JP3187686B2 - Automotive interior parts - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile interior part such as an automobile door trim.

[0002]

2. Description of the Related Art Normally, interior parts such as an automobile door trim and a rear corner trim are installed in the interior of an automobile. The configuration of the automobile door trim will be described with reference to FIG. The car door trim 1 is composed of a laminate of a core material 2 having shape-retaining properties and a skin material 3 integrated on the surface side of the core material 2 and giving a cushioning property and a good touch feeling. ing.

A conventional method of manufacturing the automobile door trim 1 will be described with reference to a few examples.

For example, in the case where a wood fiber board is used as the core material 2, the wood fiber mat M can be hot-press-molded using a process chart shown in FIG. 8 and a process explanatory diagram shown in FIG. The core material 2 is formed into a required shape by the mold 4.

[0005] Then, an adhesive 5a is applied to the surface side of the core material 2 by a spray gun 5 and the adhesive 5a is dried by a heater 6, and then the skin material 3 is softened by heating with a heater device 7, and then The skin material 3 is vacuum-adhered to the surface side of the core material 2 using the vacuum molding die 8, thereby completing the molding of the automobile door trim 1 shown in FIG.

Next, in the case where a thermoplastic resin plate is used as the core material 2, although not shown, a skin material 3 is set in a mold in advance, and a semi-molten resin is injected and filled by a stamping molding method. There is a stamping molding method in which the core material 2 and the skin material 3 are integrated, or a method in which a thermoplastic resin plate is extruded into a sheet shape in advance by an extruder, heated and softened, and then formed into a required shape by cold press molding. .

[0007]

As described above, in the conventional automobile door trim 1, when the former wood-based fiber mat M is used as the core material 2, the number of steps is very large, and the wood-based fiber mat M is used. It was not preferable in terms of working environment, for example, the organic solvent of the fiber adhesive of the mat M was scattered.

When a thermoplastic resin plate is used as the core material 2, the number of steps can be reduced, but the weight of the core material 2 is increased, which is incompatible with the reduction in the weight of the product, and the vehicle may be damaged due to an accident or the like. When an impact is applied from the side of the, the broken portion of the core material 2 becomes an edge, which is not preferable for occupant safety measures.

The present invention has been made in view of the above-mentioned circumstances, and it is preferable in terms of safety measures to prevent sharp edges even when an impact is applied, and is lightweight and has desired rigidity for an automobile interior. The purpose is to provide parts.

[0010]

[0011]

In order to achieve the above object, the present invention relates to an automobile interior part in which a skin material is laminated and integrated on a core material surface and formed into a required shape by cold press molding. The core material has a fiber length of 10 to 20.
mm of glass fibers of elongated composed of a thermoplastic resin foamed molded product obtained by mixing 10 to 30 parts by weight, the thermoplastic resin onset
The expansion ratio of the foam molded article is adjusted to 2 to 5 times .

The thermoplastic resin used for the thermoplastic resin foam molded article used as the core material includes a PP resin, a polyethylene resin, an ABS resin and the like, and a PP resin is preferred from the viewpoint of cost and moldability.

The long glass fiber to be mixed into the thermoplastic resin foam molded article has a length of 10 to 20 mm.
Use the ones in the range.

Further, the mixing ratio of the glass fiber may be appropriately selected depending on the required rigidity, but is preferably from 10 to 30 parts by weight.

The expansion ratio of the foamed thermoplastic resin article is preferably 2 to 5 times.

[0016]

As a method of integrating the skin sheet and the core material raw material, there are a heat welding method, an adhesive laminating method, a heat laminating method and the like.

Next, as a heater device for heating a material obtained by integrating the skin sheet and the core material raw material to a predetermined temperature, when polyethylene foam is used as the skin sheet, the skin sheet is heated. The temperature of the upper heater is 150 ° C, and the lower heater for heating the core material is 20
It is set to 0 ° C.

Then, by heating with a heater device,
The thickness of the core material raw material has expanded to 2-3 times.

Next, the pressing process using a cold press mold is performed under a pressing pressure of 10 to 20 kgf / cm ² , a pressing time of 20 to 30 seconds, and a core material having a thickness of 2.5 m.
m, drawn to a total thickness of about 3 mm.

As is apparent from the above configuration, the interior parts for automobiles according to the present invention are lightweight because they are based on a thermoplastic resin foam molded article mixed with long glass fiber as a core material. Sharp edges are not formed even when broken by impact.

The long glass fibers provide satisfactory rigidity.

[0023]

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments of the present invention will be described below by exemplifying an automobile door trim and a method of manufacturing the same.

FIG. 1 is a front view of an automobile door trim, and FIG.
3 is a cross-sectional view showing the configuration of the vehicle door trim, and FIGS. 3 to 6 are cross-sectional views showing the steps of a method of manufacturing the vehicle door trim.

1 and 2, a door trim 10 for an automobile has a core material 11 having shape retention and rigidity for attachment to a vehicle body panel, and is integrally adhered to the surface side of the core material 11 to provide a good cushioning property. And a skin material 12 having decorativeness.

More specifically, in this embodiment,
As the core material 11, a polypropylene resin foam molded article mixed with a long glass fiber 13 is used.
As for 3, the one having a dimensional length of 10 to 20 mm is 10 to
It is mixed in the range of 30 parts by weight, and the expansion ratio of the expanded polypropylene resin foam is set to about 2 to 5 times.

On the other hand, as the skin material 12, polyethylene foam is used.

Therefore, since the core 11 has a foamed structure in which the long glass fibers 13 are mixed, there is an advantage that sufficient rigidity can be ensured, and a reduction in weight and cost can be achieved.

The reason is that if the expansion ratio is increased,
Although less resin material is required and the weight is reduced, the rigidity may be reduced by that amount. However, the reduced rigidity is compensated for by mixing a long glass fiber 13 at a predetermined ratio.

Further, when an impact is applied from the side of the vehicle,
Even if the door trim 10 is broken, the core 11
Since has a foamed structure, sharp edges are not exposed, and it can be said that safety measures are preferable.

Next, a method of manufacturing the automobile door trim 10 as an automobile interior part having the above various advantages will be described in detail with reference to FIGS.

First, FIG. 3 shows the core material 11 and the skin material 12.
FIG. 2 is a cross-sectional view of the raw material of FIG. 1, in which a raw material for core material M and a sheet for skin S as a material of the core material 11 are integrated by heat fusion.

The core material M is extruded into a sheet by a T-die extruder, and the thickness thereof is adjusted to about 1.5 mm. A long glass fiber 13, azodicarbonamide, etc. Of foaming agent is mixed in an appropriate amount.

The length of the glass fibers 13, 10 to 20
In mm, the mixing ratio is preferably about 10 to 30 parts by weight, and the mixing ratio of the glass fiber 13 and the expansion ratio adjustment by the foaming agent can be appropriately selected depending on desired physical properties.

Next, as shown in FIG.
And a raw material M for core material are integrated into a heater 20
To expand by heating.

At this time, the upper heater 21 is adjusted to 150 ° C. to heat the skin sheet S,
The lower heater 22 is adjusted to 200 ° C., and the core material M
Is heated to a predetermined temperature.

The heating time by the heater device 20 is 2
After the heating step by the heater device 20, the thickness of the core material raw material M has expanded to about 2 to 3 times.

Next, as shown in FIG. 5, it is set in a mold 30 for cold press molding, and as shown in FIG. By performing a predetermined stroke lowering operation, the core material 11 and the skin material 12 are drawn and formed into a required shape, and the forming of the automobile door trim 10 shown in FIGS. 1 and 2 is completed.

At this time, the mold 30 for cold press molding is used.
Is set to 10 to 20 kgf / cm ² , and the press time is set to 20 to 30 seconds.

The molded automobile door trim 10
The core material 11 has a thickness of about 2.5 mm and an overall thickness of 3 mm
The inventor has found that a sufficient configuration can be ensured by the degree.

When a foamed PVC sheet is used as the material of the skin material 12, the upper heater 21 of the heater device 20 can be omitted because the foamed PVC has good moldability.

As described above, the skin sheet S and the core material web M are integrated by heat fusion, adhesion, or the like, and then heated and expanded by the heater device 20 to obtain a desired shape by cold press molding. If drawn, it can be easily formed, so the number of processes can be significantly reduced compared to the conventional manufacturing method using wood-based core material, and a great cost advantage can be achieved. In addition, there is an advantage that a favorable working environment can be ensured without adverse effects of an organic solvent specific to the adhesive.

In the above-described embodiment, the present invention is applied to an automobile door trim and a method of manufacturing the same. However, it goes without saying that the present invention can be applied to general automobile interior parts such as a rear side trim.

[0045]

As described above, the present invention has the following special functions and effects.

(1) According to the present invention, since a thermoplastic resin foam molded article mixed with long glass fiber is used as a core material of an interior part for an automobile, a desired rigidity is obtained by the glass fiber. And the foamed structure has the effect of enabling weight reduction and cost reduction.

(2) According to the present invention, since a thermoplastic resin foam molded article mixed with a long glass fiber is used as a core material of an interior part, an impact is applied from the side of the vehicle. In this case, even if the core material breaks, the structure of the core material is a foamed structure, so that a sharp edge is not exposed, which has an advantageous effect on occupant safety.

[0048]

[Brief description of the drawings]

FIG. 1 is a front view of an automobile door trim showing one embodiment of an automobile interior part according to the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a cross-sectional view showing a raw material used in the method for manufacturing the door trim shown in FIG.

FIG. 4 is a sectional view showing a step of heating a material in the method of manufacturing the door trim shown in FIG . 1 ;

FIG. 5 is a sectional view showing a step of setting a material in a press die in the method for manufacturing the door trim shown in FIG . 1 ;

FIG. 6 is a sectional view showing a cold press forming step in the method for manufacturing the door trim shown in FIG . 1 ;

FIG. 7 is a sectional view showing the configuration of a conventional automobile door trim.

FIG. 8 is a process chart showing a manufacturing process of a conventional automobile door trim.

FIG. 9 is a process explanatory view of a conventional automobile door trim.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Automotive door trim 11 Core material 12 Skin material 13 Glass fiber 20 Heating device 21 Upper heater 22 Lower heater 30 Cold press molding die 31 Cold press molding lower die 32 Cold press molding upper die S Skin coating sheet M core Raw material

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ identification code FI B29L 31:58 (58) Fields investigated (Int.Cl. ⁷ , DB name) B32B 5/18 B29C 43/18 B60J 5/00 501 B60R 13/02

Claims (1)

(57) [Claims] 1. An automobile interior part formed by laminating and integrating a skin material (12) on the surface of a core material (11) and forming it into a required shape by cold press molding, wherein the core material (11) has a fiber length. Is made of a thermoplastic resin foam molded article mixed with 10 to 30 parts by weight of a long glass fiber (13) of 10 to 20 mm, and the expansion ratio of the thermoplastic resin foam molded article is adjusted to 2 to 5 times. Automotive interior parts characterized by the following: