JP5535809B2 - Resin interior panel - Google Patents

Description

  The present invention relates to a resin interior panel formed by a so-called core back system in which a pad expands a cavity volume.

  Patent Document 1 includes a general surface portion that extends in a substantially flat shape, and a side surface portion that integrally extends from the outer peripheral edge of the general surface portion in the back side direction, and the base surface portion is made of a first resin, A resin interior panel is disclosed in which the pad is made of a second resin integrally formed on the surface of the base material, and the side surface portion is formed only of the base material. Therefore, in this resin interior panel, the second resin is filled into the cavity between the base material and the pad-side mold from the gate disposed at the position corresponding to the general surface portion of the base material, When the second resin in the vicinity of the contact surface and in the vicinity of the molding surface of the pad side mold begins to solidify due to the mold temperature, the pad side molding die is retracted from the base material, thereby expanding the cavity volume and the second resin. The pad is molded by expanding the foam.

JP 2008-74010 A

  However, in Patent Document 1, since the gate for injecting the second resin is disposed at a position corresponding to the general surface portion of the base material, the gate mark remains on the pad surface of the formed general surface portion, and the resin interior panel Appearance looks bad.

  In order to avoid this, if the gate for injecting the second resin is also formed on the side surface portion and the gate for injecting the second resin is disposed on the side surface portion, the second resin is solidified in the vicinity of the molding surface of the pad side mold on the general surface portion side. When the pad-side mold is retracted at the beginning, the second resin around the gate has a higher temperature because the progress of solidification is delayed compared to the general surface side, so the skin layer is formed on the side surface. Since it lags behind the general surface part, the internal gas of the second resin leaks around the gate through the insufficiently generated skin layer from the gap between the base material and the pad side mold generated by retreating the pad side mold. The surface property of the pad around the gate may be affected, and the appearance of the side portion may deteriorate. When the pad side mold is retracted after waiting for the skin layer to be generated to the extent that it can withstand gas leakage at the side surface, the molding cycle becomes longer and the skin layer on the general surface portion is more than necessary. It is formed thick and the tactile sensation becomes worse.

  This invention is made | formed in view of this point, and it is providing the resin interior panel provided with the pad with the touch which the molding cycle is short, the skin layer is thin, and it does not deteriorate appearance appearance.

  In order to achieve the above-mentioned object, the present invention provides a pad-side molding die at the time of pad molding on a flange portion formed by a base material extending portion formed at an extending end of a side surface portion and recessed in a side surface portion extending direction. It is characterized by being formed deeper than the amount of retreat.

  Specifically, the present invention includes a general surface portion that extends in a substantially flat shape, and a side surface portion that integrally extends in the back side direction from the outer peripheral edge of the general surface portion, and the general surface portion and the side surface portion are formed from the first resin. And a pad made of a second resin integrally formed on the surface of the substrate, and the pad is a thin skin made of a solid layer having a high resin density and being formed on the front and back surfaces. And a foamed layer sandwiched between the skin layers and having a large number of voids inside and having a resin density lower than that of the skin layer, and formed in a cavity between the base material and the pad side mold during pad molding. The second resin is filled, and when the second resin in the vicinity of the contact surface with the base material and in the vicinity of the molding surface of the pad side mold begins to solidify due to the mold temperature, the pad side molding die and the base material are separated from each other. To expand the cavity volume and foam the second resin Targeting resin interior panel to be molded by Zhang, it took solving means as follows.

  That is, in the invention according to claim 1, a flange portion having a substantially L-shaped cross section composed of a base material extension portion in which the base material extends integrally outward is formed at the extension end of the side surface portion. A base material is formed by exposing the concave groove portion recessed in the side surface portion extending direction between the base material and the pad side mold during pad molding. It is formed so as to form a space for introducing the second resin into the cavity, and the concave groove is formed deeper than the above-mentioned separation distance between the pad side mold and the base material at the time of pad molding. And

  According to a second aspect of the present invention, in the resin interior panel according to the first aspect, in the base end region excluding the groove corresponding portion of the flange portion, the thickness of the pad is integrally continuous with the base material of the side surface portion. A shelf portion having a width corresponding to is formed, the shelf portion is positioned in a separation direction from the pad side mold when the cavity volume is expanded during pad molding, and the groove portion continues to the proximal end of the flange portion. It is characterized by being formed.

  According to the first aspect of the present invention, since the gate is not disposed at the position corresponding to the general surface portion of the base material, the gate mark is not left on the pad surface of the formed general surface portion, and the appearance of the resin interior panel is improved. To do.

  In addition, even if the pad side mold and the substrate are separated from each other when the second resin starts to solidify near the molding surface of the pad side mold on the general surface side, the pad side mold is in contact with the side wall of the groove. Since the leakage of the internal gas of the second resin from the groove portion is prevented, the pressure does not escape from the groove portion where the solidification of the second resin is delayed at a high temperature, and the surface of the side surface around the groove portion follows the molding surface of the pad side mold It becomes. Therefore, it is possible to mold a resin interior panel having a thin skin layer and a touch-sensitive pad with a short molding cycle without deteriorating the appearance.

  According to the second aspect of the present invention, since the flange portion is in contact with the pad-side mold even when the pad-side mold and the base material are separated to enlarge the cavity volume, the internal gas of the second resin Can be prevented from leaking out of the groove, and pressure does not escape from the groove where the solidification of the second resin is delayed at high temperatures. Therefore, the surface of the side surface portion around the groove portion has a shape along the molding surface of the pad-side molding die, and appearance deterioration is prevented.

1 is a perspective view of an instrument panel 1 according to an embodiment of the present invention. It is an expanded sectional view in the AA line of FIG. It is an expansion perspective view corresponding to the B section of FIG. FIG. 4 is a view corresponding to FIG. 3 before pad formation. It is a molding process figure corresponding to the CC line of Drawing 3 showing the state where the 2nd resin was injected and filled in the cavity of the forming die concerning the embodiment of the present invention. FIG. 6 is a molding process diagram showing a state where the pad-side mold of the mold in FIG. 5 is retracted from the base material. It is a molding process figure corresponding to the DD line of Drawing 3 showing the state where the 2nd resin was injected and filled in the cavity of the forming die concerning the embodiment of the present invention. FIG. 8 is a molding process diagram showing a state in which the pad-side mold of the mold in FIG. 7 is retracted from the base material.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  1 and 2 show an instrument panel 1 as a resin interior panel according to an embodiment of the present invention. The instrument panel 1 includes a front surface portion 3 that extends substantially flat in the vehicle width direction at the front end portion of the vehicle body, and extends integrally from the full width of the rear end of the front surface portion 3 toward the rear of the vehicle body in a substantially flat shape. A general surface portion 5 that is bent in a substantially U-shape and a side surface portion 7 that integrally extends in the rear side direction from the full rear end width of the general surface portion 5 are provided. The front surface portion 3 is composed of a base material 9 made of a hard first resin R1, such as polypropylene, ABS (Acrylonitrile Butadiene Styrene), noryl resin, and the front surface portion 3 has a front defroster air outlet 11 formed therein. Has been. The general surface portion 5 and the side surface portion 7 are composed of the base material 9 and a pad 13 made of a thermoplastic and soft second resin R2 such as thermoplastic styrene or thermoplastic olefin integrally formed on the surface of the base material 9. It consists of and. Reference numeral 15 denotes a side vent air outlet, and reference numeral 17 denotes a center panel mounting portion.

  As shown in FIG. 2, the pad 13 of the general surface portion 5 includes a thin skin layer 23 made of a solid layer having a high resin density and a high density formed on the front and back surfaces, and a large number of skin layers 23 sandwiched between the skin layers 23. A foam layer 25 having a void and having a resin density lower than that of the skin layer 23 is provided. The pad 13 of the side surface portion 7 is composed of only a solid layer 24 which is thicker than the skin layer 23 having a high resin density and being hard.

  As shown in FIG. 3, a flange portion 19 having a substantially L-shaped cross section consisting of a base material extending portion from which the base material 9 extends integrally toward the outside is provided at the extending end of the side surface portion 7. The base material 9 is exposed. The surface of the pad 13 is represented by a mesh in FIG. As shown in FIGS. 3 and 4, the flange portion 19 is formed with a concave groove portion 21 that is recessed in the extending direction of the side surface portion 7 at a location indicated by a white arrow in FIG. 1. Each groove portion 21 continues to the base end of the flange portion 19, and the bottom surface of each groove portion 21 on the base end side is flush with the surface of the base material 9 of the side surface portion 7. In addition, the pad 13 is continuously formed in each groove portion 21. The pad 13 formed on the base end side of each groove portion 21 is composed of only the solid layer 24, and the pad 13 formed on the extending end side of the groove portion 21 includes the thin skin layer 23 made of a solid layer and the skin layer. And a foam layer 25 sandwiched between the two.

  Further, in the base end region excluding the portion corresponding to the groove portion 21 of the flange portion 19, a shelf portion 27 that is integrally continuous with the base material 9 of the side surface portion 7 has a width W 1 that corresponds to the thickness of the pad 13 of the side surface portion 7. It is formed to extend in the width direction. The surface of the pad 13 of the side surface portion 7 is flush with the surface of the flange portion 19.

  A plurality of plate-like extending piece portions 29 are extended from the extending end edge of the flange portion 19 at intervals. Each extension piece 29 is formed with a rectangular clip hole 31. By inserting and locking the clips in these clip holes 31, the instrument panel 1 can be attached to a decoration panel (not shown) or a meter panel (not shown).

  The instrument panel 1 configured as described above is molded using a molding die 101 shown in FIGS.

  The mold 101 includes a base-side mold 103 that is a fixed mold and a pad-side mold 105 that is a movable mold. The pad-side mold 105 has an insertion hole 107 that penetrates in the mold opening direction. The injection nozzle 109 is inserted into the insertion hole 107. A jet hole 111 extending in the mold opening direction is formed in the injection nozzle 109, and a needle valve 112 is attached to the jet hole 111 so as to be able to advance and retreat.

  With the base material 9 set on the base material side mold 103 and the base material side mold 103 and the pad side mold 105 closed, a cavity 114 is formed between the respective molding surfaces, and the flange portion A gate 115 is formed at a location corresponding to each groove 21 at the extending end of 19. Each gate 115 is continuous with a runner 117 extending in the extending direction from the extending end of the flange portion 19. Each runner 117 communicates with the ejection hole 111 of the injection nozzle 109.

  And the point which shape | molds the instrument panel 1 using the shaping | molding die 101 comprised as mentioned above is as follows.

  First, as shown in FIGS. 5 and 7, the base material 9 molded in advance is set in the base material side mold 103, and the base material side mold 103 and the pad side mold 105 are closed. In this state, a space S is formed between each groove portion 21 of the flange portion 19 and the pad side mold 105. This space S is a space for introducing the second resin R2 into the cavity 114 and communicates with the runner 117 via the gate 115. Further, portions corresponding to the respective groove portions 21 of the pad-side mold 105 are in contact with the side walls of the groove portions 21 in a state of being fitted in the groove portions 21. Further, the flange portion 19 is in contact with the pad side mold 105.

  Next, the needle valve 112 is moved backward, and the molten second resin R2 is injected and filled into the cavity 114 from the gate 115 through the runner 117 from the injection hole 111 of each injection nozzle 109. The second resin R2 is a mixture of foaming promoting substances such as a chemical foaming material that generates gas by a chemical reaction and an inert gas (physical foaming material) such as carbon dioxide gas and nitrogen gas. .

  Thereafter, as shown in FIGS. 6 and 8, when the second resin R2 in the vicinity of the contact surface with the base material 9 and in the vicinity of the molding surface of the pad-side molding die 105 starts to solidify due to the mold temperature, the shelf portion The pad-side mold 105 is retracted from the substrate 9 by a retraction amount (separation distance) D2 that is shorter than the depth D1 of the groove 21 so that 27 is positioned rearward (separation direction) from the retreat position of the pad-side mold 105. To increase the cavity volume. Then, as the volume of the cavity 114 is increased, the second resin R2 that has been compressed between the base material 9 and the pad side mold 105 so far (the expansion is restricted) is pulled by the pad side mold 105, and the second resin R2 is compressed. It expands and expands by an internal gas such as a gas generated by a chemical reaction in the resin R2 or an inert gas. As a result, the front and back surfaces of the pad 13 of the side surface portion 7 and the pad 13 of the general surface portion 5 are formed as solid layers, and the foam layer 25 is formed inside these solid layers. At this time, since the retraction amount D2 of the pad side mold 105 is shorter than the depth D1 of the groove portion 21, the portion corresponding to the groove portion 21 of the pad side mold 105 is in contact with the side wall of the groove portion 21 and from the groove portion 21 of the second resin R2. Prevent leakage of the internal gas. Thereby, pressure does not escape from the groove portion 21 where the solidification of the second resin R2 is delayed at high temperature, and the surface of the side surface portion 7 around the groove portion 21 has a shape along the molding surface of the pad side mold 105. Accordingly, when the molding cycle is shortened and the second resin R2 starts to solidify in the vicinity of the molding surface of the pad-side molding die 105 on the general surface portion 5 side, the pad-side molding die 105 is retracted from the substrate 9 and the skin layer 23 Even if it is made thin, the appearance does not deteriorate. Further, at this time, since the shelf portion 27 is located behind the retreat position of the pad side mold 105, the flange portion 19 is in contact with the pad side mold 105 and the groove 21 of the internal gas of the second resin R2 is formed. Leakage to the outside is prevented, and pressure does not escape from the groove 21 where the solidification of the second resin R2 is delayed at high temperatures. Therefore, the surface of the side surface portion 7 around the groove portion 21 has a shape along the molding surface of the pad-side mold 105, and appearance is prevented from deteriorating.

  Thereafter, the pad-side mold 105 is raised to open the mold 101, and the molded instrument panel 1 is removed from the base-side mold 103.

  Thereafter, the portion corresponding to the runner 117 is cut from the portion corresponding to the gate 115 and separated from the instrument panel 1. In this state, the gate trace is not formed on the surface of the general surface portion 5, and the appearance of the instrument panel 1 is improved.

  In addition, in the said embodiment, although the case where the resin interior panel was the instrument panel 1 was shown, this invention is applicable also to other resin interior panels, such as trims.

  Moreover, in the said embodiment, the base material side shaping | molding die 103 is made into a fixed type | mold, the pad side shaping | molding die 105 is made into a movable mold | type, the pad side shaping | molding die 105 is moved in the process shown in FIGS. However, the movable mold and the fixed mold may be reversed, and the base-side mold 103 may be moved so as to be separated from the pad-side mold 105.

  The present invention is useful, for example, as a resin interior panel formed by a so-called core back system in which a pad expands a cavity volume.

1 Instrument panel (resin interior panel)
5 General part
7 Side
9 Base material
13 Pad
19 Flange
21 Groove
23 Skin layer
25 Foam layer
27 shelves
105 Pad side mold
114 Cavity R1 First resin R2 Second resin S Space

Claims (2)

A general surface portion extending in a substantially flat shape, and a side surface portion integrally extending in the back side direction from the outer peripheral edge of the general surface portion, and the general surface portion and the side surface portion are made of a first resin, The pad is made of a second resin integrally formed on the front surface, and the pad is sandwiched between the skin layer and the thin skin layer made of a solid layer having a high resin density and a high density formed on the front and back surfaces. A foam layer having a large number of voids inside and having a resin density lower than that of the skin layer, and filling the second resin into a cavity between the base material and the pad side mold during pad molding, The cavity volume is increased by separating the pad-side mold from the substrate when the second resin in the vicinity of the contact surface with the substrate and the molding surface of the pad-side mold begins to solidify due to the mold temperature. A tree formed by foaming and expanding the second resin An interior panel,
A flange portion having a substantially L-shaped cross section consisting of a base material extension portion in which the base material extends integrally outward is formed at the extending end of the side surface portion, exposing the base material. In the part, the concave groove part recessed in the side part extending direction is formed so as to form a space for introducing the second resin into the cavity between the pad side mold during pad molding,
The resin interior panel, wherein the concave groove is formed deeper than the above-mentioned separation distance between the pad-side mold and the substrate at the time of pad molding. In the resin interior panel according to claim 1,
In the base end region excluding the corresponding portion of the groove portion of the flange portion, a shelf portion having a width corresponding to the thickness of the pad is formed integrally with the base material of the side surface portion, and the shelf portion is formed at the time of pad molding. A resin interior panel, wherein the resin interior panel is located in a separating direction from the pad side mold when the cavity volume is expanded, and the groove is continuously formed to the base end of the flange.

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