Method for manufacturing interior material for vehicle

Abstract

To provide an interior material for a vehicle which is less likely to be deformed, has uniform appearance, and is usable as a design material, even when having a projection part projecting from an undercut part and a plate surface.SOLUTION: A method for manufacturing an interior material for a vehicle that has a plate-like body part 15 containing a fiber and a thermoplastic resin, and an extension part 16 extending from the body part 15 includes a heating step of heating a preboard 12P, and a press molding step of pressing the preboard 12P by a molding die 30 having a body part molding part S1 for molding the body part 15 and an extension part molding part S2 for molding the extension part 16, wherein the press molding step expands a part of the preboard 12P crushed by pressing the preboard 12P by the body part molding part S1 to the extension part molding part S2, and fills the extension part molding part S2 with the part of the preboard 12P.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The technology disclosed in this specification relates to a method for manufacturing interior materials for vehicles.

Background Art

[0002] Conventionally, from the viewpoints of high rigidity and weight reduction, interior materials for vehicles formed of fibers and thermoplastic resins have been used. Such interior materials for vehicles are shaped by press-molding a pre-board containing fibers and a thermoplastic resin using a molding die. Further, when providing a so-called undercut portion that is concave in a direction intersecting the mold opening direction of the molding die or a protruding portion such as a clip seat protruding from the plate surface of the interior material for the vehicle, for example, after forming a base material using a pair of molding dies, a resin containing no fibers is injection-molded onto the base material, and a manufacturing method for integrally forming an undercut portion or a protruding portion with the base material is known (see Patent Document 1 and Patent Document 2).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] In an interior material for a vehicle in which portions formed of different materials are integrated in this way, a difference in thermal shrinkage amount occurs at their boundary portions, so there is a problem that deformation is likely to occur during cooling. To prevent deformation, jigs, operations, and equipment for correcting the deformation are required. Further, when the boundary portion is provided at a position where it can be visually recognized from the surface, the appearance is poor, and it has been necessary to cover the surface with a skin material due to a problem of designability.

[0005] The technology disclosed in this specification has been completed based on the above circumstances, and an object thereof is to provide an interior material for a vehicle that is less likely to be deformed and has a uniform appearance even when the interior material for a vehicle has an undercut portion having an undercut shape or a protruding portion protruding from the plate surface, and can be used as a decorative material.

Means for Solving the Problems

[0006] As a means for solving the above problems, the technology disclosed in this specification is a method for manufacturing an interior material for a vehicle, which includes a fiber and a thermoplastic resin, and has a plate-shaped main body portion and an extended portion extending from the main body portion. The method includes a heating step of heating a prepreg containing a fiber and a thermoplastic resin, a main body portion forming portion for forming the main body portion, and an extended portion forming portion provided continuously to the main body portion forming portion for forming the extended portion. The method includes a press molding step of pressing the prepreg with a molding die. In the press molding step, a part of the prepreg crushed by pressing the prepreg with the main body portion forming portion is spread and filled in the extended portion forming portion.

[0007] According to the above configuration, even when the interior material for a vehicle has an extended portion, the main body portion and the extended portion can be made of the same material, so that deformation due to a difference in thermal shrinkage amount hardly occurs at the boundary portion between the main body portion and the extended portion. Therefore, a jig and work for correcting deformation are not required, and manufacturing equipment, labor, and costs of work can be reduced. Further, since there is no boundary portion due to a difference in material between the main body portion and the extended portion, even when the boundary portion between the main body portion and the extended portion is provided at a position (design surface) where it can be visually recognized, the surface of the formed interior material for a vehicle can be used as the design surface as it is. That is, the skin material can be omitted. Furthermore, since the extended portion, which has conventionally been formed of only resin, can be composed of a fiber and a thermoplastic resin, the strength of the extended portion can be improved as compared with the conventional case.

[0008] Among the prepregs, a portion disposed adjacent to the extended portion forming portion when the prepreg is press-molded by the main body portion forming portion may be a thick portion having a thicker thickness than other portions.

[0009] According to the above configuration, when the pre-board is press-molded, compared with the configuration in which the thick portion is not formed, the pre-board is more likely to be pushed and expanded toward the extended portion forming portion. Further, it is easier to fill every corner of the extended portion.

[0010] The thick portion may be formed thicker than other portions by making the opposite surface of the surface that becomes the design surface of the vehicle interior material among the pre-boards protrude.

[0011] According to the above configuration, compared with the configuration in which the thick portion protrudes toward the design surface side of the vehicle interior material, when the pre-board is pressed, the influence of the thick portion on the design surface can be reduced. That is, a more uniform and beautiful design surface can be provided.

[0012] Among the pre-boards, the portion disposed adjacent to the extended portion forming portion when the pre-board is press-molded into the main body portion forming portion may be a high-density portion where the density of the fiber and the thermoplastic resin is higher than other portions.

[0013] According to the above configuration, the density of the high-density portion decreases and becomes close to the density of the portion other than the high-density portion when the pre-board is press-molded and pushed and expanded into the extended portion forming portion. That is, by reducing the density difference between the main body portion and the extended portion, the difference in thermal shrinkage amount becomes smaller, and the visual difference also becomes smaller.

[0014] The extended portion may have an undercut portion that extends in a direction intersecting the mold opening direction of the mold and inhibits the mold opening at least in part.

[0015] According to the above configuration, even when the vehicle interior material has an undercut portion, the entire vehicle interior material can be formed of the same material. That is, it is possible to provide a vehicle interior material that is less likely to be deformed, has a uniform appearance, and can be used as a decorative material.

[0016] The molding die includes an undercut portion molding part that molds the undercut portion in at least a part of the extending portion molding part, and at least a part of the undercut portion molding part is constituted by a slide die that slides in a direction intersecting the mold opening direction. After the press molding step, the molding die may be opened and the slide die may be slid to include a separating step of demolding the vehicle interior material.

[0017] According to the above configuration, a vehicle interior material having an undercut portion formed by press molding can be demolded.

[0018] The undercut portion may be formed at the outer peripheral edge portion of the main body portion. Further, the undercut portion may be formed at the upper end portion of an upper board that forms the lower end portion of a window frame in a vehicle door trim.

[0019] Further, the undercut portion may be formed at the tip side of a protruding portion provided to protrude from the back surface of the design surface of the vehicle interior material.

Advantages of the Invention

[0020] According to the technology disclosed in this specification, even when the vehicle interior material has an undercut portion having an undercut shape or a protruding portion protruding from the plate surface, it is difficult to cause deformation, and it is possible to provide a vehicle interior material that has a uniform appearance and can be used as a decorative material.

Brief Description of the Drawings

[0021]

Figure 1

Figure 2

Figure 3

Figure 4

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Figure 6

Figure 7

Figure 8

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Figure 10

Figure 11

Mode for Carrying Out the Invention

[0022] <Embodiment 1> Embodiment 1 will be described with reference to FIGS. 1 to 8. In this embodiment, as an interior material for a vehicle, the upper board 12 of the trim board 11 that constitutes the door trim 10 for a vehicle is exemplified. In the following description, the left side of FIG. 1 is the front of the vehicle, the right side is the rear of the vehicle, the upper side is the upper direction, and the lower side is the lower direction. Also, in FIG. 6, the X direction is the outside of the vehicle compartment (back side), the direction opposite to the X direction is the inside of the vehicle compartment (front side, design surface side), the Y direction is the upper direction, and the side opposite to the Y direction is the lower direction for explanation.

[0023] As shown in FIG. 1, the door trim 10 is mainly composed of the trim board 11. The trim board 11 is, for example, divided into an upper board 12, a middle board 20, and a lower board 21. The trim board 11 also includes a mounting hole 22 for attaching a door inside handle, a door pocket 23, and an armrest 24.

[0024] The upper board 12 has an inner wall portion 13 that extends substantially vertically along the main surface (the surface facing the occupant) of the trim board 11, and an upper wall portion 14 that extends from the upper end of the inner wall portion 13 toward the outside of the vehicle compartment. The edge portion on the outside of the vehicle compartment at the front end of the vehicle of the upper wall portion 14 is formed into a concave shape in a direction intersecting the mold opening direction (the vehicle compartment inside-outside direction, the X direction) when the upper board 12 is press-molded, that is, it is an undercut portion 16 having an inwardly curled shape.

[0025] More specifically, as shown in FIG. 7, the front end portion of the upper wall portion 14 extends obliquely upward from the upper end of the inner wall portion 13 and then extends slightly obliquely downward, having an inwardly curled shape. Hereinafter, among the upper board 12, the inner wall portion 13 and the portion that extends obliquely upward from the upper end of the inner wall portion 13 are referred to as a board main body portion (an example of a main body portion) 15, and the inwardly curled portion that extends obliquely downward from the upper end of the board main body portion 15 is described as an undercut portion (an example of an extended portion) 16. Note that, as shown in FIG. 7, the front end portion of the board main body portion 15 forms an acute angle in which the corner formed between the inner wall portion 13 and the upper wall portion 14 protrudes toward the inside of the vehicle compartment.

[0026] The trim board 11 (upper board 12) is formed from a material containing fibers and a thermoplastic resin. Examples of the fibers used for the trim board 11 include wood fibers and bast plant fibers such as kenaf, but the types of fibers are not limited thereto. For example, glass fibers, carbon fibers, etc. may be used as the fibers. Further, in the trim board 11, the fibers are bound by a thermoplastic resin as a binder. Examples of the thermoplastic resin used for the trim board 11 can include polyolefin resins such as polypropylene and polyethylene. The trim board 11 of the present embodiment is formed from kenaf and polypropylene.

[0027] Next, a mold 30 for molding the upper board 12 will be described. As shown in FIG. 6, the mold 30 includes a cavity mold 31 and a core mold 35 (a pair of molds) that are arranged opposite to each other side by side in the horizontal direction (X direction). At least one of the cavity mold 31 and the core mold is connected to a driving device (not shown) (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.) and can be relatively approached or separated. That is, the cavity mold 31 and the core mold 35 are configured to be able to close and open the mold. In this embodiment, although a configuration in which the opening and closing directions of the cavity mold 31 and the core mold 35 are in the horizontal direction is illustrated, the present invention is not limited to this. For example, the opening and closing directions of the cavity mold 31 and the core mold 35 may be in the vertical direction.

[0028] The core mold 35 is divided into a plurality of molds. The core mold 35 has a molding surface 36 having a shape that follows the back surface of the upper board 12 (the board main body portion 15 and the undercut portion 16). The core mold 35 has a shape in which the molding surface 36, which is the surface facing the cavity mold 31, protrudes toward the cavity mold 31. Among the core mold 35, at least the portion corresponding to the back surface of the undercut portion 16 is constituted by a slide mold 37A. The core mold 35 also has a molding surface 38 having a shape that follows the surface of the undercut portion 16. That is, the core mold 35 has a groove-shaped cavity portion that can be molded by the molding surfaces 36 and 38 on the front and back surfaces of the undercut portion 16. Hereinafter, this cavity portion will be referred to as an undercut portion molding space (an example of an extended portion molding portion and an undercut portion molding portion) S2 (see FIG. 7).

[0029] On the other hand, the cavity mold 31 has a molding surface 32, which is the surface facing the core mold 35, recessed in a shape corresponding to the shape of the core mold 35. The molding surface 32 of the cavity mold 31 has a shape that follows the surface (design surface) of the portion of the upper board 12 excluding the undercut portion 16, that is, the board main body portion 15.

[0030] In the mold-closed state shown in Fig. 7, a main body forming space (an example of a main body forming part) S1 for forming the board main body part 15 of the upper board 12 is formed between the cavity mold 31 and the core mold 35. That is, the main body forming space S1 is a space surrounded by the forming surface 32 of the cavity mold 31 and the forming surface 36 of the core mold 35. Thus, when the pre-board 12P is pressed by the cavity mold 31 and the core mold 35, the pre-board 12P is compressed into a shape corresponding to the shape of the main body forming space S1. That is, the surface (design surface) side of the upper board 12 is shaped by the cavity mold 31, and the back surface side is shaped by the core mold 35, whereby the board main body part 15 of a predetermined shape is formed. Note that the plate thickness of the board main body part 15, that is, the separation distance between the cavity mold 31 and the core mold 35 in the mold-closed state, is made smaller than the plate thickness of the thin part 12P2 of the pre-board 12P described later.

[0031] In the state where the cavity mold 31 and the core mold 35 are mold-closed, the undercut part forming space S2 of the core mold 35 described above is continuous with the main body forming space S1. The undercut part 16 formed by the undercut part forming space S2 can be demolded by the slide molds 37A and 37B moving in a direction intersecting the mold-opening direction (X direction) when the mold is opened.

[0032] Next, the manufacturing method of the upper board 12 of the present embodiment will be described. The manufacturing method of the upper board 12 of the present embodiment includes a pre-board forming step of forming a pre-board 12P having a thick part 12P3, a heating step of heating the pre-board 12P, a press forming step of press-forming the heated pre-board 12P with the cavity mold 31 and the core mold 35 to form the upper board 12, and a demolding step of demolding the formed upper board 12.

[0033] <Pre-board forming step> In the pre-board forming process, first, as shown in FIG. 2, a fiber mat composed of fibers and a thermoplastic resin is heated and pressed by a pair of flat press dies 40. As a result, the fiber mat is compressed, and the thermoplastic resin contained in the fiber mat melts and mixes together at the contact surfaces with each other. Then, the thermoplastic resin contained in the fiber mat cools and solidifies, thereby forming a flat pre-board 12P0.

[0034] The pre-board 12P of the present embodiment includes a thick portion 12P3 in which the plate thickness is formed thicker than other portions in a part of the portion along the outer peripheral edge. As shown in FIG. 3, the thick portion 12P3 is formed by overlapping a pre-board piece 12P1 formed of the same material and the same density as the pre-board 12P0 on a part of the flat pre-board 12P0, heating, and bonding them together (see FIG. 4). That is, the thick portion 12P3 is formed in a form protruding from one side of the plate surface of the pre-board 12P. The position and dimensions of this thick portion 12P3 are appropriately adjusted in accordance with the position and size of the undercut portion 16 of the upper board 12, as will be described later. Note that the portion of the pre-board 12P other than the thick portion 12P3 will be referred to as a thin portion 12P2.

[0035] <Heating process> When press-forming the upper board 12, first, the pre-board 12P is heated by a heater 45 (see FIG. 5). As a result, the pre-board 12P becomes in a softened state.

[0036] <Press-forming process> Next, the pre-board 12P in a heated and softened state is disposed between the cavity die 31 and the core die 35 so that its plate surface intersects perpendicularly to the die closing direction (X direction) (in a posture extending in the Y direction) (see FIG. 6). At this time, the pre-board 12P is disposed so that the protruding direction of the thick portion 12P3 from the thin portion 12P2 faces the core die 35 (the back surface of the upper board 12). Also, the pre-board 12P is disposed so that the thick portion 12P3 is at the position closest to the undercut portion forming space S2.

[0037] Thereafter, by closing the die of the cavity mold 31 and the core mold 35, the prepreg 12P is press-formed by the respective molding surfaces 32, 36, 38 of the cavity mold 31 and the core mold 35 (see Fig. 7). As the die is closed, the prepreg 12P is gradually bent along the molding surfaces 32, 36 from the boundary between the inner wall portion 13 and the upper wall portion 14 toward the upper and lower ends and compressed, and is formed into a shape following the shape of the main body forming space S1.

[0038] Also, along with the die closing, the thick portion 12P3 of the prepreg 12P is disposed at a position adjacent to the undercut portion forming space S2 in the main body forming space S1, and the thick portion 12P3 is pushed and spread into the inside of the undercut portion forming space S2 while being crushed. At this time, the prepreg 12P is in a softened state, and since sufficient bulk is ensured by the thick portion 12P3, it is pushed and spread to every corner of the undercut portion forming space S2 and filled. Note that the position and dimensions of the thick portion 12P3 in the prepreg 12P are adjusted in advance to be able to fill the undercut portion forming space S2 in accordance with the position and size of the undercut portion 16.

[0039] Further, a heating device can be provided in the mold 30 to reheate the prepreg 12P during press-forming. In such a configuration, it becomes possible to raise the temperature to the temperature at which the thermoplastic resin constituting the prepreg 12P becomes liquid (the temperature at which it becomes too soft to maintain the shape of the prepreg 12P), and thus it becomes easier to fill every corner of the undercut portion forming space S2 with fibers and the molten thermoplastic resin.

[0040] Thereafter, the mold 30 maintains the state of being closed until the softened thermoplastic resin cools and solidifies.

[0041] <Demolding process> When the formed upper board 12 cools and the thermoplastic resin hardens, the mold 31 and the core mold 35 are opened (see Fig. 8), and the upper board 12 is demolded from the molding die 30 by sliding the slide molds 37A and 37B. In this way, the upper board 12 in which the undercut portion 16 is integrally formed of the same type of material as the board main body portion 15 is completed.

[0042] Next, the operation and effect of this embodiment will be described. The manufacturing method of the upper board 12 of this embodiment includes a heating step of heating a pre-board 12P containing fibers and a thermoplastic resin, a main body portion molding space S1 for molding the board main body portion 15, and an undercut portion molding space S2 that is provided continuously to the main body portion molding space S1 and molds the undercut portion 16. The manufacturing method includes a press molding step of pressing the pre-board 12P with a molding die 30. In the press molding step, a part of the pre-board 12P crushed by pressing the pre-board 12P into the main body portion molding space S1 is spread and filled into the undercut portion molding space S2.

[0043] According to the above configuration, even when the upper board 12 has an undercut portion 16 that extends in a direction intersecting the mold opening direction (X direction) of the molding die 30 and inhibits mold opening, the board main body portion 15 and the undercut portion 16 can be made of the same material. Therefore, deformation due to a difference in thermal shrinkage amount is unlikely to occur at the boundary between the board main body portion 15 and the undercut portion 16. Therefore, jigs and operations for correcting deformation are not required, and manufacturing equipment, labor, and costs of the operations can be reduced. In addition, since there is no boundary portion due to a difference in material between the board main body portion 15 and the undercut portion 16, the surface of the formed upper board 12 can be used as the design surface as it is. That is, the skin material can be omitted. Furthermore, since the undercut portion, which was conventionally formed only of resin, can be composed of fibers and a thermoplastic resin, the strength of the undercut portion 16 can be improved compared to the conventional case.

[0044] Further, among the pre-boards 12P, the portion of the pre-board 12P that is arranged adjacent to the undercut portion forming space S2 when the pre-board 12P is press-formed within the main body portion forming space S1 is a thick portion 12P3 that is thicker than other portions.

[0045] According to the above configuration, when the pre-board 12P is press-formed, the pre-board 12P is more likely to be pushed and expanded toward the undercut portion forming space S2 compared to a configuration where the thick portion 12P3 is not formed. Also, it becomes easier to fill every corner of the undercut portion forming space S2.

[0046] Further, the thick portion 12P3 is formed thicker than other portions by making the opposite surface of the surface that becomes the design surface of the upper board 12 among the pre-boards 12P protrude.

[0047] According to the above configuration, compared to a configuration where the thick portion 12P3 protrudes toward the design surface side of the upper board 12, the influence of the thick portion 12P3 on the design surface when the pre-board 12P is pressed can be reduced. That is, a more uniform and beautiful design surface can be provided.

[0048] Also, the mold 30 includes slide molds 37A and 37B that slide in a direction intersecting the mold opening direction, and at least a part of the undercut portion forming space S2 is constituted by the slide mold 37A. After the press-forming process, the mold 30 is opened and the slide molds 37A and 37B are slid to include a demolding process of demolding the upper board 12.

[0049] With the above configuration, it becomes possible to demold the upper board 12 having the undercut portion 16 formed by press-forming.

[0050] Further, the undercut portion 16 is formed at the outer peripheral edge of the board main body portion 15. More specifically, the undercut portion 16 is formed at the upper end of the upper board 12 that forms the lower end of the window frame of the door trim 10. Thus, according to the manufacturing method of the present embodiment, it is possible to manufacture the upper board 12 in which the undercut portion 16 is integrally formed of the same type of material as the board main body portion 15.

[0051] <Embodiment 2> In the above-described Embodiment 1, the thick portion 12P3 is provided on the pre-board 12P, and the pre-board 12P is expanded in the undercut portion forming space S2 by crushing the thick portion 12P3. However, in the present embodiment, instead of the thick portion 12P3, a high-density portion 112P5 having a higher density of fibers and the thermoplastic resin than other portions is provided in a portion of the pre-board 112P that is arranged adjacent to the undercut portion forming space S2 when the pre-board 112P is press-formed in the main body portion forming space S1. Such a high-density portion 112P5 can be formed, for example, in a part of the flat pre-board 12P0 in the pre-board forming process by overlapping a pre-board piece 12P1 formed of the same material and the same density as the pre-board 12P0, and heating and pressing to obtain a pre-board 112P having a uniform plate thickness. The portion of the pre-board 112P other than the high-density portion 112P5 will be referred to as a low-density portion 112P4.

[0052] When such a pre-board 112P is used, the density of the high-density portion 112P5 decreases to a density close to that of the portion other than the high-density portion 112P5 (low-density portion 112P4) when the pre-board 112P is press-formed and expanded into the undercut portion forming space S2. That is, by reducing the density difference between the board main body portion 15 and the undercut portion 16, the difference in thermal shrinkage amount is reduced, and the visual difference is also reduced.

[0053] <Other Embodiments> The technology disclosed in this specification is not limited to the embodiments described in the above description and drawings. For example, the following embodiments are also included in the technical scope.

[0054] (1) In the above embodiment, the upper board 12 that constitutes the door trim 10 is exemplified as the vehicle interior material, but it is not limited thereto. The vehicle interior material may be one that constitutes vehicle interior materials other than the door trim, such as an instrument panel, a luggage trim, a package tray, etc.

[0055] (2) In the above embodiment, the form of arranging the preheated pre-board 12P in the molding die 30 and press-molding it is shown. However, it may be configured to perform the heating process and the press-molding process simultaneously, or as described above, it may be configured to heat again during press-molding after the heating process. When heating is performed during press-molding, since it becomes possible to heat up to a temperature at which the fluidity of the thermoplastic resin in the pre-board becomes higher, the fibers and the thermoplastic resin can easily spread to every corner of the undercut portion.

[0056] (3) In the above embodiment, the upper board 12 having the undercut portion 16 extending in an inwardly wound shape from the board main body portion 15 is disclosed. However, as shown in FIG. 10, an upper board 112 having an extension portion 116 extending straight along the mold opening direction (X direction) from the board main body portion 115 can also be formed in the same manner as the above embodiment. That is, it can be formed by pressing the pre-board 12P into the main body portion molding space S11 constituted by the cavity mold 131 and the core mold 135 of the molding die 130 and spreading and filling a part of the pre-board 12P that has been crushed into the extension portion molding space S12.

[0057] (4) In the above-described embodiment, the undercut portion 16 provided at the outer peripheral edge of the upper board 12 is exemplified, but the undercut portion is not limited thereto. For example, the manufacturing method disclosed in this specification can also be applied to an undercut portion formed in a protruding portion protruding from the back surface of the design surface of the main body portion. Such an interior material for a vehicle can be formed, for example, as shown in FIG. 11, by press-forming a pre-board 212P with a cavity mold 231 of a molding die 230 and a core mold 235 provided at the center of a molding surface 236 and having a protruding portion molding space S3 and an undercut portion molding space S4 having a T-shaped cross section, and expanding a thick portion 212P3 into the protruding portion molding space S3 and the undercut portion molding space S4.

[0058] (5) In the above-described embodiment, a configuration is shown in which a thick portion 12P3 or a high-density portion 112P5 is provided in the pre-boards 12P and 112P, and the pre-boards 12P and 112P are expanded into the undercut portion molding spaces S2 and S4 by crushing the thick portion 12P3 or the high-density portion 112P5. However, it is also possible to use a pre-board in which the thick portion itself is formed as a high-density portion.

[0059] (6) In the above-described embodiment, a configuration in which the core molds 35 and 235 are divided into a plurality of molds is exemplified, but the mode of division of the core mold can be appropriately changed. The main point is that the undercut portion 16 can be demolded.

Explanation of Reference Numerals

[0060] 10: Door trim, 11: Trim board, 12: Upper board (vehicle interior material), 12P, 112P, 212P: Pre-board, 12P3, 212P3: Thick part, 15: Board main body part (main body part), 16: Undercut part, 30, 130, 230: Molding die, 31, 131, 231: Cavity type, 32, 36, 38, 236: Molding surface, 35, 135, 235: Core type, 37A, 37B: Slide type, 112P4: Low-density part, 112P5: High-density part, S1, S11: Main body part molding space (main body part molding part), S2, S4: Undercut part molding space (extended part molding part, undercut part molding part), S3: Protrusion part molding space (main body part molding part), S12: Extended part molding space (extended part molding part)

Claims

1. A method for manufacturing an interior material for a vehicle, comprising a fibrous material and a thermoplastic resin, and having a plate-shaped main body portion and an extended portion extending from the main body portion, the method comprising: a heating step of heating a pre-board containing a fibrous material and a thermoplastic resin; a press molding step of pressing the pre-board with a molding die having a main body portion molding portion for molding the main body portion and an extended portion molding portion provided continuously to the main body portion molding portion for molding the extended portion; wherein the extended portion molding portion is formed in a groove shape on one of a pair of dies of the molding die; In the press molding step, a part of the pre-board crushed by pressing the pre-board with the main body portion molding portion is spread and filled inside the extended portion molding portion. A method for manufacturing an interior material for a vehicle.

2. The method for manufacturing an interior material for a vehicle according to claim 1, wherein the extended portion extends from an end portion of the main body portion, and the extended portion molding portion is formed in a groove shape capable of molding front and back surfaces of the extended portion.

3. In the pre-board, a portion disposed adjacent to the extended portion molding portion when the pre-board is press-molded into the main body portion molding portion is a thick portion having a greater thickness than other portions. The method for manufacturing an interior material for a vehicle according to claim 1 or claim 2.

4. The thick portion is formed to be thicker than other portions by making the surface opposite to the surface that becomes the design surface of the interior material for the vehicle protrude in the pre-board. The method for manufacturing an interior material for a vehicle according to claim 3.

5. In the pre-board, a portion disposed adjacent to the extended portion molding portion when the pre-board is press-molded into the main body portion molding portion is a high-density portion having a higher density of the fibrous material and the thermoplastic resin than other portions. The method for manufacturing an interior material for a vehicle according to any one of claims 1 to 4.

6. The method for manufacturing an interior material for a vehicle according to claim 1, wherein the extended portion has an undercut portion that extends at least partially in a direction intersecting the mold opening direction of the molding die and inhibits mold opening.

7. The molding die includes an undercut portion molding portion for molding the undercut portion in at least a part of the extended portion molding portion, and at least a part of the undercut portion molding portion is constituted by a slide die that slides in a direction intersecting the mold opening direction. The manufacturing method of the vehicle interior material according to claim 6, including a separation step of opening the mold and sliding the slide mold after the press molding step to demold the vehicle interior material.

8. The manufacturing method of the vehicle interior material according to claim 6 or claim 7, wherein the undercut portion is formed at the upper end of an upper board that forms the lower end of a window frame in a vehicle door trim, which is an outer peripheral edge portion of the main body portion.

9. The manufacturing method of the vehicle interior material according to claim 6 or claim 7, wherein the undercut portion is formed at the tip side of the extended portion provided to protrude from the back surface of the design surface of the vehicle interior material.

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