JPH01280535A - Method of manufacturing door rim for automobile - Google Patents

Abstract

PURPOSE:To enable an inter-connection member to be mounted simply to a door rim main body by a process wherein the inter-connection member is previously adhered to a skin material, and after a core material and the skin material are integrated each other, only the skin material is cut along the peripheral groove, wherein the peripheral termination of the inter-connection member is positioned, so that the skin material of the part is removed. CONSTITUTION:A skin material 13 for an inter-connection part is put on top of the rear surface of the skin material 12, facing the surface side thereof, and both are adhered each other along the peripheral part of the skin material 13 for the inter-connection part so as to form a double skin material 18. At this time, the skin material 13 for an inter-connection part is in advance trim cut so as to provide an approximately identical outer configuration with the outer configuration of the inter-connection part. After integrating a core material and the double skin materials 18, the skin material 12 for a general part is cut and removed along a boundary line 15. The skin material 12a is removed, afterwards in the inter-connection part, the sin material 13 for the inter-connection part is exposed in a product surface side.

Description

Detailed Description of the Invention (Field of Industrial Application) The present invention relates to a method for manufacturing an automobile door trim equipped with an intermediate member, and particularly relates to a method for manufacturing an automobile door trim that simplifies the installation process of an intermediate member. Regarding the method.

(Description of Prior Art) Recently, in order to improve the comfort of automobile interiors, the materials of interior parts such as automobile door trims have been upgraded, or decorative members such as cloth, carpets, etc. have been added to the door trim surface as appropriate. Attempts have been made to attach the device to certain locations.

FIG. 11 is a front view of an automobile door trim, and FIG. 12 is a cross-sectional view of the same door trim. In these conventional automobile door trims 1, a skin material is formed on the surface of a core material 2 formed into a desired shape. 3, and an intermediate member 5, such as a cloth, which is attached to an appropriate location on the surface of the door trim body 40 to provide decoration.

To briefly explain the outline of the method for manufacturing the door trim 1, first, the process of forming the door trim body 4 will be explained. If a thermoplastic composite resin plate is used as the core material 2, the core material 2 is heated and softened, then overlapped with the skin material 3 and cold press molded to form the door trim body 4 with the desired curved shape. Can be molded. In addition, if a core material 2 to which hot press molding is applied, such as wood fiberboard, is used, it is inappropriate to mold it simultaneously with the skin material 3.
After forming the core material 2 into a required curved shape, the skin material 3 is integrally attached to the surface side of the core material 2 by vacuum forming via an adhesive to form the door trim body 4.

In order to attach and fix the intermediate member 5 to the door trim body 4 formed in this way, it is necessary to shape the intermediate member 5 in advance so as to follow the curved shape of the intermediate member. A backing material 7 for shape retention is laminated and adhesively bonded to the back side of 6.

Furthermore, in order to adhere these middle contact members 5 to the door trim body 4 side, the middle contact portion of the door trim body 4 is coated with adhesive, and the middle contact members 5 are bonded, and the peripheral edge end 5a of the middle contact member 5 is The end of the middle contact member 5 was press-fitted into a circumferential groove 8 formed on the door trim body 4 side along the outer shape of the middle contact portion.

(Problems to be Solved by the Invention) As described above, in the conventional door trim manufacturing method, the cloth 6 and the backing material 7 are used as the intermediate member 5,
Since it is preformed by vacuum molding or the like and then adhesively fixed to the door trim body 4 side, it takes many steps and the associated equipment costs are also large, resulting in a significant cost increase (a disadvantage). was there.

Generally, the terminal treatment of the intermediate member 5 is troublesome, and the terminal 5a
If it does not fit within the circumferential groove 8 and protrudes outside, the appearance of the product will be significantly impaired, so the process of processing the end of this intermediate member requires skill and a lot of time.

In addition, adhesive is used to adhesively fix the intermediate member 5 to the door trim body 4 side, but it has been pointed out that this adhesive adheres to the product surface, causing staining of the product surface. .

The present invention has been made in view of the above-mentioned circumstances, and an object of the present invention is to enable the intermediate member to be easily attached to the door trim body side, shorten the work process, and reduce the amount of equipment. It is an object of the present invention to provide a highly practical method for manufacturing a door trim for an automobile, in which the terminal processing can be performed beautifully and easily.

(Means for Solving the Problems) In order to achieve the above object, the present invention is provided by bonding the intermediate member to the skin material in advance, integrating the core material and the skin material, and then
Cut only the skin material along the circumferential groove where the peripheral end of the intermediate member is located using a cutting tool such as a welder bar or seal cutter, remove the skin material in this area, and place the intermediate member on the product surface. It is characterized by being exposed.

(Function) According to the above means, the intermediate member trim-cut into a desired shape is joined to the back surface of the skin material, and after the core material and the skin material are integrated, the intermediate part of the skin material is bonded to the back surface of the skin material. Cut and remove
Since the intermediate connecting member is exposed on the surface of the product, there is no need for backing materials and adhesives that maintain the shape of the cloth, and there is no need for the process of preforming the cloth or the forming equipment. becomes.

Furthermore, since the end of the peripheral edge of the intermediate member as a product corresponds to the cut line of the skin material with the cutting tool, even if there are dimensional errors of the intermediate member or installation errors on the door trim body, there will always be a constant margin of error. A peripheral end line of the contact member is obtained.

In addition, because the intermediate member is joined to the core material during the process of integrating the core material and the skin material, problems such as adhesion of adhesive to the product surface, which would otherwise occur due to past bonding in a subsequent process, are avoided. is effectively resolved.

(Description of Examples) Hereinafter, examples of the door trim manufacturing method according to the present invention will be described in detail with reference to the accompanying drawings.

First, before explaining the manufacturing method, the structure of a door trim to which the method of the present invention is applied will be briefly explained based on FIGS. 1 and 2. In the drawing, the door trim 10 includes a core material 11 such as a wood fiber board hot-press molded into a desired shape or a thermoplastic composite resin board cold-press molded into a desired shape, and a core material 11 integrally formed on the surface side of the core material 11. It is generally composed of a skin material 12 to be adhered and a middle member 13 to be attached to the middle part. And intermediate member 1
3 also corresponds to a skin material in a broad sense, so for the sake of explanation, the soil-interfacing member 13 is defined as a skin material for the rear part of the body, and the skin material 12 that covers other parts is defined as a skin material for general parts, and the following explanation is given. I do.

Incidentally, the peripheral end portion 13a of the skin material 13 for the growing part is the core material 1.
1, and a boundary line 15 between the general part skin material 12 and the growing part skin material 13 is set along a little inside of this peripheral edge end part 13a, and similarly This boundary line 15 is set within the circumferential groove 14. The material of the crotch skin material 12 is a foamed layer 16 of polypropylene foam, polyethylene foam, etc., laminated on the back side of the ABS-containing PVC sheet 17. Further, the skin material 13 for the rear part may be appropriately selected from cloths such as velvet, jersey, tricot, and moquette.

Next, the manufacturing process of the automobile door trim 10 will be explained, and the method of the present invention can be roughly divided into the following steps.

(1) Formation process of double skin material.

(2) Integration process of core material and double skin material.

(3) - Cutting and removing the crotch skin material.

Each step will be explained in detail below.

(1) Formation process of double skin material.

First, as shown in FIG. 3, the skin material 13 for the growing part is overlapped on the back side of the skin material 12 for the general part with the front side facing, and the skin material 13 for the growing part of this example is stacked along the peripheral edge of the skin material 13 for the growing part. The double skin material 18 is formed by joining the two together by sewing.

In addition, at this time, the skin material 13 for the growing part is trim-cut in advance so as to have an outer shape that is substantially the same as the outer shape of the middle part.

In addition, as a method for joining the two, in addition to sewing, the two may be joined by welding, and the joining means is not particularly limited.

(2) Integration process of core material and double skin material.

This integration process differs depending on whether a wood fiberboard is used as the core material 11 or a thermoplastic composite resin board. The case where a thermoplastic composite resin plate is used and the case where a thermoplastic composite resin plate is used will be explained based on FIGS. 8 and 9.

First, the core material 11 is molded according to FIG. 4 and FIG.
is used in this example.

The resin binder is phenolic resin.

It contains a thermosetting resin such as urea resin and a thermoplastic resin such as acrylic resin, and the wood fiber contains a large amount of cotton yarn to prevent tearing.

First, this wood fiberboard M+ is placed on the upper surface of the lower mold 20 for hot press molding, as shown in FIG. The mold surface 2Oa of the lower mold 20 for hot press molding is set in a shape that gives the core material 11 curved parts such as an armrest part and a door waist part.

Furthermore, an upper mold 21 for hot press molding is located above the lower mold 20 for hot press molding in a manner that it can be raised and lowered. It has a surface 21a.

Then, as shown in FIG. 5, by driving a lifting device 22 such as a hydraulic cylinder provided on the upper mold 21 for hot press molding, the upper and lower molds 20.21 for pot press molding are engaged, and the core material 11 is molded into a required curved shape, and during this molding, the circumferential groove 14 is also molded at the same time.

Next, the core material 11 formed into the desired shape in the above step is positioned and set on the upper surface of the lower mold 30 for vacuum forming,
A double skin material 18 shown in FIG. 3 is installed above this core material 11 (see FIG. 6). After this double skin material 18 is heated and softened by the heater device 31, it is positioned above the core material 11 by the operation of a slide device (not shown).

Note that the peripheral edge of this double skin material 18 is clamped by a clamp device 32.
in a horizontal state, and the skin material 13 for the middle joint part is placed on the core material 11.
are held opposite each other.

Furthermore, an upper mold 33 for vacuum forming is located above the double skin material 18, and these upper and lower molds 30.
33 can be raised and lowered, and suction holes 34.35 are provided at appropriate locations, and these suction holes 34.
35 is a vacuum pump 38.35 via on-off valves 36.37.
It is connected to 39. In addition, this upper and lower mold for vacuum forming 3
0.33 has substantially the same mold surfaces 30a and 33a, forming a so-called mated die.

Then, after the core material 11 is set on the lower mold 30 for vacuum forming and the double skin material 18 is held above it, the lower mold 30 for vacuum forming rises, and at the same time, the upper mold 33 for vacuum forming is lowered, and the upper and lower vacuum molding molds 30 and 33 are engaged at approximately the intermediate position between the two (see FIG. 7). In this way, simultaneously with the engagement of the upper and lower molds 30 and 33 for vacuum forming,
Through the suction hole 34 provided in the lower mold 30 for vacuum forming,
The air between the double skin material 18 and the core material 11 is ignited, and the double skin material 18 is integrally attached along the surface shape of the core material 11.

In addition, regarding the integration of both, the surface side of the core material 11 is coated with an adhesive.

Further, as shown in an enlarged view in FIG. 7, the double skin material 18 is placed in an appropriate position in advance so that the peripheral edge end 13a of the skin material 13 for the intermediate portion is located within the circumferential groove 14 formed in the core material 11. Positioned.

Next, a case where a thermoplastic composite resin plate is used as the core material 11 will be explained based on FIGS. 8 and 9.

In this case, the core material 11 is made by extruding a mixture of polypropylene resin and wood powder filler in an appropriate mixing ratio into a sheet using an extrusion molding machine. Then, this material M2 is heated and softened using a heating device @ 40, and then placed on the upper surface of the lower die 41 for cold press molding. This lower die 41 for cold press has a core material 11
It has a curved surface shape for shaping into the required shape. Then, the double skin material 18 is placed on top of this, but regarding the positioning of this double skin material 18, the skin material 13 for the intermediate part
This is done appropriately so that the peripheral edge end 13a of is positioned within the circumferential groove 14 of the core material 11. That is, the peripheral edge end 13a of the intermediate section skin material 13 may be arranged along the circumferential groove forming recess 42 provided in the cold press lower mold 41.

And the upper mold 4 for cold press molding located above it
3 is provided with a lifting device @ 44 such as a hydraulic cylinder (see FIG. 8).

And thermoplastic composite resin plate M2 and double skin material 1
8 is completed, the upper die 43 for cold press molding is lowered by the driving of the lifting device 44, and the thermoplastic composite resin plate M2 and the double The skin material 18 is integrated and formed into a desired shape.

At this time, no adhesive is required between the two, and since the double skin material 18 is pressed while the thermoplastic composite resin plate M2 is in a softened state, the two are firmly joined.

(3) - Cutting and removing the crotch skin material.

After integrating the core material 11 and the double skin material 18 in the above process, as shown in FIG. A weld bar 51 is press-fitted into the weld bar 51, and the general part skin material 12 is cut and removed along the boundary line 15 shown in FIG. Note that instead of the weld bar 51, thermal cutting with a hot knife or a seal cut bar may be used, and after removing the unnecessary general part skin material 12a, insert the middle binding part skin material into this middle part. 13 will be exposed on the product surface side.

Moreover, since the boundary line 15 between the crotch skin material 12 and the middle stitching skin material 13 corresponds to the cutting line by the weld bar 51, the peripheral end 13a of the middle stitching skin material 13 corresponds to the cutting line by the weld bar 51.
The cutting line set slightly inside is the boundary line]5
Therefore, even if there is a dimensional error or an installation error in the middle stitching section covering material 13, the end treatment of the middle stitching section covering material 13 can be performed beautifully and easily by the weld bar 51.

(Effects) As explained above, according to the door trim manufacturing method according to the present invention, cloth alone can be used as the skin material for the binding part, eliminating the need for backing materials and preforming as in the past.
Since the installation process of the intermediate member can be significantly shortened and the equipment associated with it can also be reduced, there is an advantage of bringing about a significant cost reduction.

Conventionally, it required great skill to process the ends of the outer skin material for the middle stitching part, but in the present invention, the outer skin material for the general part is cut and removed using a cutting tool such as a welder bar, and the outer skin material for the middle stitching part can be made by cutting and removing the outer skin material for the general part using a cutting tool such as a welder bar. - Since the cutting line of the crotch skin material corresponds to the end of the middle binding part skin material, the end processing of the middle binding member is extremely simple, and the end part is beautiful. This makes it possible to finish the product, and in addition to the process benefits, it can greatly contribute to improving the appearance and design.

In addition, the outer skin material for the middle part is joined to the outer skin material for the general part in advance, and - when the outer skin material for the crotch part is integrated with the core material, the outer skin material for the middle stitch part is also integrated with the core material. This eliminates the need for adhesive and eliminates the problem of adhesive adhering to the product surface compared to the conventional method of adhering it to the door trim body using adhesive. In addition to eliminating the problem, there are also incidental effects such as a better working environment.

[Brief explanation of the drawing]

1 to 2 are an overall perspective view and a sectional view showing an automobile door trim to which the method of the present invention is applied; FIGS. 3 to 10 show each step of the method of the present invention; FIG. 4 to 7 are cross-sectional views showing the first embodiment of the step of integrating the core material and the double skin material, and FIGS. 8 to 9 are explanatory diagrams showing the process of forming the double skin material. The figures are cross-sectional views explaining the second embodiment of the process of integrating the core material and the double skin material, and the first
Figure 0 is a sectional view illustrating the process of cutting and removing the skin material for general parts in a double skin material, Figure 11 is a front view showing a conventional door trim, and Figure 12 is a sectional view showing the same conventional door trim. . 10... Automobile door trim 11... Core material 12... - Crotch skin material 13... Middle binding part skin material 14... Circumferential groove 15... Boundary line 18... Two Heavy skin material 20...lower die for hot press molding 21...upper die for hot press molding 30...lower die for vacuum forming 33...upper die for vacuum forming 41...lower die for cold press molding Mold 43... Upper mold 51 for cold press molding... Welder bar

Claims (1)

[Scope of Claims] 1. A core material having a required curved surface shape and having a circumferential groove formed along the outer shape of the intermediate portion, and a skin material that is integrated with the surface of the core material; In the method for manufacturing an automobile door trim, the method includes: a middle member attached to the middle part of the core material so that the peripheral edge end is located in the circumferential groove of the core material; A process of forming a double skin material by joining and integrating the circumferential edges of the intermediate members trimmed to be approximately equal to the external shape of the intermediate member with their front surfaces facing each other, and forming the circumferential groove and forming the required curved surface shape. After forming the core material, the double skin material is placed on the surface of the core material, and the process of integrating the core material and the double skin material so that the peripheral end of the intermediate member is located in the circumferential groove of the core material. and a step of exposing the intermediate member on the product surface by press-fitting a cutting tool such as a welder bar or seal cut bar into the circumferential groove and cutting and removing the skin material along the circumferential groove. A method for manufacturing an automobile door trim characterized by: 2. A core material with a required curved surface shape and a circumferential groove formed along the outer shape of the central part, a skin material attached to the surface side of this core material, and a peripheral edge end within the circumferential groove. In the manufacturing method of an automobile door trim, the trim member is attached to the intermediate part of the core material so as to be located at the middle part of the core material. A step of forming a double skin material by joining the members with their surface sides facing each other and joining and integrating the peripheral parts with the skin material, and a step of forming a core material and the above-mentioned double skin material so that the intermediate member side faces the core material. a step of pressing and integrating the core material and the double skin material into a required curved surface shape so that the peripheral end of the intermediate member is located in the circumferential groove of the core material; It is characterized by a step of exposing the intermediate member on the product surface by press-fitting a cutting tool such as a welder bar or seal cut bar into the groove and cutting and removing the skin material along the circumferential groove. A manufacturing method for automobile door trim.