US 2006/0141240 A1 · Automotive interior component and manufacturing method thereof

Abstract

To provide an interior component that partly includes a laminated assembly and a manufacturing method thereof that prevent flattening of pile of a decorative member in press molding to improve appearance. A door trim includes a laminated assembly (door trim upper portion) including a resin foam substrate that is light in weight and has a shape-holding property, a resin rib integrally laminated on a rear surface of the resin foam substrate, and a decorative member attached to a front surface of the resin foam substrate, and a resin molding (door trim lower portion). For the laminated assembly, a resin form sheet heated and softened and the decorative member that is not heated or is heated at a low temperature are placed into a forming die assembly in an laminated manner and integrated by a low pressing pressure, thereby preventing flattening of pile or thermal deformation of the decorative member, ensuring satisfactory moldability, and reducing a molding load in molding.

Claims10

Dependent claims

An automotive interior component that entirely or partly includes a laminated assembly comprising:

a resin foam substrate that is formed into a desired shape, light in weight, and has a shape-holding property;
a resin rib in a predetermined pattern shape integrally laminated on a rear surface of the resin foam substrate;
and
a decorative member attached to a front surface of said resin foam substrate,
wherein in said laminated assembly, a resin form sheet heated and softened is set into forming dies assembly, and the decorative member being overlaid on an upper surface of the resin foam sheet, are integrally formed by remaining heat from said resin foam sheet and a low pressing pressure by clamping of the forming dies.

2 more elements

A manufacturing method of an automotive interior component that entirely or partly includes a laminated assembly comprising:

a resin foam substrate that is formed in to a desired shape, light in weight, and has a shape-holding property;
a resin rib in a predetermined pattern shape integrally laminated on a rear surface of the resin foam substrate;
and a decorative member attached to a front surface of said resin foam substrate,
wherein said method comprises the steps of:
heating and softening the resin form sheet;
placing the resin foam sheet heated and softened into forming die assembly and then placing the decorative member that is not heated or is heated at a low temperature on an upper surface of said resin foam sheet;
clamping the forming dies;
molding the resin foam substrate into a desired shape at a low pressing pressure;
and
integrally attaching the decorative member to the front surface of the resin foam substrate by remaining heat from the resin foam sheet;
and then
injecting and filling a molten resin M1 into a groove in a lower die immediately before or after clamping of the forming dies to integrally laminate the resin rib on the rear surface of the resin foam substrate and form the laminated assembly.

9 more elements

Dependencies are inferred from the claim text.

Automotive interior component and manufacturing method thereof

Life of this patent

Automotive interior component and manufacturing method thereof

Life of this patent

Abstract

Claims10