JPH0439009A - Manufacture of trim component for automobile - Google Patents

Abstract

PURPOSE:To contrive an improvement in moldability of a rigid urethane core material, by a method wherein the fringe of a glass mat put on the upper side of a pad material is supported by a protrusion of a clamping device, the pad material is vacuum-drawn along a mold surface of a foam molding bottom force and then a rigid urethane resin solution is cast into the foam molding bottom force. CONSTITUTION:A pad material 13 comprised of a rigid urethane foam 15 obtained by packing the same with an urethane film 14 is set to a mold surface of a foam molding bottom force 20 by facing the urethane film on the upper side. The fringe of the pad material is clamped down by a clamping device 23, on the side of which a glass mat 11 is put and the fringe of the glass mat 11 is supported by a protrusion 25 formed on the clamping device. Then after casting of a rigid urethane resin solution M becoming a material of a core material 12 into a bottom force 20, vacuum drawing is performed so as to cause the pad material 13 to follow the mold surface of the bottom force through a vacuum drawing hole 27 provided in the bottom force 20. Simultaneously with the above, the foam molding bottom forces 20, 22 are clamped and the core material with the pad material is molded into a necessary form. Continuously, the core material with the pad material and a skin material 16 are stuck to each other and unified by press bonding molds 30, 31.

Description

[Detailed Description of the Invention] (Industrial Application Field) This invention relates to a method for manufacturing automobile interior parts such as automobile door trims, and in particular, to interior parts using a hard urethane core material for the purpose of reducing the weight of the product. The present invention relates to a method for manufacturing automotive interior parts with improved moldability.

(Prior art) For example, various interior parts are installed in the interior of a car, and these interior parts require fiberboard, resin board, etc. that have shape retention and rigidity for mounting on car body panels. A laminated structure is generally known in which a core material formed into a shape and a skin material having cushioning properties and decorative properties are laminated on the surface side of the core material.

By the way, the disadvantages of core materials made of fiberboard, resin boards, etc. are that they are heavy and unsuitable for reducing the weight of products, and their moldability is also unsatisfactory (
There was a problem in that it could not be applied to products with complicated curved shapes.

As a countermeasure to this problem, it has been proposed and implemented to promote weight reduction and improve moldability by using a hard urethane core material reinforced with a glass mat or the like.

FIG. 11 is a sectional view showing the structure of an automobile door trim using a hard urethane core material.
, a pad material 4 such as polyurethane foam, and a skin material 5 adhered to the surface side thereof.

Note that a urethane-based or polyamide-based film 4a is adhered to one side of the pad material 4.

To briefly explain the method for manufacturing the door trim 1, as shown in FIG. 12, the pad material 4 and the glass mat 2 are set in the lower mold 6 for foam molding, and the hard urethane material is The core material 3 with the pad material 4 is molded by injecting the resin liquid and clamping the foam molding upper mold 7 to the foam molding lower mold 6 as shown in FIG.

Next, the separately molded skin material 5 and the hard urethane core material 3 with the pad material 4 molded in the above process are bonded and integrated to produce the door trim 1 shown in FIG. 11.

(Problem to be Solved by the Invention) However, in the conventional mold press forming of the hard urethane core material 3, the hard urethane resin liquid does not flow well, especially in deep drawing parts such as the armrest part.
Insufficient filling of the material was likely to occur, which was a major cause of molding defects.

In addition, since the glass mat 2 is simply set on top of the pad material 4 in a free state, the two lower molds 6 and 7 for foam molding
When the mold is clamped, this glass mat 2 shifts and wrinkles occur, and these wrinkles make the flow of the hard urethane resin liquid unstable, leading to the generation of voids, etc. This also impairs the moldability of the hard urethane core material 3. This was a hindering factor.

This invention was made in view of these circumstances,
An object of the present invention is to make the flow of a hard urethane resin liquid smooth in a method of manufacturing automobile interior parts using a hard urethane core material, and to reduce the weight of the product. An object of the present invention is to provide a method for manufacturing automobile interior parts with improved moldability.

(Means for Solving the Problems) In order to achieve the above object, the method for manufacturing automotive interior parts according to the present invention provides a pad made of a soft urethane foam backed with a urethane film on the mold surface of a lower mold for foam molding. A material setting step in which the material is set with the urethane film facing upward, its periphery is clamped by a clamping device, a glass mat is placed on top of the material, and its periphery is supported by protrusions formed on the clamping device, and the above-mentioned foam molding After injecting the hard urethane resin liquid that will become the core material into the lower mold, the pad material is vacuum-suctioned to follow the mold surface of the lower mold through the vacuum suction hole provided in the lower mold for foam molding. , consisting of a step of clamping the upper and lower molds for foam molding and molding the core material with padding material into a desired shape, and a step of bonding and integrating the core material with padding material and the skin material using a pressure bonding mold. It is characterized by

(Function) As is clear from the above configuration, according to the present invention, a hard urethane resin liquid is injected into a lower mold for foam molding, and immediately before foaming starts, the pad material is applied along the mold surface of the lower mold for foam molding. By vacuum suctioning the pad material, it is possible to quickly follow the mold surface of the lower mold, and it is possible to smoothly move around the hard urethane resin liquid.

Furthermore, since the peripheral edge of the glass mat is supported by the protrusion of the clamping device, when the upper and lower molds for foam molding are clamped, the glass mat does not shift unnecessarily and wrinkles do not occur on 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, Figs. 4 to 10 are explanatory diagrams showing each step of the method of the present invention.

First, automobile door trim 1 obtained by applying the method of the present invention
0, based on FIG. 1, this automobile door trim 10 includes a hard urethane core material 12 with a glass mat 11 inside, and a pad material 13 integrated on the surface side of the hard urethane core material 12. Urethane film 14
A soft urethane foam 15 laminated with is used, and a slush-molded skin material 16 with excellent surface appearance and surface feel covers the outer surface of the foam.

The slush molded skin material 16 has a slush skin layer 17 on its surface side. A two-layer skin material with a slash foam layer 18 on the back side is preferred.

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

First, a foam molding mold shown in FIG. 2 is used to mold the hard urethane core material. This foam molding mold includes an upper mold 22 for foam molding which is rotatably attached to a lower mold 20 for foam molding via a hinge part 21, and further includes a lower mold 20 for foam molding. Similarly, the clamp device 23 is rotatably attached as shown in the figure via a hinge portion 24, and the clamp device 23 is provided with protrusions 25 at appropriate intervals on its upper surface.

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

First, as shown in FIG. 4, the pad material 13 and the glass mat 11 are set in the lower mold 20 for foam molding. , and its periphery is supported by the clamp device 23,
As shown in the enlarged view in FIG.
Supports glass mat 11. Incidentally, at this time, the glass mat 11 is set so as to allow a margin in anticipation of the deep drawing development part.

Thereafter, as shown in FIG. 5, hard urethane resin liquid M is injected from above the glass mat 11 through the nozzle 26 of the foam molding machine. The hard urethane resin liquid M is injected by moving the nozzle 26 along a pattern shown by arrows in the figure.

Next, the hard urethane resin liquid M is injected in a pattern, and just before the end of the urethane cream time (immediately before the start of foaming), vacuum suction is performed through the vacuum suction hole 27 provided in the lower mold 20 for foam molding, and the pad material 13 is removed from the lower mold. 20 mold surfaces 20
At the same time as applying hard urethane resin liquid M
Similarly, spread over the mold surface 20a.

Next, the upper mold 22 for foam molding is applied almost simultaneously with the vacuum suction.
As shown in FIG. 8, the upper and lower molds for foam molding 20
．． 22 is clamped.

At this time, the glass mat 11 is displaced due to the mold clamping of 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 protrusion 25 of the clamping device 23, the same displacement always occurs. mat 1
1. No wrinkles occur.

Furthermore, since the urethane film 14 acts as a barrier, the hard urethane resin liquid M forms the soft urethane foam 15.
It does not seep into the inside, and the soft feel of the soft urethane foam 15 is not impaired.

In this way, the hard urethane core material 1 with the pad material 13 is
2 is molded into the desired shape.

Thereafter, as shown in FIG. 9, the hard urethane core material 12 with the pad material 13 obtained by foam molding in the above process is set in the upper mold 30 for crimping, and the mold surface of the lower mold 31 for crimping is Slash molded skin material 16 and slash skin layer 1
7 is located on the lower side, and the slash foam layer 18
By applying an adhesive and clamping the upper and lower crimping molds 30° 31 as shown in FIG. 10, the manufacture of the automobile door trim 10 having the structure shown in FIG. 1 is completed.

(Effects of the Invention) As explained above, in the method for manufacturing automotive interior parts according to the present invention, when molding a hard urethane core material with a pad material, after injecting a pattern of hard urethane resin liquid and immediately before foaming starts, the pad material is By vacuum suction, the circulation of the hard urethane resin liquid can be improved, particularly in the deep drawing part of the lower die for foam molding, and filling defects of the hard urethane resin liquid can be prevented as much as possible.

Furthermore, when setting the glass mat, the periphery of the glass mat is held by the protrusion of the clamping device, so there is no wrinkles in the glass mat when molding the hard urethane core material, and there is no possibility of filling defects with the hard urethane resin liquid. It can be prevented.

Therefore, according to the present invention, it is possible to reliably prevent filling defects of the hard urethane resin liquid, thereby significantly reducing the defective rate, and thus having the effect of significantly improving production efficiency.

[Brief Description of the Drawings] Fig. 1 is a cross-sectional view showing the structure of an automobile door trim manufactured by applying the method of the present invention, Fig. 2 is a side view showing a mold for foam molding used in the method of the present invention, FIG. 3 is a plan view of the same mold for foam molding in an open state, FIGS. 4 to 8 are cross-sectional views and plan views showing the molding process of the hard urethane core material, and FIG. Fig. 10 is a cross-sectional view showing the process of crimping the hard urethane core material and the skin material, Fig. 11 is a cross-sectional view showing the structure of a conventional automobile door trim, and Figs. 12 and 13 are cross-sectional views of the conventional hard urethane core material. It is an explanatory view showing a molding process. 10... Automobile door trim 11... Glass mat 12... Hard urethane core material 13... Pad material 14... Urethane film 15... Soft urethane foam 16... Slash molded skin material 20.・Lower mold for foam molding 22 ・Upper mold for foam molding 23 ・Clamp device 25 ・Protrusion 26 ・Foam molding machine 27 ・Vacuum suction hole 30 ・Upper mold for crimping 31・・・Lower mold for crimping

Claims (1)

[Claims] 1. A flexible urethane foam (1) backed with a urethane film (14) on the mold surface of a lower mold (20) for foam molding.
The pad material (13) consisting of
4) facing upward, its peripheral edge is clamped by the clamping device (23), a glass mat (11) is placed on top of it, and its peripheral edge is clamped by the clamping device (23).
3) A material setting step supported by the protrusions (25) formed in 3), and after injecting the hard urethane resin liquid that will be the material of the core material (12) into the lower mold for foam molding (20), the lower mold for foam molding is performed. (2
Through the vacuum suction hole (27) provided in the upper and lower foam molding molds (20, 22), the pad material (13) is vacuum-suctioned so as to follow the mold surface of the lower mold (20).
a process of clamping the core material (12) with the pad material (13) and molding it into a desired shape;
) and bonding them together using a pressure mold (30, 31).