JPH0688267B2 - Manufacturing method of automobile interior parts - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing automobile interior parts such as door trims for automobiles, and particularly for automobiles that are designed to reduce the weight of products and to shorten the process. The present invention relates to a method of manufacturing interior parts for automobiles.

<< Prior Art >> For example, various interior parts are mounted in the interior of a car. The interior parts are composed of a fibreboard having shape retention and mounting rigidity to a vehicle body panel. There is generally known a laminated structure in which a core material formed by molding a resin board or the like into a required shape and a skin material having cushioning and decorative properties are laminated on the surface side of the core material.

By the way, the disadvantages of the core material made of fiberboard, resin board, etc. are that the weight is heavy and it does not match the weight reduction of the product, and the moldability is not satisfactory, and the complicated curved surface There is a problem that it cannot be applied to products with a shape.

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

FIG. 8 is a sectional view showing the structure of an automobile door trim using a hard urethane core material. This automobile door trim 1 has a glass urethane inner layer and a hard urethane core material 2 molded into a required shape, Cushioned semi-rigid urethane 3 laminated on the front side of the sheet, and a skin material 4 in which foamed vinyl chloride 4b is laminated on the back surface of the PVC sheet 4a so as to obtain decorativeness and a good surface feel. To be done.

An outline of the manufacturing process of the door trim 1 will be described. First, the hard urethane core material 2 is molded in another step, and the hard urethane core material 2 molded into a required shape is set in the foam molding male mold. By setting the skin material 4 on the foam molding female mold, injecting the semi-rigid urethane resin liquid into the foam molding male and female molds, and clamping the foam molding male and female molds, the semi-hard urethane 3 is formed. While molding, the hard urethane core material 2, the semi-hard urethane 3 and the skin material 4 are integrated.

<< Problems to be Solved by the Invention >> As described above, in the conventional automobile interior parts using the hard urethane core material 2, the foam molding step of the hard urethane core material 2 and the foam molding step of molding the semi-rigid urethane 3 It has been pointed out that the two foam molding steps of 1) and 2) are required, the number of manufacturing steps is large, the equipment is large, and the cost is significantly increased.

Furthermore, the density of the semi-rigid urethane 3 is within the range of 0.2 to 0.3 g / cm ³ , and even if the weight of the hard urethane core 2 is reduced, the weight of the semi-hard urethane 3 increases the overall weight. It has been pointed out that the weight of the product cannot be promoted, and that the semi-rigid urethane 3 is inferior in softness to the touch.

The present invention has been made in view of the above circumstances, and an object of the present invention is to manufacture an automobile interior part using a hard urethane core material for the purpose of reducing the weight of a product, and a manufacturing process. It is to provide a method of manufacturing an automobile interior part that can significantly reduce the weight, improve the weight and softness.

<< Means for Solving the Problem >> In order to achieve the above object, the method for producing an automobile interior part according to the present invention is a non-breathable high elongation in a cushion layer on a mold surface of a lower mold for foam molding. The step of placing the pad material backing the film and the glass mat in this order, and after injecting the hard urethane resin liquid as the material of the core material into the lower mold for foam molding, the upper mold for foam molding is molded. It is characterized by comprising a step of tightening and molding the core material with a pad material into a desired shape, and a step of integrating the core material with a pad material and the skin material with a crimping mold.

<Operation> As is apparent from the above configuration, according to the present invention, a cushion layer such as a soft polyurethane foam or a non-woven fabric is laminated at the same time when foaming a hard urethane core material containing a glass mat. The process is 1
The process is sufficient and the manufacturing process can be greatly shortened.

Further, the cushion layer used in the present invention is lightweight and excellent in soft feeling, and the weight reduction is promoted as compared with the conventional semi-hard urethane, and the soft feeling is improved and the feeling is also good.

<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 to 5 are sectional views for explaining each step of the method of the present invention, FIGS. 6 and 7. FIG. 4 is a cross-sectional view showing another embodiment of the first step in the method of the present invention.

First, an automobile door trim 10 obtained by applying the method of the present invention.
The structure will be described with reference to FIG. 1. The automobile door trim 10 includes a hard urethane core material 12 having a glass mat 11 as an inner layer, and a pad material integrated on the surface side of the hard urethane core material 12. 13 and a slush skin material 16 that covers the outer surface of the slush and has excellent surface appearance and surface feel.

More specifically, the pad material 13 is formed by laminating a non-breathable high elongation film 14 such as a urethane film or a polyamide film and a cushion layer 15 having a cushioning property such as polyurethane foam or nonwoven fabric, As the slush skin material 16, the slash skin layer 17 is on the front side and the slush foam layer 1 is on the back side.
A two-layered skin material formed by slush molding is used.

As described above, in the automobile door trim 10, the slush skin material 16 having an excellent surface feel and surface appearance is used, and the cushion material 15 having a good cushioning property is used as the pad material 13, which will be described later. The breathable high elongation film 14 allows this hard urethane resin liquid to form this cushion layer.
Since it is a structure that prevents it from entering the inside of the 15, by the cushion effect provided by this cushion layer 15,
It is possible to provide the door trim 10 with an extremely soft feeling.

Next, a manufacturing process of the automobile door trim 10 will be described.

First, as shown in FIG. 2, the pad material 13 and the glass mat 11 are placed in this order on the mold surface of the foam molding lower mold 20.

In this embodiment, as the structure of the pad material 13, a soft polyurethane foam is used for the cushion layer 15, and a polyurethane film is used for the non-breathable high elongation film 14.

At this time, as in this example, a non-breathable high elongation film
If a cushion layer 15 laminated with 14 is used, vacuum forming is possible at room temperature, so as shown in the figure,
By vacuum forming through the vacuum suction holes 21 formed in the foam molding lower die 20, the pad material 13 is held in close contact with the mold surface of the foam molding lower die 20.

Or thickness of the urethane film 14 is 25～50Myu, the density of the flexible polyurethane foam is set to 0.025~0.05g / cm ^3, both of which are integrated beforehand by an adhesive,
Alternatively, they are integrated by heat fusion.

In this way, when the pad material 13 and the glass mat 11 are completely set, the hard urethane resin liquid, which is the material of the hard urethane core material 12, is poured into the foam molding lower mold 20, and as shown in FIG. Then, the foam molding upper mold 22 is lowered with respect to the lower mold 20, and the upper and lower molds 20 and 22 are clamped.

At this time, since the non-breathable high elongation film 14 acts as a barrier, the hard urethane resin liquid does not enter the cushion layer 15 and the soft feeling of the cushion layer 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. 4, 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.
The slush skin material 16 is positioned on the die surface of the lower die 31 for pressure bonding with the slash skin layer 17 facing downward, and the slush foam layer 18 is coated with an adhesive.

Then, by clamping the upper and lower molds 30 and 31 for crimping,
Hard urethane core material with pad material 13, as shown in FIG.
The slush skin material 16 is integrated with 12 to complete the manufacture of the automobile door trim 10 having the structure shown in FIG.

Thus, in the method of the present invention, the hard urethane core material
Despite using two types of urethane with different densities, 12 and rigid urethane foam, only one step is required for the foam molding process, so the process can be greatly shortened compared to the conventional construction method, and the cost of the product can be reduced. It has the advantage of being connected.

Further, the flexible urethane foam has an excellent soft feeling as compared with the conventional semi-rigid urethane and can also promote the weight reduction.

Next, FIGS. 6 and 7 show another embodiment of the method of the present invention, in which a high elongation nonwoven fabric is used as the cushion layer 15 and the shape of the hard urethane core material 12 is complicated. This is an example in the case where it is not (the expansion rate is small).

As shown in FIG. 6, the pad material 13 is set on the mold surface of the foam molding lower mold 40, and a glass mat is formed from the upper side thereof.
Place 11.

Then, as shown in FIG. 7, after injecting the hard urethane resin liquid, the foam molding upper mold 41 is lowered, and the foam molding upper and lower molds 40 and 41 are clamped to each other so that the hard urethane core with the pad material 13 is attached. The forming of the material 12 is completed.

Also in this example, the high elongation nonwoven fabric used as the cushion layer 15, since the hard urethane resin liquid does not invade by the non-breathable high elongation film 14, the cushioning property of the nonwoven fabric is not impaired, and a good cushion is obtained. Not only the effect is obtained, but also the material cost of the non-woven fabric is much lower than that of the flexible polyurethane foam, so that there is an advantage that the cost of the product can be greatly reduced.

As described above, the example in which the method of the present invention is applied to the method for manufacturing a door trim has been described, but if it is an automobile interior part made of a laminated structure using a hard urethane core material,
The use is not particularly limited.

<< Effects of the Invention >> As described above, the method for manufacturing an automobile interior part according to the present invention has the following special effects.

According to the method of the present invention, a cushion layer having an excellent cushioning effect is simultaneously laminated at the time of foam-molding a hard urethane core material. Since only one process is required, the process can be shortened and the equipment can be simplified, which has the effect of significantly reducing the cost.

According to the method of the present invention, it is possible to reduce the weight by using a cushion layer such as a soft polyurethane foam or a high elongation non-woven fabric in place of the conventional semi-hard urethane. As a result, the product can be significantly reduced in weight.

According to the method of the present invention, since a cushion layer such as a soft polyurethane foam or a high elongation non-woven fabric is used in place of the semi-rigid urethane, there is an effect that the soft feeling is improved and the surface feel becomes good. .

According to the method of the present invention, as the cushion layer, particularly when using a high elongation non-woven fabric, the material cost is significantly reduced,
In addition to the above effect, it has the effect of significantly reducing the product cost.

[Brief description of 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 to 5 are sectional views showing manufacturing steps of the automobile door trim, FIG. 6, FIG. FIG. 8 is a cross-sectional view showing another embodiment of the foam molding process in the present invention, and FIG. 8 is a cross-sectional view showing the structure of a conventional automobile door trim. 10 …… Vehicle door trim 11 …… Glass mat 12 …… Hard urethane core material 13 …… Pad material 14 …… Non-breathable high elongation film 15 …… Cushion layer 16 …… Slash skin material 20,40 …… Foaming Molding lower mold 22,41 …… Foam molding upper mold 21 …… Vacuum suction hole 30 …… Crimping upper mold 31 …… Crimping lower mold

Claims (4)

[Claims] 1. A pad material (13) in which a non-breathable high elongation film (14) is backed on a cushion layer (15) on a mold surface of a foam molding lower mold (20), and a glass mat (11). Are placed in this order, and after the hard urethane resin liquid that is the material of the core material (12) is injected into the foam molding lower mold (20), the foam molding upper and lower molds (20, 2
2) Clamping the mold to mold the core material (12) with pad material (13) into the required shape, and crimping the core material (12) with pad material (13) and the skin material (16). A method of manufacturing an interior part for an automobile, characterized by comprising a step of integrating with a mold (30, 31). 2. The cushion layer (15) is composed of a flexible polyurethane foam.
A method for producing an interior part for an automobile according to the description. 3. The method for manufacturing an automobile interior part according to claim 1, wherein the cushion layer (15) is made of a high elongation nonwoven fabric. 4. The method for producing an automobile interior part according to claim 1, 2, or 3, wherein the non-breathable high elongation film (14) is composed of a polyurethane film or a polyamide film.