JP4326451B2 - instrument panel - Google Patents

Description

  The present invention relates to an instrument panel having a skin material, a core material, and a resin layer between the core material and the skin material.

  Conventionally, an instrument panel is known in which a resin material is injected from a core material injection hole between a skin material and a core material set in a mold, and the skin material and the core material are integrated by a resin layer. ing.

And, for example, in the instrument panel of Patent Document 1, at the terminal portion, the front side of the end of the skin material is brought into contact with the inner surface of the end of the core material, and between the core material and the skin material when the resin raw material is injected. Some air leaks from the small gap in the cavity. In this instrument panel, a protrusion for restricting the flow of the resin material is provided in order to prevent the resin material from leaking more than necessary while allowing air to escape to the outside of the cavity.
Japanese Patent No. 3150568 (5th page, FIGS. 10 to 12)

  By the way, in the instrument panel, it is provided with a general cross-sectional portion in which the distance between the skin material and the core material is relatively narrow, and the terminal of the skin material is inserted into the groove portion provided in the core material on at least one of the front end side or the rear end side. In some cases, the front side of the end of the skin material is brought into contact with the inner surface of the groove portion of the core material to prevent the resin raw material from leaking out when the resin raw material is injected. In this instrument panel, air in the cavity is mainly discharged from a terminal portion apart from the injection hole other than at least one of the front end side or the rear end side.

  When a urethane resin is used as the resin raw material, there is a need to make the thickness as thin as possible because the urethane resin is expensive. For this reason, the part without a restriction | limiting in particular is shape | molded by thin wall as a general cross-section part. On the other hand, at the time of mold clamping at the time of molding, the end of the skin material does not peel off due to the end of the skin material arranged in the lower mold interfering with the end of the core material arranged in the upper mold, and the front side of the end of the skin material is the core The thickness of the urethane foam layer in the groove is thicker than that of the general cross-section so as to smoothly contact the inner surface of the groove of the material.

  For example, as shown in FIG. 7, in the vehicle instrument panel 101, when a resin material is injected from the injection hole 125 of the core material 105 between the skin material 103 and the core material 105 set in the mold, As shown, the resin raw material flows. At this time, the air in the cavity between the skin material 103 of the mold and the core material 105 is mainly discharged from the left and right end portions 127 away from the injection holes 125 of the core material 105.

  At this time, in the seal portion 141 as shown in FIG. 6, since the gap between the skin material 103 and the core material 105 is wider than the thin general cross-section portion 121, the flow of the resin raw material becomes faster than the general cross-section portion 121, The flow of the resin material passing through the groove 143 of the seal portion 141 (indicated by the arrow B) reaches the terminal portion 127 earlier than the flow of the resin raw material through the general cross-sectional portion 121 (indicated by the arrow A). As a result, the air in the cavity is not discharged and remains in the instrument panel 101 to form an air reservoir 129, resulting in a problem that molding failure occurs in the resin layer 107.

  The present invention has been made in view of such points, and the object of the present invention is to devise the structure of the seal portion so that air between the core material and the skin material is discharged from the terminal portion during molding. Thus, it is intended to prevent molding defects by not leaving air inside the instrument panel.

  In order to achieve the above object, according to the present invention, the seal portion is provided with a flow rate regulating portion that regulates the flow of the resin raw material from the groove portion to the general cross-sectional portion side.

  Specifically, in the first invention, there is a skin material, a core material, and a resin layer between the core material and the skin material, between the skin material and the core material set in the mold. An instrument panel in which a skin material and a core material are integrated by a resin layer by injecting a resin raw material from a core material injection hole.

  And, at least one of the general cross-sectional portion where the distance between the skin material and the core material is relatively narrow, and the front end side or the rear end side, the end of the skin material is inserted into the groove provided in the core material, While preventing the resin raw material from leaking by bringing the front side into contact with the inner surface of the groove portion of the core material, the seal portion formed with a wider space between the skin material and the core material than the general cross-section portion, and the injection hole And a terminal portion that discharges air between the core material and the skin material when the resin raw material is injected, and the seal portion in the vicinity of the terminal portion has a flow of the resin raw material passing through the general cross section and the groove portion. The part of the skin material and the core material are partly separated along the groove part of the core material so that the flow of the resin raw material leaking from the general cross-section side merges at the terminal part. A structure provided with a flow rate restricting part that restricts the flow of the resin raw material to the cross section side. To.

  In 2nd invention, the said flow-rate control part shall consist of a protrusion projected from the core material toward the skin material.

  In 3rd invention, the said flow-rate control part shall consist of a block-shaped cushion material affixed on the core material or the skin material.

  According to the first aspect, since the gap between the skin material and the core material in the seal portion is wider than the general cross-section portion, the resin raw material flows in the groove portion of the seal portion faster than the general cross-section portion. By the time the resin raw material reaches the terminal portion, the resin raw material is filled in the groove. By pressing the end of the skin material against the inner surface of the groove with the pressure of the resin raw material, the resin raw material can be prevented from leaking out of the groove. And the resin raw material with which it filled in the groove part becomes difficult to leak to a general cross-section part by the flow-rate control part provided along the groove part. For this reason, since the flow of the resin raw material passing through the general cross section and the flow of the resin raw material leaking from the groove to the general cross section are merged at the terminal portion, the resin raw material from the groove portion does not block the terminal portion first. . Therefore, since the air between the skin material and the core material is reliably discharged, it is possible to prevent molding defects by leaving no air inside the instrument panel.

  According to the second aspect of the invention, the flow rate of the resin raw material that leaks from the groove to the general cross-section side is regulated by the flow rate regulating unit formed of the protrusion. For this reason, it is possible to prevent the formation of defective molding due to air remaining inside the instrument panel with a simple configuration.

  According to the third aspect of the invention, the block-shaped cushion material is used as the flow velocity restricting portion. Thereby, since the flow-rate control part itself has cushioning properties, it is possible to prevent the cushioning properties of the instrument panel from being impaired.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, the following embodiment is an essentially preferable illustration, Comprising: It does not intend restrict | limiting the range of this invention, its application thing, or a use.

(Embodiment 1)
FIG. 2 shows a vehicle instrument panel 1 according to an embodiment of the present invention. The instrument panel 1 includes a skin material 3, a core material 5, and a foam layer 7 as a resin layer between the core material 5 and the skin material 3. The instrument panel 1 injects a resin material (urethane resin) from the injection hole 25 of the core material 5 into the cavity 54 between the skin material 3 and the core material 5 set in the mold 51 shown in FIG. Thus, the skin material 3 and the core material 5 are integrated by the foam layer 7.

  Specifically, the instrument panel 1 includes a meter hood 11, an air conditioning outlet 12, an airbag opening 13, and the like, a center panel part 16, a handle opening 17, and a glove box opening. The lower part 19 provided with 18 etc. is integrally molded. A defroster opening 20 is provided on the vehicle front side of the upper portion 15. An instrument panel front surface portion 15a is constituted by the upper portion 15 excluding the defroster opening 20 side, and the instrument panel front surface portion 15a has a three-layer structure including the foam layer 7 in order to improve cushioning properties. Other portions of the upper portion 15 and the lower portion 19 have a structure in which the core material 5 is exposed.

  As shown in FIG. 1, the instrument panel front surface portion 15 a of the upper portion 15 is formed with a general cross-sectional portion 21 in which the distance between the skin material 3 and the core material 5 is relatively narrow except for the front end side 15 b of the front end. . The foam layer 7 of the general cross section 21 has a substantially constant thickness, for example, a thickness of about 4 mm.

  An injection hole 25 (indicated by a broken line in FIG. 2) for injecting a resin raw material at the time of molding the instrument panel 1 is provided in the core material 5 corresponding to the substantially central portion of the instrument panel front surface portion 15a.

  And the seal | sticker part 41 by which the space | interval of the skin material 3 and the core material 5 was shape | molded more widely than the said general cross-sectional part 21 in the front end side 15b of the instrument panel front surface part 15a by the side for the opening 20 for defrosters of the said instrument panel 1. Is provided over the entire length. Specifically, the core member 5 is provided with a groove portion 43 having a substantially triangular cross section on the front end side 15b of the instrument panel front surface portion 15a. The seal portion 41 is configured by contacting the front side of the terminal 3a of the skin material 3 with the inner surface of the groove portion 43 on the side of the opening 20 for the defroster and filling the inside thereof with a resin raw material. The seal portion 41 prevents the resin raw material from leaking out of the groove portion 43 during molding.

  Terminal portions 27 for discharging air between the core material 5 and the skin material 3 when the resin raw material is injected are formed at the left and right ends of the instrument panel 1 away from the injection hole 25.

  In the vicinity of the left and right terminal portions 27, that is, on the seal portion 41 over a predetermined length on the left and right end portions side of the instrument panel 1, the skin material 3 and the core material 5 along the groove 43 of the core material 5. A flow rate restricting portion 45 that partially divides the space between the two is formed. The flow rate restricting portion 45 is provided in the core material 5 at the boundary between the seal portion 41 and the general cross-sectional portion 21. For example, the core material 5 is raised with an integral thickness, or the thickness of the portion is increased. The protrusions are formed so as to project toward the skin material 3 so that the cross section is substantially triangular. The flow rate restricting portion 45 is formed from the groove portion 43 so that the flow of the resin raw material passing through the general cross-sectional portion 21 and the flow of the resin raw material leaking from the groove portion 43 to the general cross-sectional portion 21 side merge at the terminal portion 27. The flow of the resin raw material to the general cross section 21 side is regulated to reduce the flow rate.

-Method of forming the instrument panel 1-
Next, a method for forming the instrument panel 1 according to the present embodiment will be described.

  As shown in FIGS. 3 and 4, a molding die 51 including an upper die 53, a lower die 55, and a slide die 57 is used for molding the instrument panel 1.

  First, as shown in FIG. 3, the skin material 3 is placed on the lower mold 55 of the mold 51, and the core material 5 is fixed to the upper mold 53 with a locking tool (not shown).

  Next, as indicated by an arrow in FIG. 3, the mold 51 is closed by sliding the slide mold 57 to the left and lowering the upper mold 53 obliquely to the lower right. At this time, since the groove portion 43 of the core material 5 corresponding to the seal portion 41 is wide open, the terminal 3 a of the skin material 3 does not interfere with the groove portion 43.

  Next, the resin raw material of the foamed layer 7 is injected from the injection hole 25 of the core material 5 into the cavity 54 formed between the skin material 3 and the core material 5 using the injector 59.

  At this time, as shown in FIG. 2, the resin raw material spreads radially from the injection hole 25 (indicated by an arrow A). The resin material that spreads radially spreads at a substantially constant speed in the general cross section 21. On the other hand, the resin raw material that has flowed into the groove 43 of the core material 5 flows at a higher speed in the groove 43 having a lower resistance than that in the general cross-sectional portion 21 (indicated by an arrow B), and the resin raw material is in the general cross-sectional portion 21. The resin raw material is filled in the seal portion 41 before reaching the terminal portion 27 side, and the resin raw material from the seal portion 41 is pressed by pressing the terminal 3a of the skin material 3 against the inner surface of the groove portion 43 with the pressure of the resin raw material. Leakage is prevented.

  However, the resin material flowing into the seal portion 41 is easily leaked from the groove portion 43 to the terminal portion 27 side, because the flow rate restricting portion 45 restricts the flow of the resin material from the groove portion 43 to the general cross-section portion 21 side. Thus, the terminal unit 27 is not blocked.

  Then, when the resin raw material finally passes through the flow rate regulating portion 45 and arrives at the terminal portion 27, the resin raw material that has passed through the general cross-sectional portion 21 arrives at the terminal portion 27 and passes through the general cross-sectional portion 21. And the flow of the resin raw material leaking from the groove 43 to the general cross section 21 side merge at the terminal portion 27.

  In this way, the air in the cavity 54 is gradually discharged from the terminal portion 27 side, so that it does not remain between the skin material 3 and the core material 5.

-Effect of Embodiment 1-
Therefore, according to the instrument panel 1 according to the present embodiment, the interval between the skin material 3 and the core material 5 in the seal portion 41 is wider than the general cross-section portion 21, so that the inside of the groove portion 43 of the seal portion 41 is within the general cross-section portion 21. The resin material flows faster than the resin material, and the resin material in the groove section 43 is filled before the resin material in the general cross section 21 reaches the terminal portion 27. By pressing the terminal 3 a of the skin material 3 against the inner surface of the groove 43 with the pressure of the resin raw material, the resin raw material can be prevented from leaking out of the groove 43. And the resin raw material with which the groove part 43 was filled becomes difficult to leak to the general cross-section part 21 by the flow-rate control part 45 provided along the groove part 43. FIG. For this reason, since the flow of the resin raw material passing through the general cross-sectional portion 21 and the flow of the resin raw material leaking from the groove 43 toward the general cross-sectional portion 21 are merged at the terminal portion 27, the resin raw material from the groove portion 43 is the terminal portion first. 27 is not blocked. Therefore, since the air between the skin material 3 and the core material 5 is reliably discharged out of the mold 51, it is possible to prevent molding defects by leaving no air inside the instrument panel 1.

  Moreover, in this embodiment, the flow velocity of the flow of the resin raw material that leaks from the groove 43 to the general cross-section portion 21 side is regulated by the flow velocity regulating portion 45 formed of a protrusion. For this reason, it is possible to prevent a molding defect from occurring due to air remaining inside the instrument panel 1 with a simple configuration.

(Embodiment 2)
FIG. 4 shows a second embodiment of the present invention, which is different from the first embodiment in that the configuration of the flow velocity regulating unit 45 is different. In the present embodiment, the same portions as those in FIGS. 1 to 3 are denoted by the same reference numerals, and detailed description thereof is omitted.

  That is, the flow rate regulating portion of the instrument panel 1 according to the present embodiment is a block-like shape that is affixed to the core member 5 on the side of the general cross section 21 at the boundary between the seal portion 41 and the general cross section 21 by the double-sided tape 132. The cushion material 131 is used.

  In addition, you may affix this cushion material 131 to the skin material 3 side at the time of shaping | molding.

-Effect of Embodiment 2-
Therefore, according to the instrument panel 1 concerning this embodiment, the block-shaped cushion material 131 is utilized as a flow-rate control part. Thereby, since cushion material 131 itself has cushioning properties, it can prevent that cushioning properties of instrument panel 1 are spoiled.

(Other embodiments)
In each of the above embodiments, a foamed layer made of urethane resin is used as the foamed layer 7. For example, the foamed layer 7 is a resin layer made of an adhesive that bonds the skin material 3 and the core material 5. May be.

  Moreover, it is desirable that the cushion material 131 in the second embodiment has communication bubbles inside, and the communication material bubbles allow the cushion material 131 to pass air. The cushion material 131 does not cause a new molding defect.

  As described above, the present invention prevents the resin raw material from leaking to at least one of the front end side or the rear end side, and forms the gap between the skin material and the core material wider than the general cross section. This is useful for an instrument panel for a vehicle having a sealed portion.

It is the II sectional view taken on the line of FIG. It is a perspective view of the instrument panel concerning Embodiment 1 of the present invention. It is side sectional drawing of the shaping | molding die which has arrange | positioned the skin material and the core material in the open state. FIG. 4 is a view corresponding to FIG. 3 when the mold is closed. It is the FIG. 1 equivalent view of the instrument panel concerning Embodiment 2 of this invention. It is the VI-VI sectional view taken on the line of FIG. It is a perspective view of the instrument panel concerning a prior art.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Instrument panel 3 Skin material 3a Terminal 5 Core material 7 Foamed layer (resin layer)
15b Front end side 21 General cross section 25 Injection hole 27 Terminal part 41 Seal part 43 Groove part 45 Flow rate restricting part 131 Cushion material (flow rate restricting part)

Claims (3)

It has a skin material, a core material, and a resin layer between the core material and the skin material, and a resin material is injected from the core material injection hole between the skin material and the core material set in the mold. An instrument panel in which the skin material and the core material are integrated by the resin layer,
A general cross-section having a relatively narrow interval between the skin material and the core material;
At least one of the front edge and the rear edge, the end of the skin material is inserted into the groove provided in the core, and the front side of the terminal is brought into contact with the inner surface of the groove of the core to prevent the resin material from leaking out. And a seal part formed with a wider interval between the skin material and the core material than the general cross-section part,
A terminal part that separates from the injection hole and discharges air between the core material and the skin material when injecting the resin raw material,
In the seal portion in the vicinity of the terminal portion, the core is arranged such that the flow of the resin raw material passing through the general cross-sectional portion and the flow of the resin raw material leaking from the groove portion to the general cross-sectional portion side merge at the terminal portion. An instrument characterized in that a flow rate regulating portion is provided to partially divide the skin material and the core material along the groove portion of the material and regulate the flow of the resin raw material from the groove portion to the general cross-sectional portion side. Panel. In the instrument panel according to claim 1,
The instrument panel according to claim 1, wherein the flow rate restricting portion includes a ridge protruding from the core material toward the skin material. In the instrument panel according to claim 1,
The said flow-rate control part consists of a block-shaped cushion material affixed on the core material or the skin material, The instrument panel characterized by the above-mentioned.

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