JPS63242517A - Manufacture of door trim for automobile - Google Patents

Abstract

PURPOSE:To improve the surface appearance and the surface feeling of a product, while the lay down of the fuzz in the flocked part of an intermediate contact cloth is effectively prevented by press molding integrally a core member and a generally used resin sheet and by compressed air-molding integrally the core member and an intermediate contact cloth. CONSTITUTION:A skin member 2 and a core member 22 are placed, in this order, on the mold surface of the bottom force for press molding. The intermediate contact cloth 24 constituting the skin member 21 is accurately positioned on the upper surface of the cushion member 11 constituting the area for compressed air molding. The core member 2 is kept in preheated and softened state, and a hot melt sheet 25 has been laminated thereon. The top and bottom forces 10, 15 for press molding keep a prescribed clearance by means of operation of a rising and lowering mechanism 16 and engages with each other. Simultaneously, compressed air is supplied into the cushion member 11 from a compressed air feeding means 13. Since the periphery of the area for pressurized air molding is sealed with the projected streak 14 for sealing and a peripheral groove 17. This compressed air is blown off against the surface of the intermediate contact cloth 24 from the mold surface 11a of the cushion member 11.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of the Invention) The present invention relates to a door trim for an automobile, and more particularly to a method for manufacturing a door trim for an automobile using cloth as a binding member.

(Prior art and its problems) In recent years, interior parts such as automobile door trims are required to have good design appearance performance. Increasingly, we are seeing more and more products using skin materials that are made from a combination of responsible materials, such as combinations of carpets and resin sheets, and carpets and resin sheets.

The structure of this type of automobile door trim will be explained based on FIGS. 5 and 6. The door trim 1 consists of a molded core material 2 made of wood fiber board, composite resin board, etc., press-molded into a desired shape.
It is covered with two types of skin materials 3.4,
- As the skin material 3 for the crotch area, a resin sheet such as a PVC sheet is used, and as the skin material 4 for the inner layer, a cloth having a surface appearance 9 and a surface feel different from the resin sheet is usually used.

Regarding the manufacturing method of this door trim 1, when a composite resin plate made of a mixture of a thermoplastic resin material and a filler is used as the molding core material 2, first, it is placed on the mold surface of the lower mold 5 for cold press in advance. After setting the skin materials 3 and 4, which are made by joining the skin material 3 for general parts and the skin material 4 for intermediate products by sewing, etc., the molded core material in a heat-softened state is placed on top of the skin materials 3 and 4 (see Fig. 7). reference).

Next, the upper mold 6 for cold press is lowered, and the core material 2 is molded into the desired shape by the upper and lower molds 5.6 for cold press, and the skin material 3.4 is placed on the surface side of the core material 2. It is attached integrally (see Figure 7).

However, in this press construction method, the core material 2 and the skin materials 3 and 4 are clamped by the upper and lower press dies 5 and 6.
Since the material is compressed considerably, hairs fall down on the medium-sized dough cloth 4, which significantly impairs the surface appearance and surface feel of the medium-sized dough cloth 4.In this way, the design is improved by using a combination skin material. Attempts to do so have been pointed out to have the drawback that their effectiveness is halved.

(Object of the Invention) The present invention has been made in view of the above-mentioned circumstances, and the object of the present invention is to provide a skin material and a core material formed by joining a cloth for intermediate materials and a skin material for general parts. To provide a method for manufacturing a door trim for an automobile which has an extremely good surface appearance and surface feel by preventing the hairs of the medium-sized cloth from falling as much as possible. .

(Structure and Effects of the Invention) In order to achieve the above object, the present invention combines a skin material formed by joining a medium cloth and a resin sheet for general parts, and a resin core material in a preheated softened state. In a method of manufacturing an automobile door trim that is integrally molded into a desired shape by press molding, on a lower press mold in which a pressure molding area is set on a part of the mold surface, a medium cloth is positioned in the pressure molding area. The lower mold for pressing is equipped with a step of placing the skin material in such a manner and laminating a preheated and softened resin core material above it, and a mold surface that is almost the same as the lower mold for pressing described above. It consists of the step of lowering the upper press mold that is movable up and down so as to fit together and clamping the upper and lower press molds, and at the same time supplying compressed air from the compressed air supply means to the pressure forming area, The resin core material is molded and the core material is integrated with the resin sheet for general parts by press molding, and the core material and the cloth for intermediate parts are integrated by air pressure molding. shall be.

That is, according to the present invention, a pressure forming area is set on a part of the mold surface of the lower press die, and compressed air is supplied to this pressure forming area at the same time as press forming, and the medium cloth and core material are Since the integration is done by air pressure forming, the core material and the cloth for medium grade are integrated by clamping the upper and lower press dies as in the past, but the cross for medium grade There is no need to press the raised part of the cloth against the surface of the press mold, and the laminating pressure can be adjusted to a constant level.
It has the advantage of making effective use of the appearance and feel of cloth and providing a door trim with excellent design.

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

First, the configuration of the first embodiment of the mold used in the present invention will be described with reference to FIG. 1. A pressure molding area is set in a part of the lower mold 10 for press molding. That is,
In this embodiment, a cushioning material 11 made of open-cell urethane foam is installed on a lower mold 10 in a pressure molding area, and a surface 11a of this cushioning material 11 and a mold surface 10a of the lower mold 10 are used as a door trim for an automobile. This will shape the surface shape of the surface.

The cushion material 11 is connected to a compressed air supply device 13 such as a compressed air supply device 13 through an air passage 12, and the cushion material 11 is surrounded by a sealing protrusion 14.

On the other hand, the upper mold 15 for press molding that engages with the lower mold 10 for press molding can be moved up and down by the operation of a lifting mechanism 16 such as a hydraulic cylinder.
The mold surface 15a of No. 5 is the mold surface 10a of the lower mold 10 for press molding.
The upper mold 15 for press molding has almost the same shape as the one shown in FIG. It is fixed to a base 19 via a spring 20 so as to perform the process.

Next, each step of the manufacturing method according to the present invention will be explained.

First, as shown in FIG. 1, a skin material 21 is placed on the mold surface of the lower mold 10 for press molding. The core materials 22 are placed in this order. More specifically, the skin material 21 is composed of a general part skin material 23 and a saddle stitching cloth 24, which are joined together in advance by sewing or the like. Position it so that it is accurately positioned on the upper surface of the cushioning material 11. In this embodiment, the core material 22 includes 50 parts by weight of polypropylene resin and 5 parts by weight of wood powder filler.
0 parts by weight were mixed and stirred and extruded into a sheet using a T-die extrusion molding machine, and preheated and softened by heating means such as a heater (not shown), and the skin material 21 of the core material 22
Polyolefin hot melt sheet 2 on the opposite side
5 is laminated.

Next, the base 19 and the upper mold 15 for press molding are lowered by the operation of the elevating mechanism 16, and the upper and lower molds 10.15 for press molding are engaged with each other while maintaining a predetermined clearance, as shown in FIG.

At this time, simultaneously with mold clamping by the press upper and lower molds 10.15, compressed air is supplied from the compressed air supply means 13 through the air passage 12 into the cushion material 11, and the sealing ridge 14 and the circumferential groove 17 are used for pressure forming. Since the periphery of the area is sealed, this compressed air is blown out from the mold surface 11a of the cushioning material 11 to the surface side of the saddle stitching cloth 24.

Therefore, by clamping the upper and lower press molds 10.15, the core material 22 is molded along the shape of the mold surface, and the core material 22
At the same time as the general part resin sheet 23 is integrated, the saddle stitching cloth 24 is laminated to the core material 22 by compressed air pressure from the mold surface 11a of the cushion material 11.

In this way, compressed air of a predetermined pressure is blown out from the mold surface 11a of the cushioning material 11, and the saddle stitching cloth 2 is
4 is laminated to the core material 22, the raised part of the saddle stitching cloth 24 is not forcefully pressed against the core material 22 side, and uniform air pressure can be expected. Hair fall can be prevented as much as possible.

The air pressure of compressed air to the cushion material 11 is 0.5
~6-5 to 9/cm is suitable, and pressure forming may be performed in a state where compressed air is heated by a heater or the like.

Although the cushioning material 11 made of open-air @ type polyurethane foam was used in this embodiment, any material having air permeability such as ceramic bookbinding lath type may be used instead of this cushioning material 11 as appropriate. No problem.

After the above-mentioned molding process is completed, the base 19 is further lowered, but since the upper mold 15 for press molding is engaged with the lower mold 10 for press molding, only the cutting blade 18 is lowered, and as shown in FIG. Trim the terminal along the periphery of the product as shown in . When the trim cutting step is completed, the press molding upper mold 15 is raised, and then the product in which the core material 22 and the skin material 21 are integrated can be demolded.

Next, FIG. 4 shows another embodiment of the mold used in the present invention using an air bag method. It has a structure in which a sheet 26 is stretched. In this embodiment as well, the integration of the saddle stitching cloth 24 and the core material 22 uses the air pressure of compressed air applied to the elastic sheet 26. As in the above-mentioned embodiments, a door trim with good surface appearance 9 and good surface feel is obtained, in which the fall of the hairs of the contact fibers 24 can be prevented.

As explained above, in the method for manufacturing an automobile door trim according to the present invention, a pressure forming area is set in a part of the press mold to integrate the medium cloth and the core material. Use pressure molding.

With this simple structure, it is possible to effectively prevent the hair from falling in the raised cloth part for medium-sized cloth, which was a conventional problem, and to provide an automobile door trim with extremely good surface appearance and surface feel.

[Brief explanation of the drawing]

Figures 1 to 3 show an automobile door trim according to the present invention! 4 is a cross-sectional view showing a main part of another embodiment of the mold used in the present invention, FIG. 5 is a front view of an automobile door trim, and FIG. Vl in the diagram
-Vl line sectional view, FIG. 7, and FIG. 8 are each sectional drawing which shows the conventional manufacturing method of the door trim for automobiles. 10...Lower die for press molding 11...Cushion material 12...Air passage 13...Air supply means 14...Sealing ridge 15...Upper die for press molding 16...Elevating Mechanism 17... Circumferential groove 18... Cutting blade 19... Base 20... Spring 21... Skin material 22... Core material 23... - Crotch resin sheet 24... Cloth for medium dough 25...Hot melt sheet 26...Elastic sheet Fig. 1 Section 2 Fig. 3 Fig. 4 to /2 Fig. 5 v7≠ Fig. 6 Fig. 7 Fig. 8

Claims (1)

[Claims] (1) A method for manufacturing an automobile door trim in which a skin material made by joining a cloth for intermediate contact and a resin sheet for general parts and a core material made of preheated and softened resin are integrally molded into a desired shape by cold press molding. In this step, a skin material is placed on a lower press mold having a pressure molding area set on a part of the mold surface so that the intermediate contact cloth is located in the pressure molding area,
It also includes a step of laminating a preheated and softened resin core material above it, and has a mold surface that is almost the same as the lower mold for pressing, and is configured to be movable up and down so as to fit into the lower mold for pressing. The process consists of lowering the upper press die, clamping the upper and lower press dies, and simultaneously supplying compressed air from the compressed air supply means to the pressure forming area. A method for manufacturing a door trim for an automobile, characterized in that the material and the resin sheet for general parts are integrated by press molding, and the core material and the intermediate cloth are integrated by air pressure molding.