Forming device, forming method
By forming a protrusion near the tear groove of the substrate and using the concave-convex structure of the mold to fit or abut against the tear groove, the problem of substrate deformation during the attachment of the skin material is solved, and a molding effect without appearance defects is achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- HONDA MOTOR CO LTD
- Filing Date
- 2022-03-28
- Publication Date
- 2026-06-26
Smart Images
Figure CN116852620B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a forming apparatus and a forming method using the forming apparatus. Background Technology
[0002] In the airbag deployment section of an interior vehicle component, a tear groove is formed on the back side, which becomes a vulnerable part relative to the airbag's inflation force. When the airbag inflates, the airbag deployment section tears along this tear groove. A method has been proposed in which, when manufacturing an instrument panel by attaching a skin material consisting of a foam layer and a skin layer to the surface side of a sheet-like substrate such as polypropylene, the tear groove is formed using a sliding mold core during substrate forming (see Patent Document 1).
[0003] [Previous Technical Documents]
[0004] (Patent Documents)
[0005] Patent Document 1: Japanese Patent Application Publication No. 2021-84486 Summary of the Invention
[0006] [The problem the invention aims to solve]
[0007] In the method of Patent Document 1, the tear groove is formed as a through hole penetrating the substrate along the thickness direction. In contrast, sometimes the tear groove is formed as a bottomed hole that does not penetrate the substrate, and a skin material is attached to the surface of the substrate with the bottomed hole. When attaching the skin material, a pressing pressure is applied from above and below the laminate of skin material stacked on the surface of the substrate using a mold. Due to this pressing pressure, a deformed portion of the foamed layer of the skin material deforms towards the opening side of the bottomed hole at the location where the bottomed hole is formed in the substrate. When the mold is opened and the pressing pressure is released, the deformation of the deformed portion recovers. This recovery of deformation in the substrate bulges towards the outer surface of the skin material where the pressing pressure is no longer applied, resulting in an unsightly appearance. In the method of Patent Document 1, the instrument panel is based on the premise that the tear groove is formed as a through hole penetrating the substrate along the thickness direction. As mentioned above, there is no particular viewpoint regarding the unsightly appearance that occurs when forming a tear groove with a bottomed hole.
[0008] The present invention was made in view of the above circumstances, and its object is to provide a forming apparatus and a forming method using the forming apparatus, which, when attaching skin material to a substrate having a tear groove with a bottom hole, does not produce a portion that bulges outward and presents an unsightly appearance.
[0009] [Technical means to solve the problem]
[0010] (1) A forming apparatus (e.g., forming apparatus 5 described later) for forming an interior part for a vehicle (e.g., dashboard 1 described later) comprising a substrate (e.g., substrate 8 described later) and a skin material (e.g., skin material 9 described later) attached to the surface of the substrate, wherein the substrate is formed with a tear groove (e.g., tear groove 4 described later) with a bottom hole that becomes a vulnerable part when an airbag (e.g., airbag 2 described later) is inflated, and a protrusion (e.g., protrusion 15 described later) protruding from the back is formed near the tear groove, the forming apparatus comprising: a first mold (e.g., lower mold 6 described later) having a recess (e.g., recess 16 described later) at a location corresponding to the protrusion, wherein the substrate is disposed such that the protrusion and the recess are fitted together; and a second mold (e.g., upper mold 7 described later) for pressing and attaching the skin material disposed on the surface of the substrate to the substrate.
[0011] (2) The forming apparatus according to (1) above, wherein the aforementioned recess has a depth in which the bottom surface (e.g., the bottom surface 18 described later) does not abut against the aforementioned protrusion.
[0012] (3) The forming apparatus according to (1) above, wherein the aforementioned recess is provided on both sides of the aforementioned tear groove in such a way as to separate the aforementioned tear groove.
[0013] (4) The forming apparatus according to (1) above, wherein the first mold has a protrusion (e.g., protrusion 19, 19a described later) at a position corresponding to the tear groove, and when forming with the first mold and the second mold, the protrusion abuts against at least a portion of the tear groove.
[0014] (5) The forming apparatus according to (4) above, wherein when the aforementioned substrate is set on the aforementioned first mold during mold opening, the aforementioned protrusion does not abut against the aforementioned tear groove.
[0015] (6) The forming apparatus according to (4) above, wherein the aforementioned protrusion is formed to abut against the aforementioned conical surface in the aforementioned tear groove having a conical surface (e.g., the conical surface 14 described later), the conical surface being inclined such that the groove width narrows from the opening (e.g., the opening end 12 described later) toward the bottom of the groove (e.g., the bottom of the groove 13 described later).
[0016] (7) A forming method for forming an interior vehicle part (e.g., an instrument panel 1, described later) comprising a substrate (e.g., substrate 8, described later) and a skin material (e.g., skin material 9, described later) attached to the surface of the substrate, wherein the substrate is formed with a tear groove (e.g., tear groove 4, described later) having a bottom hole that becomes a vulnerable part when an airbag (e.g., airbag 2, described later) inflates, and a protrusion (e.g., protrusion 15, described later) protruding from the back side is formed near the tear groove, the forming method comprising: a setting step (e.g., the step of stage P11, described later). The substrate is disposed on a first mold (e.g., the lower mold 6 described later) having a recess (e.g., recess 16 described later) at a location corresponding to the aforementioned protrusion, such that the aforementioned protrusion and the aforementioned recess are fitted together, and the substrate is in a state where the aforementioned skin material is disposed on its surface; and, in the skin material attachment process (e.g., the process of stage P12 described later), the aforementioned skin material is pressed and attached to the aforementioned substrate using a second mold (e.g., the upper mold 7 described later), and the skin material is disposed on the surface of the aforementioned substrate disposed on the aforementioned first mold in the aforementioned setting process.
[0017] (The effect of the invention)
[0018] In the forming apparatus of (1), since the protrusion of the substrate is fitted into the recess of the mold, the tear groove can be prevented from deforming in an open manner due to the pressing pressure when the substrate is bonded to the skin material. Therefore, the bulging of the portion towards the outer surface of the skin material due to the recovery of this deformation in the substrate can be suppressed.
[0019] In the forming apparatus of (2), since the recess of the mold has a depth in which the bottom surface does not abut against the protrusion on the substrate side, forming errors can be tolerated.
[0020] In the forming apparatus of (3), since the protrusion on the substrate side is fitted into the recess of the mold that is provided on both sides of the tear groove in a manner that separates the tear groove, the tear groove can be suppressed from being compressed and deformed by the pressure when the skin material is applied to the substrate.
[0021] In the forming apparatus of (4), the protrusion on the mold side can suppress the compression deformation of the tear groove due to the pressing pressure when the substrate is bonded to the skin material.
[0022] In the forming apparatus of (5), since the protrusion of the die does not come into contact with the tear groove during the period when the compressive force applied to the substrate is in the elastic deformation region, unnecessary deformation of the substrate can be suppressed.
[0023] In the forming apparatus of (6), since the shoulder of the protrusion in the mold supports the substrate from the conical surface of the tear groove, the height of the protrusion does not need to reach the bottom of the tear groove. Therefore, the height of the protrusion can be suppressed, making it easier to manufacture the mold.
[0024] In the forming method of (7), since the protrusion of the substrate is fitted into the recess of the mold during the substrate setting process, the tear groove can be prevented from opening due to the pressing pressure when the substrate is bonded to the skin material during the skin material bonding process. Therefore, the formation of a portion bulging towards the outer surface of the skin material due to the recovery of this deformation in the substrate can be suppressed. Attached Figure Description
[0025] Figure 1 This is a schematic diagram illustrating an interior part for a vehicle formed using a forming apparatus according to one embodiment of the present invention.
[0026] Figure 2 This diagram illustrates the molding apparatus as one embodiment of the present invention and the molding method as one embodiment of the present invention, together with the process steps.
[0027] Figure 3 This diagram illustrates the molding apparatus as another embodiment of the present invention together with the molding method as an embodiment of the present invention.
[0028] Figure 4 This diagram illustrates the molding apparatus as another embodiment of the present invention together with the molding method as an embodiment of the present invention.
[0029] Figure 5 The figure illustrates the phenomenon that is the problem to be solved by the present invention. Detailed Implementation
[0030] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. Figure 1 This is a schematic diagram illustrating a vehicle interior part formed using a molding apparatus according to one embodiment of the present invention. In this example, the vehicle interior part is an instrument panel 1. An airbag 2 is housed in the instrument panel 1, directly below its rear side. The portion directly above the airbag 2 in the instrument panel 1 is the airbag deployment section 3. The airbag deployment section 3 will rupture due to the inflation pressure of the airbag 2, thereby allowing the airbag 2 to deploy normally. A tear groove 4 is formed on the back side of the airbag deployment section 3, and the tear groove 4 serves as a vulnerable part relative to the inflation force of the airbag 2.
[0031] Next, refer to Figure 2 The forming apparatus 5, which is an embodiment of the present invention, and the forming method, which is an embodiment of the present invention, will be described together.
[0032] The molding apparatus 5 is configured to include a lower mold 6 as a first mold and an upper mold 7 as a second mold. The instrument panel 1, an interior vehicle part formed by the closing of the lower mold 6 and the upper mold 7, has a skin material 9 attached to the outer surface of a substrate 8. The skin material 9 has a structure in which a skin layer 11 is laminated on the outer surface side of a foam layer 10. That is, from the inner surface side of the instrument panel 1 towards the outer surface side, the foam layer 10 is located on the substrate 8, and the skin layer 11 is located on the foam layer 10.
[0033] A tear groove 4, which has a bottom hole, is formed on the substrate 8. The tear groove 4 has an opening end 12 on the back side of the substrate 8 opposite to the skin material 9, and has a tapered surface 14 that slopes towards the bottom 13 of the groove, with the groove width narrowing from the opening end 12. A protrusion 15 is formed near the tear groove 4 on the substrate 8. The protrusion 15 is located on both sides facing the opening end 12 of the tear groove 4 and protrudes from the back side of the substrate 8 by forming a step, while the protruding end side is flat.
[0034] The lower mold 6 has a recess 16 at a location corresponding to the protrusion 15 on the side of the substrate 8. When the substrate 8 is placed on the lower mold 6, the protrusion 15 and the recess 16 are engaged. The recess 16 is formed by creating a step from the upper surface 17 of the lower mold 6, and its bottom surface 18 is flat.
[0035] Figure 2 P11 in the text indicates the process of setting up the substrate 8, which is a process of setting up the substrate 8 by fitting the protrusion 15 and the recess 16 on the lower mold 6, which has a recess 16 at the position corresponding to the protrusion 15 on the substrate 8 side. The substrate 8 is in a state where the skin material 9 is disposed on its surface.
[0036] Figure 2 P12 in the text refers to the process of stage P12, which is the process of attaching skin material. The skin material attaching process is to press and attach skin material 9 onto substrate 8 using upper mold 7. The skin material 9 is disposed on the surface of substrate 8, which is set on lower mold 6 in the process of stage P11.
[0037] Figure 2 P13 in the text indicates the process of stage P13, which is the process of removing the lower mold 6 and the upper mold 7 from the dashboard 1, which is an interior part for the vehicle. The interior part for the vehicle is formed by attaching the skin material 9 to the surface of the substrate 8 in the process of stage P12.
[0038] Here, refer to Figure 5 The diagram illustrates the phenomenon that occurs when the protrusion 15 is not provided on the substrate 8 side, and the recess 16 is not provided in the lower mold 6 at the location corresponding to the protrusion 15. This phenomenon is the problem that the present invention aims to solve.
[0039] Figure 5 P41 in the text indicates the step P41 as a setting process, in which a substrate 8 is set on a lower mold 6 with a flat upper surface, and the substrate 8 is in a state where a skin material 9 is disposed on its surface. A tear groove 4 with a bottom hole is formed on the substrate 8. The tear groove 4 has an opening end 12 on the side of the substrate 8 opposite to the skin material 9, i.e., the back side, and has a tapered surface 14 that slopes in a manner that the groove width narrows from the opening end 12 toward the bottom 13 of the groove.
[0040] Figure 5 In this context, P42 refers to the step of applying a skin material, in which the skin material 9 is pressed and attached to the substrate 8 using the upper mold 7. The skin material 9 is disposed on the surface of the substrate 8, which was set on the lower mold 6 in step P41. In step P42, the pressing force F of the upper mold 7 acts as stress on the substrate 8 via the skin material 9.
[0041] A portion of the stress generated by the pressing force F of the upper mold 7 acts as stress S1 towards the upper part of the bottom 13 of the tear groove 4. Compared with the surrounding parts, the thickness of the substrate 8 gradually decreases at the upper part of the bottom 13 of the tear groove 4, so the substrate 8 flexes downward. Consequently, the foam layer 10 of the skin material 9 deforms in a downward bulging manner, resulting in the deformed part D1.
[0042] While the stress generated by the pressing force F of the upper mold 7 acts as stress S1, other parts of the stress in the upper mold 7 act as stress S2. This stress S2 is inclined towards the flat surface of the upper surface of the lower mold 6, causing the portion of the tapered surface 14 of the tear groove 4 in the substrate 8 to be closer to it. As a component of stress S2, stress S3 acts in the direction that expands the opening width at the opening end 12 of the tear groove 4. Sometimes, the deformation also occurs in such a way that the opening width at the opening end 12 of the tear groove 4 expands due to stress S3.
[0043] Figure 5P43 in the text indicates the process of stage P43, which is the process of separating the lower mold 6 and the upper mold 7 from the dashboard 1, which is an interior part for a vehicle. This interior part is formed by attaching the skin material 9 to the surface of the base material 8 in the process of stage P42. In stage P43, the pressing pressure F of the upper mold 7, which was active in stage P42, is released. Therefore, the deformations that occurred in stage P43, such as the deformation D1 and the widening of the opening width at the opening end 12 of the tear groove 4, attempt to recover due to residual stress. At the upper part of the bottom 13 of the tear groove 4, the stress S4 that pushes the skin material 9 upward to recover takes effect, resulting in a deformation D2 that bulges outward on the skin material 9. Because the deformation D2 appears on the outer surface of the skin material 9, an appearance defect occurs on the dashboard 1, which is an interior part for a vehicle.
[0044] exist Figure 2 In stage P11, the protrusion 15 on the substrate 8 side is formed by fitting into the recess 16 of the lower mold 6. Therefore, in stage P12, when the skin material 9 is pressed onto the substrate 8 using the upper mold 7, even if... Figure 5 In stage P42, stresses S1, S2, and S3 are applied. The substrate 8 resists these stresses due to the engagement of the protrusion 15 and the recess 16, thus preventing deformation like that of the deformed part D1. Therefore, in stage P13, even if the lower mold 6 and upper mold 7 detach from the dashboard 1 (an interior part for vehicles), and the stress generated by the pressing pressure F of the upper mold 7 is released, deformation will not occur as in stage P42. Figure 5 The deformation of the deformable part D2. Therefore, no appearance defects caused by this deformation will occur.
[0045] Next, refer to Figure 3 , will have with Figure 2 The forming apparatus 5 with different shapes of lower mold 6a will be described together with the process of the forming method as an embodiment of the present invention. The lower mold 6a has a protrusion 19 at a position corresponding to the tear groove 4 of the substrate 8, and when forming with the upper mold 7 using the lower mold 6, the protrusion 19 abuts against at least a portion of the tear groove 4. Figure 3 The protrusion 19 in the lower die 6 is narrower than the upper part of the opposite region of the tapered surface 14 of the tear groove 4, and protrudes upward directly below the bottom 13 of the tear groove 4. When forming with the lower die 6 and the upper die 7, the top 20 of the protrusion 19 abuts against the bottom 13 of the tear groove 4.
[0046] Figure 3In this context, P21 refers to the "setting process," where a substrate 8 is set on the lower mold 6, with a skin material 9 disposed on its surface. In stage P21, the substrate 8 is set on the lower mold 6 by aligning the protrusion 19 of the lower mold 6 with a position corresponding to the center of the tear line groove 4. During stage P21, a gap is created between the top 20 of the protrusion 19 and the bottom 13 of the tear line groove 4.
[0047] Figure 3 P22 in the text refers to the process of step P22, which is the process of attaching skin material. The skin material attaching process is to press and attach skin material 9 onto substrate 8 using upper mold 7. The skin material 9 is disposed on the surface of substrate 8, which is set on lower mold 6 in the process of step P21.
[0048] Figure 3 P23 in the text indicates the process of stage P23, which is the process of removing the lower mold 6 and the upper mold 7 from the dashboard 1, which is an interior part for the vehicle. The interior part for the vehicle is formed by attaching the skin material 9 to the surface of the substrate 8 in the process of stage P22.
[0049] In the process of stage P22, when the pressing force F of the upper mold 7 is applied, as... Figure 5 The stress in stage P42 takes effect, but the protrusion 19 of the lower mold 6 abuts against the bottom 13 of the tear groove 4 with its top 20, thus resisting the deformation of the substrate 8 caused by stress. Therefore, the deformation of the substrate 8 caused by stress is kept to a minimum, thereby preventing deformation such as... Figure 5 The deformation of the deformable part D1.
[0050] In stage P23, the stress generated by the pressing force F of the upper mold 7 is relieved. In stage P22, since no stress is generated as described above... Figure 5 The deformation of the deformable part D1 is such that even if the stress generated by the pressing force F of the upper mold 7 is released, the deformation will not recover as expected. Figure 5 The deformation of the deformable part D2. Therefore, no appearance defects caused by this deformation will occur.
[0051] Reference Figure 4 Furthermore, the forming apparatus 5 with different shapes of lower mold 6b will be described together with the steps of the forming method as an embodiment of the present invention. The lower mold 6b has a protrusion 19a at a position corresponding to the tear groove 4 of the substrate 8, and when forming with the upper mold 7 using the lower mold 6, the protrusion 19a abuts against at least a portion of the tear groove 4. Figure 4The protrusion 19a in the lower mold 6 is narrower than the opening end 12 of the tear groove 4 and protrudes from directly below the tear groove 4 in the lower mold 6, forming a step. Its protruding end 21 is flat. When forming with the lower mold 6 and the upper mold 7, the rounded shoulder 22 of the protrusion 19a abuts against the conical surface 14 of the tear groove 4.
[0052] Figure 4 In this context, P31 refers to the "setting process," where a substrate 8 is set on the lower mold 6, with a skin material 9 disposed on its surface. In stage P31, the substrate 8 is set on the lower mold 6 by aligning the center of the width direction of the protrusion 19a of the lower mold 6 with the center of the tear groove 4. In this state, the rounded shoulder 22 of the protrusion 19a has not yet come into contact with the tapered surface 14 of the tear groove 4.
[0053] Figure 4 P32 in the text refers to the process of stage P22, which is the process of attaching skin material. The skin material attaching process is to press and attach skin material 9 onto substrate 8 using upper mold 7. The skin material 9 is disposed on the surface of substrate 8, which is set on lower mold 6 in the process of stage P31.
[0054] Figure 4 P33 in the text indicates the process of stage P33, which is the process of removing the lower mold 6 and the upper mold 7 from the dashboard 1, which is an interior part for the vehicle. The interior part for the vehicle is formed by attaching the skin material 9 to the surface of the substrate 8 in the process of stage P32.
[0055] In the process of stage P32, when the pressing force F of the upper mold 7 is applied, as follows: Figure 5 The stress in stage P42 takes effect, but the shoulder 22 of the protrusion 19a of the lower mold 6 abuts against the conical surface 14 of the tear groove 4, thus supporting the conical surface 14 and resisting the deformation of the substrate 8 caused by stress. Therefore, the deformation of the substrate 8 caused by stress is kept to a minimum, so as not to produce... Figure 5 The deformation of the deformable part D1.
[0056] In stage P33, the stress generated by the pressing force F of the upper mold 7 is relieved. In stage P32, since no stress is generated as described above... Figure 5 The deformation of the deformable part D1 is such that even if the stress generated by the pressing force F of the upper mold 7 is released, the deformation will not recover as expected. Figure 5 The deformation of the deformable part D2. Therefore, no appearance defects caused by this deformation will occur.
[0057] The forming apparatus and forming method according to this embodiment achieve the following effects.
[0058] (1) A forming apparatus 5 forms an interior vehicle part, namely an instrument panel 1, comprising a substrate 8 and a skin material 9 attached to the surface of the substrate 8. The substrate 8 has a tear groove 4 with a bottom hole that becomes a vulnerable part when the airbag 2 inflates, and a protrusion 15 protruding from the back is formed near the tear groove 4. The forming apparatus 5 includes: a lower mold 6 having a recess 16 at a location corresponding to the protrusion 15, wherein the substrate 8 is disposed in such a way that the protrusion 15 and the recess 16 are fitted together; and an upper mold 7 pressing and attaching the skin material 9 disposed on the surface of the substrate 8 to the substrate 8. Therefore, the protrusion 15 of the substrate 8 fits into the recess 16 of the lower mold 6, thereby preventing the tear groove 4 from deforming in an opening manner due to the pressing pressure when the substrate 8 is attached to the skin material 9. Therefore, it is possible to suppress the formation of a portion bulging towards the outer surface of the skin material 9 due to the recovery of this deformation in the substrate 8.
[0059] In the forming apparatus of (2), the recess 16 has a depth in which the bottom surface 18 does not abut against the protrusion 15. Therefore, forming errors can be tolerated.
[0060] In the forming apparatus (3), the recess 16 is provided on both sides of the tear groove 4 with the tear groove 4 in a manner that separates it from the tear groove 4. Therefore, in the recess of the lower mold 6 provided on both sides of the tear groove 4, the protrusion 15 of the substrate 8 is fitted into the recess 16, thereby suppressing the tear groove 4 from being compressed and deformed by the pressure applied to the substrate 8 when it is bonded to the skin material 9.
[0061] In the forming apparatus, the lower die 6 has protrusions 19, 19a at positions corresponding to the tear groove 4. When forming with the upper die 7 using the lower die 6, the protrusions 19, 19a abut against at least a portion of the tear groove 4. Therefore, the protrusions 19, 19a on the lower die 6 side can suppress the compression deformation of the tear groove 4 due to the pressing pressure when the substrate 8 is bonded to the skin material 9.
[0062] In the forming apparatus of (5), when the substrate 8 is set on the lower die 6 during mold opening, the protrusions 19, 19a do not abut against the tear groove 4. Therefore, during the period when the compressive force applied to the substrate 8 is in the elastic deformation region, the protrusions 19, 19a of the lower die 6 do not abut against the tear groove 4, thereby suppressing unnecessary deformation of the substrate 8.
[0063] In the forming apparatus of (6), the protrusion 19a is formed to abut against the tapered surface 14 in the tear groove 4, the tapered surface 14 being inclined such that the groove width narrows from the opening end 12 toward the bottom 13 of the groove. Therefore, the substrate 8 is supported from the tapered surface 14 of the tear groove 4 by the shoulder 22 in the protrusion 19a of the lower mold 6, and the height of the protrusion 19a does not need to reach the bottom 13 of the tear groove 4. Therefore, the height of the protrusion 19a can be suppressed, thereby facilitating the fabrication of the lower mold 6.
[0064] (7) The forming method forms an interior vehicle part, namely an instrument panel 1, comprising a substrate 8 and a skin material 9 attached to the surface of the substrate 8. The substrate 8 forms a tear groove 4 with a bottom hole that becomes a vulnerable part when the airbag 2 is inflated, and a protrusion 15 protruding from the back is formed near the tear groove 4. The forming method includes: a setting step, namely a step P11, in which the substrate 8 is set on a lower mold 6 having a recess 16 at a location corresponding to the protrusion 15 in such a way that the protrusion 15 and the recess 16 are fitted together, and the substrate 8 is in a state in which the skin material 9 is disposed on the surface; and a skin material attaching step, namely a step P12, in which the skin material 9 is pressed and attached to the substrate 8 using an upper mold 7, and the skin material 9 is disposed on the surface of the substrate 8 set on the lower mold 6 in the step P11. Therefore, in stage P11, which is the setting process, the protrusion 15 of the substrate 8 fits into the recess 16 of the lower mold 6, thereby preventing the tear groove 4 from deforming in an open manner due to the pressing pressure when the substrate 8 is bonded to the skin material 9 in stage P12, which is the skin material bonding process. Thus, it is possible to suppress the formation of a portion bulging towards the outer surface of the skin material 9 due to the recovery of this deformation in the substrate 8.
[0065] The embodiments of the present invention have been described above, but the present invention is not limited thereto. Appropriate changes can be made to the details of the construction within the scope of the present invention. For example, in the above embodiments, the form of the lower mold with a concave portion and the form of the lower mold with a convex portion are set to be different, but both forms of the lower mold with a concave portion and a convex portion may be used.
[0066] Figure Labels
[0067] D1, D2 Deformation
[0068] F Pressing pressure
[0069] Stages of forming methods (P11, P12, P13)
[0070] Pages 21, 22, and 23: Stages of another forming method
[0071] Pages 31, 32, and 33: Stages of another forming method
[0072] S1, S2, S3, S4 Deformation stress
[0073] 1. Dashboard
[0074] 2 airbags
[0075] 3. Airbag deployment section
[0076] 4. Tear groove
[0077] 5. Forming device
[0078] 6, 6a, 6b Lower molds
[0079] 7 upper mold
[0080] 8. Substrate
[0081] 9. Surface Material
[0082] 10 foam layers
[0083] 11 Epidermis
[0084] 12 Open end
[0085] 13 Bottom of the slot
[0086] 14 Conical surface
[0087] 15. Protrusion
[0088] 16 recess
[0089] 17. Top surface
[0090] 18 Bottom
[0091] 19, 19a convex part
[0092] 20 Top
[0093] 21 Protruding end
[0094] 22 Shoulders
Claims
1. A molding apparatus comprising a first mold and a second mold for molding a vehicle interior part comprising a substrate and a skin material attached to the surface of the substrate, wherein the substrate has a tear groove with a bottom hole that becomes a vulnerable part when an airbag inflates, and a protrusion protruding from the back side is formed near the tear groove, the molding apparatus comprising: The aforementioned first mold has a recess at the location corresponding to the aforementioned protrusion. The aforementioned substrate is disposed on the aforementioned first mold in a state where the aforementioned protrusion and the aforementioned recess are engaged. The aforementioned second mold is configured to press and attach the aforementioned skin material disposed on the surface of the aforementioned substrate onto the aforementioned substrate. The aforementioned skin material has a structure in which a skin layer is laminated on the outer surface of the foam layer. From the inner surface side of the instrument panel formed by molding the first mold and the second mold to the outer surface side, the foam layer is located on the substrate and the skin layer is located on the foam layer.
2. The forming apparatus according to claim 1, wherein, The aforementioned recess has a depth to which the bottom surface does not abut against the aforementioned protrusion.
3. The forming apparatus according to claim 1, wherein, The aforementioned recesses are provided on both sides of the aforementioned tear groove in a manner that separates them from the aforementioned tear groove.
4. The forming apparatus according to claim 1, wherein, The aforementioned first mold has a protrusion at a position corresponding to the aforementioned tear groove. When forming using the aforementioned first mold and the aforementioned second mold, the protrusion abuts against at least a portion of the aforementioned tear groove.
5. The forming apparatus according to claim 4, wherein, When the aforementioned substrate is placed on the aforementioned first mold during mold opening, the aforementioned protrusion does not abut against the aforementioned tear groove.
6. The forming apparatus according to claim 4, wherein, The aforementioned protrusion is formed to abut against the aforementioned conical surface in the aforementioned tear groove, the conical surface being inclined such that the groove width narrows from the opening toward the bottom of the groove.
7. The forming apparatus according to claim 6, wherein, The aforementioned protrusion forms a step and protrudes from directly below the aforementioned tear groove in the aforementioned first mold, and the protruding end of the aforementioned protrusion is flat.
8. A molding method using a molding apparatus for molding a vehicle interior part comprising a substrate and a skin material attached to the surface of the substrate, wherein the substrate has a bottomed tear groove forming a vulnerable part when an airbag inflates, and a protrusion protruding from the back side is formed near the tear groove, the molding method comprising: In the setting process, with the aforementioned protrusion engaged with the recess of the first mold, the aforementioned substrate is set on the aforementioned first mold. The aforementioned first mold has the aforementioned recess at the location corresponding to the aforementioned protrusion, and the substrate is in a state where the aforementioned skin material is disposed on its surface. and, In the skin material attachment process, the aforementioned skin material is pressed and attached to the aforementioned substrate using a second mold. The skin material is disposed on the surface of the aforementioned substrate that was set on the aforementioned first mold in the aforementioned setting process. The aforementioned molding apparatus is configured to include the aforementioned first mold and the aforementioned second mold. The aforementioned skin material has a structure in which a skin layer is laminated on the outer surface of the foam layer. The dashboard, formed by molding the first mold and the second mold together, has its inner surface facing outwards, with the foam layer on top of the substrate and the skin layer on top of the foam layer.