JPH0677935B2 - Manufacturing method of automobile interior parts - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing automobile interior parts such as automobile door trims, and in particular, interior parts using a hard urethane core material for the purpose of reducing the weight of the product. Relates to a method for manufacturing an automobile interior part having improved moldability.

<Prior art> For example, various interior parts are installed in the interior of an automobile, but the interior parts must be made of fiberboard, resin plate, etc. that have shape retention and mounting rigidity to the vehicle body panel. A laminated structure having a core material formed into a shape and a skin material having a cushioning property and a decorative property on the surface side of the core material is generally known.

By the way, the disadvantages of the core material made of fiber board, resin board, etc. are that it is heavy and does not correspond to the weight reduction of the product, and it is not satisfactory in terms of moldability as well. There was a problem that it could not be applied to products equipped with.

As a countermeasure against this, it has been proposed and implemented that a hard urethane core material reinforced in a glass mat or the like is used to promote weight reduction and improve moldability.

FIG. 11 is a cross-sectional view showing the structure of an automobile door trim using a hard urethane core material. This automobile door trim 1 has a hard urethane core material 3 containing a glass mat 2 therein.
And a pad material 4 such as polyurethane foam and a skin material 5 which are adhered to the surface side thereof.

A urethane-based or polyamide-based film 4a is attached to one side of the pad material 4.

The outline of the method of manufacturing the door trim 1 will be briefly described. As shown in FIG. 12, the pad material 4 and the glass mat 2 are set in the foam molding lower die 6, and the hard urethane resin is placed from above. The liquid is injected, and as shown in FIG. 13, the foam molding upper die 7 is clamped to the foam molding lower die 6 to mold the core material 3 with the pad material 4.

Then, the separately molded skin material 5 and the hard urethane core material 3 with the pad material 4 molded in the above step are bonded and integrated to manufacture the door trim 1 shown in FIG.

<Problems to be Solved by the Invention> However, in the conventional mold press molding of the hard urethane core material 3, especially in the deep drawing portion such as the armrest portion, the hard urethane resin liquid does not swirl well,
Insufficient filling of the material was likely to occur, which was a major cause of defective molding.

Further, since the glass mat 2 is simply set on the upper side of the pad material 4 in a free state, when the upper and lower molds 6 and 7 for foam molding are clamped, the glass mat 2 slips and wrinkles occur, and the wrinkles hard The flow of the urethane resin liquid was not stable, leading to the generation of voids and the like, which was also a factor that hinders the moldability of the hard urethane core material 3.

The present invention has been made in view of such circumstances,
The purpose of the present invention is, for the purpose of reducing the weight of the product, in a method of manufacturing an automobile interior part using a hard urethane core material, to make the flow of the hard urethane resin liquid smooth, An object of the present invention is to provide a method of manufacturing an automobile interior part having improved moldability.

<< Means for Solving the Problems >> In order to achieve the above object, the method for producing an automobile interior part according to the present invention is a pad made of a soft urethane foam in which a urethane film is backed on the mold surface of a foam molding lower mold. A material setting step of setting a urethane film with the urethane film facing upward, clamping the peripheral edge with a clamp device, placing a glass mat on the upper side, and supporting the peripheral edge with a protrusion formed on the clamp device, and the foam molding described above. After injecting a hard urethane resin liquid as the material of the core material into the lower mold, vacuum suction is performed at the same time as the pad material follows the mold surface of the lower mold through the vacuum suction hole provided in the lower foam molding mold. A step of clamping the foam molding upper and lower molds to mold the core material with a pad material into a desired shape, and the core material with a pad material and a skin material Characterized in that comprising the step of bonding together by crimping-type.

<< Function >> As is apparent from the above configuration, according to the present invention, the hard urethane resin liquid is injected into the foam molding lower mold, and the pad material is provided along the mold surface of the foam molding lower mold immediately before the start of foaming. By vacuum suctioning the pad material, the pad material can be quickly made to follow the mold surface of the lower mold, and the hard urethane resin liquid can be smoothly moved around.

Further, since the peripheral edge of the glass mat is supported by the projections of the clamp device, it does not unnecessarily shift when the upper and lower molds for foam molding are clamped, and wrinkles do not occur in the glass mat.

<Example> Hereinafter, a method for manufacturing an automobile interior part according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a sectional view showing the structure of an automobile door trim manufactured by applying the method of the present invention, and FIGS. 2 and 3 are a side view and a plan view showing a foaming mold for molding a hard urethane core material. 4 to 10 are explanatory views showing each step of the method of the present invention.

First, an automobile door trim 10 obtained by applying the method of the present invention.
With reference to FIG. 1, this vehicle door trim 10 is a hard urethane core material containing a glass mat 11 inside.
12 and a soft urethane foam 15 laminated with a urethane film 14 is used as the pad material 13 integrated on the surface side of the hard urethane core material 12, and the surface appearance and surface feel of the outer surface of the soft urethane foam 15 are covered. Is composed of an excellent slush molded skin material 16.

The slush molded skin material 16 is preferably a skin material having a two-layer structure of a slash skin layer 17 on the front surface side and a slush foam layer 18 on the back surface side.

The manufacturing process of the automobile door trim 10 will be described.

First, the foaming mold shown in FIG. 2 is used to mold the rigid urethane core material. This foam-molding die is composed of a foam-molding lower mold 20 and a foam-molding upper mold 22 that is rotatably attached to the foam-molding lower mold 20 via a hinge portion 21. Similarly, the clamp device 23 also has a hinge portion 24.
It is rotatably attached as shown via
The clamp device 23 has protrusions on its upper surface at appropriate intervals.
25 are provided.

As shown in FIG. 3, the shape of the clamp device 23 is set to be slightly larger than the outer peripheral shape of the door trim 10.

First, as shown in FIG. 4, the pad material 13 and the glass mat 11 are set in the foam molding lower die 20.
Sets the flexible urethane foam 15 downward and the urethane film 14 upward, and supports the periphery of the urethane film 14 by the clamp device 23, and as shown in an enlarged view in FIG. The glass mat 11 is supported by piercing the periphery of the glass mat 11 with the protrusion 25. At this time, the glass mat 11 should be set with some allowance for the deep-drawn area.

Then, as shown in FIG. 5, the hard urethane resin liquid M is passed from above the glass mat 11 through the nozzle 26 of the foam molding machine.
The nozzles are injected along the pattern as shown by the arrow in FIG. 6 so as to reach the mold surface of the foam molding lower mold 20.
26 is moved to inject the hard urethane resin liquid M.

Next, the hard urethane resin liquid M is injected in a pattern, and vacuum suction is performed through the vacuum suction holes 27 formed in the foam molding lower die 20 immediately before the end of the urethane cream time (immediately before the start of foaming), and the pad material 13 is placed in the lower die. The hard urethane resin liquid M is spread over the mold surface 20a in the same manner while being closely adhered along the mold surface 20a of 20.

Then, almost simultaneously with the vacuum suction, the foam molding upper mold 22 descends as shown in FIG.
Is clamped.

At this time, the glass mat 11 is displaced by clamping the upper and lower molds 20 and 22 for foam molding, but since the outer periphery of the glass mat 11 is fixed by the protrusions 25 of the clamp device 23, the same displacement is always performed. Wrinkles do not occur on the mat 11.

Further, since the urethane film 14 acts as a barrier, the hard urethane resin liquid M does not soak into the soft urethane foam 15 and the soft feeling of the soft urethane foam 15 is not impaired.

In this way, the hard urethane core material 12 with the pad material 13 is molded into a required shape.

Then, as shown in FIG. 9, a hard urethane core material 12 with a pad material 13 obtained by foam-molding the upper die 30 for crimping in the above step
While setting, the mold surface of the lower die 31 for crimping, the slush molding skin material 16 is located on the lower side of the slash skin layer 17, and the slush foam layer 18 is coated with an adhesive, as shown in FIG. Thus, the manufacture of the automobile door trim 10 having the configuration shown in FIG. 1 is completed by clamping the upper and lower crimping dies 30, 31.

<Effects of the Invention> As described above, the method for manufacturing an automobile interior part according to the present invention, when molding the hard urethane core material with a pad material, after injecting the pattern of the hard urethane resin solution, immediately before starting foaming, By vacuum suction, it is possible to improve the circumference of the hard urethane resin liquid, especially in the deep-drawn portion of the foam molding lower die, and prevent defective filling of the hard urethane resin liquid as much as possible.

Further, in the setting of the glass mat, since the peripheral edge of the glass mat is held by the projection of the clamp device, wrinkles do not occur in the glass mat during molding of the hard urethane core material, and the filling failure of the hard urethane resin liquid is prevented. It can be prevented.

Therefore, according to the present invention, defective filling of the hard urethane resin liquid can be reliably prevented, and thus the defective rate can be significantly reduced, which has the effect of significantly improving the production efficiency.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing the structure of an automobile door trim which is manufactured by applying the method of the present invention, FIG. 2 is a side view showing a foam molding die used in the method of the present invention, and FIG. 3 is the same foam molding. 4 to 8 are sectional views and plan views showing the molding process of the hard urethane core material, and FIGS. 9 and 10 are the hard urethane core material and the skin material. 11 is a cross-sectional view showing the crimping step with, FIG. 11 is a cross-sectional view showing the configuration of a conventional automobile door trim, and FIGS. 12 and 13 are explanatory views showing a conventional hard urethane core material forming step. 10 …… Vehicle door trim 11 …… Glass matte 12 …… Hard urethane core material 13 …… Pad material 14 …… Urethane film 15 …… Soft urethane foam 16 …… Slush molding skin material 20 …… Lower mold for foam molding 22 …… Foam molding upper mold 23 …… Clamping device 25 …… Protrusion 26 …… Foam molding machine 27 …… Vacuum suction hole 30 …… Crimping upper mold 31 …… Crimping lower mold

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Claims (1)

[Claims] A pad material (13) made of a soft urethane foam (15) having a urethane film (14) backed on a mold surface of a foam molding lower mold (20).
4) is set to the upper side, the peripheral edge is clamped by the clamp device (23), the glass mat (11) is placed on the upper side, and the peripheral edge is clamped by the protrusion (25) formed on the clamp device (23). A supporting material setting step and a vacuum suction hole (20) provided in the foam molding lower mold (20) after injecting a hard urethane resin liquid as a material of the core material (12) into the foam molding lower mold (20). 27) Through the above pad material (13)
Vacuum suction so that it follows the mold surface of the lower mold (20) and at the same time clamp the upper and lower molds (20,22) for foam molding to make the core material (12) with pad material (13) into the required shape. An automobile interior characterized by a step of molding and a step of adhering and integrating the core material (12) with the pad material (13) and the skin material (16) with a pressure bonding mold (30, 31). Manufacturing method of parts.