JPH0528983B2 - - Google Patents

Description

[Detailed Description of the Invention] <<Industrial Application Field>> 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 the Prior Art》 Recently, in order to improve the comfort inside the car interior, materials for interior parts such as car door trims have been upgraded, or decorative members such as cloth and carpets have been attached to appropriate locations on the surface of the door trims. A method is being tried.

Figure 11 is a front view of an automobile door trim.
2 each shows a cross-sectional view of the same door trim. These conventional door trims 1 for automobiles include a door trim body 4 formed by integrally bonding a skin material 3 to the surface of a core material 2 formed into a desired shape. and an intermediate member 5, such as a cloth, which is attached to the door trim body 4 in order to provide decoration at appropriate locations on the surface thereof.

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 described. As core material 2,
If a thermoplastic composite resin plate is used, the door trim body 4 having the desired curved shape can be formed by heating and softening the core material 2, overlapping it with the skin material 3, and performing cold press molding. In addition, if a core material 2 to which hot press molding is applied, such as a wood fiberboard, is used, it is inappropriate to mold it simultaneously with the skin material 3, so after molding the core material 2 into the required curved shape, the skin material is formed using an adhesive. The door trim body 4 is formed by integrally adhering the material 3 to the surface side of the core material 2 by vacuum forming.

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 attached to the back side of 6.

Furthermore, in order to attach 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 to adhere the middle contact members 5, and the peripheral 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 along the outer shape of the middle contact portion of the door trim body 4 side.

<<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, and after preforming by vacuum molding etc., the door trim body 4 is Since it is adhesively fixed to the side, it requires many steps and the associated equipment costs are also large, resulting in a significant cost increase.

Furthermore, the terminal treatment of the intermediate member 5 is troublesome;
If the end 5a does not fit within the circumferential groove 8 and protrudes outside, the aesthetics of the product will be significantly impaired, and therefore, the process of processing the end of the 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 was made in view of the above circumstances, and
The purpose of the present invention is to enable the intermediate member to be easily attached to the door trim main body, to shorten the work process and reduce the amount of equipment, and to perform terminal processing beautifully and easily. An object of the present invention is to provide an extremely practical method for manufacturing an automobile door trim.

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

<<Operation>> According to the above means, the intermediate member, which has been trim-cut into a desired shape in advance, 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 cut. Since the intermediate contact member is exposed on the surface of the product by removing it, there is no need for backing materials and adhesives that maintain the shape of the cloth as in the past, and the process of preforming the cloth and its forming equipment are becomes unnecessary.

Furthermore, since the peripheral end of the intermediate member as a product corresponds to the cutting line of the skin material with the cutting tool,
Even if there is a dimensional error in the intermediate member, an error in attachment to the door trim body, etc., a constant peripheral end line of the intermediate member can always be 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>> Examples of the method for manufacturing a door trim according to the present invention will be described in detail below 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-pressed into a desired shape or a thermoplastic composite resin board cold-pressed into a desired shape, and is integrally attached to the surface side of the core material 11. It is generally composed of a skin material 12 and a middle contact member 13 attached to the middle contact portion. Since the middle contact member 13 also corresponds to a skin material in a broad sense, for convenience of explanation, the middle contact member 13 will be referred to as a skin material for the middle contact portion,
The following description will be made assuming that the skin material 12 that covers other parts is defined as the skin material for general parts.

In addition, the peripheral end portion 13a of the skin material 13 for the middle contact portion
is located in the circumferential groove 14 formed in the core material 11, and a boundary line 15 between the general part skin material 12 and the intermediate part skin material 13 is set along a little inside of this peripheral edge end part 13a. Similarly, this boundary line 15 is set within the circumferential groove 14. As the material of the skin material 12 for general parts, the foam layer 16 is made of polypropylene foam, polyethylene foam, etc.
It is constructed by laminating the back side of ABS-containing PVC sheet 17. Moreover, the skin material 13 for the middle joint part is
It 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 removal process of skin material for general parts.

Each step will be explained in detail below.

(1) Formation process of double skin material.

First, as shown in FIG.
The skin material 13 for the middle joint part is stacked on the back side of the skin material 13 for the middle joint part with the front side facing each other, and the two are joined by sewing along the peripheral edge of the skin material 13 for the middle joint part as in this example to form a double skin material. A material 18 is formed.

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

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.

Regarding this integration process, as the core material 11,
There are differences when using wood fiberboard and when using thermoplastic composite resin board, so when using wood fiberboard based on Figures 4 to 7,
The case in which a thermoplastic composite resin plate is used will be explained separately based on FIGS. 8 and 9.

First, the core material 11 is molded according to FIGS. 4 and 5. The material for the core material 11 is wood fiber 70.
In this example, a wood fiber board M ₁ mixed with 30 parts by weight of resin binder is used.

In addition, as the resin binder, phenol 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 fiber board _M1 is placed on the upper surface of the lower mold 20 for hot press molding, as shown in FIG. Mold surface 2 of this lower mold 20 for hot press molding
0a is set to a shape that provides the core material 11 with curved portions such as an armrest portion and a door waist portion.

Furthermore, an upper mold 21 for hot press molding is located above the lower mold 20 for hot press molding so as to be movable up and down.
It has a mold surface 21a that is almost the same as the mold surface 20a of No. 0.

Then, by driving a lifting device 22 such as a hydraulic cylinder provided on the upper die 21 for hot press molding, the upper and lower dies 20 and 21 for hot press molding are engaged as shown in FIG. 5, and the core material 11 is moved as required. 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, and the double skin material 18 shown in FIG. 3 is installed above the core material 11. (See Figure 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). In addition,
The peripheral edge of this double skin material 18 is connected to a clamping device 32.
It is held in a horizontal state with the middle connecting part skin material 13 facing the core material 11 side.

Furthermore, an upper mold 33 for vacuum forming is located above this double skin material 18, and these upper and lower molds 30, 33 for vacuum forming can be moved up and down, and suction holes 34, 35, and these suction holes 34, 35 are connected to the on-off valve 3.
It is connected to vacuum pumps 38 and 39 via 6 and 37. In addition, this upper and lower mold for vacuum forming 30, 3
No. 3 has substantially the same mold surfaces 30a and 33a, and constitutes a so-called mated die.

After the core material 11 is set on the vacuum forming lower mold 30 and the double skin material 18 is held above it, the vacuum forming lower mold 30 is raised, and at the same time, the vacuum forming upper mold 33 is raised. is lowered, and these upper and lower molds 30, 33 for vacuum forming are placed at a position approximately halfway between the two.
(See Figure 7). In this way, at the same time as the upper and lower vacuum molding molds 30 and 33 are engaged, through the suction hole 34 provided in the lower vacuum molding mold 30,
The air between the double skin material 18 and the core material 11 is removed, and the double skin material 18 is removed along the surface shape of the core material 11.
are attached together.

In order to integrate the two, 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 flour filler in an appropriate mixing ratio into a sheet using an extrusion molding machine. And this material
After M2 is heated and softened by the heater device 40, it is placed on the upper surface of the lower die 41 for cold press molding. This lower die 41 for cold pressing has a curved surface shape for shaping the core material 11 into a desired shape. Then, the double skin material 18 is placed on top of this, and the positioning of the double skin material 18 is such that the peripheral end 13a of the skin material 13 for the middle part is located in the circumferential groove 14 of the core material 11. properly done. 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 an upper mold 43 for cold press molding located above it
is provided with a lifting device 44 such as a hydraulic cylinder (see FIG. 8).

When the positioning of the thermoplastic composite resin plate M2 and the double skin material 18 is completed, the lifting device 4
4, the upper mold 43 for cold press molding
descends, and the upper and lower molds 41, 43 for cold press
The mold clearance between this thermoplastic composite resin plate
M2 and the double skin material 18 are integrated and formed into the 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 removal process of skin material for general parts.

After integrating the core material 11 and the double skin material 18 in the above process, as shown in FIG. Press fit the welder bar 51 into the
The general part skin material 12 is cut and removed along the boundary line 15 shown in FIG. In addition, welder bar 5
Instead of step 1, thermal cutting with a hot knife or a seal cut bar may be used. After removing the unnecessary general part skin material 12a, the middle part skin material 13 is attached to this middle part on the product surface side. will be exposed to.

Moreover, since the boundary line 15 between the general part skin material 12 and the middle joint part skin material 13 corresponds to the cutting line by the welder bar 51, it is set slightly inside the peripheral end 13a of the middle joint part skin material 13. Since the cutting line is the boundary line 15, even if there is a dimensional error or installation error in the middle part skin material 13, the welder bar 51 allows the middle part skin material 1 to be
3 terminal processing can be performed beautifully and easily.

<<Effects>> As explained above, according to the door trim manufacturing method of the present invention, a single piece of cloth can be used as the skin material for the middle contact part, eliminating the need for backing material or preforming as in the past, and reducing the need for the middle contact member. Since the installation process 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.

Furthermore, conventionally, it required a great deal of skill to process the ends of the skin material for the intermediate joint part, but in the present invention, the skin material for the general part is cut and removed using a cutting tool such as a welder bar.
This involves exposing the skin material for the middle part.
The cutting line of the skin material for the general part corresponds to the end of the skin material for the middle part, making it extremely easy to process the end of the middle part, and making it possible to finish the end part beautifully. In addition to the process benefits, it can greatly contribute to improving the appearance design.

In addition, the skin material for the middle part is already joined to the skin material for the general part, and when the skin material for the general part is integrated with the core material, the skin material for the middle part is also integrated with the core material. Compared to the conventional way of adhering to the door trim body using adhesive, this method eliminates the need for adhesive and eliminates the problem of adhesive adhering to the product surface. In addition to eliminating the problem, there are also incidental effects such as a better working environment.

[Brief explanation of drawings]

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 illustrating a second embodiment of the process of integrating the core material and double skin material, and FIG. 10 is a sectional view illustrating the process of cutting and removing the skin material for general parts in the double skin material. FIG. 11 is a front view of a conventional door trim, and FIG. 12 is a sectional view of the same conventional door trim. 10... Automobile door trim, 11... Core material,
12...Skin material for general part, 13...Skin material for intermediate part, 14...Peripheral groove, 15...Boundary line, 18...
...Double skin material, 20...Lower mold for hot press molding, 21...Upper mold for hot press molding, 30...
Lower mold for vacuum forming, 33... Upper mold for vacuum forming, 41
... lower mold for cold press molding, 43 ... upper mold for cold press molding, 51 ... welder bar.

[Claims]

1 A weather strip that is attached to the periphery of an automobile door, which is formed into a basic shape using an extrusion molding die, and which can be divided into cross-sectional shapes perpendicular to the extrusion direction before vulcanization treatment. 1. A weather strip characterized by forming an adhesive bonded portion and having a predetermined shaped portion and an unnecessary portion peeled off at the adhesive bonded portion after vulcanization. 2. In a method for manufacturing a weather strip to be attached to the peripheral edge of an automobile door by extrusion molding,
While extruding a basic-shaped product using an extrusion molding die, a divisible adhesive joint is formed in the cross-sectional shape perpendicular to the extrusion direction, the extruded product is vulcanized, and then a predetermined shape is formed at the adhesive joint. 1. A method for manufacturing a weather strip, which comprises manufacturing a weather strip having a different cross-sectional shape in the longitudinal direction by peeling off a portion and an unnecessary portion. 3 Consists of a basic forming die having an extrusion opening for forming a basic shape, a movable die slidably disposed on the front end surface of the basic forming die, and a drive device for sliding the movable die. The die has a slit portion through which the lip portion of the weather strip is inserted in the direction in which the extrusion molded product is extruded, the slit portion has a divided forming portion at the lower part thereof, and the movable die is vulcanized. Placed in the previous process of

Claims (1)

In the manufacturing method of an automobile door trim, the trim member is attached to the middle part of the core material so as to be located inside the middle part of the core material. A step of forming a double skin material by aligning the contact members with their front surfaces facing each other and joining and integrating the peripheral portions with the skin material; a step of press-integrating the core material and the double skin material into a desired curved shape so that they are overlapped in proper positions so as to face each other, and the peripheral end of the intermediate member is located within the circumferential groove of the core material; It is characterized by a process 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.