JPS5841740B2 - Manufacturing method of instrument panel with partial padding - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing an instrument panel in which each member is integrated without special fixing devices and in which pad material is partially formed. This makes it possible to obtain a high-quality instrument panel.

Conventionally, when attaching this type of crash pad to an instrument panel, a semi-rigid urethane foam pad material with a PVC skin separately molded on a frame material made of sheet metal, acrylic-styrene graft copolymer, ABS resin, etc. is used. A cavity is formed by attaching or preforming a PVC skin and a frame material using a vacuum forming method,
It was integrally molded by injecting semi-rigid urethane foam into the cavity.

However, the former method has the disadvantage that it must be mechanically attached using bolts or nuts, which requires a separate process, and the latter method requires a folded surface material to be formed at the end of the frame when forming a full-surface pad. Apart from the fact that the ends of the epidermis are scraped away, when forming a partial pad, a blind must be attached to treat the ends of the epidermis, which still has the drawback of increasing the number of steps and parts.

The method of manufacturing an instrument panel partially formed with a pad material according to the present invention eliminates the above-mentioned drawbacks of the conventional example. and a skin material, which has been previously formed into a predetermined shape, are placed in a mold with a cavity formed in such a way that it is closed leaving only the part that requires the pad, and then a mold is placed between the frame material and the skin material. This method of manufacturing an instrument panel with a partial pad is characterized by injecting and foaming urethane foam into the formed cavity.

In the present invention, the plastic film or sheet serving as the skin material is preferably a textured vinyl chloride film, and the material for the frame material with poor adhesiveness is typically composite polypropylene (containing an inorganic filler).

Note that it is desirable to perform primer treatment or frame treatment on the surface of the frame material in the portion that comes into contact with the urethane foam in order to further enhance the adhesion to the urethane foam.

An embodiment of the present invention will be described below with reference to the drawings.

Figure 1 shows a composite polypropylene frame in which a skin material 1 preformed into the external shape of a partial pad by vacuum forming is set in a lower mold 2, and a step 10 is provided on the periphery of the part that requires padding. The material 3 is placed and fixed with the upper die 4, and the urethane foam 5 is injected and foamed into the cavity formed by the skin material 1 and the frame material 3.

At this time, the composite polypropylene frame material, which has poor adhesion to the semi-rigid urethane foam 5, and the skin material have surfaces 7 that are in direct contact with each other at the stepped portions 10.

Next, as shown in FIG. 2, the frame material on which the padding material has been partially formed is taken out of the mold, and the unnecessary portion 6 of the skin material is cut out along the step 10 with the cutter 8.
The unnecessary portion is very easily peeled off from the frame material 3.

Note that if you drill a large number of small holes in advance at positions corresponding to the pad ends of the frame material, the injected urethane foam will protrude from the back side of the frame material when the urethane foam is injected, and the pad material will become firmly attached to the frame material. This becomes the anchor 9 that is fixed.

FIG. 3 shows a typical manufacturing process of a conventional example, and FIG. 4 shows a manufacturing process of the present invention.

The present invention has the following effects.

(a) The urethane foam burr protruding from the edge of the pad material can be removed at the same time as the skin material is cut out, eliminating the need for a burr treatment process.

(b) An instrument panel in which the stud material is firmly integrated with the frame material without special fixing devices can be obtained, and there is no risk of occupants being injured by the fixing devices in the event of a collision.

(c) The terminal portion of the pad can be visually covered without any special covering material.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view showing one step of the method for producing an instrument panel according to the present invention during injection and foaming of urethane foam, and similarly, FIG. 2 is a cross-sectional view showing a state in which unnecessary portions of the skin material have been cut. FIG. 3 is a flowchart showing the manufacturing process of the conventional example, and FIG. 4 is a flowchart showing the manufacturing process of the present invention. Explanation of symbols: 1...Skin material, 2...Lower mold, 3...Frame material, 4...Upper mold,
5... Semi-rigid urethane foam, 6...
・Unnecessary part of the skin material, 7...Contact surface between the skin material and frame material, 8...Cutter, 9...
・Urethane anchor, 10...Step, 11...
...Cutter guide groove.

Claims (1)

[Claims] 1. A method for forming a pad partially on the surface of an instrument panel, which includes a frame material with poor adhesiveness that has a step on the periphery of the area where the pad is required, and a frame material that is preformed into a predetermined shape. The prepared skin material is placed in a mold with a cavity formed so as to close it leaving only the part that requires padding, and then urethane foam is placed in the cavity formed between the frame material and the skin material. A method for manufacturing an instrument panel with a partial pad, characterized by injecting and foaming. 2. The method for manufacturing an instrument panel according to claim 1, wherein the frame material is made of composite polypropylene.