JP4601481B2 - Method for forming epidermal cleavage planned portion and method for manufacturing instrument panel - Google Patents

Method for forming epidermal cleavage planned portion and method for manufacturing instrument panel Download PDF

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JP4601481B2
JP4601481B2 JP2005125553A JP2005125553A JP4601481B2 JP 4601481 B2 JP4601481 B2 JP 4601481B2 JP 2005125553 A JP2005125553 A JP 2005125553A JP 2005125553 A JP2005125553 A JP 2005125553A JP 4601481 B2 JP4601481 B2 JP 4601481B2
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伸治 横井
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Inoac Corp
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本発明は、表皮開裂予定部の成形方法およびインストルメントパネルの製造方法に関し、更に詳細には、ポリウレタンを材質とし、エアバッグドアの外面に配設される表皮の外面に、所要形状をなす突刃部の先端部を押付けて突入させ、薄肉化された表皮開裂予定部を成形する方法およびインストルメントパネルの製造方法に関するものである。 TECHNICAL FIELD The present invention relates to a method for forming a skin tear scheduled portion and a method for manufacturing an instrument panel, and more specifically, a protrusion made of polyurethane and having a required shape on the outer surface of the skin disposed on the outer surface of an airbag door. The present invention relates to a method of forming a thinned skin cleavage scheduled portion by pressing a tip portion of a blade portion so as to enter, and a method of manufacturing an instrument panel .

自動車等の乗員室内に取付けられるインストルメントパネル、フロアコンソール、ドアパネルおよびピラーガーニッシュ等の種々車両内装部材は、高級車種や高級グレードの場合、所要形状に形成された基材の外側に合成樹脂製の表皮を被着して構成されている。また、表皮と基材との間に所要厚の発泡体を介在させて基材、発泡体および表皮からなる３層構造とし、適宜の弾力性を付与して触感向上を図るようにした車両内装部材も実用化されている。   Various vehicle interior parts such as instrument panels, floor consoles, door panels and pillar garnishes installed in passenger compartments of automobiles, etc. are made of synthetic resin on the outside of the base material formed in the required shape in the case of luxury cars and luxury grades. It is composed of an epidermis. Also, a vehicle interior that has a three-layer structure consisting of a base material, a foam and a skin by interposing a foam of the required thickness between the skin and the base material, and imparts appropriate elasticity to improve the tactile sensation. Members have also been put into practical use.

一方、近年生産される殆どの自動車には、対向車との正面衝突事故または側面衝突事故の発生時に乗員保護を図るためのエアバッグ装置が標準的に装備されており、例えば助手席用のエアバッグ装置は、インストルメントパネルに内部格納した状態で搭載されている。このためインストルメントパネルには、エアバッグ装置の搭載位置に対応してエアバッグドアが設けられており、エアバッグ装置の作動時に外方へ開放するようになっている。図８は、基材１２、発泡体１４および表皮１６の３層構造を呈したインストルメントパネル１０を、各構成部材を分離させた状態で示した部分斜視図であって、ＴＰＯ(オレフィン系の熱可塑性エラストマ)等の合成樹脂材料から形成されたエアバッグドア２０が、基材１２に設けた設置部１８に設けられている。ここで、図示例示のエアバッグドア２０は、両Ｙ字形に延設されたドア開裂予定部２４がエアバッグ装置の作動時に破断し、これにより分離した４枚のドアパネル２２がインストルメントパネル１０の前後方向および左右方向へ開放する四方開きタイプである。   On the other hand, most automobiles produced in recent years are equipped with an air bag device for protecting passengers in the event of a frontal collision or a side collision with an oncoming vehicle. The bag device is mounted in a state of being stored inside the instrument panel. For this reason, the instrument panel is provided with an airbag door corresponding to the mounting position of the airbag device, and is opened outward when the airbag device is activated. FIG. 8 is a partial perspective view showing the instrument panel 10 having a three-layer structure of the base material 12, the foam 14 and the skin 16 in a state in which the respective constituent members are separated from each other. An airbag door 20 formed from a synthetic resin material such as a thermoplastic elastomer is provided in an installation portion 18 provided in the base material 12. Here, in the illustrated airbag door 20, the door opening scheduled portion 24 extending in both Y-shapes is broken when the airbag device is operated, and the four door panels 22 separated thereby are the instrument panel 10. A four-way opening type that opens in the front-rear and left-right directions.

そして、基材１２にエアバッグドア２０が設けられていることに伴い、この基材１２およびエアバッグドア２０の外側に配設される表皮１６には、ドア開裂予定部２４に沿って延在する表皮開裂予定部３０を形成する必要がある。この表皮開裂予定部３０は、厚さＴ＝０.８〜１.５ｍｍ程度の表皮１６の外面(裏面)に、厚さＴの１／２程度の深さの溝を延設することで薄肉化した部分であり(図１０)、例えば図９に例示するような溝成形装置４０を使用して形成する場合が多い。この溝成形装置４０は、表皮開裂予定部３０の延在形状を前提とした両Ｙ字形状の突刃部４２を固定した支持体４４と、この支持体４４を昇降移動させるシリンダ４６とから構成されている。突刃部４２は、先端部の刃先角度が３０〜６０°、厚さＷ＝１.０〜１.５ｍｍ程度とされ、図示しないヒータや電磁誘導等により所定温度まで加熱可能となっている。   Then, along with the airbag door 20 being provided on the base material 12, the skin 16 disposed outside the base material 12 and the airbag door 20 extends along the door tear scheduled portion 24. It is necessary to form the epidermal cleavage planned portion 30 to be formed. This epidermis cleavage portion 30 is thinned by extending a groove having a depth of about ½ of the thickness T on the outer surface (back surface) of the skin 16 having a thickness T of about 0.8 to 1.5 mm. In many cases, it is formed using a groove forming apparatus 40 as illustrated in FIG. 9, for example. The groove forming apparatus 40 is composed of a support body 44 to which both Y-shaped projecting blade portions 42 are fixed on the premise of the extending shape of the skin cleavage scheduled portion 30, and a cylinder 46 that moves the support body 44 up and down. Has been. The protruding blade portion 42 has a cutting edge angle of 30 to 60 ° and a thickness W of about 1.0 to 1.5 mm, and can be heated to a predetermined temperature by a heater, electromagnetic induction, or the like (not shown).

図１０は、図９に例示した溝成形装置４０により、裏面を上にした状態でセットテーブル４８上に展張セットした表皮１６の外面に対し、表皮開裂予定部３０を成形する方法を示した説明図である。具体的には、先ず、突刃部４２を所定温度まで加熱したもとで表皮１６側へ近接移動させ、その先端部を表皮１６の外面に押付けて所要深さ(表皮１６の厚さＴの１／２程度)に突入させる(図１０(ａ))。次いで、この突入状態に保持しながら突刃部４２を冷却させ、冷却完了後に該突刃部４２を上昇させることで、所要深さの溝が成形されるために薄肉化された表皮開裂予定部３０が形成される(図１０(ｂ))。このような表皮１６に対する表皮開裂予定部３０の成形方法は、例えば引用文献１に開示されている。
特開平４−１５１３４５号公報 FIG. 10 shows a method of forming the skin-splitting planned portion 30 on the outer surface of the skin 16 that is stretched and set on the set table 48 with the back surface up by the groove forming device 40 illustrated in FIG. FIG. Specifically, first, the protruding blade portion 42 is heated to a predetermined temperature and moved close to the skin 16 side, and its tip is pressed against the outer surface of the skin 16 to obtain a required depth (of the thickness T of the skin 16). (Approx. 1/2) (FIG. 10A). Next, the cutting edge portion 42 is cooled while being held in this protruding state, and the cutting edge portion 42 is raised after the cooling is completed, so that a groove having a required depth is formed, so that the skin-splitting planned portion is thinned. 30 is formed (FIG. 10B). Such a method for forming the epidermis cleaving portion 30 with respect to the epidermis 16 is disclosed in, for example, cited document 1.
Japanese Patent Laid-Open No. 4-151345

ここで前述した表皮１６は、真空成形技術により樹脂シート材から真空成形されたもの、パウダースラッシュ成形技術により樹脂粉末からスラッシュ成形されたもので、塩化ビニル(ＰＶＣ)等を材質としたものが主流であった。しかるに近年に至っては、環境問題等の面から塩化ビニルの使用が中止されつつあり、これに代わって所要のポリウレタン原料から成形されたポリウレタン製の表皮が採用される比率が高まっている。   The skin 16 described above is vacuum-molded from a resin sheet material by vacuum molding technology, slush-molded from resin powder by powder slush molding technology, and is mainly made of vinyl chloride (PVC) or the like. Met. However, in recent years, the use of vinyl chloride is being discontinued from the viewpoint of environmental problems and the like, and instead of this, the ratio of adopting a polyurethane skin molded from a required polyurethane raw material is increasing.

ところで、前述した溝成形装置４０の突刃部４２を突入させて薄肉化された表皮開裂予定部３０を形成する方法は、前述した真空成形やパウダースラッシュ成形により成形された熱可塑性樹脂を材質とする表皮１６に最も適合した方法である。しかしながら、ポリウレタンを材質とする表皮１６、特にウレタンスプレー成形技術または反応射出(ＲＩＭ：Reaction injection molding)成形技術により成形された表皮１６は、顕著な熱可塑性の性質を有していないポリウレタン原料から成形される。このため、図１０(ａ)に例示したように、突刃部４２を外面に突入させた場合、この突入部位の樹脂が側方へ移動して突刃部４２の形状に倣うように溶融して変形するわけではない。すなわち、突刃部４２の突入部位だけが単に押し潰されて圧縮的に変形しているだけであり、このため突入部位およびその近傍部位では内部応力が発生した状態となっている。   By the way, the method of forming the thinned skin-splitting planned portion 30 by inserting the protruding portion 42 of the groove forming apparatus 40 described above is made of the thermoplastic resin formed by the above-described vacuum forming or powder slush forming as a material. This method is most suitable for the epidermis 16. However, the skin 16 made of polyurethane, in particular, the skin 16 molded by urethane spray molding technology or reaction injection molding (RIM) molding technology, is molded from a polyurethane raw material that does not have remarkable thermoplastic properties. Is done. For this reason, as illustrated in FIG. 10A, when the protruding portion 42 is inserted into the outer surface, the resin at the protruding portion is moved sideways and melted so as to follow the shape of the protruding portion 42. It does not change. That is, only the entry portion of the protruding blade portion 42 is simply crushed and deformed in a compressive manner, and therefore, internal stress is generated at the entry portion and the vicinity thereof.

従って、加熱した突刃部４２を突入させて表皮１６を塑性変形させたとしても、その周辺部位には依然として圧縮による内部応力が発生したままである。このため、表皮開裂予定部３０の成形完了後に突刃部４２の突入を解除した場合には、図１１に例示したように、この内部応力が解消されるように表皮１６全体が撓んだり捻れるように変形する不都合が生じてしまう。殊に、ポリウレタンを材質とする表皮１６は比較的硬度が高くて硬いため、表皮１６と基材１２(エアバッグドア２０)との間で発泡成形される発泡体１４の発泡圧が加わっても変形状態が解消され難く、これが製品不良の発生原因となる問題を内在していた。   Therefore, even if the heated cutting edge portion 42 is inserted and the skin 16 is plastically deformed, internal stress due to compression still remains in the peripheral portion. For this reason, when the protrusion of the projecting blade portion 42 is released after the formation of the skin cleavage planned portion 30 is completed, as shown in FIG. 11, the entire skin 16 is bent or twisted so that this internal stress is eliminated. Inconvenience of deformation occurs. In particular, since the skin 16 made of polyurethane is relatively hard and hard, even if the foaming pressure of the foam 14 formed by foaming between the skin 16 and the base material 12 (airbag door 20) is applied. The deformation state is difficult to be solved, and this inherently causes problems that cause product defects.

また、突刃部４２を突入させた際には、その深さが大きい部位ほど圧縮量が多くなり、図１０に例示した鋭角状の先端部を有する突刃部４２が突入した場合は、その先端部に対応した部位が最も圧縮量が大きくなる。従って、この先端部に対応した表皮１６の表側外面(意匠面)では、表皮開裂予定部３０に沿った線状の膨出部分が形成され易く、これによっても意匠面側の外観的な製品不良が発生し易くなっていた。   Further, when the cutting edge portion 42 is plunged, the amount of compression increases as the depth of the portion increases, and when the cutting edge portion 42 having the acute-angled tip illustrated in FIG. The portion corresponding to the tip has the largest amount of compression. Accordingly, a linear bulging portion along the epidermis cleavage portion 30 is easily formed on the outer surface (design surface) of the outer skin 16 corresponding to the tip portion, and this also causes an appearance defect on the design surface side. It was easy to occur.

従って本発明は、ポリウレタンを材質とする表皮に対し、表皮開裂予定部を好適に成形するようにした表皮開裂予定部の成形方法およびインストルメントパネルの製造方法を提供することを目的とする。 Accordingly, an object of the present invention is to provide a method for forming an expected skin cleavage portion and a method for manufacturing an instrument panel, in which an expected skin cleavage portion is suitably formed on an outer skin made of polyurethane.

前記課題を解決し、所期の目的を達成するため、請求項１記載の発明は、
ポリウレタンを材質としてスプレー成形により成形され、エアバッグドアの外面に配設される表皮の外面に、所要形状をなす突刃部の先端部を押付けて突入させ、薄肉化された表皮開裂予定部を成形する方法において、
前記突刃部の突入に先立ち、少なくとも前記表皮開裂予定部の成形予定部位に８０〜１００℃の水蒸気を接触させ、該成形予定部位の吸水率を１.０〜２.０％としたことを要旨とする。 In order to solve the problem and achieve the intended object, the invention according to claim 1
The polyurethane and the material is molded by injection forming, on the outer surface of the epidermis disposed on the outer surface of the air bag door, to rush to push the distal end portion of the突刃portion forming the required shape, skin cleavage scheduled portion which is thinner In the method of molding
Prior to entry of the projecting blade portion, water vapor at 80 to 100 ° C. is brought into contact with at least a portion to be molded of the planned skin cleavage portion at 80 to 100 ° C., and the water absorption rate of the portion to be molded is set to 1.0 to 2.0%. The gist.

従って、請求項１に係る発明によれば、成形予定部位が加湿により軟化しているため、突刃部を突入させた際に表皮の内部応力の発生を好適に抑えることができるから、表皮開裂予定部の成形完了後に突刃部を退避させた際に、表皮が変形することを防止できる。   Therefore, according to the invention according to claim 1, since the part to be molded is softened by humidification, it is possible to suitably suppress the generation of internal stress of the skin when the projecting blade portion is inserted. It is possible to prevent the skin from being deformed when the projecting blade portion is retracted after completion of forming the planned portion.

請求項２記載の発明は、請求項１記載の発明において、前記水蒸気を接触させた成形予定部の５０％モジュラスを１.５〜４.０ＭＰａとしたことを要旨とする。従って、請求項２に係る発明によれば、成形予定部位へ突刃部を突入させても内部応力の発生を最小限に抑え得る。 According to a second aspect of the present invention, in the first aspect, the subject matter that was pre-Symbol 1.5~4.0MPa 50% modulus of forming shapes scheduled portion contacting the steam. Therefore, according to the invention which concerns on Claim 2, even if it makes a projecting blade part penetrate into a shaping | molding planned site | part, generation | occurrence | production of an internal stress can be suppressed to the minimum.

請求項３記載の発明は、請求項１または２記載の表皮開裂予定部の成形方法により表皮開裂予定部が成形された前記表皮の裏側に、エアバッグドアを設けた基材を臨ませ、前記表皮開裂予定部の加湿状態においてこれら基材と表皮との間で発泡体を発泡成形することを要旨とする。
従って、請求項３に係る発明によれば、表皮に多少の変形が生じていたとしても、該表皮は発泡体の発泡圧により適切な形状へ容易に矯正され得る。 According to a third aspect of the invention, the back side of the skin to skin cleaved scheduled portion by a molding method skin cleavage scheduled portion of claim 1, wherein is formed, to face the substrate provided with the air bag door, wherein The gist is that the foam is foam- molded between the base material and the skin in the humidified state of the planned skin cleavage .
Therefore, according to the third aspect of the invention, even if some deformation occurs in the skin, the skin can be easily corrected to an appropriate shape by the foaming pressure of the foam.

本発明に係る表皮開裂予定部の成形方法によれば、ポリウレタンを材質とする表皮を、加湿して軟化させたもとで突刃部を突入させるようにしたので、該表皮の変形を抑えたもとで表皮開裂予定部を好適に成形することができる利点がある。
また、本発明に係るインストルメントパネルの製造方法によれば、表皮開裂予定部の加湿状態において、表皮と基材との間で発泡体を発泡成形することにより、表皮に多少の変形が生じていたとしても、該表皮は発泡体の発泡圧により適切な形状へ容易に矯正され得る。 According to the method for forming the skin cleavage planned portion according to the present invention, the skin made of polyurethane is made humid and softened so that the protruding blade portion is inserted, so that the skin can be prevented from being deformed. There is an advantage that the planned cleavage portion can be suitably formed.
Further, according to the method for manufacturing an instrument panel according to the present invention, in the humidified state of the epidermis cleavage portion, the foam is foam-molded between the epidermis and the base material, so that the skin is somewhat deformed. Even so, the skin can be easily corrected to an appropriate shape by the foaming pressure of the foam.

次に、本発明に係る表皮開裂予定部の成形方法およびインストルメントパネルの製造方法につき、好適な実施例を挙げて、添付図面を参照しながら以下説明する。 Next, preferred embodiments of the method for forming a skin tear planned portion and the method for manufacturing an instrument panel according to the present invention will be described below with reference to the accompanying drawings.

本実施例に係る表皮開裂予定部の成形方法は、ポリウレタンを材質とする所要形状の表皮１６の外面に、図９に例示した溝成形装置４０における突刃部４２の先端部を押付けて突入させ、薄肉化された表皮開裂予定部３０を成形する方法である。そして、突刃部４２の突入による表皮開裂予定部３０の成形に先立ち、後述するように、該表皮開裂予定部３０の成形予定部位３２を加湿して軟化させることで、突刃部４２の突入による表皮１６の変形を抑えるようにした成形方法である。従って、ポリウレタンを材質とする表皮１６において、特に前述したウレタンスプレー成形技術または反応射出成形技術に基づいて予備成形された表皮１６は、当該ポリウレタンが熱可塑性を殆ど有していないため、より一層の効果が期待できる。   In the method for forming the skin tear planned portion according to the present embodiment, the tip of the protruding blade portion 42 in the groove forming apparatus 40 illustrated in FIG. 9 is pressed into the outer surface of the skin 16 having a required shape made of polyurethane. This is a method of forming the thinned epidermal cleavage planned portion 30. Then, prior to the formation of the skin-splitting planned portion 30 by the penetration of the projecting blade portion 42, the molding-scheduled portion 32 of the skin-splitting planned portion 30 is humidified and softened, as will be described later, so that the projecting blade portion 42 enters. This is a molding method in which the deformation of the skin 16 due to the above is suppressed. Therefore, in the skin 16 made of polyurethane, the skin 16 preliminarily molded based on the above-described urethane spray molding technique or reaction injection molding technique has a higher thermoplasticity because the polyurethane has almost no thermoplasticity. The effect can be expected.

本願発明者は、例えばスプレー成形技術に基づいて成形されたポリウレタン製の表皮１６の外面(裏面)に、突刃部４２を突入させて薄肉化された表皮開裂予定部３０を成形するに際し、内部応力の発生を如何に減少させることができるかにつき検討した。その結果、表皮開裂予定部３０の成形に先立ち、少なくとも表皮開裂予定部３０を成形する成形予定部位３２を軟化させることができれば、突刃部４２の突入に際して内部応力の発生を小さくできる筈であると考えた。   The inventor of the present application, for example, when forming the skin-splitting planned portion 30 which is thinned by making the projecting blade portion 42 enter the outer surface (back surface) of the polyurethane skin 16 molded based on a spray molding technique, We examined how the generation of stress can be reduced. As a result, if at least the molding site 32 for molding the epidermis cleavage part 30 can be softened prior to the molding of the epidermis cleavage part 30, it is possible to reduce the generation of internal stress when the projecting blade part 42 enters. I thought.

そこで先ず、表皮１６の軟化が何に依存するのかを確認するため、(ａ)表皮１６のサンプルである表皮試験片の温度を変化させた場合(湿度５５％一定)と、(ｂ)表皮試験片の湿度を変化させた場合(温度２３℃一定)とにつき、夫々の破断時の引張強度および５０％モジュラスを測定することにした。ここで、本願が規定する「引張強度」は、ＪＩＳ Ｋ７３１１に一部準拠した試験方法において、２００ｍｍ／ｍｉｎの引張速度で表皮試験片を引張り、これにより破断した時点で発生していた応力である。また、「５０％モジュラス」は、表皮試験片を元の長さの５０％だけ伸ばした際(元の長さの１.５倍の長さまで引張った際)に発生する応力である。   Therefore, first, in order to confirm what the softening of the epidermis 16 depends on, (a) when the temperature of the epidermis specimen which is a sample of the epidermis 16 is changed (humidity 55% constant), and (b) the epidermal test When the humidity of the piece was changed (temperature was constant at 23 ° C.), the tensile strength and 50% modulus at each break were measured. Here, the “tensile strength” defined in the present application is a stress generated when a skin test piece is pulled at a tensile rate of 200 mm / min and is broken in a test method partially compliant with JIS K7311. . The “50% modulus” is a stress generated when the skin specimen is stretched by 50% of the original length (when it is pulled to 1.5 times the original length).

表１および図５は、温度変化(湿度一定)による引張強度および５０％モジュラスの測定結果を示し、表２および図６は、湿度変化(温度一定)による引張強度および５０％モジュラスの測定結果を示したものである。   Table 1 and FIG. 5 show the measurement results of tensile strength and 50% modulus with temperature change (constant humidity), and Tables 2 and 6 show the measurement results of tensile strength and 50% modulus with humidity change (constant temperature). It is shown.

Figure 0004601481
Figure 0004601481

Figure 0004601481
Figure 0004601481

表１および図５から明らかなように、ポリウレタンを材質とする表皮１６の引張強度および５０％モジュラスは、該表皮１６の温度を変化させても大きな変化はなく、従って該表皮１６は温度依存性が低いことが判明した。例えば、表皮１６の温度５℃の場合と温度３５℃の場合では、硬度が約１２％程度だけ低下したに過ぎない。従って、ポリウレタンを材質とする表皮１６は、加熱したとしても軟化する度合が僅かに留まることから、突刃部４２の突入に際して発生する内部応力を低減させるには効果的ではないと判定し得る。   As is clear from Table 1 and FIG. 5, the tensile strength and 50% modulus of the skin 16 made of polyurethane are not greatly changed even when the temperature of the skin 16 is changed. Was found to be low. For example, when the temperature of the skin 16 is 5 ° C. and when the temperature is 35 ° C., the hardness is only reduced by about 12%. Therefore, since the skin 16 made of polyurethane has a slight degree of softening even when heated, it can be determined that it is not effective in reducing the internal stress generated when the projecting blade portion 42 enters.

一方、表２および図６から明らかなように、ポリウレタンを材質とする表皮１６の引張強度および５０％モジュラスは、該表皮１６の湿度を変化させると大きく変化し、従って該表皮１６は湿度依存性が高いことが判明した。すなわち、湿度が高くなるに従って引張強度および５０％モジュラスの何れもが漸次低下しており、表皮１６の湿度３０％の場合と湿度９０％の場合とを比較すると、５０％モジュラスが５.３３ＭＰａから３.６４ＭＰａへ低下しており、硬度が約３２％も低下している。従って、ポリウレタンを材質とする表皮１６は、加湿することで硬度が低下して軟化度合が大きく変化し、突刃部４２の突入に際して発生する内部応力の低減に効果的であると判断できる。   On the other hand, as is apparent from Table 2 and FIG. 6, the tensile strength and 50% modulus of the skin 16 made of polyurethane change greatly when the humidity of the skin 16 is changed. Turned out to be expensive. That is, as the humidity increases, both the tensile strength and the 50% modulus gradually decrease, and when the humidity of the skin 16 is 30% and the humidity is 90%, the 50% modulus is from 5.33 MPa. The hardness is reduced to 3.64 MPa, and the hardness is reduced by about 32%. Therefore, it can be determined that the skin 16 made of polyurethane is effective in reducing the internal stress generated when the projecting blade portion 42 enters due to a decrease in hardness and a significant change in softening degree due to humidification.

そこで本願発明者は、加湿時間に対する表皮１６の吸水率および５０％モジュラスの変化、そしてそれに基づいて突刃部４２の突入により表皮開裂予定部３０を成形した後の表皮１６の変形有無を試験することにした。ここで、表皮１６のサンプルである表皮試験片は、サイズが２００ｍｍ(縦)×１００ｍｍ(横)×１ｍｍ(厚さ)であり、重量が２３.２０ｇ(比重が１.１６)とされた矩形シート状を呈し、この表皮試験片を後述の加湿手段５０で加湿するようにした。なお吸水率とは、絶乾状態における表皮試験片の重量に対する加湿により吸収された水分量(重量)の比率である。   Therefore, the inventor of the present application tests the change in the water absorption rate and 50% modulus of the skin 16 with respect to the humidification time, and whether or not the skin 16 is deformed after the skin-splitting scheduled portion 30 is formed by the penetration of the projecting blade portion 42 based on the change. It was to be. Here, the skin specimen, which is a sample of the skin 16, is a rectangle having a size of 200 mm (length) × 100 mm (width) × 1 mm (thickness) and a weight of 23.20 g (specific gravity 1.16). A sheet form was formed, and the skin specimen was humidified by the humidifying means 50 described later. The water absorption rate is the ratio of the amount of moisture (weight) absorbed by humidification to the weight of the skin test piece in the absolutely dry state.

なお、加湿手段５０は、例えば図１に例示するように、表皮試験片を覆蓋可能なサイズに形成された加湿ボックス５２と、この加湿ボックス５２の内部に配設されて水蒸気を噴出させ得る蒸気噴出部５６を備えている。従って、加湿ボックス５２の開口部５４を表皮試験片の外面へ整合させたもとで、蒸気噴出部５６から噴出させた所定温度の水蒸気を、所要時間に亘って該表皮試験片へ接触させることで加湿するようにした。なお、蒸気噴出部５６から噴出された水蒸気の温度は、表皮１６の表面付近において９８℃とした。但し、表皮１６の表面付近における水蒸気の温度は、前述したように、８０〜１００℃の範囲内で設定すればよい。   For example, as illustrated in FIG. 1, the humidifying unit 50 includes a humidifying box 52 that is formed in a size that can cover the skin test piece, and a steam that is disposed inside the humidifying box 52 and can eject water vapor. The ejection part 56 is provided. Therefore, with the opening 54 of the humidification box 52 aligned with the outer surface of the skin test piece, the steam at a predetermined temperature ejected from the steam ejection part 56 is brought into contact with the skin test piece for a required time. I tried to do it. The temperature of the water vapor ejected from the steam ejection part 56 was 98 ° C. near the surface of the skin 16. However, the temperature of water vapor in the vicinity of the surface of the skin 16 may be set within the range of 80 to 100 ° C. as described above.

Figure 0004601481
Figure 0004601481

表３および図７は、加湿時間に対する表皮試験片の吸水率および５０％モジュラスの変化を示したものである。この試験結果によれば、加湿時間が３０秒以下の場合は、表皮開裂予定部３０の成形完了後の表皮試験片は、突刃部４２の突入を解除した後に図１１に例示したように変形してしまい、この変形度合(変形量)は加湿時間が短いほど大きかった。そして、加湿時間を３０秒以上とした場合には、表皮開裂予定部３０の成形完了後した表皮１６は、突刃部４２の突入を解除した後でも、その変形度合は微細に留まるか殆ど変形することはなかった。なお、加湿時間を３０秒とした場合では、吸水率が１.００％であり、５０％モジュラスは４.０１ＭＰａであった。   Table 3 and FIG. 7 show changes in the water absorption rate and 50% modulus of the skin specimen with respect to the humidification time. According to this test result, when the humidification time is 30 seconds or less, the skin test piece after the completion of molding of the skin tear scheduled portion 30 is deformed as illustrated in FIG. Thus, the degree of deformation (deformation amount) was larger as the humidification time was shorter. When the humidification time is set to 30 seconds or longer, the skin 16 after the completion of the formation of the skin tear scheduled portion 30 remains fine or almost deformed even after the protrusion of the projecting blade portion 42 is released. I never did. When the humidifying time was 30 seconds, the water absorption was 1.00% and the 50% modulus was 4.01 MPa.

そして、加湿時間が６０秒までは、吸水率が漸次増加するに従って５０％モジュラスも漸次低下している。しかしながら、加湿時間が６０秒以上になると、吸水率は依然として漸次増加するものの、５０％モジュラスの低下は微小に留まっている。これは、６０秒程度で、表皮試験片の軟化が略完了するようになり、これ以上に加湿時間を長くしても軟化が余り進行しないことを意味する。従って、加湿時間を６０秒以上にした場合には、成形サイクルタイムが長くなる分、表皮開裂予定部３０の成形効率が低下してしまう。なお、加湿時間を６０秒とした場合では、吸水率が２.０３％であり、５０％モジュラスは１.５０ＭＰａであった。   Then, until the humidification time reaches 60 seconds, the 50% modulus gradually decreases as the water absorption rate increases gradually. However, when the humidification time is 60 seconds or more, the water absorption rate still increases gradually, but the decrease in the 50% modulus remains small. This means that in about 60 seconds, the softening of the skin specimen is almost completed, and the softening does not progress much even if the humidification time is increased beyond this. Therefore, when the humidification time is set to 60 seconds or more, the molding efficiency of the planned skin tearing portion 30 is reduced by the increase in the molding cycle time. When the humidifying time was 60 seconds, the water absorption was 2.03% and the 50% modulus was 1.50 MPa.

前述した試験結果によれば、表皮１６の成形予定部位３２における５０％モジュラスは、４.０ＭＰａ〜１.５ＭＰａ程度に設定するのが望ましい。また吸水率は、１.０〜２.０％程度に設定するのが望ましい。更に、加湿時間は３０〜６０秒程度とすればよい。このような条件とすれば、成形予定部位３２を好適に軟化させることができ、この成形予定部位３２に突刃部４２を突入させた場合に、内部応力の発生を好適に抑えることが可能となる。なお、成形予定部位３２の加湿は、前述した加湿手段５０を使用すればよく、この加湿手段５０で発生する水蒸気の温度は、例えば８０〜１００℃で設定される。   According to the test results described above, it is desirable to set the 50% modulus at the molding target portion 32 of the skin 16 to about 4.0 MPa to 1.5 MPa. The water absorption rate is desirably set to about 1.0 to 2.0%. Furthermore, the humidifying time may be about 30 to 60 seconds. Under such conditions, it is possible to suitably soften the part to be molded 32, and it is possible to suitably suppress the occurrence of internal stress when the projecting blade portion 42 is plunged into this part to be molded 32. Become. In addition, the humidification means 50 should just be used for humidification of the shaping | molding site | part 32, and the temperature of the water vapor | steam generated with this humidification means 50 is set at 80-100 degreeC, for example.

従って、本実施例の表皮開裂予定部の成形方法では、先ず、突刃部４２の突入に先立ち、図１に例示したように、少なくとも表皮１６の成形予定部位３２に、加湿手段５０で発生させた８０〜１００℃の適宜温度の水蒸気を３０〜６０秒間に亘って接触させ、該成形予定部位３２を加湿する。すなわち図１に例示するように、加湿手段５０における加湿ボックス５２の開口部５４を表皮１６の成形予定部位３２に整合させ、次いで図２に例示するように、蒸気噴出部５６から噴出させた水蒸気を該成形予定部位３２へ所定時間に亘って接触させる。これにより、少なくとも成形予定部位３２には、吸水率が１.０〜２.０％となる水分が吸収されるようになるから、この成形予定部位３２の５０％モジュラスは１.５〜４.０ＭＰａの範囲内となり、該成形予定部位３２は好適に軟化するようになる。   Therefore, in the method for forming the skin cleavage scheduled portion of the present embodiment, first, prior to the entry of the projecting blade portion 42, the humidifying means 50 generates at least the formation planned portion 32 of the skin 16 as illustrated in FIG. Further, water vapor having an appropriate temperature of 80 to 100 ° C. is brought into contact for 30 to 60 seconds to humidify the portion to be molded 32. That is, as illustrated in FIG. 1, the opening 54 of the humidifying box 52 in the humidifying means 50 is aligned with the molding planned portion 32 of the skin 16, and then the steam ejected from the steam ejecting portion 56 as illustrated in FIG. 2. Is brought into contact with the part to be molded 32 for a predetermined time. As a result, at least the part to be molded 32 absorbs moisture with a water absorption rate of 1.0 to 2.0%, so the 50% modulus of the part to be molded 32 is 1.5 to 4. Within the range of 0 MPa, the molding planned portion 32 is suitably softened.

そして、加湿手段５０を使用した加湿工程により成形予定部位３２を軟化させたら、該加湿手段５０を退避させた後、図３に例示するように、加熱された突刃部４２の先端部を押付けて突入させる。この際に、成形予定部位３２は、加湿されて軟化状態にあるため、突刃部４２の先端が突入したとしても、内部応力の発生が殆ど抑えられる。   And if the shaping | molding plan site | part 32 is softened by the humidification process using the humidification means 50, after evacuating this humidification means 50, as shown in FIG. 3, the front-end | tip part of the heated blade part 42 will be pressed. Rush into. At this time, since the part to be molded 32 is humidified and is in a softened state, even if the tip of the projecting blade part 42 enters, generation of internal stress is hardly suppressed.

従って、突刃部４２を冷却して、表皮１６を塑性変形させた後に該突刃部４２を退避させた場合には、図４に例示するように、内部応力が殆ど発生していなかったため、表皮１６が撓んだり捻れたりする等の変形は殆ど発生しない。   Therefore, when the projecting blade portion 42 is cooled and the skin 16 is plastically deformed and then retracted, the internal stress is hardly generated as illustrated in FIG. Almost no deformation such as bending or twisting of the skin 16 occurs.

このような本実施例の表皮開裂予定部の成形方法によれば、以下のような効果を得ることができる。先ず、突刃部４２の突入に先立ち、少なくとも表皮開裂予定部３０の成形予定部位３２を、加湿手段５０で発生する水蒸気により加湿して軟化させるようにしたので、突刃部４２を突入させた際に表皮１６の内部応力の発生を好適に抑えることができる。従って、表皮開裂予定部３０の成形完了後に突刃部４２を退避させた際に、表皮１６が変形することを好適に防止できる。なお、加湿した成形予定部位３２の５０％モジュラスを１.５〜４.０ＭＰａとなるようにすれば、該成形予定部位３２へ突刃部４２を突入させても内部応力の発生を最小限に抑え得る。また、加湿による成形予定部位３２の吸水率を１.０〜２.０％となるようにすれば、該成形予定部位３２へ突刃部４２を突入させても内部応力の発生を最小限に抑え得る。   According to such a method of forming the skin cleavage planned portion of this embodiment, the following effects can be obtained. First, prior to the entry of the cutting edge portion 42, at least the molding planned portion 32 of the skin cleavage scheduled portion 30 is humidified and softened by water vapor generated by the humidifying means 50, so that the cutting edge portion 42 is entered. At this time, generation of internal stress in the skin 16 can be suitably suppressed. Therefore, it is possible to suitably prevent the skin 16 from being deformed when the projecting blade portion 42 is retracted after the formation of the skin-splitting scheduled portion 30 is completed. If the 50% modulus of the humidified molding target portion 32 is set to 1.5 to 4.0 MPa, the generation of internal stress is minimized even when the projecting blade portion 42 is inserted into the molding planned portion 32. Can be suppressed. Further, if the water absorption rate of the part to be molded 32 due to humidification is set to 1.0 to 2.0%, the generation of internal stress is minimized even if the projecting blade portion 42 enters the part to be molded 32. Can be suppressed.

また、加湿手段５０で発生させた水蒸気を、成形予定部位３２に接触させるようにしたことにより、該成形予定部位３２を効果的に加湿することができる。特に、水蒸気の温度を８０〜１００℃の範囲内であれば、成形予定部位３２を効率的に加湿することができる。更に、水蒸気による加湿時間を３０〜６０秒間に設定すれば、成形予定部位３２を適切に加湿することができる。   In addition, since the water vapor generated by the humidifying means 50 is brought into contact with the molding site 32, the molding site 32 can be effectively humidified. In particular, when the temperature of the water vapor is in the range of 80 to 100 ° C., the molding planned portion 32 can be efficiently humidified. Furthermore, if the humidification time by water vapor | steam is set to 30 to 60 second, the shaping | molding site | part 32 can be humidified appropriately.

なお、前述した表皮開裂予定部３０の成形が完了したら、この成形作業の完了後に、エアバッグドア２０を設けた基材１２を表皮１６の裏側に臨ませ、これら基材１２と表皮１６との間で発泡体１４を発泡成形するようにしてもよい。すなわち、図示しない発泡成形型に表皮１６および基材１２をセットしたもとで、これら表皮１６および発泡体１４の間に画成された発泡空間内で発泡体１４を発泡成形すれば、前述したインストルメントパネル１０を製造することができる。   When the above-described formation of the skin-splitting scheduled portion 30 is completed, the base material 12 provided with the airbag door 20 faces the back side of the skin 16 after the completion of the molding operation. You may make it foam-mold the foam 14 between. That is, if the foam 14 is foam-molded in the foaming space defined between the skin 16 and the foam 14 with the skin 16 and the base material 12 set in a foam molding die (not shown), the above-described process is performed. The instrument panel 10 can be manufactured.

このように、表皮開裂予定部３０の成形後において、成形予定部位３２がまだ加湿されて軟化状態となっている時に、表皮１６と基材１２との間で発泡体１４を発泡成形することにより、表皮１６に多少の変形が生じていたとしても、該表皮１６は発泡体１４の発泡圧により適切な形状へ容易に矯正され得る。   In this way, by foam molding of the foam 14 between the skin 16 and the base material 12 when the molding planned portion 32 is still humidified and softened after molding of the skin cleavage planned portion 30. Even if the skin 16 is somewhat deformed, the skin 16 can be easily corrected to an appropriate shape by the foaming pressure of the foam 14.

なお、前述した加湿方法により表皮１６の成形予定部位３２を加湿した場合には、概ね２時間程度は充分な軟化状態が維持されることが判った。従って、後工程である発泡体１４の発泡成形作業は、成形予定部位３２に対する加湿完了後から２時間以内に実施すればよい。   In addition, when the shaping | molding scheduled part 32 of the skin 16 was humidified with the humidification method mentioned above, it turned out that a sufficient softened state is maintained for about 2 hours. Therefore, the foam molding operation of the foam 14 as a subsequent process may be performed within 2 hours after the humidification of the molding planned portion 32 is completed.

表皮開裂予定部３０の延在形状は、前述した両Ｙ字形のものに限定されるものではなく、エアバッグドア２０の開放態様に応じて設定されるものであり、コ字形、Ｈ字形等にも応用可能である。   The extending shape of the skin-splitting scheduled portion 30 is not limited to the above-described both Y-shaped ones, but is set according to the opening mode of the airbag door 20, such as a U-shape or an H-shape. Is also applicable.

本発明に係る表皮開裂予定部の成形方法は、ポリウレタンを材質とし、エアバッグドアの外面に配設される表皮の外面に、所要形状をなす突刃部の先端部を押付けて突入させ、薄肉化された表皮開裂予定部を成形する方法であり、エアバッグドアが設けられた車両内装部材に配設される表皮の成形に好適に実施可能である。   The method for molding the skin tear scheduled portion according to the present invention is made of polyurethane, and the outer surface of the skin disposed on the outer surface of the airbag door is pressed against the distal end portion of the projecting blade portion having a required shape so as to be thinned. This is a method of forming a cut-out skin-scheduled scheduled portion, and can be suitably implemented for forming a skin disposed on a vehicle interior member provided with an airbag door.

本実施例の表皮開裂予定部の成形方法を示した説明断面図であって、成形予定部位に加湿手段を到来させた状態を示している。It is explanatory sectional drawing which showed the shaping | molding method of the epidermis cleavage part of a present Example, Comprising: The state which made the humidification means arrive at the shaping | molding plan site | part is shown. 加湿ボックス内に噴出させた水蒸気を成形予定部位に接触させ、成形予定部位を加湿により軟化させる状態を示した説明断面図。Explanatory sectional drawing which showed the state which made the water vapor sprayed in the humidification box contact a shaping | molding site | part, and softens the shaping | molding site | part by humidification. 成形予定部位の加湿完了後に、溝成形装置の突刃部を突入させて表皮開裂予定部を成形している状態を示した説明断面図。Explanatory sectional drawing which showed the state which made the protrusion part of a groove-forming apparatus penetrate and shape | mold the skin-splitting planned part after completion of humidification of the shaping | molding planned site | part. 表皮開裂予定部の成形完了後に突刃部を後退させても、表皮が変形しないことを示した説明断面図。Explanatory sectional drawing which showed that even if it retreats a blade part after completion | finish of shaping | molding of a skin-splitting planned part, a skin does not deform | transform. 温度変化による引張強度および５０％モジュラスの変化を示したグラフ。The graph which showed the change of the tensile strength and 50% modulus by a temperature change. 湿度変化による引張強度および５０％モジュラスの変化を示したグラフ。The graph which showed the change of the tensile strength and 50% modulus by a humidity change. 吸水率と５０％モジュラスとの関係を示したグラフ。The graph which showed the relationship between a water absorption rate and 50% modulus. 基材、発泡体および表皮からなるインストルメントパネルを、各構成部材を分離させた状態で示した部分斜視図。The fragmentary perspective view which showed the instrument panel which consists of a base material, a foam, and a skin in the state which isolate | separated each structural member. 表皮に表皮開裂予定部を成形するための溝成形装置を示した斜視図。The perspective view which showed the groove forming apparatus for shape | molding an epidermis cleavage part on an outer skin. 図９に例示した溝成形装置の突刃部を表皮に突入させて表皮開裂予定部を成形する際に、表皮に内部応力が発生することを示した説明断面図。FIG. 10 is an explanatory cross-sectional view showing that an internal stress is generated in the skin when forming the skin-splitting scheduled portion by causing the protruding portion of the groove forming apparatus illustrated in FIG. 9 to enter the skin. 突刃部による表皮開裂予定部の成形完了後に、内部応力により表皮が変形する不都合を示した説明断面図。Explanatory sectional drawing which showed the inconvenience which a skin deform | transforms according to an internal stress after completion | finish of shaping | molding of the skin-splitting planned part by a blade part.

符号の説明Explanation of symbols

１２ 基材，１４ 発泡体，１６ 表皮，２０ エアバッグドア，３０ 表皮開裂予定部，
３２ 成形予定部位，４２ 突刃部，５０ 加湿手段
12 base material, 14 foam, 16 skin, 20 air bag door, 30 planned skin tear,
32 parts to be molded, 42 cutting edge, 50 humidification

Claims (3)

ポリウレタンを材質としてスプレー成形により成形され、エアバッグドアの外面に配設される表皮(16)の外面に、所要形状をなす突刃部(42)の先端部を押付けて突入させ、薄肉化された表皮開裂予定部(30)を成形する方法において、
前記突刃部(42)の突入に先立ち、少なくとも前記表皮開裂予定部(30)の成形予定部位(32)に８０〜１００℃の水蒸気を接触させ、該成形予定部位(32)の吸水率を１.０〜２.０％とした
ことを特徴とする表皮開裂予定部の成形方法。 The polyurethane and the material is molded by injection forming, on the outer surface of the skin (16) disposed on the outer surface of the air bag door, to rush to push the distal end portion of the突刃portion forming the required shape (42), thin In the method of forming the planned epidermal cleavage part (30),
Prior to the entry of the projecting blade portion (42), at least the molding planned portion (32) of the skin cleavage planned portion (30) is brought into contact with water vapor at 80 to 100 ° C, and the water absorption rate of the molding planned portion (32) is determined. A method for forming a portion to be cleaved, characterized by being 1.0 to 2.0% . 前記水蒸気を接触させた成形予定部(32)の５０％モジュラスを１.５〜４.０ＭＰａとした請求項１記載の表皮開裂予定部の成形方法。 Molding method of the preceding Symbol epidermal cleavage scheduled portion of claim 1, wherein that the 1.5~4.0MPa 50% modulus of forming shapes scheduled portion contacting the steam (32). 請求項１または２記載の表皮開裂予定部の成形方法により表皮開裂予定部(30)が成形された前記表皮(16)の裏側に、エアバッグドア(20)を設けた基材(12)を臨ませ、前記表皮開裂予定部(30)の加湿状態においてこれら基材(12)と表皮(16)との間で発泡体(14)を発泡成形する
ことを特徴とするインストルメントパネルの製造方法。 A base material (12) provided with an airbag door (20) on the back side of the skin (16) on which the skin tear planned portion (30) is molded by the method for molding a skin tear planned portion according to claim 1 or 2. The foam (14) is foam- molded between the base material (12) and the skin (16) in a humidified state of the planned skin cleavage part (30).
An instrument panel manufacturing method characterized by the above .
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JP4834607B2 (en) * 2007-05-18 2011-12-14 株式会社仲田コーティング Airbag fracture groove forming apparatus and interior member manufacturing method

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JPS5573533A (en) * 1978-11-29 1980-06-03 Meiwa Sangyo Kk Production of formed polystyrene bead foam covered on its surface with cloth skin
JPS58171921A (en) * 1982-04-02 1983-10-08 Honda Motor Co Ltd Manufacture of foam resin molded object shaped surface skin
JPH01212631A (en) * 1988-02-19 1989-08-25 Howa Seni Kogyo Kk Inside applying member for vehicle and manufacture thereof
JPH1142717A (en) * 1997-07-28 1999-02-16 Kansei Corp Production of interior member for vehicle
JPH11333960A (en) * 1998-05-25 1999-12-07 Sekisui Plastics Co Ltd Foamed molded body with skin material and manufacture of the same
JP2000159047A (en) * 1998-11-30 2000-06-13 Inoac Corp Manufacture of surface skin having cleavage-expected part for air bag door
JP2001040056A (en) * 1999-05-25 2001-02-13 Inoac Corp Thermoplastic polyurethane elastomer for slash molding, thermoplastic polyurethane elastomer powder for slash molding and skin material by using the same
JP2003334827A (en) * 2002-05-20 2003-11-25 Toyota Motor Corp Resin film and method for manufacturing resin molding using the film

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5573533A (en) * 1978-11-29 1980-06-03 Meiwa Sangyo Kk Production of formed polystyrene bead foam covered on its surface with cloth skin
JPS58171921A (en) * 1982-04-02 1983-10-08 Honda Motor Co Ltd Manufacture of foam resin molded object shaped surface skin
JPH01212631A (en) * 1988-02-19 1989-08-25 Howa Seni Kogyo Kk Inside applying member for vehicle and manufacture thereof
JPH1142717A (en) * 1997-07-28 1999-02-16 Kansei Corp Production of interior member for vehicle
JPH11333960A (en) * 1998-05-25 1999-12-07 Sekisui Plastics Co Ltd Foamed molded body with skin material and manufacture of the same
JP2000159047A (en) * 1998-11-30 2000-06-13 Inoac Corp Manufacture of surface skin having cleavage-expected part for air bag door
JP2001040056A (en) * 1999-05-25 2001-02-13 Inoac Corp Thermoplastic polyurethane elastomer for slash molding, thermoplastic polyurethane elastomer powder for slash molding and skin material by using the same
JP2003334827A (en) * 2002-05-20 2003-11-25 Toyota Motor Corp Resin film and method for manufacturing resin molding using the film

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