JPH07171847A - Production of interior part for car - Google Patents

Abstract

PURPOSE:To shorten a press molding process by abolishing a conventional gate cutting process in the production of an interior part for a car having an opening for attaching a separate part. CONSTITUTION:The resin injection ports 32a, 32b, 32c of a plurality of the gates 32 provided to a lower mold 30 are set to the scheduled places of the openings 13, 14, 16 formed to a door trim 10. By this constitution, an end material and a gate part 60 can be simultaneously cut and removed in the punching process of the openings 13, 14, 16 and, therefore, a gate cutting process can be abolished and productivity and workability can be enhanced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing automobile interior parts such as automobile door trims.

[0002]

11 and 12 are a front view and a cross-sectional view showing an automobile door trim which is one of automobile interior parts. For convenience of explanation, an inside handle unit and a pull handle unit are attached to the door trim. It shows a semi-finished product in which attached parts such as are omitted.

In the drawings, an automobile door trim 1 is
It is formed by integrally adhering a skin material 3 which imparts decorativeness and cushioning property to the surface of a resin core material 2 which is molded into a desired curved surface shape and has shape retention and mounting rigidity to a vehicle body panel. .

The door trim 1 has an opening 4a for mounting an inside handle unit, an opening 4b for mounting a speaker grill, an opening 4c for mounting a pull handle unit, and an opening 4d for mounting a pocket escutcheon. Thus, many openings are formed.

By the way, recently, as a molding method of the resin core material 2, a mold press molding method is often used.

[0006] In this mold press molding method, a molten resin material is distributed and supplied into the upper and lower molds for mold press molding, and by clamping the upper and lower molds, an interior part having less material loss and excellent moldability is obtained. It is possible.

Then, in order to mold the door trim 1 shown in FIGS. 11 and 12 using this mold press molding method, as shown in FIG. 13, a skin material is formed on the mold surface of the upper mold press molding mold 5a. 3 is set in advance, and the upper die 5a
After a predetermined stroke, the molten resin M is distributed and supplied to the mold surface of the lower mold 5b through the gate 5c, and the upper and lower molds 5a and 5b for mold press molding are engaged with each other to tighten the resin core material 2. In addition to molding into the required shape, the skin material 3 is integrally pressed onto the surface side of the resin core material 2.

The gates 5c are usually set at a few places.

By the way, the upper and lower molds 5 for mold press molding
When the molded product is taken out from a and 5b, as shown in FIG. 14, the gate portion 6 is integrated with the back surface of the resin core material 2.

Therefore, a gate cutting step for cutting and removing the gate portion 6 is required first, and then, FIG.
As shown in FIG.
The a, 4b, 4c, and 4d are pierced by the cutting blade 8 installed in the pierce upper die 7b, and the production of the automobile door trim 1 shown in FIGS. 11 and 12 is completed.

[0011]

As described above, when the interior parts are manufactured by using the mold press molding method, after the mold press molding, the gate cutting step of cutting and removing the extra gate portion 6 from the resin core material 2 is performed. In addition, two steps of the piercing step of punching the plurality of openings 4a to 4d in the door trim 1 are required, which is a major factor in significantly lowering workability and productivity in the manufacturing process of the interior parts.

Furthermore, since the resin around the gate 5c has a high resin temperature, the back surface of the skin material 3 is likely to be adversely affected. Particularly, as the skin material 3, a material having a cushioning property is used, which is lined with foam. It has been pointed out that when it is used, the cells of the foam are liable to be broken, good cushioning performance cannot be obtained, and the product surface at the portion corresponding to the gate 5c has irregularities and pockmarks.

In the case where the resin core material alone is used to form the interior parts, appearance defects such as flow marks (wavy flow patterns) and silva streaks (silver) are likely to occur on the product surface at the gate setting location. In order to prevent defects and increase the molding accuracy, it is necessary to precisely manage various molding conditions, and this management is very troublesome, which is also a factor that reduces productivity.

The present invention has been made in view of the above circumstances and utilizes mold press molding.
In a method of manufacturing an automobile interior part having a large number of openings for attaching separate parts, the interior process for the automobile has a significantly improved workability and productivity by shortening the manufacturing process, and the appearance performance is improved. It is intended to provide a manufacturing method of.

[0015]

In order to achieve the above-mentioned object, the present invention distributes and supplies molten resin into upper and lower molds for mold press molding to mold interior parts having a desired curved surface shape, In a method of manufacturing an automobile interior part in which an opening for mounting another part is punched and formed in a predetermined part of the part, a resin injection port of a gate formed in the lower mold for press molding is set at a planned opening part in the interior part. Therefore, in the punching process of the opening, the gate portion is cut and removed together with the end material of the opening.

[0016]

[Function] As is apparent from the above structure, the gate is set at the planned location of each opening of the resin core material, so if the opening is punched in the piercing process of the molded product, the gate part will be cut together with the end material. It can be eliminated and the conventional gate cutting process can be eliminated.

Further, since the resin around the gate has a high resin temperature, when integrally molding the skin material on the surface of the resin core material, defects such as irregularities and pockmarks are likely to occur on the surface of the skin material in the gate setting portion. However, this part becomes the end material of the opening, and the appearance performance is not deteriorated.

Further, even if a defective appearance such as a flow mark or a sylva streak occurs on the surface of the resin molded body at the gate setting location, this portion becomes the end material of the opening, so that various molding conditions can be relaxed. .

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a method for manufacturing an automobile interior part according to the present invention will be described in detail below with reference to the accompanying drawings.

FIG. 1 is a front view showing an automobile door trim manufactured by the method of the present invention, FIG. 2 is a sectional view showing the structure of the automobile door trim, and FIGS. 3 and 4 are molds used in the method of the present invention. 5 and 8 are sectional views showing the steps of the method of the present invention, and FIGS. 9 and 10 are sectional views showing another embodiment of the method of the present invention. .

First, the structure of an automobile door trim 10 manufactured by the method of the present invention will be briefly described with reference to FIGS.

However, the state before mounting the inside handle unit attached to the door trim, the speaker grill, the pull handle unit and the like is shown.

The automobile door trim 10 is composed of a resin core material 11 formed in a desired curved shape and a skin material 12 press-integrated on the surface of the resin core material 1.
A polypropylene composite resin material in which talc is mixed as a filler in a polypropylene resin is used as 1, and a material having a good cushioning property in which polyethylene foam is lined on the back surface of the PVC sheet is used as the skin material 12.

Further, the vehicle door trim 10 has an opening 13 for mounting an inside handle unit, an opening 14 for mounting a speaker grill, an opening 15 for mounting a pull handle unit, and an opening 16 for mounting a pocket escutcheon. As shown in, many openings are opened.

A feature of the method of the present invention is that the door trim 10 shown in FIGS. 1 and 2 (where a large number of openings 13, 14, 15, 16 are formed) can be manufactured by a simple process.

FIGS. 3 and 4 show a mold 20 used for molding the door trim 10 by mold press molding.
The mold press molding die 20 includes a mold press molding lower mold 30 having a desired curved surface shape, and a mold press molding upper mold 40 that can be raised and lowered by engaging and tightening with the mold press molding lower mold 30. , The molten resin M, which is the material of the resin core material 11, on the mold surface of the mold press molding lower mold 30.
And an injection molding machine 50 for supplying the same.

More specifically, as shown in FIG. 4, the lower mold 30 is provided with a cavity 31 for forming the outer shape of the door trim 10, and the molten resin M is injected from the injection molding machine 50 to the lower mold 30. A plurality of gates 32 for distribution and supply are provided.

The present invention is characterized in that the resin injection ports 32a, 32b, 32c of the gate 32 are set at positions corresponding to the openings 13, 14, 16 formed in the door trim 10.

The upper die 40 has a lifting cylinder 41.
Are connected, and set pins 42 for setting the skin material 12 are installed on the mold surface of the upper mold 40.

Next, the manufacturing process of the automobile door trim 10 shown in FIGS. 1 and 2 will be described. First, as shown in FIG. 5, the skin material 12 is set on the upper mold 40. 40 is located in the uppermost position.

When the setting of the skin material 12 is completed, the elevating cylinder 41 is operated and the upper die 40 for mold press molding is moved downward by a predetermined stroke, and the upper and lower dies 3 are moved.
It stops when the clearance of 0, 40 is 10 to 20 mm.

At this stage, as shown in FIG. 6, from the injection molding machine 50 through the gate 32, three resin injection ports 3 are provided.
The molten resin M is distributed and supplied from 2a, 32b, 32c to three locations on the mold surface of the lower mold 30.

After that, as shown in FIG. 7, the upper die 40 starts to descend again, and the upper and lower dies 30, 40 are tightened by engaging pressure.
The molten resin M is shaped, the resin core material 11 having a desired curved surface shape is formed, and the skin material 12 is formed on the surface side of the resin core material 11.
Are integrated to complete the mold press molding process.

By the way, in the state after completion of the mold press molding, the gate portion 60 is integrated at three places on the back surface of the resin core material 11. However, as shown in FIG.
After setting the molded product after the mold press molding, the cutting blade 72 provided on the pierce upper die 71 punches through the opening 13 for the inside handle unit, and the end material 13a and the gate portion 60 at this portion are integrated. Because
The gate portion 60 can be cut and removed at the same time, the conventional gate cutting step can be eliminated, and workability and productivity are greatly improved.

Although FIG. 8 shows only the cutting blade 72 for punching the opening 13 for mounting the inside handle unit, the opening 14 for mounting the speaker grill is shown.
Alternatively, cutting blades for punching the opening 15 of the pull handle unit and the opening 16 of the pocket escutcheon into a predetermined shape are set, and similarly, the gate portion can be cut simultaneously with the punching process of the openings 14 and 16.

Next, FIGS. 9 and 10 show a second embodiment of the present invention, in which the method of the present invention is applied to a single resin core material 11.

FIG. 9 shows a mold press molding process, in which the resin core material 11 is molded into a desired shape by the mold press molding upper and lower molds 30 and 40.

If an appearance defect such as a flow mark or sylva streak occurs on the surface side of the gate portion 60, this portion is cut and removed by a piercing process to open the opening 13 as shown in FIG. Therefore, even if a defective appearance occurs at the gate setting location, it does not hinder the appearance performance of the product, so that various molding conditions can be relaxed.
It has the advantage that process control can be performed easily.

[0039]

As described above, according to the method of the present invention, the following special operational effects are obtained.

(1) According to the method of the present invention, since the resin injection port of the gate is set at the planned opening portion of the interior part, the surplus gate portion can be cut and removed at the same time in the piercing process of the opening. This has the effect that the cutting process can be eliminated and workability and productivity are greatly improved.

(2) According to the method of the present invention, since the resin injection port of the gate is set at the planned opening portion of the interior part, for example, when the skin material is integrally molded on the surface of the resin core material, Defects such as irregularities and pockmarks tend to concentrate on the surface of the skin material in the gate setting part, but since this defective surface part is cut and removed as the end material of the opening, it does not adversely affect the appearance performance and has excellent designability. Has the effect of being obtained.

(3) According to the method of the present invention, since the resin injection port of the gate is set at the planned opening portion of the interior part, for example, when the interior part is composed of only the resin molding, the appearance defect is likely to occur. Since the vicinity of the portion is cut and removed as the end material of the opening, even if various molding conditions are relatively rough, the appearance performance is not hindered, and the molding management can be easily performed.

[Brief description of drawings]

FIG. 1 is a front view showing an automobile door trim manufactured by using the method of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a cross-sectional view showing the structure of a mold for press molding used in the method of the present invention.

FIG. 4 is a view on arrow A in FIG.

FIG. 5 is a cross-sectional view showing one step of the method of the present invention, showing the step of setting the skin material.

FIG. 6 is a cross-sectional view showing a step of supplying a molten resin, showing one step of the method of the present invention.

FIG. 7 is a cross-sectional view showing one step of the method of the present invention, showing a mold press molding step.

FIG. 8 is a cross-sectional view showing one step of the method of the present invention, showing a piercing step.

FIG. 9 is a sectional view showing a mold press molding step in the second embodiment of the method of the present invention.

FIG. 10 is a sectional view showing a piercing process in the second embodiment of the method of the present invention.

FIG. 11 is a front view showing a conventional automobile door trim.

12 is a sectional view taken along line XII-XII in FIG.

FIG. 13 is a cross-sectional view showing a conventional mold press molding process.

FIG. 14 is an explanatory view showing a conventional gate cutting step.

FIG. 15 is a sectional view showing a conventional piercing process.

[Explanation of symbols]

 10 Automotive Door Trim 11 Resin Core Material 12 Skin Material 13, 14, 15, 16 Opening 20 Mold Press Molding Mold 30 Mold Press Molding Lower Mold 32 Gates 32a, 32b, 32c Resin Injection Port 40 Mold Press Molding Upper Mold 50 injection molding machine 60 gate section

Continuation of the front page (51) Int.Cl. ⁶ Identification number Internal reference number in the agency FI technical display location B29C 69/00 2126-4F B29D 31/00 2126-4F // B29L 31:58

Claims (1)

[Claims] 1. Upper and lower molds (30, 4) for mold press molding
0) The molten resin (M) is distributed and supplied to the interior part (10) having a desired curved shape, and then the interior part (10) is formed.
Openings (13, 14, 16) for mounting separate parts on the specified part of
In a method for manufacturing an automobile interior part formed by punching, a resin injection port (32a, 32b, 32c) of a gate (32) formed in the lower mold for press molding (30).
Are openings (13, 14, 16) in the interior part (10)
The opening (13, 1
A method for manufacturing an automobile interior part, characterized in that the gate part (60) is cut off at the same time as the end material of the openings (13, 14, 16) in the punching step of (4, 16).