JP4739979B2 - Method for manufacturing an instrument panel integrated with an air bag door - Google Patents

Method for manufacturing an instrument panel integrated with an air bag door Download PDF

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JP4739979B2
JP4739979B2 JP2006043304A JP2006043304A JP4739979B2 JP 4739979 B2 JP4739979 B2 JP 4739979B2 JP 2006043304 A JP2006043304 A JP 2006043304A JP 2006043304 A JP2006043304 A JP 2006043304A JP 4739979 B2 JP4739979 B2 JP 4739979B2
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door
airbag
panel body
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airbag door
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孝二 伊藤
孝弘 山口
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三ツ星化成品株式会社
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Description

本発明は、エアバッグの作動時に展開するエアバッグドアを一体的に備えたエアバッグドア一体型インストルメントパネルの製造方法に関する。
The present invention relates to a method of manufacturing an air bag door integrated instrument panel integrally provided with the air bag door deployment when the airbag deployment.

計器類等が取り付けられる自動車用のインストルメントパネルとして、助手席用エアバッグを搭載したものが知られている。このようなインストルメントパネルは、一般的に、通常状態ではエアバッグが膨出するインストルメントパネルの開口部を閉止するとともに、エアバッグ作動時にはその膨張圧力により展開して開口部を開放するエアバッグドアを備えている。   2. Description of the Related Art As an instrument panel for automobiles to which instruments and the like are attached, a panel equipped with a passenger seat airbag is known. Such an instrument panel generally closes the opening of the instrument panel in which the airbag inflates in a normal state, and expands by the inflation pressure when the airbag is activated to open the opening. It has a door.

例えば、特許文献１に記載のエアバッグドア一体型インストルメントパネルは、パネル本体（インストルメントパネル芯材）と、このパネル本体に形成されたエアバッグ膨出用の開口部を閉止するエアバッグドア（エアバッグドア芯材）とを備えている。エアバッグドアは、パネル本体の開口部に取り付けられた平板状のドア部と、このドア部の外周部に一体形成され、エアバッグを収納するエアバッグケースが取り付けられる筒状の取付部を有する。また、パネル本体とエアバッグドアの表面にはウレタンフォーム等の発泡体と表皮が積層されており、パネル本体とエアバッグドアとが一体化されている。   For example, an instrument panel integrated with an airbag door described in Patent Document 1 includes an airbag door that closes a panel body (instrument panel core) and an airbag inflation opening formed in the panel body. (Airbag door core material). The airbag door has a flat door portion attached to the opening of the panel body and a cylindrical attachment portion integrally formed on the outer periphery of the door portion to which an airbag case for storing the airbag is attached. . Further, a foam body such as urethane foam and a skin are laminated on the surfaces of the panel body and the airbag door, and the panel body and the airbag door are integrated.

このインストルメントパネルは以下のようにして製造される。まず、パネル本体の開口部にエアバッグドアのドア部を取り付けた後に、パネル本体及びエアバッグドアと表皮をそれぞれ成形型により支持する。そして、パネル本体及びエアバッグドアと表皮との間に発泡樹脂を注入して発泡させ、発泡体を成形する。   This instrument panel is manufactured as follows. First, after attaching the door part of an airbag door to the opening part of a panel main body, a panel main body, an airbag door, and an outer skin are each supported by a shaping | molding die. And a foaming resin is inject | poured between a panel main body and an airbag door, and an outer skin, it is made to foam, and a foam is shape | molded.

ところで、一般的に、パネル本体は、ＡＢＳ樹脂やタルクを混合したポリプロピレン等の硬質樹脂が使用される。一方、エアバッグドアには、エアバッグの膨出性能を確保するために、熱可塑性ポリオレフィン系軟質樹脂（サーモプラスチックオレフィン（ＴＰＯ）樹脂）等の、低温（−４０℃程度）から高温（９０℃程度）までの温度域において柔軟性が失われない軟質樹脂が主に使用されており、エアバッグドアの剛性はパネル本体と比べてかなり低くなっている。そのため、インストルメントパネルの製造段階において、パネル本体とエアバッグドアを成形型に取り付けたときの成形型との干渉や、エアバッグドアの表面に注入された発泡樹脂の発泡圧力により、エアバッグドアが変形して、表皮に凹凸が生じやすい。   By the way, generally, the panel body is made of hard resin such as polypropylene mixed with ABS resin or talc. On the other hand, in order to ensure the bulging performance of the airbag, the airbag door has a low temperature (about −40 ° C.) to a high temperature (90 ° C.) such as thermoplastic polyolefin soft resin (thermoplastic olefin (TPO) resin). A soft resin that does not lose its flexibility in the temperature range up to about) is mainly used, and the rigidity of the airbag door is considerably lower than that of the panel body. Therefore, in the manufacturing stage of the instrument panel, the air bag door is caused by interference between the panel main body and the air bag door when the air bag door is attached to the metal mold and the foaming pressure of the foamed resin injected on the surface of the air bag door. Will deform and the surface will be uneven.

そこで、特許文献１には、発泡樹脂注入時におけるエアバッグドアの変形を抑制可能な、エアバッグドア一体型インストルメントパネルの製造方法が開示されている。この製造方法においては、エアバッグドアを支持する成形型が可動型で、エアバッグドアのドア部の裏面との間のクリアランスを調整可能に構成されている。そして、このクリアランスを所定の量に保持した状態で、エアバッグドアの表面に発泡樹脂を注入して発泡させる。このように、エアバッグドアが適度なクリアランスを空けて可動型に支持されることから、発泡樹脂の発泡圧力や成形型との干渉に起因するドア部の変形が抑制され、表皮に生じる凹凸が小さくなる。   Therefore, Patent Document 1 discloses a method for manufacturing an airbag door integrated instrument panel that can suppress deformation of the airbag door at the time of injecting the foamed resin. In this manufacturing method, the mold that supports the airbag door is a movable mold, and the clearance between the back surface of the door portion of the airbag door can be adjusted. Then, in a state where this clearance is maintained at a predetermined amount, a foamed resin is injected into the surface of the airbag door to cause foaming. As described above, since the airbag door is supported by the movable mold with an appropriate clearance, the deformation of the door portion due to the foaming pressure of the foamed resin and the interference with the mold is suppressed, and the unevenness generated in the skin is prevented. Get smaller.

特開２００４−２３１０７７号公報JP 2004-231077 A

前述した特許文献１に記載の製造方法では、発泡樹脂の注入時に、ドア部の中央部は可動型に支持されているものの、パネル本体に固定される部分であるドア部の外周部（取付部との連結部分）は可動型に支持されていない。そのため、発泡樹脂の発泡圧力によりドア部の外周部が変形して、この部分を覆う表皮に凹凸が生じやすくなっていた。   In the manufacturing method described in Patent Document 1 described above, when the foamed resin is injected, the central portion of the door portion is supported by a movable mold, but the outer peripheral portion (attachment portion) of the door portion that is fixed to the panel body. Is not supported by the movable mold. For this reason, the outer peripheral portion of the door portion is deformed by the foaming pressure of the foamed resin, and unevenness is likely to occur on the skin covering this portion.

本発明の目的は、発泡樹脂注入時のエアバッグドアの変形を確実に抑制して、表皮に凹凸が生じてしまうのを確実に防止することである。   An object of the present invention is to surely prevent deformation of the airbag door at the time of injecting the foamed resin and to surely prevent the skin from being uneven.

課題を解決するための手段及び発明の効果Means for Solving the Problems and Effects of the Invention

第１の発明のエアバッグドア一体型インストルメントパネルの製造方法は、エアバッグが膨出する開口部を有するパネル本体と、前記開口部を閉止するとともに前記エアバッグの作動時にはその膨張圧力により展開して前記開口部を開放するエアバッグドアであって、前記パネル本体よりも軟質な材料で形成されるとともに、前記パネル本体の前記開口部を塞ぐドア部と、このドア部の外周部から延びて前記エアバッグを収納するエアバッグケースが取り付けられる取付部とを有するエアバッグドアと、前記パネル本体及び前記エアバッグドアの前記ドア部の表面に連続的に積層された発泡体及び表皮とを備えた、エアバッグドア一体型インストルメントパネルの製造方法であって、前記パネル本体と前記エアバッグドアとを別々の成形型により支持する支持工程と、前記成形型により支持された前記パネル本体及び前記エアバッグドアの、前記成形型と反対側の面に発泡樹脂を注入する注入工程とを備え、前記支持工程において前記エアバッグドアを支持する成形型は、前記パネル本体を支持する成形型に対して移動可能な可動型であり、前記支持工程において、前記可動型の位置を調整して前記ドア部と前記可動型との間のクリアランスを所定の量に保持しつつ、前記可動型を前記取付部に当接させて、前記エアバッグドアを支持するものであり、前記可動型は、前記ドア部を支持する第１支持部と、前記取付部との当接方向に付勢されて前記第１支持部に対してその当接方向に移動可能で、前記取付部を支持する第２支持部を備え、前記支持工程において、前記第２支持部を前記取付部に当接させた後に、前記第２支持部を前記第１支持部に対して移動不能に固定することを特徴とするものである。
 A method for manufacturing an instrument panel integrated with an airbag door according to a first aspect of the present invention includes a panel body having an opening through which an airbag is inflated, and the opening is closed by the inflation pressure when the airbag is in operation. An air bag door that opens the opening, and is formed of a softer material than the panel main body, and extends from an outer peripheral portion of the door portion that closes the opening of the panel main body. And an airbag door having an attachment portion to which an airbag case for housing the airbag is attached, and a foam and an outer skin continuously laminated on the surface of the door body portion of the panel body and the airbag door. A method for manufacturing an instrument panel integrated with an airbag door, comprising the panel body and the airbag door in separate molds A support step for supporting the mold, and an injection step for injecting a foamed resin into a surface of the panel body and the airbag door supported by the molding die on the side opposite to the molding die. The mold that supports the bag door is a movable mold that is movable with respect to the mold that supports the panel body. In the supporting step, the position of the movable mold is adjusted, and the door portion and the movable mold The movable mold is brought into contact with the mounting portion to support the airbag door while the clearance between the first and second movable portions is held at a predetermined amount , and the movable mold supports the door portion. A second support portion that is urged in a contact direction between the support portion and the attachment portion and is movable in the contact direction with respect to the first support portion, and supports the attachment portion; In the second support part After brought into contact with the serial attachment portion, and is characterized in that the immovably fixed to the second said supporting portion first support portion.

この製造方法においては、まず、支持工程において、パネル本体とエアバッグドアとを別々の成形型により支持してから、注入工程において、パネル本体及びエアバッグドアの成形型と反対側の面に発泡樹脂を注入して発泡させ、エアバッグドア一体型インストルメントパネルを形成する。   In this manufacturing method, first, in the supporting process, the panel body and the airbag door are supported by separate molds, and then in the injection process, foaming is performed on the surface opposite to the panel body and the airbag door mold. Resin is injected and foamed to form an instrument panel integrated with an airbag door.

ここで、エアバッグドアを支持する成形型は、パネル本体を支持する成形型に対して移動可能な可動型である。そして、支持工程において、ドア部と可動型との間のクリアランスを所定の値に保持しつつ、可動型を取付部に当接させて、エアバッグドアを支持する。そのため、発泡樹脂の注入時に、ドア部の表面をパネル本体とほぼ面一となる適切な位置に保持しつつ、パネル本体に取り付けられるドア部の外周部を、取付部を介して可動型で支持することができ、ドア部を覆う表皮に凹凸が生じるのを極力防止できる。   Here, the mold that supports the airbag door is a movable mold that is movable with respect to the mold that supports the panel body. In the support step, the airbag door is supported by bringing the movable mold into contact with the mounting section while maintaining the clearance between the door section and the movable mold at a predetermined value. For this reason, when foam resin is injected, the outer surface of the door attached to the panel body is supported by a movable type via the attachment part while holding the surface of the door part at an appropriate position that is substantially flush with the panel body. It is possible to prevent as much as possible unevenness in the skin covering the door.

また、この製造方法によれば、第２支持部が取付部に当接した状態で、第２支持部を第１支持部に固定するため、エアバッグドアの取付部の寸法のばらつきが大きい場合でも、取付部に第２支持部が当接するため、取付部が確実に支持される。
 Further , according to this manufacturing method, when the second support portion is in contact with the attachment portion, the second support portion is fixed to the first support portion, and therefore, the variation in the size of the attachment portion of the airbag door is large. However, since the second support portion comes into contact with the attachment portion, the attachment portion is reliably supported.

次に、本発明の実施の形態について説明する。まず、図１〜図３を参照して、本実施形態のエアバッグ一体型インストルメントパネルの構造について説明する。   Next, an embodiment of the present invention will be described. First, with reference to FIGS. 1-3, the structure of the airbag integrated instrument panel of this embodiment is demonstrated.

図１〜図３に示すように、本実施形態に係る自動車用インストルメントパネル１は、インストルメントパネルの芯材であり、エアバッグ１３が膨出する開口部２ａを有するパネル本体２と、このパネル本体２の開口部２ａを閉止するエアバッグドア３とを備えている。また、パネル本体２及びエアバッグドア３の表面には発泡体４と表皮５が連続的に積層されており、パネル本体２とエアバッグドア３とが一体化された構造となっている。   As shown in FIGS. 1 to 3, an automotive instrument panel 1 according to the present embodiment is a core member of the instrument panel, and a panel body 2 having an opening 2 a through which an airbag 13 bulges, An airbag door 3 for closing the opening 2a of the panel body 2 is provided. Further, the foam body 4 and the skin 5 are continuously laminated on the surfaces of the panel body 2 and the airbag door 3 so that the panel body 2 and the airbag door 3 are integrated.

パネル本体２は、ＡＢＳ樹脂やタルクを混合したポリプロピレン等の比較的硬質の樹脂で形成されている。また、このパネル本体２の助手席側部分（図１の左側部分）の前面部には、エアバッグ１３の膨出用の開口部２ａが形成されている。尚、開口部２ａの縁には、パネル本体２の表面よりも内側の位置において張り出した張出部２ｂが、開口部２ａの全周に亙って環状に形成されている。   The panel body 2 is formed of a relatively hard resin such as polypropylene mixed with ABS resin or talc. Further, an opening 2a for inflating the airbag 13 is formed in the front surface portion of the passenger seat side portion (left side portion in FIG. 1) of the panel body 2. Note that an overhanging portion 2b that protrudes at a position inside the surface of the panel body 2 is formed in an annular shape over the entire circumference of the opening 2a at the edge of the opening 2a.

図２、図３に示すように、エアバッグドア３は、パネル本体２の開口部２ａを塞ぐ平板状のドア部１０と、このドア部１０の外周部から内側に延びて、エアバッグ１３を収納するエアバッグケース１５が取り付けられる筒状の取付部１１とが、一体形成された構造を有する。そして、エアバッグケース１５内のエアバッグ１３が膨張したときに、その膨張圧力によってエアバッグドア３が外側へ展開し、開口部２ａを開放するように構成されている。   As shown in FIG. 2 and FIG. 3, the airbag door 3 includes a flat door portion 10 that closes the opening 2 a of the panel body 2, and an airbag 13 that extends inward from the outer peripheral portion of the door portion 10. A cylindrical attachment portion 11 to which the airbag case 15 to be stored is attached has a structure integrally formed. And when the airbag 13 in the airbag case 15 expand | swells, the airbag door 3 expand | deploys outside with the expansion | swelling pressure, and it is comprised so that the opening part 2a may be open | released.

また、このエアバッグドア３は、低温（−４０℃程度）から高温（９０℃程度）までの温度域にわたって柔軟性を確保するために、熱可塑性ポリオレフィン系樹脂（ＴＰＯ）エラストマー等の、パネル本体２よりも軟質の樹脂により形成されている。つまり、エアバッグ１３の動作温度に関わらずエアバッグドア３には常にある程度の柔軟性が確保されており、エアバッグ１３の作動時にその膨張圧力によってエアバッグドア３が確実に展開できるようになっている。さらに、エアバッグ１３の作動時にその膨張圧力によりエアバッグドア３を確実に破断することができるように、ドア部１０の中央部には局所的に剛性の低くなった開裂線部１６（ティアーライン）が設けられている。そのため、エアバッグドア３の剛性はかなり低いものとなっている。   The airbag door 3 is made of a panel body such as a thermoplastic polyolefin resin (TPO) elastomer in order to ensure flexibility over a temperature range from a low temperature (about −40 ° C.) to a high temperature (about 90 ° C.). It is formed of a softer resin than 2. In other words, the airbag door 3 always has a certain degree of flexibility regardless of the operating temperature of the airbag 13, and the airbag door 3 can be reliably deployed by the inflation pressure when the airbag 13 is activated. ing. Furthermore, the tear line portion 16 (the tear line) having a locally low rigidity is provided at the central portion of the door portion 10 so that the airbag door 3 can be reliably broken by the inflation pressure when the airbag 13 is operated. ) Is provided. For this reason, the rigidity of the airbag door 3 is considerably low.

ドア部１０の外周部は、パネル本体２の開口部２ａに全周に亙って設けられた張出部２ｂに載置されており、このドア部１０により開口部２ａが塞がれている。また、パネル本体２とエアバッグドア３の表面に発泡樹脂を注入して発泡体４を形成するときの、発泡樹脂の漏れを防止するために、パネル本体２の張出部２ｂとドア部１０の外周部との間には、ウレタン等の発泡樹脂からなるクッションテープ１７が介装されている。そして、図２、図３に示すように、パネル本体２の表面と、クッションテープ１７を介して張出部２ｂに載置されたドア部１０の表面は、略面一となっている。   The outer peripheral portion of the door portion 10 is placed on an overhang portion 2 b provided over the entire periphery of the opening portion 2 a of the panel body 2, and the opening portion 2 a is blocked by the door portion 10. . Further, in order to prevent leakage of the foamed resin when the foamed resin is formed by injecting the foamed resin into the surfaces of the panel body 2 and the airbag door 3, the overhanging portion 2b and the door portion 10 of the panel body 2 are prevented. A cushion tape 17 made of a foamed resin such as urethane is interposed between the outer peripheral portion and the outer peripheral portion. As shown in FIGS. 2 and 3, the surface of the panel main body 2 and the surface of the door portion 10 placed on the overhanging portion 2 b via the cushion tape 17 are substantially flush with each other.

取付部１１は、ドア部１０の外周部の裏面（内面）からインストルメントパネルの内側へ筒状に延びている。この取付部１１の筒長方向途中部の外面には環状に突出する爪部１１ａが形成されている。そして、この爪部１１ａとドア部１０の外周部との間にパネル本体２の張出部２ｂが係合した構造となっており、エアバッグドア３の開口部２ａからの抜けが防止されている。また、取付部１１の端部にはエアバッグケース１５が取り付けられており、取付部１１とエアバッグケース１５の内部に、エアバッグ１３と、このエアバッグ１３を膨張させるインフレータ１４とが収納されている。   The attachment portion 11 extends in a cylindrical shape from the back surface (inner surface) of the outer peripheral portion of the door portion 10 to the inside of the instrument panel. A claw portion 11 a that protrudes in an annular shape is formed on the outer surface of the middle portion in the cylinder length direction of the attachment portion 11. And it has the structure where the overhang | projection part 2b of the panel main body 2 engaged between this nail | claw part 11a and the outer peripheral part of the door part 10, and the removal from the opening part 2a of the airbag door 3 is prevented. Yes. An airbag case 15 is attached to the end of the attachment portion 11, and an airbag 13 and an inflator 14 for inflating the airbag 13 are housed inside the attachment portion 11 and the airbag case 15. ing.

パネル本体２とエアバッグドア３のドア部１０の表面には、ウレタンフォーム等の発泡体４が全面的に積層されている。さらに、この発泡体４の表面は、熱可塑性ウレタン（ＴＰＵ）、熱可塑性オレフィン（ＴＰＯ）、塩化ビニル（ＰＶＣ）、あるいは、熱硬化性ウレタン（ＰＵＲ）等からなる表皮５により覆われている。ここで、パネル本体２の表面とドア部１０の表面は略面一となっているため、パネル本体２とドア部１０の外周部との境界部分において表皮５には凹凸が生じておらず、略面一の平滑な形状となっている。   Foam 4 such as urethane foam is entirely laminated on the surfaces of the panel body 2 and the door portion 10 of the airbag door 3. Further, the surface of the foam 4 is covered with a skin 5 made of thermoplastic urethane (TPU), thermoplastic olefin (TPO), vinyl chloride (PVC), thermosetting urethane (PUR), or the like. Here, since the surface of the panel body 2 and the surface of the door portion 10 are substantially flush with each other, there is no unevenness in the skin 5 at the boundary portion between the panel body 2 and the outer peripheral portion of the door portion 10, It has a substantially flat and smooth shape.

次に、インストルメントパネル１の製造方法について図４及び図５を参照して説明する。
まず、パネル本体２とエアバッグドア３を射出成形等により成形した後に、エアバッグドア３のドア部１０を、ウレタン等の発泡樹脂からなるクッションテープ１７を介してパネル本体２の張出部２ｂに取り付ける。 Next, a method for manufacturing the instrument panel 1 will be described with reference to FIGS.
First, after the panel body 2 and the airbag door 3 are molded by injection molding or the like, the door portion 10 of the airbag door 3 is attached to the overhanging portion 2b of the panel body 2 via a cushion tape 17 made of foamed resin such as urethane. Attach to.

次に、パネル本体２とエアバッグドア３の表面に発泡体４を成形するが、その前に、図４に示すように、予め、パネル本体２とエアバッグドア３を成形型２０，２１により支持する（支持工程）。その際、エアバッグドア３を、パネル本体２を支持する成形型２０に対して、エアバッグドア３に離接する方向（図４の上下方向）に相対移動可能な可動型２１により支持する。さらに、この可動型２１は、中央に配置されてドア部１０を裏面（内面）側から支持する第１支持部材２３（第１支持部）と、この第１支持部材２３の外周に配置されて取付部１１を支持する筒状の第２支持部材２４とを備えている。   Next, the foam 4 is formed on the surfaces of the panel body 2 and the airbag door 3. Before that, as shown in FIG. 4, the panel body 2 and the airbag door 3 are previously formed by the molding dies 20 and 21. Support (support process). At that time, the airbag door 3 is supported by a movable mold 21 that can move relative to the mold 20 that supports the panel body 2 in the direction of moving away from and contacting the airbag door 3 (vertical direction in FIG. 4). Further, the movable mold 21 is disposed at the center and is disposed on the outer periphery of the first support member 23 (first support portion) that supports the door 10 from the back surface (inner surface) side. And a cylindrical second support member 24 that supports the attachment portion 11.

第１支持部材２３はエアシリンダー等で構成される駆動部２５とロッド２６を介して接続されており、この駆動部２５は制御部２７からの指令に基づいて第１支持部材２３を図４の上下方向に駆動する。また、第１支持部材２３の表面（上面）はドア部１０の裏面に対向する平面に形成されており、さらに、第１支持部材２３の端部には、その表面とドア部１０の裏面の面間距離ｄ（クリアランス）を検出する検出部２８が設けられている。この検出部２８としては、例えば、リニアセンサ、静電容量近接センサ、変位センサなどを用いることができる。   The first support member 23 is connected to a drive unit 25 composed of an air cylinder or the like via a rod 26. The drive unit 25 connects the first support member 23 in FIG. Drive up and down. Further, the front surface (upper surface) of the first support member 23 is formed in a plane opposite to the rear surface of the door portion 10, and the end portion of the first support member 23 is formed between the front surface and the rear surface of the door portion 10. A detection unit 28 for detecting the inter-surface distance d (clearance) is provided. As the detection unit 28, for example, a linear sensor, a capacitance proximity sensor, a displacement sensor, or the like can be used.

検出部２８で検出されたクリアランスｄの値は制御部２７に送られる。そして、検出されたクリアランスｄに基づいて制御部２７は駆動部２５を制御して、クリアランスｄが所定の値となる位置に第１支持部材２３を移動させる。従って、第１支持部材２３は、エアバッグドア３のドア部１０の裏面との間のクリアランスｄを所定の量に保持した状態で、ドア部１０の中央部を支持する。   The value of the clearance d detected by the detection unit 28 is sent to the control unit 27. Then, based on the detected clearance d, the control unit 27 controls the driving unit 25 to move the first support member 23 to a position where the clearance d becomes a predetermined value. Accordingly, the first support member 23 supports the central portion of the door portion 10 in a state where the clearance d between the airbag door 3 and the back surface of the door portion 10 is maintained at a predetermined amount.

筒状の第２支持部材２４は、型部材２９により内側（図４の下側）から支持されている。この型部材２９はロッド２６の周囲においてこのロッド２６に対して図４の上下方向に移動可能に配設されており、さらに、型部材２９はバネ３０により外方（取付部１１に当接する方向）に付勢されている。従って、第２支持部材２４は、型部材２９を介してバネ３０により外方へ付勢されて、第１支持部材２３に対して相対移動し、取付部１１の端部に確実に当接することになる。   The cylindrical second support member 24 is supported by the mold member 29 from the inside (the lower side in FIG. 4). The mold member 29 is disposed around the rod 26 so as to be movable in the vertical direction of FIG. 4 with respect to the rod 26. Further, the mold member 29 is moved outward (in a direction contacting the mounting portion 11) by a spring 30. ). Accordingly, the second support member 24 is biased outward by the spring 30 through the mold member 29, moves relative to the first support member 23, and reliably contacts the end portion of the mounting portion 11. become.

さらに、第２支持部材２４が取付部１１に当接した状態で型部材２９をロッド２６に固定する。ここで、型部材２９をロッド２６に固定するロック機構として、例えば、図４に示すように、型部材２９の側面に接触する２つの樹脂３１をエアシリンダー等により両側から押圧することで、型部材２９を挟み込んでロッド２６に固定するものなどを採用できるが、ロック機構はこのような構成に限られるものではない。そして、このように型部材２９をロッド２６に固定することで、第２支持部材２４が第１支持部材２３に対して相対移動不能に固定されることになる。   Further, the mold member 29 is fixed to the rod 26 with the second support member 24 in contact with the attachment portion 11. Here, as a lock mechanism for fixing the mold member 29 to the rod 26, for example, as shown in FIG. 4, the two resins 31 contacting the side surfaces of the mold member 29 are pressed from both sides by an air cylinder or the like. A member that sandwiches the member 29 and is fixed to the rod 26 can be employed, but the lock mechanism is not limited to such a configuration. Then, by fixing the mold member 29 to the rod 26 in this way, the second support member 24 is fixed so as not to move relative to the first support member 23.

以上のように可動型２１によりエアバッグドア３を支持するとともに、図示しない成形型により表皮５を支持する。そして、図５に示すように、パネル本体２及びエアバッグドア３のドア部１０の表面（可動型２１と反対側の面）と、表皮５との間に、ウレタン等の発泡樹脂を注入して発泡させ（注入工程）、発泡体４を形成する。   As described above, the airbag door 3 is supported by the movable mold 21 and the skin 5 is supported by a molding mold (not shown). Then, as shown in FIG. 5, a foamed resin such as urethane is injected between the surface of the panel body 2 and the door portion 10 of the airbag door 3 (surface opposite to the movable mold 21) and the skin 5. To foam (injection step) to form the foam 4.

このとき、発泡樹脂の発泡圧力がパネル本体２とエアバッグドア３のドア部１０に作用するが、パネル本体２よりも剛性の低いエアバッグドア３は特に変形しやすい。しかし、前述したように、エアバッグドア３は可動型２１により支持されており、さらに、可動型２１の第１支持部材２３とドア部１０との間のクリアランスｄは所定の量に保持されている。従って、発泡樹脂の発泡圧力や成形型との干渉に起因するドア部１０の変形が抑制され、ドア部１０の表面がパネル本体２とほぼ面一である状態が維持され、ドア部１０を覆う表皮５に生じる凹凸が小さくなる。   At this time, the foaming pressure of the foamed resin acts on the panel body 2 and the door portion 10 of the airbag door 3, but the airbag door 3 having rigidity lower than that of the panel body 2 is particularly easily deformed. However, as described above, the airbag door 3 is supported by the movable mold 21, and the clearance d between the first support member 23 of the movable mold 21 and the door portion 10 is maintained at a predetermined amount. Yes. Therefore, the deformation of the door portion 10 due to the foaming pressure of the foamed resin and the interference with the molding die is suppressed, the state where the surface of the door portion 10 is substantially flush with the panel body 2 is maintained, and the door portion 10 is covered. The unevenness generated in the skin 5 is reduced.

また、パネル本体２に取り付けられるドア部１０の外周部は第１支持部材２３により支持されていない上に、この外周部とパネル本体２の張出部２ｂとの間には発泡樹脂からなるクッションテープが介装されていることから、エアバッグドア３が第１支持部材２３のみで支持されている場合には、発泡圧力が作用したときにドア部１０の外周部が特に変形しやすい。しかし、本実施形態では、エアバッグドア３の取付部１１に可動型２１の第２支持部材２４が当接し、ドア部１０の外周部は、取付部１１を介して第２支持部材２４により支持される。そのため、このドア部１０の外周部における変形が効果的に抑制され、表皮５に生じる凹凸がさらに小さくなる。従って、パネル本体２とドア部１０の境界部分における表皮５の形状を、略面一の平滑な形状にすることができるようになる。   Further, the outer peripheral portion of the door portion 10 attached to the panel main body 2 is not supported by the first support member 23, and a cushion made of foamed resin is provided between the outer peripheral portion and the overhanging portion 2b of the panel main body 2. Since the tape is interposed, when the airbag door 3 is supported only by the first support member 23, the outer peripheral portion of the door portion 10 is particularly easily deformed when the foaming pressure is applied. However, in the present embodiment, the second support member 24 of the movable mold 21 abuts on the attachment portion 11 of the airbag door 3, and the outer peripheral portion of the door portion 10 is supported by the second support member 24 via the attachment portion 11. Is done. Therefore, the deformation in the outer peripheral portion of the door portion 10 is effectively suppressed, and the unevenness generated in the skin 5 is further reduced. Therefore, the shape of the skin 5 at the boundary between the panel body 2 and the door portion 10 can be made to be a substantially flat and smooth shape.

尚、第２支持部材２４は、バネ３０により取付部１１との当接方向に付勢されて第１支持部材２３に対してその当接方向に移動可能である。そして、支持工程において、第２支持部材２４を取付部１１の下端に当接させた後に、第２支持部材２４を第１支持部材２３に対して移動不能に固定する。そのため、取付部１１の長さのばらつきが大きい場合でも、取付部１１が第２支持部材２４により確実に支持されることになる。   The second support member 24 is urged in the contact direction with the mounting portion 11 by the spring 30 and can move in the contact direction with respect to the first support member 23. In the support step, the second support member 24 is fixed to the first support member 23 so as not to move after the second support member 24 is brought into contact with the lower end of the mounting portion 11. For this reason, even when the length of the mounting portion 11 varies greatly, the mounting portion 11 is reliably supported by the second support member 24.

次に、さらに具体的な実施例について説明する。まず、パネル本体２を、タルクを混合したポリプロピレン樹脂で成形し、一方、エアバッグドア３を、ポリプロピレン樹脂よりも軟質な樹脂であるＴＰＯ樹脂で成形した。   Next, more specific examples will be described. First, the panel body 2 was molded from a polypropylene resin mixed with talc, while the airbag door 3 was molded from a TPO resin that is a softer resin than the polypropylene resin.

次に、可動型２１の第１支持部材２３をエアシリンダーにより移動させて、エアバッグドア３のドア部１０とのクリアランスを０．３ｍｍに調整した。また、エアバッグドア３の取付部１１の内径は５０φであり、この取付部１１を線径２．５ｍｍの比較的弱いバネ３０により付勢された第２支持部材２４で支持した。ここで、エアバッグドア３がパネル本体２に取り付けられた状態では、バネ３０が５ｍｍ程度圧縮することになるように位置を調整した。尚、この実施例においては、５ｍｍ圧縮した状態でのバネ３０の反発力は約２００ｇｆである。そして、このバネ３０の圧縮量は、その反発力によりパネル本体２からエアバッグドア３が外れることがないように設定されている。   Next, the first support member 23 of the movable mold 21 was moved by the air cylinder, and the clearance between the airbag door 3 and the door portion 10 was adjusted to 0.3 mm. The inner diameter of the attachment portion 11 of the airbag door 3 is 50φ, and this attachment portion 11 is supported by the second support member 24 biased by a relatively weak spring 30 having a wire diameter of 2.5 mm. Here, in a state where the airbag door 3 is attached to the panel body 2, the position is adjusted so that the spring 30 is compressed by about 5 mm. In this embodiment, the repulsive force of the spring 30 when compressed by 5 mm is about 200 gf. The compression amount of the spring 30 is set so that the airbag door 3 is not detached from the panel body 2 due to the repulsive force.

このように、バネ３０に付勢された第２支持部材２４を取付部１１の下端に当接させた後に、第２支持部材２４を支える型部材２９を、その両側からエアシリンダーの先に取り付けられた樹脂３１で挟み込んでロッド２６に押しつけ、第２支持部材２４を第１支持部材２３に対して移動不能に固定した。   As described above, after the second support member 24 biased by the spring 30 is brought into contact with the lower end of the mounting portion 11, the mold member 29 supporting the second support member 24 is attached to the tip of the air cylinder from both sides thereof. The second support member 24 was fixed to the first support member 23 so that the second support member 24 cannot move.

この状態で、パネル本体２及びエアバッグドア３のドア部１０の表面にウレタンを注入して発泡させ、発泡体４を成形した。すると、目視、及び、手で触ることによって、ドア部１０を覆う表皮５の表面状態を確認したところ、表皮５に凹凸が生じていなかった。特に、第２支持部材２４により取付部１１を介して支持されたドア部１０の外周部（ドア部１０とパネル本体２との境界部分）において表皮表面が略面一となり、平滑な面の製品を得ることができた。   In this state, urethane was injected into the surfaces of the panel body 2 and the door portion 10 of the airbag door 3 to foam, and the foam 4 was molded. Then, when the surface state of the skin 5 covering the door portion 10 was confirmed by visual observation and touching with the hand, the skin 5 was not uneven. In particular, the outer skin portion of the door portion 10 supported by the second support member 24 via the attachment portion 11 (the boundary portion between the door portion 10 and the panel body 2) has a substantially flush skin surface and a smooth surface product. Could get.

尚、以上説明した実施形態では、第２支持部材２４は、バネ３０により取付部１１との当接方向に付勢されて第１支持部材２３に対してその当接方向に移動可能となっているが（図４参照）、取付部１１の長さのばらつきが小さく、バネ３０により付勢されなくても第２支持部材２４が取付部１１に確実に当接する場合などには、図６に示す参考例のように、第２支持部材２４が第１支持部材２３に一体的に設けられて、常に第１支持部材２３と共に移動するように構成されていてもよい。
In the embodiment described above, the second support member 24 is urged in the contact direction with the mounting portion 11 by the spring 30 and can move in the contact direction with respect to the first support member 23. 6 (see FIG. 4), the variation in the length of the mounting portion 11 is small, and the second support member 24 reliably contacts the mounting portion 11 without being biased by the spring 30. As in the reference example shown, the second support member 24 may be provided integrally with the first support member 23 so as to always move together with the first support member 23.

本実施形態に係るエアバッグドア一体型インストルメントパネルの斜視図である。It is a perspective view of the air bag door integrated instrument panel concerning this embodiment. 図１のII-II線断面図である。It is the II-II sectional view taken on the line of FIG. 図２のエアバッグドア付近の拡大図である。FIG. 3 is an enlarged view of the vicinity of the airbag door of FIG. 2. 本実施形態に係るインストルメントパネルの製造工程の中の、エアバッグドアの支持工程を示す図である。It is a figure which shows the support process of an airbag door in the manufacturing process of the instrument panel which concerns on this embodiment. 発泡樹脂の注入工程を示す図である。It is a figure which shows the injection | pouring process of foamed resin. 参考例に係るインストルメントパネルの製造工程の中の、エアバッグドアの支持工程を示す図である。It is a figure which shows the support process of an airbag door in the manufacturing process of the instrument panel which concerns on a reference example .

符号の説明Explanation of symbols

１ インストルメントパネル
２ パネル本体
２ａ 開口部
３ エアバッグドア
４ 発泡体
５ 表皮
１０ ドア部
１１ 取付部
１３ エアバッグ
１５ エアバッグケース
２０ 成形型
２１ 可動型
２３ 第１支持部材
２４ 第２支持部材
３０ バネ DESCRIPTION OF SYMBOLS 1 Instrument panel 2 Panel main body 2a Opening part 3 Airbag door 4 Foam 5 Outer skin 10 Door part 11 Attachment part 13 Airbag 15 Airbag case 20 Mold 21 Movable mold 23 First support member 24 Second support member 30 Spring

Claims (1)

エアバッグが膨出する開口部を有するパネル本体と、
前記開口部を閉止するとともに前記エアバッグの作動時にはその膨張圧力により展開して前記開口部を開放するエアバッグドアであって、前記パネル本体よりも軟質な材料で形成されるとともに、前記パネル本体の前記開口部を塞ぐドア部と、このドア部の外周部から延びて前記エアバッグを収納するエアバッグケースが取り付けられる取付部とを有するエアバッグドアと、
前記パネル本体及び前記エアバッグドアの前記ドア部の表面に連続的に積層された発泡体及び表皮とを備えた、エアバッグドア一体型インストルメントパネルの製造方法であって、
前記パネル本体と前記エアバッグドアとを別々の成形型により支持する支持工程と、
前記成形型により支持された前記パネル本体及び前記エアバッグドアの、前記成形型と反対側の面に発泡樹脂を注入する注入工程とを備え、
前記支持工程において前記エアバッグドアを支持する成形型は、前記パネル本体を支持する成形型に対して移動可能な可動型であり、
前記支持工程において、前記可動型の位置を調整して前記ドア部と前記可動型との間のクリアランスを所定の量に保持しつつ、前記可動型を前記取付部に当接させて、前記エアバッグドアを支持するものであり、
前記可動型は、前記ドア部を支持する第１支持部と、前記取付部との当接方向に付勢されて前記第１支持部に対してその当接方向に移動可能で、前記取付部を支持する第２支持部を備え、
前記支持工程において、前記第２支持部を前記取付部に当接させた後に、前記第２支持部を前記第１支持部に対して移動不能に固定することを特徴とするエアバッグドア一体型インストルメントパネルの製造方法。 A panel body having an opening through which the airbag bulges;
An airbag door that closes the opening and opens the opening by being inflated when the airbag is operated, and is formed of a softer material than the panel body. An airbag door having a door portion that closes the opening, and an attachment portion that is attached to an airbag case that extends from an outer peripheral portion of the door portion and stores the airbag;
A method for manufacturing an instrument panel integrated with an airbag door, comprising a foam and a skin continuously laminated on surfaces of the panel body and the door portion of the airbag door,
A support step of supporting the panel body and the airbag door by separate molds;
An injection step of injecting a foamed resin into the opposite surface of the panel body and the airbag door supported by the mold;
The mold that supports the airbag door in the supporting step is a movable mold that is movable with respect to the mold that supports the panel body,
In the supporting step, the position of the movable mold is adjusted to maintain a predetermined clearance between the door portion and the movable mold, and the movable mold is brought into contact with the mounting portion to It supports the bag door ,
The movable mold is urged in a contact direction between the first support portion that supports the door portion and the attachment portion, and is movable in the contact direction with respect to the first support portion. A second support part for supporting
In the supporting step, after the second support portion is brought into contact with the mounting portion, the second support portion is fixed to the first support portion so as to be immovable. Instrument panel manufacturing method.
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JPH1095029A (en) * 1996-09-24 1998-04-14 Toyota Motor Corp Instrument panel having air bag door part integrally and manufacture thereof
JPH11342818A (en) * 1998-06-02 1999-12-14 Inoac Corporation:Kk Air bag door integral instrument panel and its forming method
JP2000071921A (en) * 1998-09-02 2000-03-07 Kansei Corp Air bag lid structure
JP2003146173A (en) * 2001-11-13 2003-05-21 Kanto Auto Works Ltd Airbag door of automobile and manufacture method thereof
JP2004231077A (en) * 2003-01-30 2004-08-19 Mitsuboshi Belting Ltd Method for manufacturing airbag door integrated type instrument panel, and molding die to be used for the same
JP2004243594A (en) * 2003-02-12 2004-09-02 Inoac Corp Molding member with foamed body

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH1095029A (en) * 1996-09-24 1998-04-14 Toyota Motor Corp Instrument panel having air bag door part integrally and manufacture thereof
JPH11342818A (en) * 1998-06-02 1999-12-14 Inoac Corporation:Kk Air bag door integral instrument panel and its forming method
JP2000071921A (en) * 1998-09-02 2000-03-07 Kansei Corp Air bag lid structure
JP2003146173A (en) * 2001-11-13 2003-05-21 Kanto Auto Works Ltd Airbag door of automobile and manufacture method thereof
JP2004231077A (en) * 2003-01-30 2004-08-19 Mitsuboshi Belting Ltd Method for manufacturing airbag door integrated type instrument panel, and molding die to be used for the same
JP2004243594A (en) * 2003-02-12 2004-09-02 Inoac Corp Molding member with foamed body

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