を低下させる大きな要因となっている。
【００１４】
更に、ドアトリム１の外周縁においては、図２３に示すように、表皮同時プレス成形を行なった場合、外周の端末処理が困難で、見栄えが悪く、外観性能を低下させる欠点があるとともに、図２４に示すように、別工程で表皮３を巻込み処理する方法では、工数が多く、コストアップが避けられない。
【００１５】
本発明は、このような事情に鑑みてなされたもので、軽量化を促進でき、高剛性でコストダウンを図れる自動車用内装部品を提供でき、成形金型費用を低減でき、成形サイクルも短縮化できるとともに、特に、製品外周端末部の見栄え並びに剛性を高めることで、外観性能を向上させた自動車用内装部品及びその製造方法並びに成形金型を提供することを目的とする。
【００１６】
【課題を解決するための手段】
本発明者らは、上記課題を解決するために、鋭意研究の結果、従来から表皮として使用していた発泡樹脂シートに保形性を付与することで、芯材としての機能をもたせ、より以上に剛性が必要な箇所、すなわち製品の周縁部分やパネル、相手部品との合わせ部で密接可能、または一定クリアランスを確保する箇所、あるいは部品取付箇所並びに荷重がかかる部分には、剛性に優れた樹脂リブを配置することで従来の投影面積の広い樹脂芯材に比べ軽量化して対応するとともに、製品の外周端末処理については、発泡樹脂基材に巻込み部を付設するだけで、簡単かつ美麗に端末処理を達成できることを見い出し、本発明を完成するに至った。
【００１７】
すなわち、本発明に係る自動車用内装部品は、軽量で、かつ保形性を有する発泡樹脂基材と、この発泡樹脂基材の裏面に積層一体化される樹脂リブと、上記発泡樹脂基材の表面に積層一体化される加飾材からなる自動車用内装部品であって、製品外周のやや内側に沿って、発泡樹脂基材に設けられた薄肉ヒンジ部を基に該薄肉ヒンジ部外周の巻込みシロを発泡樹脂基材の裏面に巻込み処理してなることを特徴とする。
【００１８】
更に、本発明の別の実施態様は、軽量で、かつ保形性を有する発泡樹脂基材と、この発泡樹脂基材の裏面に積層一体化される樹脂リブと、上記発泡樹脂基材の表面に積層一体化される加飾材とからなる自動車用内装部品であって、製品外周の内側に沿って設定された折返しラインから外周端末にかけて発泡樹脂基材が切削され、可撓性を備えた巻込みシロとして形成され、該折返しラインを基に発泡樹脂基材の裏面側に上記巻込みシロを巻込み処理してなることを特徴とする。
【００１９】
ここで、自動車用内装部品としては、ドアトリム、リヤパーセルシェルフ、フロアトリム、ラゲージトリム、トランクトリム、リヤサイドトリム等に適用できる。
【００２０】
軽量で、かつ保形性を有する発泡樹脂基材は、フラット形状に近い場合は、加熱軟化工程を省略して、成形型により所望形状に成形するが、三次元形状の製品に適用する場合は、発泡樹脂シートを加熱軟化処理した後、成形金型内で所要の曲面形状に成形することで、その形状を保持する。尚、ここで言う「保形性」とは、リブ等の補強材がなくても、成形後脱型したとき、その形状を保持する程度の剛性を備えていることである。また、製品形状が高展開率部分を含む場合には、発泡樹脂シートを加熱軟化処理した後、成形金型に真空吸引機構を配設して成形金型の内面に沿って発泡樹脂シートに真空吸引力を作用させるようにしても良い。
【００２１】
上記発泡樹脂シートとしては、熱可塑性樹脂に発泡剤を添加した素材を使用する。尚、熱可塑性樹脂は、１種類の熱可塑性樹脂でも２種類以上の熱可塑性樹脂からなっても良い。好ましくは、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、アイオノマー系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂などが使用できる。
【００２２】
また、発泡剤としては、アゾ化合物、スルホヒドラジド化合物、ニトロソ化合物、アジド化合物等の有機発泡剤、あるいは重炭酸ナトリウム等の無機発泡剤の使用が可能である。
【００２３】
上記発泡樹脂シートを加熱軟化処理後、所要形状に成形して得た発泡樹脂基材は、製品の重量と強度とのバランスを考慮した場合、２〜１０倍の発泡倍率が好ましい。そのときの発泡樹脂基材のセル径は、０．１μｍ〜２．０ｍｍの範囲であることが好ましく、厚みは０．５〜３０ｍｍ、好ましくは１〜１０ｍｍのものが良い。
【００２４】
一方、樹脂リブとして使用する熱可塑性樹脂材料は、広範な熱可塑性樹脂から適宜選択することができる。通常好ましく使用できるものとして、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、アイオノマー系樹脂、ポリアミド系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂、ポリカーボネート樹脂等が使用できる。
【００２５】
また、これら熱可塑性樹脂中に各種充填剤を混入しても良い。使用できる充填剤としては、ガラス繊維、カーボン繊維等の無機繊維、タルク、クレイ、シリカ、炭酸カルシウム等の無機粒子などがある。また、酸化防止剤、紫外線吸収剤、着色剤、難燃剤、低収縮剤等の各種の添加剤が配合されても良い。
【００２６】
そして、外観意匠性を高めるために、発泡樹脂基材の表面に積層一体化される加飾材としては、織布、不織布、編布、シート、フィルム、発泡体、網状物などが使用できる。これら加飾材を構成する材料は特に限定されないが、織布、不織布、編布等、通気性を有する素材を使用したほうが、発泡樹脂基材の吸音性能を生かす上で好ましい。また、加飾材としてＴＰＯシートを使用した場合、材料をオレフィン系樹脂に統一できることから、リサイクル作業を円滑に行なえる。
【００２７】
更に、内装部品の外周縁は、折返しラインとなる薄肉ヒンジ部が発泡樹脂基材に形成されており、この薄肉ヒンジ部を基に外側の巻込みシロが発泡樹脂基材の裏面側に巻込み処理されている。
【００２８】
また、端末処理の別態様としては、折返しラインから外側部分における発泡樹脂基材が削り取られ、折返しラインより外側部分がほぼ加飾材のみの可撓性を備えた巻込み部として形成され、この巻込み部を発泡樹脂基材の裏面側に巻込み処理すれば良い。
【００２９】
そして、本発明に係る自動車用内装部品によれば、保形性を有する発泡樹脂基材の表面側に加飾性を有する加飾材が積層され、かつ裏面側に剛性を強化する意味で樹脂リブが積層一体化されるという構成であるため、従来の樹脂芯材を廃止することができる。従って、従来の投影面積の非常に広い樹脂芯材を廃止することで、製品の軽量化を図ることができ、しかも、樹脂材料を節約できることから、材料コストの低減化も同時に達成できる。
【００３０】
更に、内装部品の外周部については、薄肉ヒンジ部を折返し基点に外側部分を巻込みシロとして巻込み処理されるため、切断木口等が外部に目立たず、外観意匠性に優れ、かつ端末部分は、発泡樹脂基材が二重構造となり、剛性も強化できる。
【００３１】
更に、発泡樹脂基材の折返しラインより外側部分の発泡樹脂基材を削り取る構成を採用すれば、切断木口が外部に目立たないとともに、ほぼ加飾材のみの巻込み部の構成となるため、可撓性を有することから、巻込み作業が円滑に行なえる。
【００３２】
加えて、発泡樹脂基材の多孔質吸音機能により、吸音性能に優れた内装部品が得られるとともに、発泡樹脂基材及び樹脂リブの素材として、ポリオレフィン系樹脂を使用した場合、オールオレフィン系樹脂に統一されるため、分離工程が廃止でき、リサイクル作業が簡素化できる。
【００３３】
更に、樹脂リブのリブ厚みは、例えば、製品に外力が大きく加わる部位などはリブ厚みを厚く設定し、比較的外力が加わりにくい部位はリブ厚みを薄肉にするなど、リブ厚みを適宜可変させることができる。従って、必要最小限度の樹脂材料を使用すれば足り、製品の軽量化やコストダウンに寄与できる。また、樹脂リブにクリップ座、あるいは各種エスカッション部品を取り付けるための取付座を一体に形成することもできる。
【００３４】
次いで、本発明に係る自動車用内装部品の製造方法は、軽量で、かつ保形性を有する発泡樹脂基材と、該発泡樹脂基材の裏面に積層一体化される樹脂リブと、上記発泡樹脂基材の表面に積層される加飾材とからなる自動車用内装部品の製造方法において、成形金型内に、発泡樹脂基材の素材である発泡樹脂シートをセットする発泡樹脂シートのセット工程と、成形金型同士を型締めして、成形金型の製品キャビティ形状に発泡樹脂基材を所要形状に成形し、上記発泡樹脂基材の外周縁からやや内側の折返しラインに沿って薄肉ヒンジ部を形成する一方、成形金型の型締め直前、または型締め後のいずれかのタイミングで成形下型の溝部内に溶融樹脂を射出充填して、樹脂リブを発泡樹脂基材の裏面側に積層一体化する発泡樹脂基材と樹脂リブの一体化工程と、一体化した積層品を成形金型の型開き後、脱型し、巻込みシロを上記薄肉ヒンジ部を基に発泡樹脂基材の裏面に折返し固着する内装部品の端末処理工程とからなることを特徴とする。
【００３５】
ここで、本発明方法に使用する成形金型は、所定ストローク上下動可能な成形上型と、この成形上型の下方側に位置する固定側である成形下型と、成形下型に連結される射出機から構成される。
【００３６】
射出機から供給される溶融樹脂は、成形下型に設けられたマニホールド、ゲート等の樹脂通路を通じて成形下型の型面、詳しくは、成形下型の型面上に形成される溝部内に供給されるが、成形上型が下死点まで下降して、成形上下型を型締めした後、溶融樹脂を所定の射出圧で成形下型の型面に設けられた溝部に射出充填しても良いが、溶融樹脂の射出充填のタイミングとして、型締め前に行なうようにしても良い。
【００３７】
更に、成形上下型の型面は、製品形状に合致する所望の曲面形状に設定されているが、外周端末部の巻込み処理を考慮して、成形上下型のいずれか一方側に凸条が設けられ、巻込みシロの折返し基点となる薄肉ヒンジ部が発泡樹脂基材に形成される。
【００３８】
従って、成形上下型の型締めにより、発泡樹脂シートは成形金型の型面形状に沿って所望の曲面形状に成形されるとともに、外周縁に沿うやや内側には薄肉ヒンジ部が形成されることになる。更に、溶融樹脂が射出充填されることで、発泡樹脂基材の裏面に樹脂リブが積層一体化される。
【００３９】
そして、製品形状が三次元形状に設定されている場合には、全工程でヒーター等により加熱軟化処理を行なった後、発泡樹脂シートを成形金型内にセットする。
【００４０】
更に、成形金型内に加熱軟化状態の発泡樹脂シートを供給した後、成形金型を型締めすれば、所望形状に成形された保形性を有する発泡樹脂基材が得られ、この発泡樹脂基材には、巻込みシロの折返し処理の際、折返し基点となる薄肉ヒンジ部が形成される。
【００４１】
そして、発泡樹脂基材の成形と同時に、発泡樹脂基材裏面に樹脂リブを積層一体化すれば良い。尚、最終製品形状が高展開率部分を備えている場合には、成形金型の型締めを複数回行ない、最終の型締め工程で溶融樹脂の射出充填を行なうと良い。また、製品形状がより高展開率部分を含む場合には、成形上型に真空吸引機構を配設し、成形上型の型面に沿って真空吸引力により発泡樹脂基材を所要形状に成形するのが良い。
【００４２】
従って、本発明方法によれば、従来の投影面積の広い樹脂芯材に比べ、樹脂リブだけを成形するため、射出圧力を従来に比べて低く設定できることにより、成形金型の負荷が少なくて済むとともに、樹脂量も少なく、材料費を節約でき、しかも、従来の樹脂芯材に比べ、冷却時間も少なくて済むため、製品の成形サイクルも短縮化できる。
【００４３】
更に、端末処理工程としては、加飾材、発泡樹脂基材、樹脂リブを一体化した積層成形体を成形金型から取り出し、発泡樹脂基材に設けられている薄肉ヒンジ部を折返し基点として外周に沿う巻込みシロを発泡樹脂基材の裏面に折返し固着すれば良く、製品の外周縁は薄肉ヒンジ部が対応するため、シャープな外周ラインが確保でき、かつ端末部分は二重構造であるため、剛性が強化でき、変形の恐れがない。
【００４４】
次いで、本発明方法の別の実施態様としては、前記発泡樹脂基材と樹脂リブの一体化工程において、成形金型同士を型締めして、成形金型の製品キャビティ形状に発泡樹脂基材を成形し、成形金型の型締め直前、または型締め後のいずれかのタイミングで成形下型の溝部内に溶融樹脂を射出充填して、樹脂リブを発泡樹脂基材の裏面側に積層一体化する一方、成形下型の外周のうち、巻込み処理する部位に沿って押圧機構が設けられ、該押圧機構における押圧ブロックが駆動シリンダにより上下駆動され、発泡樹脂基材の外周縁からやや内側に沿って巻込みシロの折返し基点となる薄肉ヒンジ部が形成されることを特徴とする。
【００４５】
ここで、該方法に使用する成形金型は、軽量で、かつ保形性を有する発泡樹脂基材と、該発泡樹脂基材の裏面に積層一体化される樹脂リブと、上記発泡樹脂基材の表面に積層される加飾材とからなる自動車用内装部品を成形する成形金型であって、前記成形金型は、相互に型締め、型開き可能な成形上型並びに成形下型と、成形下型に連結され、樹脂リブの素材である溶融樹脂を供給する射出機とから構成され、前記成形上下型間の製品キャビティは、発泡樹脂基材の製品形状に即した形状に設定されるとともに、樹脂リブに対応する溝部が成形下型のコア部型面に設けられ、かつ成形下型の外周縁部に沿って、発泡樹脂基材の巻込みシロの折返し基点となる薄肉ヒンジ部を形成するための押圧機構が配置されていることを特徴とする。
【００４６】
また、本発明方法の更に別の実施態様としては、軽量で、かつ保形性を有する発泡樹脂基材と、該発泡樹脂基材の裏面に積層一体化される樹脂リブと、上記発泡樹脂基材の表面に積層される加飾材とからなる自動車用内装部品の製造方法において、成形金型内に、発泡樹脂基材の素材である発泡樹脂シートをセットする発泡樹脂シートのセット工程と、成形金型同士を型締めして、成形金型の製品キャビティ形状に沿って発泡樹脂基材を成形し、発泡樹脂基材の製品端縁部に沿って、成形下型の壁面に形成した鋸刃形状により、巻込みシロに相当する発泡樹脂基材を削ぎ落とし、成形金型の型締め直前、または型締め後のいずれかのタイミングで成形下型の溝部内に溶融樹脂を射出充填して、樹脂リブを発泡樹脂基材の裏面側に積層一体化する発泡樹脂基材と樹脂リブの一体化工程と、成形金型から樹脂リブを一体化した発泡樹脂基材を脱型し、発泡樹脂基材を削ぎ落とした薄肉状の可撓性を有する巻込みシロを発泡樹脂基材裏面に折返し固着する内装部品の端末処理工程とからなることを特徴とする。
【００４７】
そして、これに使用する成形金型は、軽量で、かつ保形性を有する発泡樹脂基材と、該発泡樹脂基材の裏面に積層一体化される樹脂リブと、上記発泡樹脂基材の表面に積層される加飾材とからなる自動車用内装部品を成形する成形金型であって、この成形金型は、相互に型締め、型開き可能な成形上型並びに成形下型と、成形下型に連結され、樹脂リブの素材である溶融樹脂を供給する射出機とから構成され、前記成形下型の外周面には、発泡樹脂基材の外周縁の巻込みシロを切削するための鋸刃形状の切削部が設定されていることを特徴とする。
【００４８】
【発明の実施の形態】
以下、本発明に係る自動車用内装部品及びその製造方法並びに成形金型の好適な実施の形態について、自動車用ドアトリム及びその製造方法を例示して説明する。
【００４９】
図１乃至図１２は本発明の第１実施形態を示し、図１はツートンタイプの自動車用ドアトリムを示す正面図、図２は同自動車用ドアトリムの構成を示す断面図、図３は同自動車用ドアトリムにおけるドアトリムアッパーの樹脂リブとドアトリムロアを示す正面図、図４は同自動車用ドアトリムにおけるドアトリムアッパーの外周縁の構成を示す断面図、図５乃至図７は同自動車用ドアトリムの製造方法に使用する成形金型をそれぞれ示し、図５は成形金型の全体図、図６は成形金型におけるドアトリムアッパー形成部分を示す断面図、図７はドアトリムアッパー形成部分における外周部の拡大断面図である。更に、図８乃至図１２は同自動車用ドアトリムの製造方法の各工程を示し、図８は発泡樹脂シートの予熱工程、図９は発泡樹脂シートの成形金型へのセット工程、図１０はドアトリムの成形工程、図１１は巻込みシロの成形工程、図１２は巻込みシロの端末処理工程をそれぞれ示す説明図である。
【００５０】
また、図１３乃至図１５は本発明の第２実施形態を示すもので、図１３，図１４はドアトリムアッパーの外周縁部の巻込みシロの形成工程を示す各説明図、図１５は巻込みシロの端末処理工程を示す説明図である。また、図１６乃至図１９は本発明の第３実施形態を示すもので、図１６，図１７は第３実施形態に使用する成形金型の要部を示す斜視図並びに断面図、図１８は成形金型を使用して巻込み部を形成する説明図、図１９は巻込みシロの端末処理工程を示す説明図である。
【００５１】
まず、図１乃至図１２に基づいて、本発明の第１実施形態を説明する。図１，図２において、ツートンタイプの自動車用ドアトリム１０は、積層構造体からなるドアトリムアッパー２０と樹脂単体品からなるドアトリムロア３０との上下２分割体から構成されている。
【００５２】
ドアトリム１０に装着される機能部品としては、ドアトリムアッパー２０にインサイドハンドルエスカッション１１、パワーウインドウスイッチエスカッション１２が取り付けられている。ドアトリムロア３０には、ドアポケット用開口１３が開設され、その背面側には、図２に示すように、ポケットバックカバー（樹脂成形体からなる）１４が取り付けられており、ドアトリムロア３０のフロント側にスピーカグリル１５が一体あるいは別体に形成されている。
【００５３】
ところで、本発明に係る自動車用ドアトリム１０は、積層構造体であるドアトリムアッパー２０の構造に本発明を適用し、製品の軽量化を図るとともに、外周端末部の見栄えを高め、かつ成形工程、端末処理工程を簡素化したことが特徴である。
【００５４】
すなわち、ドアトリムアッパー２０は、図２に示すように、所望の曲面形状に成形され、保形性を有する発泡樹脂基材２１と、この発泡樹脂基材２１の裏面側に積層一体化される樹脂リブ２２と、発泡樹脂基材２１の表面側に積層一体化される加飾機能をもつ加飾材２３とから大略構成されている。尚、図中符合１６は車体パネルを示す。
【００５５】
また、上記発泡樹脂基材２１は、保形性を備えるように発泡樹脂シートを加熱軟化処理後、所要形状に熱成形、例えば、所望の型面を有する成形金型でコールドプレス成形されるが、更に高展開率部分については、真空成形により発泡樹脂基材２１を賦形しても良い。尚、ジャッキリッド等のリッド部品のようなフラット形状の部品においては、発泡樹脂シートに加熱軟化処理を行なわずにフラット形状に成形することができる。
【００５６】
上記発泡樹脂シートは、汎用の熱可塑性樹脂に発泡剤を添加した構成であり、熱可塑性樹脂としては、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、アイオノマー系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂等が使用でき、発泡剤としては、アゾジカルボンアミド等の有機発泡剤や重炭酸ナトリウム等の無機発泡剤が使用できる。この実施形態では、ポリプロピレン系樹脂に発泡剤として重炭酸ナトリウムを適宜添加した発泡樹脂シートを使用している。また、この発泡樹脂基材２１の発泡倍率は、２〜１０倍に設定され、厚みは０．５〜３０ｍｍ、特に１〜１０ｍｍの範囲に設定されている。
【００５７】
次いで、樹脂リブ２２は、発泡樹脂基材２１の裏面側に配設され、特に、図３に示すように、交差状に延びる所定パターンに設定されている。尚、このパターンは、縦横方向、斜め方向、あるいはその組み合わせ等、交差状であれば任意のパターンが選択されて良い。この樹脂リブ２２は、汎用の合成樹脂成形体からなり、通常好ましく使用できる合成樹脂として、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリスチレン系樹脂、ポリエチレンテレフタレート系樹脂、ポリビニルアルコール系樹脂、塩化ビニル系樹脂、アイオノマー系樹脂、ポリアミド系樹脂、アクリロニトリル／ブタジエン／スチレン（ＡＢＳ）樹脂、ポリカーボネート樹脂等から適宜選択されて良く、本実施形態では、環境面、リサイクル面を考慮してポリプロピレン系樹脂が使用されている。
【００５８】
また、この樹脂リブ２２には、上記熱可塑性樹脂中に適宜フィラー、例えば、ガラス繊維、カーボン繊維等の無機繊維や、タルク、クレイ、シリカ、炭酸カルシウム等の無機粒子等の充填剤が混入されていても良い。
【００５９】
このように、図１乃至図３に示すドアトリム１０は、積層構造体からなるドアトリムアッパー２０と、合成樹脂単体のドアトリムロアとから構成され、外観上のアクセント効果により、優れた外観意匠性を備えている。更にドアトリムアッパー２０は、保形性を有する発泡樹脂基材２１と、発泡樹脂基材２１の裏面に積層一体化される樹脂リブ２２と、加飾性を有する加飾材２３とから構成されているため、従来のように製品の全周に亘り占有していた樹脂芯材を廃止でき、かつ軽量な発泡樹脂基材２１を使用する関係で、製品の重量について、従来例に比し４０％以上の軽量化を図ることができるとともに、樹脂材料も大幅に節約でき、コストダウンにも貢献できる。
【００６０】
更に、発泡樹脂基材２１は、多孔質構造であるため、ドアトリムアッパー２０は、吸音性能に優れ、車室内の騒音を低減することができる。また、発泡樹脂基材２１の吸音性を維持するために、発泡樹脂基材２１の表面に予めラミネートされるか、または成形時に一体化されて積層一体化される加飾材２３は、織布、不織布、編布等の通気性を備えたシート材料が好ましい。尚、加飾材２３は、織布、不織布、編布等の通気性シート以外にも塩ビシートやＴＰＯシート等の合成樹脂シート、合成樹脂フィルム、発泡体、網状体を使用することができる。尚、ＴＰＯシートを使用した場合、オレフィン系樹脂材料で統一できるため、リサイクル面で有利である。
【００６１】
次に、ドアトリム１０におけるドアトリムアッパー２０の外周端末に沿う構造について、図４を基に説明する。すなわち、ドアトリムアッパー２０は、上述したように、保形性を有する軽量な発泡樹脂基材２１の裏面に、剛性を強化する樹脂リブ２２が一体化され、かつ発泡樹脂基材２１の表面には、加飾性を有する加飾材２３が積層一体化されている。更に、ドアトリムアッパー２０の製品外周部に沿って、製品に立体感を現出させるためのフランジ２１１が下向きに形成されるとともに、フロント側縁部は、このフランジ２１１から更に延長部２１２が水平状に延設され、その先端には、薄肉ヒンジ部２４を基に巻込み処理される巻込みシロ２５が設定されている。そして、この巻込みシロ２５は、延長部２１２の裏面に超音波溶着、あるいは熱溶着、接着止め等により固着され、車体パネル１６に対して面当て状態で当接している。
【００６２】
一方、ドアトリムアッパー２０のリヤ側縁部は、延長部２１２が省略され、フランジ２１１の先端に薄肉ヒンジ部２４を基に巻込み処理される巻込みシロ２５が設定されている。そして、ドアトリムアッパー２０のリヤ側縁部は、車体パネル１６に対して上記薄肉ヒンジ部２４が点当て状態で当接している。
【００６３】
従って、ドアトリムアッパー２０の外周縁部に薄肉ヒンジ部２４が該当するため、シャープな外周ラインが確保でき、外観見栄えに優れるとともに、延長部２１２の裏面に巻込みシロ２５が折り返された二重構造となっているため、外周部の剛性が強化でき、波打ち変形等の恐れがなく、車体パネル１６に対してスキなく密着でき、合わせ精度を高めることができるという利点がある。また、相手部品と一定クリアランスを設けた合わせ形状とする場合においても、その合わせ精度を高めることができる。
【００６４】
次に、ドアトリムアッパー２０の外周端末部の端末処理工程を含めたドアトリム１０の製造方法の概要について、以下に説明する。まず、図５で成形金型４０の全体構造について説明し、図６でドアトリムアッパー２０に対応する部位について、図７はドアトリムアッパーにおける外周部に対応するそれぞれ成形金型４０の構成について説明する。
【００６５】
図５において、ドアトリム１０の成形に使用する成形金型４０は、所定ストローク上下動可能な成形上型４１と、成形上型４１と対をなす固定側の成形下型４２と、成形下型４２に接続される２基の射出機４３ａ，４３ｂとから大略構成されている。
【００６６】
更に詳しくは、成形上型４１は、製品形状に合致したキャビティ部４１１が形成されており、成形上型４１の上面に連結された昇降シリンダ４１２により所定ストローク上下駆動される。また、成形上型４１の４隅部には、ガイド機構となるガイドブッシュ４１３が設けられている。
【００６７】
一方、成形下型４２には、成形上型４１のキャビティ部４１１に対応するコア部４２１が設けられている。また、このコア部４２１の型面に溶融樹脂を供給するために、マニホールド４２２ａ，４２２ｂ、ゲート４２３ａ，４２３ｂが設けられており、このマニホールド４２２ａ，４２２ｂ、ゲート４２３ａ，４２３ｂの樹脂通路を経て射出機４３ａ，４３ｂから供給される溶融樹脂Ｍ１，Ｍ２がコア部４２１の上面に形成された溝部４２４内、及びドアトリムロア３０を形成するためのキャビティ内に供給される。
【００６８】
また、成形下型４２の４隅部には、ガイド機構となるガイドポスト４２５が突設され、このガイドポスト４２５は、成形上下型４１，４２が型締めされる際、ガイドブッシュ４１３内に案内されることで成形上型４１のプレス姿勢を適正に維持できる。
【００６９】
図６は、図５に示す成形金型のＶＩ−ＶＩ線断面図を示すもので、ドアトリムアッパー２０を構成する発泡樹脂基材２１、樹脂リブ２２、加飾材２３を成形するための成形金型４０は、特に、成形下型４２において、コア部４２１の型面に所定パターン形状の樹脂リブ２２に対応する溝部４２４が設けられている。
【００７０】
また、このドアトリムアッパー２０に対応する部分における成形金型４０においては、特に、図７に示すように、ドアトリムアッパー２０の外周端末の巻込みシロ２５を形成するために、成形上型４１に凸条４１４が形成されており、この凸条４１４が発泡樹脂基材２１に薄肉ヒンジ部２４を形成する。
【００７１】
次いで、図８乃至図１２に基づいて、上述したドアトリム１０の製造方法の各工程について説明する。まず、図８に示すように、ヒーター装置５０により発泡樹脂シートＳの一方面に加飾材２３をラミネートしたものを所定温度に加熱軟化させる。この発泡樹脂シートＳとしては、ポリプロピレン製発泡シート（住化プラステック製、商品名：スミセラー発泡ＰＰシート、発泡倍率＝３倍、厚み３ｍｍ）が使用されている。
【００７２】
続いて、図９に示すように、加熱軟化処理した発泡樹脂シートＳ（加飾材２３をラミネートしている）をドアトリムアッパー２０対応箇所における成形上型４１のキャビティ部４１１と成形下型４２のコア部４２１で画成されるキャビティの上半部分にセットする。
【００７３】
そして、発泡樹脂シートＳをセットした後、成形上型４１の昇降シリンダ４１２が動作して、成形上型４１が所定ストローク下降して、図１０に示すように、成形上下型４１，４２が型締めされて発泡樹脂シートＳが所望の型面形状に沿って賦形され、発泡樹脂基材２１が成形されるとともに、第１の射出機４３ａからマニホールド４２２ａ、ゲート４２３ａを通じてドアトリムアッパー２０における樹脂リブ２２を形成するために、溶融樹脂Ｍ１がコア部４２１の溝部４２４内に射出充填される。
【００７４】
同時に、ドアトリムロア３０を成形するために、第２の射出機４３ｂからマニホールド４２２ｂ、ゲート４２３ｂを通じてキャビティの略下半部分に溶融樹脂Ｍ２が射出充填され、ドアトリムロア３０が所要形状に成形される。
【００７５】
従って、第１の射出機４３ａ、第２の射出機４３ｂからそれぞれ溶融樹脂Ｍ１，Ｍ２をキャビティ内に射出充填することにより、ドアトリムアッパー２０における樹脂リブ２２を所要形状に成形するとともに、これと一体にドアトリムロア３０が成形される。尚、この溶融樹脂Ｍ１，Ｍ２としては、住友ノーブレンＢＵＥ８１Ｅ６（住友化学工業製ポリプロピレン、メルトインデックス＝６５ｇ／１０分）でタルクが適宜割り合いで混入されている。尚、溶融樹脂Ｍ１，Ｍ２の射出のタイミングを成形上下型４１，４２の型締め前に設定しても良い。
【００７６】
このように、ツートンタイプのドアトリム１０を製造するには、成形下型４２に２基の射出機４３ａ，４３ｂを連結して、ドアトリムアッパー２０とドアトリムロア３０とについて、各樹脂通路を通じて溶融樹脂Ｍ１，Ｍ２を射出充填することで、単一の成形金型４０で、かつ工程数が短縮化された形でツートンタイプのドアトリム１０を製造することができる。
【００７７】
そして、上述したドアトリム１０の製造方法において、特に、ドアトリムアッパー２０については、図１１に示すように、成形上型４１と成形下型４２との間で発泡樹脂基材２１及び加飾材２３が所望の曲面形状に成形され、かつ成形下型４２の溝部４２４内に溶融樹脂が射出充填され、樹脂リブ２２を一体成形する際、成形上型４１に形成されている凸条４１４により、発泡樹脂基材２１に薄肉ヒンジ部２４が形成され、その外側部分は、巻込みシロ２５として画定される。
【００７８】
従って、ドアトリムアッパー２０及びドアトリムロア３０の成形完了後、成形上型４１が上昇して型開きが行なわれた後、成形金型４０から成形品を取り出し、次いで、図１２に示すように、ドアトリムアッパー２０における外周端末において、薄肉ヒンジ部２４を折返し基点としてその外周に位置する巻込みシロ２５を発泡樹脂基材２１の裏面に超音波溶着、あるいは熱溶着、または接着止め、機械止め等により固着すれば、図４に示すように、ドアトリムアッパー２０の外周端末は、薄肉ヒンジ部２４が対応し、外周端末の見栄えが良く、かつ二重構造となり、剛性も強化されたドアトリムアッパー２０の端末処理が完了する。尚、この方式では、ドアトリムアッパー２０における樹脂リブ２２の素材とドアトリムロア３０の素材を相違させることができ、それぞれの要求される項目に応じて、材料を適宜変更することができる。
【００７９】
また、ドアトリムアッパー２０とドアトリムロア３０とに分岐して供給される溶融樹脂Ｍ１，Ｍ２を同一素材として、１基の射出機４３から供給することもできる。この場合は、射出機４３と連通するメインのマニホールドからドアトリムアッパー２０側に供給する溶融樹脂Ｍ１の通路となる分岐マニホールドと、ドアトリムロア３０に溶融樹脂Ｍ２を供給する樹脂通路の分岐マニホールドとを設定して行なえば良い。
【００８０】
次いで、図１３乃至図１５は、本発明の第２実施形態を示すもので、この第２実施形態においては、成形金型４０において、成形下型４２のドアトリムアッパー２０対応箇所において押圧機構４４が設けられている。
【００８１】
この押圧機構４４は、押圧ブロック４４１と、駆動シリンダ４４２により構成されており、この押圧機構４４は、成形上型４１に形成されている薄肉ヒンジ部２４を形成するための凸条４１４の直下に位置する。
【００８２】
そして、まず、図１３に示すように、加熱軟化状態にある発泡樹脂シートＳ（表面側に加飾材２３の原反シートがラミネートされている）を成形下型４２の型面上に加熱軟化状態でセットした後、成形上型４１が下降動作すると同時に、押圧機構４４における押圧ブロック４４１が駆動シリンダ４４２の動作により上昇し、この押圧ブロック４４１が成形上型４１の型面に対して発泡樹脂シートＳを押圧することで、発泡樹脂シートＳに薄肉ヒンジ部２４が形成される。
【００８３】
更に、この状態、すなわち、発泡樹脂シートＳの外周部に沿って成形上型４１と押圧ブロック４４１とで挟み込んだ状態で成形上型４１が下降して発泡樹脂基材２１を所望形状に成形すると同時に、駆動シリンダ４４２が収縮動作することで、成形上型４１と連繋して押圧ブロック４４１もそれと連動して下降する（図１４参照）。
【００８４】
そして、成形が完了して、成形上型４１が上昇して型開きが行なわれた後、ドアトリムアッパー２０（図示はしないがドアトリムロア３０と一体化されている）を脱型した後、薄肉ヒンジ部２４を折返し基点として巻込みシロ２５を発泡樹脂基材２１の裏面側に巻込み処理すれば、簡単に端末処理が行なえる。
【００８５】
また、この第２実施形態においては、成形上型４１と成形下型４２との側壁面とのクリアランスを適切位置に設定することで、剛性の強化された剛性強化部２６を設定することができる利点がある。
【００８６】
次いで、図１６乃至図１９は、本発明の第３実施形態を示すもので、図１６，図１７は、第３実施形態に使用する成形金型４０の要部を示す斜視図並びに断面図、図１８は、第３実施形態における端末部の成形工程を示す説明図、図１９は、端末処理工程を示す説明図である。
【００８７】
すなわち、この第３実施形態においては、図１６，図１７に示すように、成形下型４２の外側面に成形金型４０の開閉方向と同一方向の断面において鋸刃形状をなす切削部４５がドアトリムアッパー２０該当部分の外周縁に沿って形成されている。
【００８８】
従って、成形金型４０内に加熱軟化処理を施した発泡樹脂シートＳ（一面に加飾材２３の原反シートがラミネートされている）をセットした後、成形金型４０の型締め時、成形上下型４１，４２のキャビティ形状に沿って発泡樹脂基材２１及び加飾材２３が所望の曲面形状に成形される成形工程において、特にコア部４２１の側壁面に沿って切削部４５が形成されているため、成形上型４１の下降により、この切削部４５と成形上型４１の内面との間で発泡樹脂基材２１が押し切られるように削り取られ、巻込みシロ２５相当箇所（折返しラインＰより下部側）の発泡樹脂基材２１が切削されることで、薄肉状の巻込みシロ２５を簡単に形成できる。次いで、図１８に示すように、加飾材２３と削り取られた後の発泡樹脂の残骸からなる巻込みシロ２５を発泡樹脂基材２１の裏面に巻込み処理すれば良く、この第３実施形態においては、発泡樹脂基材２１の成形と同時に巻込みシロ２５を薄肉状及び可撓性をもつように形成することができ、巻込みシロ２５の巻込み端末処理工程を円滑に行なうことができるという利点がある。
【００８９】
【発明の効果】
以上説明した通り、本発明に係る自動車用内装部品は、軽量でかつ保形性を有する発泡樹脂基材と、この発泡樹脂基材の裏面で、かつ製品の外周縁など、剛性が要求される部位に積層一体化される樹脂リブと、発泡樹脂基材の表面に積層される加飾材とから構成されるため、従来の重量の嵩む樹脂芯材を廃止できることから、軽量で低コスト、しかも多孔質素材であるため、吸音性能に優れた自動車用内装部品を提供できるという効果を有する。
【００９０】
更に、成形金型のキャビティ形状に沿って、発泡樹脂基材を所要形状に成形すると同時に発泡樹脂基材の裏面側に樹脂リブを成形するという工程を採用すれば、樹脂成形体である樹脂リブの投影面積が少ないため、従来の樹脂芯材に比べ、成形金型にかかる負荷も少なく、かつ冷却時間も短縮化でき、歩留まりを高めることができることから、作業能率を高めることができるとともに、大幅なコストダウンを招来できるという作用効果を有する。
【００９１】
また、本発明に係る自動車用内装部品における外周端縁部は、発泡樹脂基材に形成された薄肉ヒンジ部を折返し基点として巻込みシロが発泡樹脂基材裏面に巻込み処理されていることにより、外周端末部は薄肉ヒンジ部が該当するため、シャープな外周ラインが形成でき、外観意匠性に優れるとともに、特に、端末部分においては、折り返した二重構造であるため、剛性が強化されており、波打ち不良等が生じることがなく、かつパネルまたは隣接する相手部品に対する合わせ精度を高めるなどの種々の効果を有する。
【００９２】
更に、本発明方法の別態様として、発泡樹脂基材の成形時に折返し基点を基に外周部の外側部分を成形金型の合わせにより切削処理して薄肉状の巻込みシロを形成する構成を採用すれば、巻込みシロの可撓性を利用して裏面への巻込み処理を円滑に行なえ、端末処理作業を円滑に行なうことができるという効果を有する。
【図面の簡単な説明】
【図１】本発明に係る自動車用内装部品を適用した自動車用ドアトリムの第１実施形態を示す正面図である。
【図２】図１中ＩＩ−ＩＩ線断面図である。
【図３】図１に示す自動車用ドアトリムにおけるドアトリムアッパーの樹脂リブとドアトリムロアとを示す正面図である。
【図４】図１中ＩＶ−ＩＶ線断面図であり、ドアトリムアッパーの外周端末部の構成を示す断面図である。
【図５】図１に示す自動車用ドアトリムを成形する際に使用する成形金型の構成を示す全体図である。
【図６】図５中ＶＩ−ＶＩ線断面図である。
【図７】図６に示す成形金型の外周部を示す断面図である。
【図８】図１に示す自動車用ドアトリムの製造方法における発泡樹脂シートの予熱工程を示す説明図である。
【図９】図１に示す自動車用ドアトリムの製造方法における発泡樹脂シートのセット工程を示す説明図である。
【図１０】図１に示す自動車用ドアトリムの製造方法における発泡樹脂基材及び樹脂リブの成形工程を示す説明図である。
【図１１】図１に示すドアトリムアッパーにおける薄肉ヒンジ部の形成工程を示す説明図である。
【図１２】図１に示すドアトリムアッパーにおける巻込みシロの端末処理工程を示す説明図である。
【図１３】本発明方法の第２実施形態に使用する成形金型の要部を示す説明図である。
【図１４】図１３に示す成形金型を使用してドアトリムアッパーを成形する工程を示す説明図である。
【図１５】本発明方法の第２実施形態で成形されたドアトリムアッパーの外周部を示す断面図である。
【図１６】本発明方法の第３実施形態に使用する成形金型の要部を示す斜視図である。
【図１７】本発明方法の第３実施形態に使用する成形金型の要部を示す図１６中ＸＶＩＩ−ＸＶＩＩ線断面図である。
【図１８】図１６に示す成形金型を使用してドアトリムアッパーを成形する工程を示す説明図である。
【図１９】本発明方法の第３実施形態におけるドアトリムアッパーの端末処理工程を示す説明図である。
【図２０】従来の自動車用ドアトリムを示す正面図である。
【図２１】図２０中ＸＸＩ −ＸＸＩ 線断面図である。
【図２２】従来の自動車用ドアトリムの成形金型を示す説明図である。
【図２３】プレス成形による自動車用ドアトリムの端末部分の従来例を示す説明図である。
【図２４】表皮巻込みタイプの自動車用ドアトリムにおける端末部分の従来例を示す説明図である。
【符号の説明】
１０ ツートンタイプの自動車用ドアトリム
１１ インサイドハンドルエスカッション
１２ パワーウインドウスイッチエスカッション
１３ ポケット用開口
１４ ポケットバックカバー
１５ スピーカグリル
２０ ドアトリムアッパー
２１ 発泡樹脂基材
２１１ フランジ
２１２ 延長部
２２ 樹脂リブ
２３ 加飾材
２４ 薄肉ヒンジ部
２５ 巻込みシロ
２６ 剛性強化部
３０ ドアトリムロア
４０ 成形金型
４１ 成形上型
４２ 成形下型
４３ａ，４３ｂ 射出機
４４ 押圧機構
４４１ 押圧ブロック
４４２ 駆動シリンダ
４５ 切削部
５０ ヒーター装置
Ｓ 発泡樹脂シート
Ｍ１，Ｍ２ 溶融樹脂
Ｐ 折返しライン[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, rear side trims and the like, and a method of manufacturing the same and a molding die, and in particular, is lightweight and has excellent appearance at the outer peripheral end and excellent mechanical strength. In addition, the present invention relates to an automobile interior part which can be manufactured easily and at low cost, a method for manufacturing the same, and a molding die.
[0002]
[Prior art]
For example, the configuration of an interior part for a vehicle will be described with reference to FIGS. 20 and 21 exemplifying a door trim. The door trim 1 has a shape retention property and a rigidity for mounting to a vehicle body panel, and is formed by laminating and integrating a skin 3 having excellent surface appearance on a surface of a resin core material 2 extending over almost the entire product surface. I have.
[0003]
The resin core material 2 is made of a polypropylene-based resin mixed with talc, and the skin 3 itself does not have a shape-retaining property, and a polyethylene foam or the like is formed on the back surface of a synthetic resin sheet such as a PVC sheet. A laminated sheet material in which a cushion material is laminated is used, and in recent years, an elastomer sheet such as a TPO (thermoplastic olefin) sheet tends to be frequently used in consideration of environment and recycling.
[0004]
Next, a conventional example of the method of forming the door trim 1 will be described with reference to FIG. First, a molding die 4 for molding the door trim 1 is connected to a molding upper die 5 that can move up and down by a predetermined stroke, a fixed lower molding die 6 that forms a pair with the molding upper die 5, and a molding lower die 6. It is generally constituted by an injection machine 7.
[0005]
When the upper and lower molds 5 and 6 are clamped, a cavity 5a is formed in the upper mold 5 and a core 6a is provided in the lower mold 6 to form the product shape of the door trim 1. I have. In order to move the upper molding die 5 up and down by a predetermined stroke, an elevating cylinder 5b is connected, and the lower molding die 6 is provided with a manifold 6b and a gate 6c that serve as a passage for the molten resin from the injection machine 7.
[0006]
The upper mold 5 that moves up and down is provided with guide posts 6d at four corners of the lower mold 6 in order to maintain a proper posture, and the upper mold 5 corresponds to the guide posts 6d. A bush 5c is provided.
[0007]
Therefore, when the upper and lower molds 5 and 6 are in the mold open state, the skin 3 is set in the mold, and thereafter, either immediately before or after the mold upper and lower molds 5 and 6 are clamped. The resin core material 2 is formed into a required curved surface shape by injecting and filling the molten resin M from the injection machine 7 into the product cavity between the two dies through the manifold 6b and the gate 6c at the timing. The skin 3 is integrally formed on the surface (for example, see Patent Document 1).
[0008]
In FIG. 22, for convenience of explanation, the molten resin M is supplied to the mold surface of the core portion 6a in an open state, but actually, the molten resin M is injected into the cavity after clamping the upper and lower molds 5, 6. It may be filled.
[0009]
Further, as for the treatment of the outer peripheral end of the door trim 1 product, as shown in FIG. Cut processing is being performed.
[0010]
Further, as shown in FIG. 24, after press-molding the core material 2, the skin 3 is integrated by a separate process such as vacuum pressure bonding and press bonding, and then the terminal 3 a of the skin 3 is wound around the back surface of the core material 2. Processing is also conventionally performed.
[0011]
[Patent Document 1]
JP-A-10-138268 (page 2, FIG. 3, FIG. 4)
[0012]
[Problems to be solved by the invention]
However, it has been pointed out that the conventional door trim 1 has a problem that the projected area of the resin core 2 is large, so that the material cost is high and the product is heavy.
[0013]
In addition, since the projected area of the resin core material 2 is large, the injection pressure at the time of molding must be set high, and a mold structure that can withstand the high injection pressure is required. In addition, since a large amount of molten resin is cooled and solidified, the molding cycle is prolonged, which is a major factor in lowering productivity.
[0014]
Further, as shown in FIG. 23, when the skin is simultaneously pressed at the outer peripheral edge of the door trim 1, it is difficult to finish the outer periphery, the appearance is poor, and there are disadvantages that the appearance performance is deteriorated. As shown in (1), in the method of winding and treating the skin 3 in a separate step, the number of steps is large and the cost is unavoidable.
[0015]
The present invention has been made in view of such circumstances, and it is possible to provide an automobile interior part that can promote weight reduction, achieve high rigidity and reduce costs, reduce molding die costs, and shorten the molding cycle. It is an object of the present invention to provide an automobile interior part having improved appearance performance by enhancing the appearance and rigidity of a product outer peripheral end portion, and a method of manufacturing the same, and a molding die.
[0016]
[Means for Solving the Problems]
The present inventors have conducted intensive studies to solve the above-mentioned problems, and as a result of imparting shape retention to a foamed resin sheet conventionally used as a skin, have a function as a core material. In places where rigidity is required, that is, in areas where products can be closely contacted at the periphery, panels, mating parts with mating parts, or places where a certain clearance is secured, or where parts are attached and where loads are applied, resin with excellent rigidity is used. By arranging the ribs, the weight can be reduced as compared with the conventional resin core material with a large projected area, and the outer peripheral end treatment of the product is simple and beautiful simply by attaching the winding part to the foamed resin base material They have found that terminal processing can be achieved, and have completed the present invention.
[0017]
That is, the automotive interior part according to the present invention is a lightweight, foamed resin base material having shape retention properties, a resin rib laminated and integrated on the back surface of the foamed resin base material, An automotive interior part made of a decorative material laminated and integrated on the surface, the winding of the outer periphery of the thin hinge portion based on the thin hinge portion provided on the foamed resin base material, slightly along the outer periphery of the product. It is characterized in that the shiro is wound around the back surface of the foamed resin base material.
[0018]
Further, another embodiment of the present invention is a light-weight, shape-retaining foamed resin substrate, a resin rib laminated and integrated on the back surface of the foamed resin substrate, and a surface of the foamed resin substrate. An automotive interior part comprising a decorative material laminated and integrated with the foamed resin base material from the folding line set along the inner periphery of the product outer periphery to the outer peripheral end, and provided with flexibility. It is formed as a roll-in roll, and is characterized in that the roll-in roll is wound on the back side of the foamed resin base material based on the folded line.
[0019]
Here, as interior parts for automobiles, door trim, rear parcel shelf, floor trim, luggage trim, trunk trim, rear side trim, and the like can be applied.
[0020]
When the foamed resin base material that is lightweight and has shape retention properties is close to a flat shape, the heating and softening step is omitted and it is molded into a desired shape by a molding die. After heating and softening the foamed resin sheet, the foamed resin sheet is formed into a required curved shape in a molding die, thereby maintaining the shape. The term "shape retention" as used herein means that even if there is no reinforcing material such as a rib, when the mold is released from the mold, it has such a rigidity that the shape is maintained. When the product shape includes a high expansion rate portion, after heating and softening the foamed resin sheet, a vacuum suction mechanism is arranged in the molding die and a vacuum is applied to the foamed resin sheet along the inner surface of the molding die. A suction force may be applied.
[0021]
As the foamed resin sheet, a material obtained by adding a foaming agent to a thermoplastic resin is used. Incidentally, the thermoplastic resin may be composed of one kind of thermoplastic resin or two or more kinds of thermoplastic resins. Preferably, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin and the like can be used.
[0022]
As the foaming agent, an organic foaming agent such as an azo compound, a sulfohydrazide compound, a nitroso compound, and an azide compound, or an inorganic foaming agent such as sodium bicarbonate can be used.
[0023]
The foamed resin substrate obtained by molding the foamed resin sheet into a required shape after the heat softening treatment has a foaming ratio of 2 to 10 times in consideration of the balance between the weight and the strength of the product. The cell diameter of the foamed resin substrate at that time is preferably in the range of 0.1 μm to 2.0 mm, and the thickness is preferably 0.5 to 30 mm, and more preferably 1 to 10 mm.
[0024]
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 preferred are polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, ionomer resins, polyamide resins, acrylonitrile / butadiene / styrene (ABS). Resin, polycarbonate resin and the like can be used.
[0025]
Various fillers may be mixed in these thermoplastic resins. Examples of the filler that can be used include inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica, and calcium carbonate. Further, various additives such as an antioxidant, an ultraviolet absorber, a coloring agent, a flame retardant, and a low shrinkage agent may be blended.
[0026]
As the decorative material laminated and integrated on the surface of the foamed resin base material in order to enhance the appearance design, a woven fabric, a nonwoven fabric, a knitted fabric, a sheet, a film, a foam, a mesh, and the like can be used. The material constituting these decorating materials is not particularly limited, but it is preferable to use a material having air permeability such as a woven fabric, a nonwoven fabric, and a knitted fabric in order to make use of the sound absorbing performance of the foamed resin base material. Further, when a TPO sheet is used as a decorating material, the material can be unified to an olefin-based resin, so that the recycling operation can be performed smoothly.
[0027]
Further, the outer peripheral edge of the interior part has a thin hinge portion which is a folded line formed on the foamed resin base material, and the outer winding roll is wound on the back side of the foamed resin base material based on the thin hinge portion. Is being processed.
[0028]
Further, as another mode of the terminal treatment, the foamed resin base material in the outer portion from the folding line is scraped off, and the outer portion from the folding line is formed as a winding portion having flexibility of only the decorative material. What is necessary is just to carry out a winding part to the back side of a foamed resin base material.
[0029]
According to the automotive interior part according to the present invention, a decorative material having a decorative property is laminated on the front side of the foamed resin base material having a shape-retaining property, and the resin is formed on the back side in the sense of enhancing rigidity. Since the ribs are laminated and integrated, the conventional resin core material can be eliminated. Therefore, by eliminating the conventional resin core material having a very large projected area, the weight of the product can be reduced, and the resin material can be saved, so that the material cost can be reduced at the same time.
[0030]
Furthermore, as for the outer peripheral portion of the interior part, since the outer portion is rolled up as a wrap around the thin hinge portion as a base point, the cut end is not conspicuous outside, the appearance is excellent in design and the terminal portion is In addition, the foamed resin substrate has a double structure, and the rigidity can be enhanced.
[0031]
Furthermore, if a configuration is adopted in which the foamed resin base material on the outer side of the folded line of the foamed resin base material is scraped off, the cutting edge is not conspicuous to the outside and the structure of the roll-in portion is almost entirely made of decorative material. Since it has flexibility, the winding operation can be performed smoothly.
[0032]
In addition, due to the porous sound absorbing function of the foamed resin base, interior parts with excellent sound absorption performance can be obtained, and when polyolefin based resin is used as the material of the foamed resin base and the resin ribs, Because they are unified, the separation process can be eliminated and the recycling operation can be simplified.
[0033]
In addition, the rib thickness of the resin rib should be appropriately changed, for example, by setting the rib thickness to be thicker at a part where external force is greatly applied to the product, and by thinning the rib thickness at a part where relatively less external force is applied. Can be. Therefore, it is sufficient to use the minimum necessary resin material, which can contribute to a reduction in the weight and cost of the product. Further, a clip seat or a mounting seat for mounting various escutcheon parts can be integrally formed with the resin rib.
[0034]
Next, the method for manufacturing an automobile interior part according to the present invention comprises: a lightweight and foam-retaining foamed resin substrate; a resin rib laminated and integrated on the back surface of the foamed resin substrate; In a method for manufacturing an automotive interior part comprising a decorative material laminated on a surface of a base material, a setting step of a foamed resin sheet for setting a foamed resin sheet as a material of a foamed resin base material in a molding die Then, the molding dies are clamped to each other, and the foamed resin base material is formed into a required shape in a product cavity shape of the molding die, and a thin hinge portion is formed along a folding line slightly inside from the outer peripheral edge of the foamed resin base material. On the other hand, the molten resin is injected and filled into the groove of the lower mold immediately before or after the mold clamping of the molding die, and the resin rib is laminated on the back side of the foamed resin base material. Integrated resin foam and resin rib An integrated process and a terminal treatment process of an interior component in which the integrated laminated product is opened after the mold is opened, then released, and the wraparound shiro is folded and fixed to the back surface of the foamed resin base material based on the thin hinge portion. And characterized by the following.
[0035]
Here, the molding die used in the method of the present invention is connected to the molding upper die that can move up and down by a predetermined stroke, the molding lower die that is a fixed side located below the molding upper die, and the molding lower die. It consists of an injection machine.
[0036]
The molten resin supplied from the injection machine is supplied through a resin passage such as a manifold or a gate provided in the lower mold to a mold surface of the lower mold, specifically, a groove formed on the mold surface of the lower mold. However, after the upper mold is lowered to the bottom dead center and the upper and lower molds are clamped, the molten resin may be injected and filled into the groove provided on the mold surface of the lower mold at a predetermined injection pressure. Although good, the timing of injection filling of the molten resin may be performed before the mold clamping.
[0037]
Furthermore, the mold surface of the upper and lower molds is set to a desired curved shape that matches the product shape, but in consideration of the winding process of the outer peripheral end portion, a ridge is formed on one side of the upper and lower molds. A thin hinge portion which is provided and serves as a turning base of the winding white is formed on the foamed resin base material.
[0038]
Therefore, by closing the upper and lower molds, the foamed resin sheet is formed into a desired curved shape along the mold surface shape of the molding die, and a thin hinge portion is formed slightly inside along the outer peripheral edge. become. Further, the resin rib is laminated and integrated on the back surface of the foamed resin base material by injection filling with the molten resin.
[0039]
Then, when the product shape is set to a three-dimensional shape, after performing heat softening treatment by a heater or the like in all steps, the foamed resin sheet is set in a molding die.
[0040]
Further, after supplying the foamed resin sheet in a heat-softened state into the molding die, the molding die is clamped to obtain a foamed resin base material having a shape retention property molded into a desired shape. A thin hinge portion serving as a turning base point is formed on the base material during the turning process of the winding white.
[0041]
Then, simultaneously with the molding of the foamed resin substrate, the resin ribs may be laminated and integrated on the back surface of the foamed resin substrate. In the case where the final product shape has a high expansion rate portion, it is preferable to perform mold clamping of the molding die a plurality of times and perform injection filling of the molten resin in the final mold clamping step. If the product shape includes a higher expansion rate part, a vacuum suction mechanism is provided on the upper mold, and the foamed resin base material is formed into the required shape by the vacuum suction force along the mold surface of the upper mold. Good to do.
[0042]
Therefore, according to the method of the present invention, since only the resin rib is molded as compared with the conventional resin core material having a large projected area, the injection pressure can be set lower than in the conventional case, so that the load on the molding die can be reduced. At the same time, the resin amount is small, the material cost can be saved, and the cooling time can be reduced as compared with the conventional resin core material, so that the molding cycle of the product can be shortened.
[0043]
Further, as a terminal treatment step, a decorative molded material, a foamed resin base material, and a laminated molded body in which the resin ribs are integrated are taken out of a molding die, and the thin hinge portion provided on the foamed resin base material is turned back as a starting point to form an outer periphery. It is only necessary to fold the wrap around the back along the back of the foamed resin substrate, and the outer peripheral edge of the product corresponds to the thin hinge part, so a sharp outer peripheral line can be secured, and the terminal part has a double structure , The rigidity can be strengthened and there is no fear of deformation.
[0044]
Next, as another embodiment of the method of the present invention, in the step of integrating the foamed resin substrate and the resin rib, the molding dies are clamped with each other, and the foamed resin substrate is formed into a product cavity shape of the molding die. Molding, injection of molten resin into the groove of the lower mold at any time immediately before or after clamping of the molding die, and lamination and integration of resin ribs on the back side of the foamed resin base material On the other hand, a pressing mechanism is provided along the part to be wound in the outer periphery of the lower molding die, and a pressing block in the pressing mechanism is driven up and down by a driving cylinder to be slightly inward from the outer peripheral edge of the foamed resin base material. A thin hinge portion serving as a folding base point of the winding white is formed along the thinner hinge portion.
[0045]
Here, a molding die used in the method is a lightweight and foam-retaining foamed resin substrate, a resin rib laminated and integrated on the back surface of the foamed resin substrate, and the foamed resin substrate. A molding die for molding an automotive interior part comprising a decorative material laminated on the surface of the molding die, wherein the molding dies are mutually clamped, and a mold upper mold and a mold lower mold capable of opening the mold, An injection machine connected to a lower molding die and supplying a molten resin as a material of a resin rib, and a product cavity between the upper and lower molding dies is set to a shape corresponding to a product shape of a foamed resin base material. At the same time, a groove corresponding to the resin rib is provided on the core portion mold surface of the lower molding die, and along the outer peripheral edge of the lower molding die, a thin hinge portion serving as a turning base point of the winding white of the foamed resin base material is formed. A pressing mechanism for forming is provided.
[0046]
As still another embodiment of the method of the present invention, a foamed resin base material which is lightweight and has shape retention properties, a resin rib laminated and integrated on the back surface of the foamed resin base material, In a method for manufacturing an automotive interior component comprising a decorative material laminated on a surface of a material, a setting step of a foamed resin sheet for setting a foamed resin sheet as a material of a foamed resin base material in a molding die, A saw formed on the wall of the lower molding die by clamping the molding dies together, molding the foamed resin base along the product cavity shape of the molding die, and along the product edge of the foamed resin base. By cutting off the foamed resin base material corresponding to the wrap-around white, the molten resin is injected and filled into the groove of the lower molding die immediately before or after the die clamping of the molding die. The resin ribs are laminated and integrated on the back side of the foamed resin base material. The process of integrating the foamed resin base and the resin ribs, and the removal of the foamed resin base in which the resin ribs are integrated from the molding die, and the thin-walled flexible roll-in obtained by scraping off the foamed resin base. And a terminal treatment step of the interior component in which the shiro is folded and fixed to the back surface of the foamed resin base material.
[0047]
The molding die used for this is a lightweight and foam-retaining foamed resin substrate, a resin rib laminated and integrated on the back surface of the foamed resin substrate, and a surface of the foamed resin substrate. A molding die for molding an automotive interior part comprising a decorative material laminated on the upper and lower molding dies, which are mold-clamped and openable with each other. An injection machine connected to the mold and supplying a molten resin as a material for the resin ribs, and a saw for cutting a roll-in roll on the outer peripheral edge of the foamed resin base material on the outer peripheral surface of the lower molding die. A cutting portion having a blade shape is set.
[0048]
BEST MODE FOR CARRYING OUT THE INVENTION
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of an automotive interior part, a method for manufacturing the same, and a molding die according to the present invention will be described below by exemplifying an automobile door trim and a method for manufacturing the same.
[0049]
1 to 12 show a first embodiment of the present invention. FIG. 1 is a front view showing a two-ton type vehicle door trim, FIG. 2 is a sectional view showing a configuration of the vehicle door trim, and FIG. FIG. 4 is a front view showing a resin trim and a door trim lower of the door trim upper in the door trim; FIG. 4 is a cross-sectional view showing a configuration of an outer peripheral edge of the door trim upper in the automobile door trim; FIGS. FIG. 5 is an overall view of the molding die, FIG. 6 is a cross-sectional view showing a door trim upper forming portion in the molding die, and FIG. 7 is an enlarged cross-sectional view of an outer peripheral portion of the door trim upper forming portion. . 8 to 12 show steps of a method for manufacturing the automobile door trim, FIG. 8 shows a preheating step of the foamed resin sheet, FIG. 9 shows a step of setting the foamed resin sheet in a molding die, and FIG. 10 shows a door trim. FIG. 11 is an explanatory view showing a winding white molding step, and FIG. 12 is an explanatory view showing a winding white end processing step.
[0050]
FIGS. 13 to 15 show a second embodiment of the present invention. FIGS. 13 and 14 are explanatory views showing a step of forming a winding white on an outer peripheral edge of a door trim upper, and FIG. It is explanatory drawing which shows the terminal processing process of Shiro. FIGS. 16 to 19 show a third embodiment of the present invention. FIGS. 16 and 17 are a perspective view and a sectional view showing a main part of a molding die used in the third embodiment, and FIG. FIG. 19 is an explanatory view of forming a winding portion using a molding die, and FIG. 19 is an explanatory view showing a terminal processing step of a winding white.
[0051]
First, a first embodiment of the present invention will be described with reference to FIGS. 1 and 2, a two-ton type vehicle door trim 10 is composed of an upper and lower two-piece body including a door trim upper 20 formed of a laminated structure and a door trim lower 30 formed of a single resin product.
[0052]
As functional components mounted on the door trim 10, an inside handle escutcheon 11 and a power window switch escutcheon 12 are attached to a door trim upper 20. An opening 13 for a door pocket is opened in the door trim lower 30, and a pocket back cover (made of a resin molded body) 14 is attached to the back side of the door trim lower 30, as shown in FIG. The speaker grill 15 is formed integrally or separately on the side.
[0053]
By the way, the automotive door trim 10 according to the present invention applies the present invention to the structure of the door trim upper 20, which is a laminated structure, to reduce the weight of the product, enhance the appearance of the outer peripheral terminal portion, and form The feature is that the processing steps are simplified.
[0054]
That is, as shown in FIG. 2, the door trim upper 20 is formed into a desired curved shape and has a shape-retaining foamed resin base material 21 and a resin laminated and integrated on the back side of the foamed resin base material 21. A rib 22 and a decorating material 23 having a decorating function that is laminated and integrated on the surface side of the foamed resin base material 21 are roughly constituted. Reference numeral 16 in the figure indicates a vehicle body panel.
[0055]
In addition, the foamed resin base material 21 is subjected to a heat-softening treatment on the foamed resin sheet so as to have shape-retaining properties, and then thermoformed into a required shape, for example, cold-pressed with a molding die having a desired mold surface. Further, the foamed resin base material 21 may be shaped by vacuum molding for a portion having a higher expansion rate. In the case of a flat component such as a lid component such as a jack lid, the foamed resin sheet can be formed into a flat shape without performing a heat softening treatment.
[0056]
The foamed resin sheet has a configuration in which a foaming agent is added to a general-purpose thermoplastic resin. Examples of the thermoplastic resin include polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, and chloride resin. A vinyl resin, an ionomer resin, an acrylonitrile / butadiene / styrene (ABS) resin or the like can be used. As a foaming agent, an organic foaming agent such as azodicarbonamide or an inorganic foaming agent such as sodium bicarbonate can be used. In this embodiment, a foamed resin sheet obtained by appropriately adding sodium bicarbonate as a foaming agent to a polypropylene resin is used. The expansion ratio of the foamed resin substrate 21 is set to 2 to 10 times, and the thickness is set to 0.5 to 30 mm, particularly 1 to 10 mm.
[0057]
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 crosswise as shown in FIG. Note that any pattern may be selected as long as the pattern is a cross, 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, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, a vinyl chloride resin, The resin may be appropriately selected from an ionomer resin, a polyamide resin, an acrylonitrile / butadiene / styrene (ABS) resin, a polycarbonate resin, and the like. In the present embodiment, a polypropylene resin is used in consideration of the environment and recycling. .
[0058]
In addition, fillers such as inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica, and calcium carbonate are mixed into the resin rib 22 as appropriate. May be.
[0059]
As described above, the door trim 10 shown in FIGS. 1 to 3 includes the door trim upper 20 formed of a laminated structure and the door trim lower made of a synthetic resin alone, and has excellent appearance design due to an accent effect on the appearance. ing. Further, the door trim upper 20 is composed of a foamed resin base material 21 having shape retention properties, a resin rib 22 laminated and integrated on the back surface of the foamed resin base material 21, and a decorating material 23 having decorating properties. Therefore, the resin core material occupying the entire circumference of the product as in the related art can be eliminated, and the weight of the product is reduced by 40% compared to the conventional example because the lightweight foamed resin base material 21 is used. The above reduction in weight can be achieved, and the amount of resin material can be greatly reduced, contributing to cost reduction.
[0060]
Furthermore, since the foamed resin base material 21 has a porous structure, the door trim upper 20 has excellent sound absorbing performance and can reduce noise in the vehicle interior. Further, in order to maintain the sound absorbing property of the foamed resin base material 21, the decorative material 23 which is preliminarily laminated on the surface of the foamed resin base material 21 or integrated and laminated and integrated at the time of molding is made of a woven fabric. A sheet material having air permeability, such as a nonwoven fabric or a knitted fabric, is preferable. In addition, as the decorative material 23, a synthetic resin sheet such as a PVC sheet or a TPO sheet, a synthetic resin film, a foam, or a net can be used in addition to a breathable sheet such as a woven fabric, a nonwoven fabric, and a knitted fabric. In addition, when a TPO sheet is used, it can be unified with an olefin-based resin material, which is advantageous in terms of recycling.
[0061]
Next, the structure of the door trim 10 along the outer peripheral terminal of the door trim upper 20 will be described with reference to FIG. That is, as described above, the door trim upper 20 has the resin ribs 22 for enhancing rigidity integrated on the back surface of the lightweight foamed resin base material 21 having shape-retaining property, and the front surface of the foamed resin base material 21 The decorative material 23 having decorative properties is laminated and integrated. Further, a flange 211 for giving a three-dimensional appearance to the product is formed downward along the outer peripheral portion of the door trim upper 20, and the front side edge portion is further extended horizontally from the flange 211 so that the extension portion 212 is horizontal. , And at the end thereof, a winding white 25 which is wound on the basis of the thin hinge portion 24 is set. Then, the winding silo 25 is fixed to the back surface of the extension portion 212 by ultrasonic welding, heat welding, adhesive stop, or the like, and is in contact with the vehicle body panel 16 in a surface contact state.
[0062]
On the other hand, at the rear edge of the door trim upper 20, the extension portion 212 is omitted, and the end of the flange 211 is provided with a winding white 25 which is wound on the basis of the thin hinge portion 24. The thin hinge portion 24 is in contact with the vehicle body panel 16 at the rear edge of the door trim upper 20.
[0063]
Therefore, since the thin hinge portion 24 corresponds to the outer peripheral edge of the door trim upper 20, a sharp outer peripheral line can be secured, the appearance is excellent, and the double-sided structure in which the winding white 25 is folded back on the back surface of the extension portion 212 is provided. Therefore, there is an advantage that the rigidity of the outer peripheral portion can be strengthened, there is no possibility of waving deformation or the like, the body can be closely attached to the vehicle body panel 16, and the alignment accuracy can be improved. Further, even in the case of a mating shape having a certain clearance with the mating component, the mating accuracy can be improved.
[0064]
Next, an outline of a method of manufacturing the door trim 10 including a terminal processing step of the outer peripheral terminal portion of the door trim upper 20 will be described below. First, the overall structure of the molding die 40 will be described with reference to FIG. 5, a portion corresponding to the door trim upper 20 will be described with reference to FIG. 6, and a configuration of the molding die 40 corresponding to the outer peripheral portion of the door trim upper will be described with reference to FIG.
[0065]
In FIG. 5, a molding die 40 used for molding the door trim 10 includes a molding upper die 41 that can move up and down by a predetermined stroke, a fixed lower molding die 42 paired with the molding upper die 41, and a molding lower die 42. And two injection machines 43a and 43b which are connected to each other.
[0066]
More specifically, the upper molding die 41 is formed with a cavity 411 conforming to 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 upper molding die 41. At four corners of the upper mold 41, guide bushes 413 serving as a guide mechanism are provided.
[0067]
On the other hand, the lower molding die 42 is provided with a core portion 421 corresponding to the cavity portion 411 of the upper molding die 41. Further, manifolds 422a and 422b and gates 423a and 423b are provided to supply the molten resin to the mold surface of the core portion 421. The injection machine passes through the resin passages of the manifolds 422a and 422b and the gates 423a and 423b. The molten resins M1 and M2 supplied from 43a and 43b are supplied into a groove 424 formed on the upper surface of the core 421 and into a cavity for forming the door trim lower 30.
[0068]
Guide posts 425 serving as a guide mechanism project from four corners of the lower molding die 42. The guide posts 425 are guided into the guide bush 413 when the upper and lower molding dies 41 and 42 are clamped. Thus, the pressing posture of the upper mold 41 can be properly maintained.
[0069]
FIG. 6 is a sectional view taken along the line VI-VI of the molding die shown in FIG. 5, and shows a molding metal for molding the foamed resin base material 21, the resin rib 22, and the decorative material 23 constituting the door trim upper 20. In the mold 40, in particular, in the lower mold 42, a groove 424 corresponding to the resin rib 22 having a predetermined pattern is provided on the mold surface of the core 421.
[0070]
Further, in the molding die 40 corresponding to the door trim upper 20, in particular, as shown in FIG. The ridge 414 is formed, and the ridge 414 forms the thin hinge portion 24 on the foamed resin base material 21.
[0071]
Next, based on FIGS. 8 to 12, each step of the above-described method for manufacturing the door trim 10 will be described. First, as shown in FIG. 8, a material obtained by laminating the decorative material 23 on one surface of the foamed resin sheet S is heated and softened to a predetermined temperature by the heater device 50. As the foamed resin sheet S, a polypropylene foamed sheet (manufactured by Sumika Plustech Co., Ltd., trade name: Sumicellar foamed PP sheet, foaming ratio = 3 times, thickness 3 mm) is used.
[0072]
Subsequently, as shown in FIG. 9, the foamed resin sheet S (on which the decorative material 23 is laminated) subjected to the heat softening treatment is applied to the cavity portion 411 of the upper mold 41 and the lower mold 42 at the location corresponding to the door trim upper 20. It is set in the upper half of the cavity defined by the core 421.
[0073]
Then, after setting the foamed resin sheet S, the elevating cylinder 412 of the upper molding die 41 operates to lower the molding upper die 41 by a predetermined stroke, and as shown in FIG. The foamed resin sheet S is shaped according to a desired mold surface shape, the foamed resin base material 21 is formed, and the resin ribs in the door trim upper 20 are passed from the first injection machine 43a through the manifold 422a and the gate 423a. In order to form 22, the molten resin M <b> 1 is injection-filled into the groove 424 of the core 421.
[0074]
At the same time, in order to mold the door trim lower 30, the molten resin M2 is injected and filled from the second injection machine 43b into the substantially lower half of the cavity through the manifold 422b and the gate 423b, and the door trim lower 30 is formed into a required shape.
[0075]
Therefore, the resin ribs 22 in the door trim upper 20 are formed into a required shape by injecting and filling the molten resins M1 and M2 into the cavities from the first injection machine 43a and the second injection machine 43b, respectively. The door trim lower 30 is formed. As the molten resin M1, M2, talc is appropriately mixed with Sumitomo Noblen BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 65 g / 10 minutes). The injection timing of the molten resins M1 and M2 may be set before the upper and lower molds 41 and 42 are clamped.
[0076]
As described above, in order to manufacture the two-ton type door trim 10, the two injection machines 43 a and 43 b are connected to the lower molding die 42, and the molten resin M <b> 1 is connected to the door trim upper 20 and the door trim lower 30 through each resin passage. , M2, the two-ton type door trim 10 can be manufactured with a single molding die 40 and with a reduced number of steps.
[0077]
In the above-described method of manufacturing the door trim 10, in particular, as for the door trim upper 20, as shown in FIG. 11, the foamed resin base material 21 and the decorative material 23 are interposed between the upper mold 41 and the lower mold 42. Molded into a desired curved surface shape, and molten resin is injected and filled into the groove 424 of the lower molding die 42, and when the resin rib 22 is integrally molded, the ridges 414 formed on the upper molding die 41 form the foamed resin. A thin hinge portion 24 is formed on the base material 21, and an outer portion thereof is defined as a roll-in sill 25.
[0078]
Accordingly, after the molding of the door trim upper 20 and the door trim lower 30 is completed, the upper mold 41 is lifted and the mold is opened, and then the molded product is taken out of the molding die 40. Then, as shown in FIG. At the outer peripheral end of the upper 20, the winding white 25 positioned on the outer periphery of the thin hinge portion 24 is fixed to the back surface of the foamed resin base material 21 by ultrasonic welding or thermal welding, or by adhesive bonding, mechanical stopping, or the like, with the thin hinge portion 24 as a turning base. Then, as shown in FIG. 4, the outer peripheral terminal of the door trim upper 20 corresponds to the thin hinge portion 24, the outer peripheral terminal has a good appearance, has a double structure, and has enhanced rigidity. Is completed. In this method, the material of the resin rib 22 in the door trim upper 20 and the material of the door trim lower 30 can be made different, and the material can be appropriately changed according to each required item.
[0079]
Further, the molten resins M1 and M2 which are branched and supplied to the door trim upper 20 and the door trim lower 30 can be supplied from one injection machine 43 as the same material. In this case, a branch manifold serving as a passage of the molten resin M1 supplied from the main manifold communicating with the injection machine 43 to the door trim upper 20 side, and a branch manifold serving as a resin passage supplying the molten resin M2 to the door trim lower 30 are set. And do it.
[0080]
13 to 15 show a second embodiment of the present invention. In the second embodiment, in a molding die 40, a pressing mechanism 44 is provided at a position corresponding to a door trim upper 20 of a lower molding die 42. Is provided.
[0081]
The pressing mechanism 44 includes a pressing block 441 and a drive cylinder 442. The pressing mechanism 44 is provided immediately below a convex ridge 414 for forming the thin hinge portion 24 formed on the upper molding die 41. To position.
[0082]
First, as shown in FIG. 13, the foamed resin sheet S in the heat-softened state (the original sheet of the decorative material 23 is laminated on the front surface side) is heat-softened on the mold surface of the lower mold 42. After the setting, the upper mold 41 is moved down, and at the same time, the pressing block 441 of the pressing mechanism 44 is raised by the operation of the drive cylinder 442. By pressing the sheet S, the thin hinge portion 24 is formed on the foamed resin sheet S.
[0083]
Further, in this state, that is, when the molding upper die 41 is lowered while being sandwiched between the molding upper die 41 and the pressing block 441 along the outer peripheral portion of the foamed resin sheet S, and the foamed resin base material 21 is molded into a desired shape. At the same time, when the drive cylinder 442 contracts, the pressing block 441 is linked to the upper mold 41 and lowered in conjunction therewith (see FIG. 14).
[0084]
Then, after the molding is completed, the upper mold 41 is raised and the mold is opened, and after the door trim upper 20 (not shown, but integrated with the door trim lower 30) is removed, the thin hinge is removed. When the winding white 25 is wound around the back surface of the foamed resin base material 21 with the portion 24 as the turning base, the terminal processing can be easily performed.
[0085]
In the second embodiment, by setting the clearance between the side walls of the upper molding die 41 and the lower molding die 42 at an appropriate position, the rigidity-enhancing portion 26 with increased rigidity can be set. There are advantages.
[0086]
Next, FIGS. 16 to 19 show a third embodiment of the present invention. FIGS. 16 and 17 are perspective views and sectional views showing main parts of a molding die 40 used in the third embodiment. FIG. 18 is an explanatory diagram showing a terminal portion forming process in the third embodiment, and FIG. 19 is an explanatory diagram showing a terminal processing process.
[0087]
That is, in the third embodiment, as shown in FIGS. 16 and 17, a cutting portion 45 having a saw blade shape in a cross section in the same direction as the opening and closing direction of the molding die 40 is provided on the outer surface of the lower molding die 42. The door trim upper 20 is formed along the outer peripheral edge of the corresponding portion.
[0088]
Therefore, after setting the foamed resin sheet S subjected to the heat softening treatment (the original sheet of the decorative material 23 is laminated on one side) in the molding die 40, the molding is performed when the molding die 40 is clamped. In the forming step in which the foamed resin base material 21 and the decorative material 23 are formed into a desired curved surface shape along the cavity shape of the upper and lower dies 41 and 42, the cutting portion 45 is formed particularly along the side wall surface of the core portion 421. Therefore, when the upper mold 41 is lowered, the foamed resin base material 21 is scraped off between the cutting portion 45 and the inner surface of the upper mold 41 so as to be pushed off. By cutting the foamed resin base material 21 (on the lower side), the thin-walled winding white 25 can be easily formed. Next, as shown in FIG. 18, it is only necessary to wind up a wrapping white 25 composed of the decorative material 23 and the remains of the foamed resin after being scraped off on the back surface of the foamed resin base material 21. In the above, at the same time as the molding of the foamed resin base material 21, the winding white 25 can be formed so as to have a thin shape and flexibility, and the winding terminal processing step of the winding white 25 can be performed smoothly. There is an advantage.
[0089]
【The invention's effect】
As described above, the automotive interior parts according to the present invention require rigidity such as a lightweight and shape-retaining foamed resin base material, and a rear surface of the foamed resin base material and an outer peripheral edge of the product. Because it is composed of resin ribs that are laminated and integrated on the part and decorative materials that are laminated on the surface of the foamed resin base material, it is possible to eliminate the conventional heavy resin core material, so it is lightweight, low cost, and Since it is a porous material, it has an effect of being able to provide interior parts for automobiles having excellent sound absorption performance.
[0090]
Furthermore, if the process of molding the foamed resin base material into a required shape along with the cavity shape of the molding die and simultaneously molding the resin ribs on the back surface side of the foamed resin base material is adopted, the resin ribs as the resin molded body can be obtained. Because the projected area of the resin is small, the load on the molding die is smaller than that of the conventional resin core material, the cooling time can be shortened, and the yield can be increased. This has the effect of being able to bring about a significant cost reduction.
[0091]
In addition, the outer peripheral edge of the automotive interior part according to the present invention, the wraparound white has been wound around the back of the foamed resin base material with the thin hinge portion formed on the foamed resin base as a turning base point. Since the outer peripheral end portion corresponds to a thin hinge portion, a sharp outer peripheral line can be formed, and the external appearance is excellent, and the rigidity is enhanced because the terminal portion has a folded double structure, especially. In addition, there are various effects such as no occurrence of undulation failure and the like, and an improvement in alignment accuracy with a panel or an adjacent partner component.
[0092]
Further, as another embodiment of the method of the present invention, a configuration is employed in which a thin-walled wrap-around is formed by cutting the outer portion of the outer peripheral portion by aligning a molding die based on a turning base point during molding of the foamed resin base material. This has the effect that the winding process on the back surface can be performed smoothly by utilizing the flexibility of the winding white, and the terminal processing operation can be performed smoothly.
[Brief description of the drawings]
FIG. 1 is a front view showing a first embodiment of an automobile door trim to which an automobile interior part according to the present invention is applied.
FIG. 2 is a sectional view taken along line II-II in FIG.
FIG. 3 is a front view showing a resin rib and a door trim lower of a door trim upper in the automobile door trim shown in FIG. 1;
FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. 1, and is a cross-sectional view illustrating a configuration of an outer peripheral end portion of the door trim upper.
5 is an overall view showing a configuration of a molding die used when molding the automobile door trim shown in FIG.
FIG. 6 is a sectional view taken along line VI-VI in FIG. 5;
FIG. 7 is a sectional view showing an outer peripheral portion of the molding die shown in FIG.
FIG. 8 is an explanatory view showing a preheating step of the foamed resin sheet in the method of manufacturing the automobile door trim shown in FIG.
FIG. 9 is an explanatory view showing a setting step of a foamed resin sheet in the method of manufacturing the automobile door trim shown in FIG.
FIG. 10 is an explanatory view showing a molding step of a foamed resin base material and a resin rib in the method of manufacturing the automobile door trim shown in FIG.
FIG. 11 is an explanatory view showing a step of forming a thin hinge portion in the door trim upper shown in FIG. 1;
FIG. 12 is an explanatory view showing a terminal processing step of a wrapping white in the door trim upper shown in FIG. 1;
FIG. 13 is an explanatory view showing a main part of a molding die used in a second embodiment of the method of the present invention.
14 is an explanatory view showing a step of molding a door trim upper using the molding die shown in FIG.
FIG. 15 is a cross-sectional view showing an outer peripheral portion of a door trim upper formed by a second embodiment of the method of the present invention.
FIG. 16 is a perspective view showing a main part of a molding die used in a third embodiment of the method of the present invention.
FIG. 17 is a sectional view taken along the line XVII-XVII in FIG. 16 showing a main part of a molding die used in a third embodiment of the method of the present invention.
FIG. 18 is an explanatory view showing a step of molding a door trim upper using the molding die shown in FIG.
FIG. 19 is an explanatory view showing a terminal processing step of a door trim upper in a third embodiment of the method of the present invention.
FIG. 20 is a front view showing a conventional automobile door trim.
21 is a sectional view taken along line XXI-XXI in FIG. 20;
FIG. 22 is an explanatory view showing a molding die of a conventional automobile door trim.
FIG. 23 is an explanatory view showing a conventional example of a terminal portion of an automobile door trim by press molding.
FIG. 24 is an explanatory view showing a conventional example of a terminal portion in an automobile door trim of a skin winding type.
[Explanation of symbols]
10 Two-tone type car door trim
11 Inside Handle Escussion
12 Power window switch escussion
13 Pocket opening
14 Pocket back cover
15 Speaker grill
20 door trim upper
21 Foam resin substrate
211 Flange
212 extension
22 Resin rib
23 Decorative materials
24 Thin hinge
25 Involvement White
26 Rigidity reinforcement
30 door trim lower
40 Mold
41 Upper mold
42 Lower Mold
43a, 43b Injection machine
44 Pressing mechanism
441 Press block
442 drive cylinder
45 Cutting part
50 heater device
S foam resin sheet
M1, M2 molten resin
P Turnaround line

Claims (8)

軽量で、かつ保形性を有する発泡樹脂基材（２１）と、この発泡樹脂基材（２１）の裏面に積層一体化される樹脂リブ（２２）と、上記発泡樹脂基材（２１）の表面に積層一体化される加飾材（２３）とからなる自動車用内装部品（２０）であって、製品外周のやや内側に沿って、発泡樹脂基材（２１）に設けられた薄肉ヒンジ部（２４）を基に該薄肉ヒンジ部（２４）外周の巻込みシロ（２５）を発泡樹脂基材（２１）の裏面に巻込み処理してなることを特徴とする自動車用内装部品。A lightweight and foam-retaining foamed resin substrate (21), a resin rib (22) laminated and integrated on the back surface of the foamed resin substrate (21), and a foamed resin substrate (21). An automotive interior part (20) comprising a decorative material (23) laminated and integrated on the surface, and a thin hinge portion provided on a foamed resin base material (21) along a slightly inner periphery of the product. An interior part for automobiles, characterized in that a winding white (25) on the outer periphery of the thin hinge portion (24) is wound on the back surface of the foamed resin base material (21) based on (24). 軽量で、かつ保形性を有する発泡樹脂基材（２１）と、この発泡樹脂基材（２１）の裏面に積層一体化される樹脂リブ（２２）と、上記発泡樹脂基材（２１）の表面に積層一体化される加飾材（２３）とからなる自動車用内装部品（２０）であって、製品外周の内側に沿って設定された折返しライン（Ｐ）から外周端末にかけて発泡樹脂基材（２１）が切削され、可撓性を備えた巻込みシロ（２５）として形成され、該折返しライン（Ｐ）を基に発泡樹脂基材（２１）の裏面側に上記巻込みシロ（２５）を巻込み処理してなることを特徴とする自動車用内装部品。A lightweight and foam-retaining foamed resin substrate (21), a resin rib (22) laminated and integrated on the back surface of the foamed resin substrate (21), and a foamed resin substrate (21). An automotive interior part (20) comprising a decorative material (23) laminated and integrated on the surface, wherein a foamed resin base material extends from a folding line (P) set along the inside of the outer periphery of the product to an outer peripheral end. (21) is cut and formed as a wrap-around shiro (25) having flexibility, and the wrap-around shiro (25) is formed on the back side of the foamed resin base material (21) based on the folding line (P). An interior part for an automobile, characterized by being rolled up. 軽量で、かつ保形性を有する発泡樹脂基材（２１）と、該発泡樹脂基材（２１）の裏面に積層一体化される樹脂リブ（２２）と、上記発泡樹脂基材（２１）の表面に積層される加飾材（２３）とからなる自動車用内装部品（２０）の製造方法において、
成形金型（４１，４２）内に、発泡樹脂基材（２１）の素材である発泡樹脂シート（Ｓ）をセットする発泡樹脂シート（Ｓ）のセット工程と、
成形金型（４１，４２）同士を型締めして、成形金型（４１，４２）の製品キャビティ形状に発泡樹脂基材（２１）を所要形状に成形し、上記発泡樹脂基材（２１）の外周縁からやや内側の折返しライン（Ｐ）に沿って薄肉ヒンジ部（２４）を形成する一方、成形金型（４１，４２）の型締め直前、または型締め後のいずれかのタイミングで成形下型（４２）の溝部（４２４）内に溶融樹脂を射出充填して、樹脂リブ（２２）を発泡樹脂基材（２１）の裏面側に積層一体化する発泡樹脂基材（２１）と樹脂リブ（２２）の一体化工程と、
一体化した積層品を成形金型（４１，４２）の型開き後、脱型し、巻込みシロ（２５）を上記薄肉ヒンジ部（２４）を基に発泡樹脂基材（２１）の裏面に折返し固着する内装部品（２０）の端末処理工程と、
からなることを特徴とする自動車用内装部品の製造方法。A lightweight and foam-retaining foamed resin substrate (21), a resin rib (22) laminated and integrated on the back surface of the foamed resin substrate (21), and a foamed resin substrate (21). A method for manufacturing an automobile interior part (20) comprising a decorative material (23) laminated on a surface,
Setting a foamed resin sheet (S) for setting a foamed resin sheet (S) as a material of a foamed resin base material (21) in a molding die (41, 42);
The molding dies (41, 42) are clamped together to form the foamed resin base material (21) into a required shape in the product cavity shape of the molding dies (41, 42). A thin hinge portion (24) is formed from the outer peripheral edge of the molding die (41, 42) along a slightly inward folding line (P), and is formed immediately before or after the clamping of the molding dies (41, 42). A molten resin is injected and filled into the groove (424) of the lower mold (42), and the resin rib (22) is laminated and integrated on the back side of the foamed resin substrate (21). A step of integrating the ribs (22);
The integrated laminate is opened after the molds (41, 42) are opened, and then removed, and the wrap-around shiro (25) is placed on the back surface of the foamed resin base material (21) based on the thin hinge portion (24). A terminal treatment step of the interior part (20) to be fixed back,
A method for manufacturing an automobile interior part, comprising: 前記発泡樹脂基材（２１）と樹脂リブ（２２）の一体化工程において、成形金型（４１，４２）同士を型締めして、成形金型（４１，４２）の製品キャビティ形状に発泡樹脂基材（２１）を成形し、成形金型（４１，４２）の型締め直前、または型締め後のいずれかのタイミングで成形下型（４２）の溝部（４２４）内に溶融樹脂を射出充填して、樹脂リブ（２２）を発泡樹脂基材（２１）の裏面側に積層一体化する一方、成形下型（４２）の外周のうち、巻込み処理する部位に沿って押圧機構（４４）が設けられ、該押圧機構（４４）における押圧ブロック（４４１）が駆動シリンダ（４４２）により上下駆動され、発泡樹脂基材（２１）の外周縁からやや内側に沿って巻込みシロ（２５）の折返し基点となる薄肉ヒンジ部（２４）が形成されることを特徴とする請求項３に記載の自動車用内装部品の製造方法。In the step of integrating the foamed resin base material (21) and the resin rib (22), the molding dies (41, 42) are clamped together to form a foamed resin into the product cavity shape of the molding dies (41, 42). The base material (21) is molded, and the molten resin is injected and filled into the groove (424) of the lower molding die (42) immediately before or after the clamping of the molding dies (41, 42). Then, while the resin rib (22) is laminated and integrated on the back surface side of the foamed resin base material (21), the pressing mechanism (44) is arranged along the portion of the outer periphery of the lower molding die (42) to be wound. The pressing block (441) of the pressing mechanism (44) is driven up and down by a driving cylinder (442), so that the roll-in roll (25) extends slightly inward from the outer peripheral edge of the foamed resin base material (21). A thin hinge part (24) is formed as a turning base point Automobile interior part manufacturing method according to claim 3, characterized in that it is. 前記押圧機構（４４）により発泡樹脂基材（２１）に薄肉ヒンジ部（２４）を形成する際、発泡樹脂基材（２１）は、成形上下型（４１，４２）のシャークリアランスを狭く設定することで、端末部分を支持する剛性強化部（２６）が形成されることを特徴とする請求項４に記載の自動車用内装部品の製造方法。When forming the thin hinge portion (24) on the foamed resin base material (21) by the pressing mechanism (44), the foamed resin base material (21) sets the shear clearance of the upper and lower molds (41, 42) to be narrow. The method for manufacturing an automobile interior part according to claim 4, wherein the rigidity enhancement part (26) for supporting the terminal part is formed. 軽量で、かつ保形性を有する発泡樹脂基材（２１）と、該発泡樹脂基材（２１）の裏面に積層一体化される樹脂リブ（２２）と、上記発泡樹脂基材（２１）の表面に積層される加飾材（２３）とからなる自動車用内装部品（２０）の製造方法において、
成形金型（４１，４２）内に、発泡樹脂基材（２１）の素材である発泡樹脂シート（Ｓ）をセットする発泡樹脂シートのセット工程と、
成形金型（４１，４２）同士を型締めして、成形金型（４１，４２）の製品キャビティ形状に沿って発泡樹脂基材（２１）を成形し、発泡樹脂基材（２１）の製品端縁部に沿って、成形下型（４２）の壁面に形成した鋸刃形状により、巻込みシロ（２５）に相当する発泡樹脂基材（２１）を削ぎ落とし、成形金型（４１，４２）の型締め直前、または型締め後のいずれかのタイミングで成形下型（４２）の溝部（４２４）内に溶融樹脂を射出充填して、樹脂リブ（２２）を発泡樹脂基材（２１）の裏面側に積層一体化する発泡樹脂基材（２１）と樹脂リブ（２２）の一体化工程と、
成形金型（４１，４２）から樹脂リブ（２２）を一体化した発泡樹脂基材（２１）を脱型し、発泡樹脂基材（２１）を削ぎ落とした薄肉状の可撓性を有する巻込みシロ（２５）を発泡樹脂基材（２１）裏面に折返し固着する内装部品（２０）の端末処理工程と、
からなることを特徴とする自動車用内装部品の製造方法。A lightweight and foam-retaining foamed resin substrate (21), a resin rib (22) laminated and integrated on the back surface of the foamed resin substrate (21), and a foamed resin substrate (21). A method for manufacturing an automobile interior part (20) comprising a decorative material (23) laminated on a surface,
A setting step of a foamed resin sheet for setting a foamed resin sheet (S) as a material of the foamed resin base material (21) in a molding die (41, 42);
The molding dies (41, 42) are clamped together to form a foamed resin base material (21) along the product cavity shape of the molding dies (41, 42). Along the edge portion, the foamed resin base material (21) corresponding to the wrap-around shiro (25) is scraped off by the saw blade shape formed on the wall surface of the lower mold (42), and the forming dies (41, 42) are formed. The molten resin is injected and filled into the groove (424) of the lower molding die (42) immediately before or after the mold clamping in (2), and the resin rib (22) is filled with the foamed resin base material (21). A step of integrating a foamed resin substrate (21) and a resin rib (22) to be laminated and integrated on the back side of
The foamed resin substrate (21) having the resin ribs (22) integrated therefrom is removed from the molding dies (41, 42), and the foamed resin substrate (21) is scraped off to form a thin flexible winding. A terminal treatment step of an interior component (20) for folding and fixing the embedded white (25) to the back surface of the foamed resin substrate (21);
A method for manufacturing an automobile interior part, comprising: 軽量で、かつ保形性を有する発泡樹脂基材（２１）と、該発泡樹脂基材（２１）の裏面に積層一体化される樹脂リブ（２２）と、上記発泡樹脂基材（２１）の表面に積層される加飾材（２３）とからなる自動車用内装部品（２０）を成形する成形金型（４０）であって、
前記成形金型（４０）は、相互に型締め、型開き可能な成形上型（４１）並びに成形下型（４２）と、成形下型（４２）に連結され、樹脂リブ（２２）の素材である溶融樹脂を供給する射出機（４３）とから構成され、前記成形上下型（４１，４２）間の製品キャビティは、発泡樹脂基材（２１）の製品形状に即した形状に設定されるとともに、樹脂リブ（２２）に対応する溝部（４２４）が成形下型（４２）のコア部（４２１）型面に設けられ、かつ成形下型（４２）の外周縁部に沿って、発泡樹脂基材（２１）の巻込みシロ（２５）の折返し基点となる薄肉ヒンジ部（２４）を形成するための押圧機構（４４）が配置されていることを特徴とする成形金型。A lightweight and foam-retaining foamed resin substrate (21), a resin rib (22) laminated and integrated on the back surface of the foamed resin substrate (21), and a foamed resin substrate (21). A molding die (40) for molding an automotive interior part (20) comprising a decorative material (23) laminated on the surface,
The molding die (40) is connected to the upper molding die (41), the lower molding die (42), and the lower molding die (42), which are mutually mold-clampable and openable. And an injection machine (43) for supplying a molten resin, and the product cavity between the upper and lower molds (41, 42) is set to a shape corresponding to the product shape of the foamed resin base material (21). At the same time, a groove (424) corresponding to the resin rib (22) is provided on the mold surface of the core portion (421) of the lower mold (42), and the foamed resin is formed along the outer peripheral edge of the lower mold (42). A molding die, characterized in that a pressing mechanism (44) for forming a thin hinge portion (24) serving as a turning base of a winding white (25) of a substrate (21) is arranged. 軽量で、かつ保形性を有する発泡樹脂基材（２１）と、該発泡樹脂基材（２１）の裏面に積層一体化される樹脂リブ（２２）と、上記発泡樹脂基材（２１）の表面に積層される加飾材（２３）とからなる自動車用内装部品（２０）を成形する成形金型（４０）であって、
前記成形金型（４０）は、相互に型締め、型開き可能な成形上型（４１）並びに成形下型（４２）と、成形下型（４２）に連結され、樹脂リブ（２２）の素材である溶融樹脂を供給する射出機（４３）とから構成され、前記成形下型（４２）の外周面には、発泡樹脂基材（２１）の外周縁の巻込みシロ（２５）を切削するための鋸刃形状の切削部（４５）が設定されていることを特徴とする成形金型。A lightweight and foam-retaining foamed resin substrate (21), a resin rib (22) laminated and integrated on the back surface of the foamed resin substrate (21), and a foamed resin substrate (21). A molding die (40) for molding an automotive interior part (20) comprising a decorative material (23) laminated on the surface,
The molding die (40) is connected to the upper molding die (41), the lower molding die (42), and the lower molding die (42), which are mutually mold-clampable and openable. And an injection machine (43) for supplying a molten resin, which is formed on the outer peripheral surface of the lower molding die (42). Characterized in that a cutting portion (45) in the shape of a saw blade for setting is provided.
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