JPH0911261A - Manufacture of interior material such as roof trim for automobile and forming mold therefor - Google Patents
Manufacture of interior material such as roof trim for automobile and forming mold thereforInfo
- Publication number
- JPH0911261A JPH0911261A JP18786394A JP18786394A JPH0911261A JP H0911261 A JPH0911261 A JP H0911261A JP 18786394 A JP18786394 A JP 18786394A JP 18786394 A JP18786394 A JP 18786394A JP H0911261 A JPH0911261 A JP H0911261A
- Authority
- JP
- Japan
- Prior art keywords
- ppo resin
- ppo
- base material
- resin base
- mold
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Landscapes
- Moulds For Moulding Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、自動車の所謂成形天井
と称されるルーフトリム等の内装材の製造方法並びにこ
れに使用する金型に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an interior material such as a roof trim, which is a so-called molded ceiling of an automobile, and a mold used for the method.
【０００２】[0002]
【従来の技術】自動車のルーフトリムは、段ボール等を
用いる場合もあるが、吸音性や防音性に優れしかも高級
感や質感等を向上させるために、基材として、図１及び
図２に示すように、ＰＰＯ（ポリフェニレンオキシド）
樹脂発泡層１の表裏面にやはりＰＰＯ樹脂スキン層２を
形成したＰＰＯ樹脂基材３が用いられており、このＰＰ
Ｏ樹脂基材３の表面に更に図示しないパッド材及びクロ
ス材を張設し、型成形して構成している。2. Description of the Related Art In some cases, a corrugated cardboard or the like is used for an automobile roof trim, but it is shown in FIGS. Like PPO (polyphenylene oxide)
The PPO resin base material 3 having the PPO resin skin layer 2 formed on the front and back surfaces of the resin foam layer 1 is also used.
A pad material and a cloth material (not shown) are further stretched on the surface of the O resin base material 3 and are molded.
【０００３】そして、このように成形されたルーフトリ
ムは、前記型成形時に同時にクリップブラケット４をホ
ットメルト付き不織布等を用いて取り付けるための凹部
５を、裏面側に複数個形成してあり、クリップブラケッ
ト４にクリップ６を取り付け、クリップ６を車体パネル
７の取付孔８に縮設することにより、車体パネル７に付
設されている。In the roof trim thus formed, a plurality of recesses 5 are formed on the back side for attaching the clip bracket 4 using a non-woven fabric with hot melt at the same time when the mold is formed. The clip 6 is attached to the bracket 4, and the clip 6 is attached to the vehicle body panel 7 by shrinking the clip 6 into the attachment hole 8 of the vehicle body panel 7.
【０００４】このように構成するルーフトリムのＰＰＯ
樹脂基材３は、例えば天井の内壁形状に適合するため
に、金型内に挿入し加熱成形等して図１に示すような所
定の形状に成形されている。A roof trim PPO having such a structure
The resin base material 3 is molded into a predetermined shape as shown in FIG. 1 by inserting the resin base material 3 into a mold and heat-molding it so as to conform to the shape of the inner wall of the ceiling.
【０００５】そして、従来、このようなＰＰＯ樹脂基材
３の成形用の金型として、図４に示すような金型１０が
用いられている。Conventionally, a mold 10 as shown in FIG. 4 has been used as a mold for molding such a PPO resin base material 3.
【０００６】この金型１０は、上型１１及び下型１２か
ら構成し、下型１２或いは上型１１の成形面１１ａに
は、ルーフトリムの凹部５を形成すべく凸部１３が形成
されている。そして、下型１２に先ずＰＰＯ樹脂基材３
をセットして、上型１１を下型１２側に移動させ、上下
型１１，１２が形成するキャビティー１４内で所定形状
に成形するのである。This mold 10 is composed of an upper mold 11 and a lower mold 12, and a convex portion 13 is formed on the molding surface 11a of the lower mold 12 or the upper mold 11 so as to form the concave portion 5 of the roof trim. There is. Then, first the PPO resin base material 3 is applied to the lower mold 12.
Is set, the upper mold 11 is moved to the lower mold 12 side, and is molded into a predetermined shape in the cavity 14 formed by the upper and lower molds 11, 12.
【０００７】そして、成形天井の基材として、ＰＰＯ樹
脂基材３を考えた場合、室内スペースをより広くするた
めに、できる限り薄材を用いることが望ましく、さらに
はクリップブラケット４を設ける凹部５の深さもでき得
る限り小さい方が望ましい。When considering the PPO resin base material 3 as the base material of the molded ceiling, it is desirable to use a thin material as much as possible in order to make the indoor space wider, and further, the concave portion 5 in which the clip bracket 4 is provided. It is desirable that the depth of is as small as possible.
【０００８】そこで、従来ＰＰＯ樹脂基材３を成形する
前に、例えば厚さ３mmの原反を、プレヒートして６mmの
厚さに拡大し、その後上記のように金型１０によって成
形するようにしている。この場合上下型１１，１２間の
間隙（モールドギャップ）を５〜１mmになるまでＰＰＯ
樹脂基材３を圧縮して型成形を行い、一般部の厚さｔ１
を５mmに形成していた。Therefore, before molding the conventional PPO resin base material 3, for example, a raw material having a thickness of 3 mm is preheated to be expanded to a thickness of 6 mm, and then molded by the mold 10 as described above. ing. In this case, PPO until the gap between the upper and lower dies 11 and 12 (mold gap) becomes 5 to 1 mm.
The resin base material 3 is compressed and molded to obtain a thickness t 1 of the general portion.
Was formed to be 5 mm.
【０００９】[0009]
【発明が解決しようとする課題】このように成形された
ＰＰＯ樹脂基材３の凹部５における厚さｔ２を、モール
ドギャップとの関係で見るべく実験した結果、表１のよ
うになる。As a result of an experiment to see the thickness t 2 of the recess 5 of the PPO resin base material 3 thus molded in relation to the mold gap, the results are shown in Table 1.
【００１０】[0010]
【表１】 即ち、ＰＰＯ樹脂基材３の凹部における厚さｔ２を薄く
すべく、モールドギャップ寸法を下げていったとして
も、３．０mm以下にはならないことが分かった。[Table 1] That is, it was found that even if the mold gap dimension was reduced in order to reduce the thickness t 2 in the recess of the PPO resin base material 3, it would not be 3.0 mm or less.
【００１１】これは、たとえモールドギャップ寸法を２
mmや１mmにしたとしても、ＰＰＯ樹脂基材３を構成する
ＰＰＯ樹脂発泡層１が多くの独立気泡によって形成され
ているために、この気泡内の空気を圧縮するだけであ
り、しかもＰＰＯ樹脂発泡層１の組織が密で気泡内の空
気を外部に逃がすことができずにいるため、成形後の所
謂スプリングバックを起こすことが原因している。Even if the mold gap size is 2
mm or 1 mm, the PPO resin foam layer 1 constituting the PPO resin base material 3 is formed by many closed cells, so that only the air in the bubbles is compressed, and the PPO resin foam is formed. This is because the structure of the layer 1 is dense and the air in the bubbles cannot escape to the outside, which causes so-called springback after molding.
【００１２】また、上記実験例中、成形後のＰＰＯ樹脂
基材３をが３mmにしたものは、基材表面側に、凸状の潰
し部（図２の２点鎖線示）が認められ、商品性を減じて
しまうことがあった。In the above experimental example, the molded PPO resin base material 3 having a length of 3 mm has a convex crushed portion (shown by a chain double-dashed line in FIG. 2) on the surface of the base material. There were times when it reduced the commercial value.
【００１３】本発明は、かかる点に鑑み、商品性を損な
わずに、凹部におけるＰＰＯ樹脂基材の厚さを十分小さ
くして成形できるように意図した自動車用ルーフトリム
等内装材の製造方法及びこれに使用する成形金型を提供
することを目的とする。In view of the above points, the present invention is directed to a method of manufacturing an interior material such as a roof trim for an automobile, which is intended to be molded so that the thickness of the PPO resin base material in the concave portion can be sufficiently reduced without impairing the commercial property. An object is to provide a molding die used for this.
【００１４】[0014]
【課題を解決するための手段】本発明の自動車用ルーフ
トリム等内装材の製造方法の製造方法は、ＰＰＯ樹脂ス
キン層及び／又はＰＰＯ樹脂発泡層に予め細孔を多数穿
設し、次に前記ＰＰＯ樹脂基材を成形型内にセットし型
成形をするようにしたものであり、また成形金型を構成
する上型又は下型の成形面に、ＰＰＯ樹脂スキン層及び
／又はＰＰＯ樹脂発泡層に多数の細孔を形成するための
針状突起体を植設して構成している。A method of manufacturing an interior material such as an automobile roof trim according to the present invention is a method for manufacturing a PPO resin skin layer and / or a PPO resin foam layer, in which a large number of pores are previously formed, and then The PPO resin base material is set in a molding die for molding, and a PPO resin skin layer and / or a PPO resin foam is formed on the molding surface of an upper die or a lower die constituting a molding die. The layer is formed by implanting needle-like projections for forming a large number of pores.
【００１５】[0015]
【作用】上記製造方法又は成形金型によれば、成形前に
ＰＰＯ樹脂スキン層及び／又はＰＰＯ樹脂発泡層に多数
の細孔が穿設され、この結果、成形時にＰＰＯ樹脂発泡
層の気泡内の空気が外部に放出され、ＰＰＯ樹脂発泡層
を塑性変形することとなり、成形後のスプリングバック
を防止する。According to the above-described manufacturing method or molding die, a large number of pores are formed in the PPO resin skin layer and / or the PPO resin foam layer before molding, and as a result, inside the bubbles of the PPO resin foam layer during molding. The air is released to the outside, which plastically deforms the PPO resin foam layer, and prevents springback after molding.
【００１６】[0016]
【実施例】次に、本発明の実施例につき、図３を用いて
説明する。EXAMPLE An example of the present invention will be described below with reference to FIG.
【００１７】図３は、本発明の実施例を示す成形金型２
０の一部の拡大断面図であり、成形金型２０は、上型２
１及び下型２２により構成されている。上型２１の成形
面２１ａには、凹部５を形成すべく凸部２３が形成され
ている。FIG. 3 shows a molding die 2 showing an embodiment of the present invention.
FIG. 2 is an enlarged cross-sectional view of a part of 0 of FIG.
1 and the lower mold 22. A convex portion 23 is formed on the molding surface 21 a of the upper mold 21 to form the concave portion 5.
【００１８】突部２３における下型２２の成形面２２ａ
に対向する側には、多数の針状突起体２４が植設されて
いる。Molding surface 22a of the lower die 22 at the protrusion 23
A large number of needle-shaped protrusions 24 are planted on the side opposite to.
【００１９】このように構成する成形金型２０を用い
て、ＰＰＯ樹脂基材３を成形する場合、従来と同様、Ｐ
ＰＯ樹脂基材３の原反として、厚さ３mmのものを使用
し、予めプレヒートして６mmの厚さに拡大しておく。そ
の後成形金型２０うち下型２２に、先ずＰＰＯ樹脂基材
３をその表面側が下型２２ａ側に面するようセットし
て、上型２１を下型２２側に移動させる。この結果、上
型２１に植設した針状突起体２４によって、ＰＰＯ樹脂
基材３の裏面側のＰＰＯ樹脂スキン層２或いはＰＰＯ樹
脂発泡層１に、細孔が穿設されることとなる。この後、
上下型２１，２２が形成するキャビティー２５内で所定
形状に成形するのである。この時、細孔によって、ＰＰ
Ｏ樹脂発泡層１の気泡内の空気が外部に放出され、ＰＰ
Ｏ樹脂発泡層１を塑性変形することとなり、成形後のス
プリングバックを防止する。When the PPO resin substrate 3 is molded using the molding die 20 having the above-described structure, the P
A raw material of the PO resin base material 3 having a thickness of 3 mm is used and preheated to a thickness of 6 mm. After that, the PPO resin base material 3 is first set in the lower die 22 of the molding die 20 so that the surface side faces the lower die 22a side, and the upper die 21 is moved to the lower die 22 side. As a result, the needle-shaped projections 24 implanted in the upper mold 21 form pores in the PPO resin skin layer 2 or the PPO resin foam layer 1 on the back surface side of the PPO resin base material 3. After this,
It is molded into a predetermined shape in the cavity 25 formed by the upper and lower molds 21 and 22. At this time, due to the pores, PP
The air in the bubbles of the O resin foam layer 1 is released to the outside, and PP
The O resin foam layer 1 is plastically deformed, and spring back after molding is prevented.
【００２０】上記方法を用いてＰＰＯ樹脂基材３を成形
した場合において、針状突起体２４の突出長さ即ち細孔
深さを１．３mmにし、モールドギャップを１．５mmにし
て成形した場合、、針状突起体２４間の間隙寸法とＰＰ
Ｏ樹脂基材３の凹部５における厚さｔ２との関係を見る
べく実験した結果、表２のようになった。When the PPO resin substrate 3 is molded by using the above method, the protrusion length of the needle-shaped projection 24, that is, the pore depth is 1.3 mm and the mold gap is 1.5 mm. ,, the gap between the needle-like protrusions 24 and PP
As a result of an experiment conducted to see the relationship with the thickness t 2 of the recess 5 of the O resin substrate 3, the results are shown in Table 2.
【００２１】[0021]
【表２】 この結果、有効な針状突起体２４の間隙は、３mm以下で
あり、これ以上では若干の復元が生じることが分かっ
た。[Table 2] As a result, it was found that the effective gap between the needle-shaped protrusions 24 was 3 mm or less, and if the gap was more than 3 mm, some restoration occurred.
【００２２】また、針状突起体２４の突出長さ即ち細孔
深さをいかにすべきかを次のような実験例で検討した。
即ち、針状突起体２４間の間隙寸法を、３mmにして、且
つモールドギャップ１．５mmとした場合に、針状突起体
２４の突出長さ即ち細孔深さを１．３mm、１．０mm、
０．５mmにして、ＰＰＯ樹脂基材３の凹部５における厚
さｔ２の変化を見るべく実験した結果、表３のようにな
った。Further, how the protruding length of the needle-shaped projection 24, that is, the pore depth, should be examined in the following experimental example.
That is, when the gap size between the needle-like protrusions 24 is 3 mm and the mold gap is 1.5 mm, the protrusion length of the needle-like protrusions 24, that is, the pore depth is 1.3 mm and 1.0 mm. ,
As a result of an experiment conducted to see the change of the thickness t 2 in the concave portion 5 of the PPO resin base material 3 with 0.5 mm, the results are shown in Table 3.
【００２３】[0023]
【表３】 この結果、針状突起体２４の突出長さ即ち細孔深さが、
１．３mmで、モールドギャップ１．５mmした場合、ＰＰ
Ｏ樹脂基材３の凹部５における厚さｔ２が１．５mmとな
り、この場合、ＰＰＯ樹脂基材３の表面側に凸状の潰し
部（図２の２点鎖線示）が発生せず、最も好数値となっ
た。[Table 3] As a result, the protrusion length of the needle-shaped protrusion 24, that is, the pore depth is
When the mold gap is 1.3 mm and the mold gap is 1.5 mm, PP
The thickness t 2 of the concave portion 5 of the O resin base material 3 is 1.5 mm, and in this case, a convex crushed portion (shown by a chain double-dashed line in FIG. 2) does not occur on the surface side of the PPO resin base material 3, It was the best value.
【００２４】また他の実験例として、モールドキャップ
を１mm、針状突起体２４の突出長さ即ち細孔深さを０．
８mm、針状突起体２４間の間隙を３mmとして成形した場
合、ＰＰＯ樹脂基材３の凹部５における厚さｔ２は、
１．５mmとなった。As another experimental example, the mold cap is 1 mm and the protrusion length of the needle-shaped projection 24, that is, the pore depth is 0.
8 mm and the gap between the needle-shaped projections 24 is 3 mm, the thickness t 2 of the PPO resin base material 3 in the recess 5 is:
It became 1.5 mm.
【００２５】上記実施例において、ルーフトリムに限定
して説明したが、本発明はこれに限定されるものでな
く、例えばトランクルームトリム等の内装材に適用でき
ること明白である。In the above embodiment, the description has been limited to the roof trim, but the present invention is not limited to this, and it is obvious that the present invention can be applied to an interior material such as a trunk trim.
【００２６】[0026]
【発明の効果】以上の自動車用ルーフトリム等の内装材
の製造方法並びこれに使用する成形金型によれば、ＰＰ
Ｏ樹脂スキン層及び／又はに予め細孔を多数穿設し、次
に前記ＰＰＯ樹脂基材を成形型内にセットし型成形をす
るようにしたものであり、また成形金型を構成する上型
又は下型の成形面に、ＰＰＯ樹脂スキン層に多数の細孔
を形成するための針状突起体を植設して構成しているこ
とから、成形前にＰＰＯ樹脂スキン層及び／又はＰＰＯ
樹脂発泡層に多数の細孔が穿設され、成形時にＰＰＯ樹
脂発泡層の気泡内の空気が外部に放出され、ＰＰＯ樹脂
発泡層を塑性変形することとなり、成形後のスプリング
バックを防止する。この結果、成形天井の基材として、
室内スペースをより広くすべく、従来品に比して、薄い
ＰＰＯ樹脂基材であり、しかもクリップブラケット４を
設ける凹部５の深さも非常に小さく形成することができ
るルーフトリム等内装材を得ることができる。EFFECT OF THE INVENTION According to the above-described method of manufacturing an interior material such as a roof trim for an automobile and the molding die used for the same, PP
A large number of pores are preliminarily formed in the O resin skin layer and / or the PPO resin base material is set in a molding die for molding, and the molding die is constructed. Since the needle-shaped projections for forming a large number of pores are implanted in the PPO resin skin layer on the molding surface of the mold or the lower mold, the PPO resin skin layer and / or the PPO is molded before molding.
A large number of pores are formed in the resin foam layer, the air in the bubbles of the PPO resin foam layer is released to the outside during molding, and the PPO resin foam layer is plastically deformed to prevent springback after molding. As a result, as a base material for the molded ceiling,
To obtain an interior material such as a roof trim, which is made of a PPO resin base thinner than conventional products so that the indoor space can be made wider, and in which the depth of the concave portion 5 in which the clip bracket 4 is provided can be made very small. You can
【００２７】また、ＰＰＯ樹脂基材の表面側に、凸状の
潰し部がないルーフトリム等内装材を得ることができ、
商品性を向上させることとなる。Further, it is possible to obtain an interior material such as a roof trim having no convex crushed portion on the surface side of the PPO resin base material.
Productivity will be improved.
【図１】一般的な自動車用ルーフパネルを車室内側から
見た斜視図である。FIG. 1 is a perspective view of a typical automobile roof panel as viewed from a vehicle interior side.
【図２】図１のＡ−Ａ断面図である。FIG. 2 is a sectional view taken along line AA of FIG.
【図３】本発明の実施例による成形金型の一部を示す断
面図である。FIG. 3 is a sectional view showing a part of a molding die according to an embodiment of the present invention.
【図４】従来の成形金型の一部を示す断面図である。FIG. 4 is a cross-sectional view showing a part of a conventional molding die.
１ ＰＰＯ樹脂発泡層 ２ ＰＰＯ樹脂スキン層 ３ ＰＰＯ樹脂基材 ４ クリップブラケット ５ 凹部 ７ 車体パネル ２０ 成形金型 ２１ 上型 ２２ 下型 ２１ａ，２２ａ 成形面 ２３ 凸部 ２４ 針状突起体 DESCRIPTION OF SYMBOLS 1 PPO resin foam layer 2 PPO resin skin layer 3 PPO resin base material 4 Clip bracket 5 Recessed portion 7 Body panel 20 Molding die 21 Upper die 22 Lower die 21a, 22a Molding surface 23 Convex portion 24 Needle-like protrusion
Claims (2)
樹脂スキン層を形成してＰＰＯ樹脂基材を構成し、該Ｐ
ＰＯ樹脂基材の裏面所定箇所に車体パネルに取り付ける
ためのクリップブラケットを設ける凹部を形成した自動
車用ルーフトリム等の内装材の製造方法において、前記
ＰＰＯ樹脂スキン層及び／又はＰＰＯ樹脂発泡層に予め
細孔を多数穿設し、次に前記ＰＰＯ樹脂基材を成形型内
にセットし型成形をするようにしたことを特徴とする自
動車用ルーフトリム等内装材の製造方法。1. A PPO resin foam layer having PPO on both front and back surfaces thereof.
A resin skin layer is formed to form a PPO resin base material, and the P
In a method of manufacturing an interior material such as a roof trim for an automobile, in which a recess for providing a clip bracket for attaching to a vehicle body panel is formed at a predetermined position on the back surface of a PO resin base material, the PPO resin skin layer and / or the PPO resin foam layer are previously formed in advance. A method for producing an interior material such as a roof trim for an automobile, characterized in that a large number of pores are formed, and then the PPO resin base material is set in a molding die for molding.
樹脂スキン層を形成してなるＰＰＯ樹脂基材を構成し、
該ＰＰＯ樹脂基材の裏面所定箇所に車体パネルに取り付
けるためのクリップブラケットを設ける凹部を形成した
自動車用ルーフトリム等の内装材を製造するために用い
る成形金型であって、該成形金型を構成する上型又は下
型の成形面に、前記ＰＰＯ樹脂スキン層及び／又はＰＰ
Ｏ樹脂発泡層に多数の細孔を形成するための針状突起体
を植設したことを特徴とする自動車用ルーフトリム等内
装材の製造方法に使用する成形金型。2. The PPO resin foam layer is coated with PPO on both front and back surfaces.
A PPO resin base material formed by forming a resin skin layer,
A molding die used for manufacturing an interior material such as a roof trim for an automobile, which has a recessed portion provided with a clip bracket for attaching to a vehicle body panel at a predetermined position on the back surface of the PPO resin base material. The PPO resin skin layer and / or PP is formed on the molding surface of the upper mold or the lower mold constituting
A molding die for use in a method of manufacturing an interior material such as a roof trim for an automobile, wherein needle-like protrusions for forming a large number of pores are implanted in an O resin foam layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP18786394A JPH0911261A (en) | 1994-07-19 | 1994-07-19 | Manufacture of interior material such as roof trim for automobile and forming mold therefor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP18786394A JPH0911261A (en) | 1994-07-19 | 1994-07-19 | Manufacture of interior material such as roof trim for automobile and forming mold therefor |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH0911261A true JPH0911261A (en) | 1997-01-14 |
Family
ID=16213538
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP18786394A Pending JPH0911261A (en) | 1994-07-19 | 1994-07-19 | Manufacture of interior material such as roof trim for automobile and forming mold therefor |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0911261A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007503331A (en) * | 2003-08-27 | 2007-02-22 | レクティセル | Manufacturing method of composite trim parts for automobile interior |
-
1994
- 1994-07-19 JP JP18786394A patent/JPH0911261A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007503331A (en) * | 2003-08-27 | 2007-02-22 | レクティセル | Manufacturing method of composite trim parts for automobile interior |
| JP4914213B2 (en) * | 2003-08-27 | 2012-04-11 | レクティセル アウトモビールジステーム ゲーエムベーハー | Manufacturing method of composite trim parts for automobile interior |
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