JP2019209656A - Manufacturing method of vehicle interior having pad - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent a void from being generated in an instrument panel with a pad at the time of manufacturing, and to omit or simplify a burr removal treatment performed after manufacturing the instrument panel. A pad (20) including a skin (30) and a foam material (40) is placed on the core material (10) by filling a filling space (50) between a core material (10) and a skin material (30) while foaming a foaming raw material from an injection port (13a). In the method of manufacturing the instrument panel 1 with the pad 20 that is integrally laminated, a relief formed between the core material 10 and the outer skin 30 at a position apart from the injection port 13a in the peripheral portion of the filling space 50. The passage 60 is continuous and communicates with the outside of the filling space 50. A guide portion 70 is formed outside the filling space 50 in a continuous manner with the escape passage 60. In the foam filling process of the foaming raw material, air in the filling space 50 is released from the escape passage 70 and a part of the foaming raw material is discharged. It leaks and is guided to the guide portion 70. [Selection diagram]

Description

  The present invention relates to a method for manufacturing padded vehicle interior parts such as automobile instrument panels.

  For example, some vehicle interior products such as an instrument panel and a glove box of an automobile have a pad integrally laminated on a hard core material. The pad has a soft skin whose surface is a design surface and an elastic foam material provided on the back surface. In a vehicle interior with a pad, the core material obtains the required strength, the skin improves the decorativeness, the foam improves the tactile sensation, and reduces the impact when an accident occurs.

  Patent Document 1 below discloses a method for manufacturing a padded instrument panel (vehicle interior). Briefly, first, a pre-formed skin and core material are placed on a lower mold and an upper mold, respectively. A protrusion is formed in advance at the joint portion of the core material with the skin. When the upper mold and the lower mold are combined and the protrusion is brought into close contact with the skin and sealed, the gap between the core material and the skin is determined. A filling space is formed. By filling the filling space while foaming the foaming raw material, the skin and the pad made of the foamed material are integrally laminated on the core material.

  In the manufacturing method of the instrument panel with a pad disclosed in Patent Document 1, it is possible to prevent the foaming raw material from leaking out from the filling space by bringing the protrusion provided on the core material into close contact with the skin. However, when filling the foaming raw material, the air in the filling space and the gas generated from the foaming raw material cannot escape from the filling space to the outside, causing voids (air pockets) in the manufactured instrument panel. Therefore, the product value of the instrument panel was impaired.

  Patent Document 2 below discloses a method for manufacturing an instrument panel with a pad as in Patent Document 1. In the method disclosed in Patent Document 2, a large number of small gas venting grooves are provided over almost the entire circumference of the filling space at a portion of the core material that is in close contact with the skin, and the inside and outside of the filling space are communicated. Thereby, at the time of filling with the foaming raw material, the air generated in the filling space and the gas generated from the foaming raw material can be released from the filling space to the outside, and generation of voids in the manufactured instrument panel is suppressed.

Japanese Examined Patent Publication No. 4-15091 (Fig. 5) JP-A-6-344358 (FIGS. 1, 2, and 5)

  When an instrument panel with a pad is manufactured by the manufacturing method of Patent Document 2, it is possible to suppress the generation of voids, but only gas is released from the filling space through the gas vent groove so that the foaming raw material does not leak. In order to achieve this, fine adjustments such as the width, depth, and length of the gas vent groove and the interval between adjacent gas vent grooves have been required. However, it has been difficult to satisfy both the fact that no void is generated and the foaming raw material does not leak from the gas vent groove. If the foaming raw material is not leaked from the gas vent groove or the amount of leakage is reduced, generation of voids cannot be avoided. Therefore, in order not to generate voids, a certain amount of foaming raw material has to be leaked from the filling space.

  The foaming material leaked from the filling space flowed from the outer edge of the gas vent groove provided, and the solidified burr of the foamed material adhered to the core material and the skin, thereby deteriorating the appearance of the instrument panel. For this reason, post-processing for removing the attached burrs has been complicated.

  In order to solve the above problems, the present invention provides a pad including the skin and the foam material by filling the filling space between the core material and the skin while foaming the foaming raw material from the injection port. In the method of manufacturing a vehicle interior with a pad, which is integrally laminated thereon, an escape passage formed between the core material and the skin at a position away from the inlet at the peripheral edge of the filling space Are connected to the outside of the filling space, and a guide portion is formed outside the filling space and connected to the escape passage. In the foam filling step of the foaming raw material, air in the filling space escapes from the escape passage, and part of the foaming raw material leaks and is guided to the guide portion.

  According to the above configuration, by providing the escape passage at a location away from the injection port, air in the filling space that has been replenished by filling with the foaming raw material is gathered and escapes from the filling space, thereby suppressing the generation of voids. it can. Moreover, the location where the foaming raw material leaks can be concentrated by this escape passage. Furthermore, the leaked foaming raw material can be guided to a desired position by the guide portion formed continuously to the escape passage. Thereby, the adhesion position of the burr | flash of the foam material which arises by solidification of the foaming raw material which leaked can be restrict | limited to the position which is not easily visible or a position which is easy to remove. Accordingly, it is possible to omit or simplify the burr removal process performed as a post-process after the manufacture of the vehicle interior with a pad.

Preferably, the guide portion penetrates the core material, and in the foam filling step of the foam material, a part of the foam material leaked from the escape passage passes through the guide portion to the back side of the core material. Led.
According to the above configuration, in the area around the filling space, such as the end of the core material where there is no room for the leaked foam raw material to escape, or where it is not desired to cause burr of the foam material for reasons such as being noticeable The foaming raw material can be guided to the back side of the core material by the guide portion penetrating the core material. Therefore, the freedom degree of selection of the installation position of an escape passage and a guide part can be raised.

  Preferably, the vehicle interior product is an instrument panel.

  ADVANTAGE OF THE INVENTION According to this invention, while a void is not produced in the vehicle interior goods with a pad, the burr removal process performed after manufacture of the vehicle interior goods with a pad can be abbreviate | omitted or simplified.

It is a perspective view which shows the instrument panel with a pad manufactured with the manufacturing method which concerns on one Embodiment of this invention, and the post-processing was completed. It is a principal part enlarged plan view of the instrument panel, Comprising: The part of the vehicle width direction right side is shown. (A) It is the figure which expanded the circle part III of FIG.1 and FIG.2, Comprising: The guide part of the instrument panel is shown. (B) It is a perspective view which shows the guide rib which comprises the guide part. FIG. 3 is a cross-sectional view showing a core material and an outer skin that are set in the mold upside down when the instrument panel is mounted on the vehicle body, and a foam material formed between them; ) Shows the site along the IV-IV line. (A) It is the figure which expanded the circle part V of FIG.1 and FIG.2, Comprising: The guide part as a modification of the same instrument panel is shown. (B) It is a perspective view which shows the guide rib and through-hole which comprise the guide part. FIG. 5A is a cross-sectional view showing a core material and an outer skin that are set in the mold upside down when the instrument panel is mounted on the vehicle body, and a foam material molded between them; ) Shows the part along the VI-VI line.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a schematic configuration of a padded instrument panel 1 (a vehicle interior product with a pad) as a product. The instrument panel 1 includes a core member 10 extending in the left-right direction and a pad 20 that covers a predetermined region of the core member 10 and is laminated integrally with the core member 10. The pad 20 has a skin 30 whose surface is a design surface, and a foam material 40 provided in a state sandwiched between the skin 30 and the core material 10 on the back side.

  The core material 10 is formed by injection molding or the like of a hard thermoplastic resin such as a composite resin blended with talc using polypropylene as a base material, ABS resin, and the like in the center in the vehicle width direction. An opening 11 for installing the device is formed. The core member 10 has a first covering region 12 a and a second covering region 12 b that are covered by the pad 20 on the left and right in the vehicle width direction through the opening 11.

  In the core material 10, an injection portion 13 in which a plurality of injection ports 13 a are formed is provided near the center of the upper edge of the opening 11. A first runner constituting portion 14 extends from the inlet 13a into the first covering region 12a, and a second runner constituting portion 15 extends into the second covering region 12b.

  The first and second covering regions 12a and 12b are each defined by a sealing rib 16 shown in FIG. The sealing rib 16 is formed integrally with the core material 10. In this sealing rib 16, at a position away from the injection portion 13, for example, at the position of the circle III in FIGS. 1 and 2, the top of the sealing rib 16 is V-shaped as shown in FIG. A groove portion 16a cut out in a shape is formed.

  As will be described later, the first and second coating regions 12a and 12b defined by the sealing rib 16 are covered with the skin 30 to form a filling space 50 in the second coating region 12b as shown in FIG. Although not shown, the filling space 50 is also formed in the first covering region 12a. This filling space 50 is filled with the foaming raw material. Further, when the groove 16 a of the sealing rib 16 is covered with the skin 30, an escape passage 60 is formed by the skin 30 and the groove 16 a. The escape passage 60 allows air in the filling space 50 to escape and a part of the foaming material in the filling space 50 to leak out in the foaming material filling process.

  As shown in FIG. 3B, on the opposite side of the sealing rib 16 from the filling space 50, two guide ribs 17 and 17 are provided in parallel so as to sandwich the groove 16a therebetween. It extends toward the edge of the core material 10. The guide rib 17 is formed integrally with the core material 10. The base end of the guide rib 17 intersects with the sealing rib 16 and intersects substantially vertically in this embodiment. The top of the base end of the guide rib 17 is flush with the top of the sealing rib 16. The protruding height of the guide rib 17 from the surface 10a of the core member 10 gradually decreases from the proximal end to the distal end, and the protruding height is constant from the midway point 17a near the sealing rib 16.

  As shown in FIGS. 3A and 4, the guide ribs 17 and 17 are covered with the skin 30, so that the space surrounded by the skin peripheral edge portion 30 a, the surface 10 a of the core material 10, and the guide ribs 17 and 17 is the guide portion. 70. The guide portion 70 is connected to the escape passage 60 and guides the foaming material leaking from the filling space 50 toward the tip of the guide rib 17 in the foaming material filling step, as will be described later.

  As shown in FIG. 2, another guide rib 17, 17 is provided at a position close to the left side in the vehicle width direction with respect to the guide rib 17, 17 of the circle part III, and is similar to the guide rib 17 of the circle part III. By covering the core material 10 with the skin 30, a guide portion 70 is formed, and an escape passage 60 that is continuous with the guide portion 70 is formed.

The skin 30 is made of polyvinyl chloride, thermoplastic urethane, thermoplastic olefin, or the like, and is molded by powder slush molding, hot press molding, vacuum molding, or the like depending on the material.
As shown in FIG. 1, the skin 30 has a shape corresponding to the first covering region 12 a and the second covering region 12 b in the core material 10. Specifically, the skin 30 has a first region 32a corresponding to the first covering region 12a and a second region 32b corresponding to the second covering region 12b. The first region 32a and the second region 32b are each formed larger than the first covering region 12a and the second covering region 12b of the core material 10, respectively. Further, the skin 30 has a runner cover region 33 having a shape corresponding to the injection portion 13, the first runner constituting portion 14, and the second runner constituting portion 15 in the core material 10.

The manufacturing method of the instrument panel with a pad using the core material of the said structure and skin is demonstrated.
As shown in FIG. 4, the core member 10 and the skin 30 are set in the mold 80 by turning the instrument panel 1 upside down when the instrument panel 1 is mounted on the vehicle body. The skin 30 is set on the lower mold 81 and fixed by vacuum suction from a suction hole (not shown) provided on the lower mold 81. The core material 10 is set in the upper die 82, and the inlet 13a of the core material 10 shown in FIG. 1 is connected to the gate (not shown) of the upper die 82.

  The lower die 81 is matched with the upper die 82, and the sealing rib 16 of the core member 10 is brought into close contact with the skin 30 and sealed. At this time, the core material 10 and the skin 30 are disposed to face each other in the cavity of the mold 80, and a filling space 50 is formed therebetween. Specifically, filling is performed between the first covering region 12a of the core material 10 and the first region 32a of the skin 30 and between the second covering region 12b of the core material 10 and the second region 32b of the skin 30. A space 50 is formed.

When the upper die 82 and the lower die 81 are matched, the escape passage 60 is formed by the groove 16a of the sealing rib 16 of the core material 10 and the skin 30 and the guide portion 70 is formed on the surface of the core material 10. 10a, guide ribs 17 and 17, and a skin peripheral edge portion 30a.
Further, the filling space 50 is also formed between the injection portion 13 of the core material 10, the first runner constituting portion 14 and the second runner constituting portion 15 shown in FIG. 1, and the runner cover region 33 of the skin 30. As a result, the first runner 4 is formed on the first runner component 14, and the second runner 5 is formed on the second runner component 15.

Next, a foaming raw material is injected into the filling space 50 and foamed to form a foam material.
The foaming raw material is an elastic foam material 40 by foaming and solidifying. As a foaming raw material, for example, a two-component mixed urethane foam raw material is injected into the inlet 13 a of the core member 10 from a gate (not shown) in the upper mold 82 of the mold 80. The foaming raw material is diverted from the injection port 13a and directly supplied to the first runner 4 and the second runner 5. The foaming raw material supplied to the first runner 4 is filled into the filling space 50 of the first covering region 12a, and the foaming raw material supplied to the second runner 5 is filled into the filling space 50 of the second covering region 12b.

  The foaming raw material is filled into the filling space 50 while foaming. At that time, the air generated in the filling space 50 and the gas generated from the foaming raw material are driven away from the inlet 15 in the filling space 50 by the filled foaming raw material, and finally the escape shown in FIG. The passage 60 exits from the filling space 50. When the foaming material is filled in the filling space 50, excess foaming material escapes and leaks out of the passage 60 to the outside. The injection of the foaming material is stopped when a sufficient amount has leaked to suppress the formation of voids. As shown in FIG. 4, the foaming material that has leaked from the filling space 50 flows in the guide portion 70 toward the edge of the core material 10, and remains in the guide portion 70 and the tip portion of the guide rib 17 from the tip.

  The foam material is foamed and solidified in the filling space 50 to form the foam material 40. The foam material 40 is integrated with the core material 10 and the skin 30 due to the adhesiveness of the foam material when foaming. That is, the pad 20 made of the skin 30 and the foam material 10 is laminated on the core material 10. The foaming material leaking from the filling space 50 is also foamed and solidified, and the burr 40a of the foaming material 40 adheres to the inside of the guide part 70 and the tip of the guide rib 17.

After the foam molding is completed, the manufactured padded instrument panel 1 is taken out from the mold 80.
As post-processing, the outer peripheral edge portion 30a of the sealing rib 16 in the skin 30 shown in FIGS. 3 (A) and 4 is excised. At this time, the burr 40a of the foam material 40 is also removed. If the attachment position of the burr 40a is in a place where it cannot be touched by human eyes, the removal process of the burr 40a may be omitted. At this time, the injection portion 13 of the core material 10, the runner cover region 33 of the skin 30, and the foam material 40 in the injection portion 13, the first and second runners 4, 5 shown in FIG.

According to the above embodiment, by providing the escape passage 60 at a location away from the inlet 13a, the air in the filling space 50 that has been driven up by the filling of the foaming raw material is gathered and escapes to the outside. Thereby, generation | occurrence | production of a void in the pad 20 can be suppressed.
Further, the escape passage 60 can concentrate the location where the foamed raw material leaks, and the guide portion 70 formed continuously to the escape passage 60 can guide the leaked foam raw material to a desired position. That is, it is possible to limit the position where the burr 40a of the foam material 40 generated due to solidification of the leaked foam raw material can be restricted, for example, the position where it is not visible to the human eye or the position where it can be easily removed. Accordingly, it is possible to omit or simplify the burr removal process performed as a post-process after the manufacture of the vehicle interior with a pad 1.

  Next, a modified example of the present invention will be described. In addition, about the following modifications, only a different structure from the said embodiment is demonstrated, the same code | symbol is attached | subjected to the same component and the description is abbreviate | omitted.

  1 and 2, FIG. 5 and FIG. 6 show modifications of the present invention. In this modification, the place where the foaming raw material leaking from the filling space is guided by the guide portion is different from that in the above embodiment.

  As shown in FIG. 5B, a guide rib 18 having a U-shape in plan view is provided integrally with the core member 10 on the opposite side of the sealing rib 16 from the filling space 50, and the sealing rib 16 The groove part 16a formed in is enclosed. The guide rib 18 has side wall portions 18a and 18a extending in parallel with the groove portion 16a interposed therebetween, and an opposing wall portion 18b that connects the tip portions of the side wall portions 18a and faces the groove portion 16a.

  As shown in FIGS. 5A and 5B, a through hole 19 penetrating the core material 10 is formed on the surface 10 a of the core material 10 surrounded by the guide rib 18 and the sealing rib 16. As shown in FIGS. 5A and 6, the guide rib 70 is covered with the skin 30, thereby forming a guide portion 70 </ b> A. The guide portion 70 </ b> A includes a space surrounded by the skin peripheral edge portion 30 a, the guide rib 18 and the sealing rib 16, and the through hole 19. The guide portion 70 </ b> A is connected to an escape passage 60 formed by the skin 30 and the groove portion 16 a of the sealing rib 16.

  In the foaming raw material filling process, after the foaming raw material is filled in the filling space 50, excess foaming raw material leaked from the escape passage 60 flows in the guide portion 70A as shown in FIG. The lead is directed toward the back surface 10b opposite to the skin 30 side. As a result, the burr 40a of the foam material 40 in which the foam material is solidified adheres to the back surface 10b of the core material 10.

  According to the modified example, the burr 40 a can be generated on the back surface 10 b of the core material 10 by introducing the foaming raw material to the back side of the core material 10. Therefore, in the periphery of the filling space 50, the foam material is formed on the surface 10 a of the core material 10 because there is no room for the leaked foam raw material to escape, such as the end of the core material 10, or because it is touched by human eyes. Even if the burr 40a is not desired to be generated, the escape passage 60 and the guide portion 70A can be provided. Therefore, the freedom degree of the installation position selection of the escape passage 60 and the guide part 70A can be raised.

The present invention is not limited to the above-described embodiment, and various modes are possible without departing from the scope of the invention. The present invention is not limited to an instrument panel, and can be applied to the manufacture of vehicle interior parts having pads, such as a glove box.
In the above-described embodiment, the molding space, the escape passage, and the guide portion on the second covering region 12b side on the right side in the vehicle width direction of the core member of the instrument panel have been described. Similarly, the escape passage and the guide passage on the first covering region 12a side are also described. A guide portion is provided.
In the above embodiment, as shown in FIG. 2, the escape passage and the guide portion are provided at three locations on the one covering region 12b side of the instrument panel, but may be provided at one or two locations. You may provide in the above and the installation position of an escape passage and a guide part is not limited to the said embodiment.

  The present invention can be applied to the manufacture of vehicle interior parts having pads such as instrument panels.

1 Instrument panel (vehicle interior)
DESCRIPTION OF SYMBOLS 10 Core material 10a Core material surface 10b Core material back surface 13a Inlet 16 Sealing rib 16a Groove part 17 Guide rib 18 Guide rib 19 Through-hole 20 Pad 30 Skin 30a Skin peripheral part 30a
40 foam material 40a burr of foam material 50 filling space 60 escape passage 70, 70A guide portion 80 mold 81 lower mold (mold)
82 Upper mold (mold)

Claims (3)

For a vehicle with a pad, a pad including the skin and the foam material is integrally laminated on the core material by filling the filling space between the core material and the skin while foaming the foaming raw material from the injection port. In a method of manufacturing an interior product,
The escape passage formed between the core material and the outer skin is connected to the peripheral portion of the filling space away from the inlet, and leads to the outside of the filling space.
Outside the filling space, a guide portion is formed continuously to the escape passage,
In the foam filling step of the foaming raw material, a padded vehicle interior product characterized in that air in the filling space escapes from the escape passage and a part of the foaming raw material leaks out and is guided to the guide portion. Manufacturing method.   The guide portion penetrates the core material, and in the foam filling process of the foam material, a part of the foam material leaked from the escape passage flows to the back side of the core material through the guide portion. The manufacturing method of the interior goods for vehicles with a pad of Claim 1 characterized by the above-mentioned.   The method for producing a padded vehicle interior product according to claim 1, wherein the vehicle interior product is an instrument panel.

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