JP2000289101A - Interior part and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain an interior part advantageous from an aspect of cost and easy in molding work. SOLUTION: An interior part is advantageous from an aspect of cost and easy in molding work because of a three-layered structure consisting of two olefin resin sheets 2, 3 and one polyester nonwoven fabric 4. Particularly, since the polyester nonwoven fabric 4 interposed between two olefin resin sheets 2, 3 has a melting temp. higher than that of an olefin resin and not fused to two olefin resin sheets 2, 3 until mold clamping pressure is applied to both sheets and nonwoven fabric in a mold, it is easy to handle when setting to the mold.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior part used for a vehicle such as an automobile or an aircraft, an indoor wall, and a method of manufacturing the same.

[0002]

2. Description of the Related Art It has been conventionally known that an interior part having a hollow portion can be obtained by arranging a plurality of heated synthetic resin sheets between molding dies and pressure-forming them. See Japanese Unexamined Patent Publication No. Hei 10-24487).

[0003]

However, in such a conventional technique, since the synthetic resin sheet has a multilayer structure in order to increase rigidity, it is disadvantageous not only in cost but also in molding. The work of setting in the mold is also troublesome.

The present invention has been made by paying attention to such a conventional technique, and provides an interior part which is advantageous in cost and which can be easily formed, and a method of manufacturing the same.

[0005]

According to the first aspect of the present invention,
A hollow portion is defined by forming at least one of the mating surfaces of the two thermoformed non-permeable air-permeable olefin resin sheets, and a hollow portion is formed between the two olefin resin sheets by the melting temperature of the olefin resin. This is an interior part in which a polyester nonwoven fabric having a high melting temperature is interposed.

According to a second aspect of the present invention, there is provided an interior part in which a polyester non-woven fabric is disposed in a hollow portion in a cross-linked state.

The invention according to claim 3 is an interior part in which a skin material is provided in a laminated state on the outer surface of at least one olefin resin sheet.

According to a fourth aspect of the present invention, there is provided an interior part in which the skin material is non-permeable and a non-woven fabric made of synthetic resin and having good air permeability is interposed between the skin material and the olefin resin sheet.

According to a fifth aspect of the present invention, in the olefin resin sheet, a portion forming the hollow portion is provided with a reinforcing member wrapped by the olefin resin sheet and directed to the inside of the hollow portion. I have.

According to a sixth aspect of the present invention, there is provided an interior part in which the tip of the reinforcing material wrapped by the olefin resin sheet is in contact with the facing surface of the hollow portion.

The invention according to claim 7 is a molding material in which a base material has a three-layer structure by interposing a polyester nonwoven fabric having a melting temperature higher than the melting temperature of the olefin resin between two olefin resin sheets. After heating the molding material, it is disposed between a pair of molding dies provided with a cavity of a desired shape, and after clamping the molding die and applying a mold clamping pressure to the olefin resin sheet, Insert a needle nozzle between two olefin resin sheets to blow air,
While the two olefin resin sheets are in close contact with the inner surface of the mold and thermoformed, at least one of the mating surfaces of the two olefin resin sheets is concavely formed to form an interior part in which a hollow portion is defined. It is a manufacturing method.

An eighth aspect of the present invention is a method for manufacturing an interior part in which a notch is formed at a position corresponding to a needle nozzle on a surface of one of the molds which presses the olefin resin sheet.

A ninth aspect of the present invention is a method of manufacturing an interior part in which the periphery of a molding material is trimmed simultaneously with clamping.

According to a tenth aspect of the present invention, a step is formed in one olefin resin sheet at the time of mold clamping, and a needle nozzle is inserted into the step so that the tip of the needle nozzle is positioned between the two olefin resin sheets. This is a method for manufacturing interior parts to be manufactured.

An eleventh aspect of the present invention is a method of manufacturing an interior part in which an air vent hole is formed near an insertion portion of a needle nozzle in at least one mold, and a corresponding olefin resin sheet is sucked from the air vent hole.

[0016]

According to the first aspect of the present invention, the three-layer structure of two olefin resin sheets and one polyester non-woven fabric is advantageous in terms of cost and easy in molding. . In particular, the nonwoven fabric of polyester interposed between the two olefin resin sheets has a melting temperature higher than the melting temperature of the olefin resin. Since it does not fuse with the mold, it is easy to handle when it is set in a mold.

According to the second aspect of the present invention, when the hollow portion is deformed, the non-woven fabric provided in a cross-linked state therein is pulled to generate a reaction force against the non-woven fabric. The rigidity is improved and the deformation is suppressed.

According to the third aspect of the present invention, when the skin material is provided, the olefin resin sheet on the skin material side is covered with the skin material and is not exposed to the outside. Can be used.

According to the fourth aspect of the present invention, air can be entrapped in the nonwoven fabric, and air can be prevented from being trapped between the skin material and the olefin resin sheet. Therefore, the surface of the skin material does not bulge partially, and is always flat and has good appearance and tactile sensation.

According to the fifth aspect of the invention, the rigidity of the hollow portion is improved by the reinforcing material. In addition, since the reinforcing material faces inward, there is no change in the appearance of the hollow portion, which is advantageous in appearance.

According to the sixth aspect of the present invention, the reinforcing member is a "stretch member", and the rigidity of the hollow portion is improved.

According to the seventh aspect of the present invention, since the needle nozzle is used, even after the mold is fastened, the needle nozzle is kept in position.
Air can be blown in between olefin resin sheets. Therefore, there is no need to insert a nozzle for blowing air between the molds together with the molding material, and the molding operation is facilitated. Further, since the needle nozzle is used, traces of the needle nozzle are small, which is advantageous in terms of appearance of the finished product.

According to the eighth aspect of the present invention, since the notch is formed in the molding die, the mold clamping pressure at a portion where the needle nozzle is inserted is partially reduced. Therefore, the melting force between the olefin resin sheets in that portion is weakened, and it becomes easier to insert the needle nozzle therebetween.

According to the ninth aspect of the invention, the entire circumference of the molding material can be trimmed at the stage of mold clamping before inserting the needle nozzle.

According to the tenth aspect of the present invention, the trace of the needle nozzle being left remains on one olefin resin sheet side.
Since it does not remain at the joining portion of two olefin resin sheets, it is suitable for a product where the appearance of the joining portion is important.

According to the eleventh aspect of the present invention, since one olefin resin sheet is suctioned and fixed, the tip of the inserted needle nozzle is positioned exactly between the two olefin resin sheets. .

[0027]

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.

1 to 7 show a first embodiment of the present invention. FIG. 1 shows a molding material 1 of this embodiment. Reference numerals 2 and 3 are non-breathable olefin resin sheets, which are made of recycled polypropylene material and filler (mica) added thereto. A polyester nonwoven fabric 4 is interposed between the two olefin resin sheets 2 and 3. Although the base material has a three-layer structure of the olefin resin sheets 2 and 3 and the nonwoven fabric 4, in this embodiment,
A skin material 6 via a nonwoven fabric 5 similar to the intermediate nonwoven fabric 4
Is provided. This skin material 6 is also formed of an air-impermeable olefin resin sheet. Since the skin material 6 needs to be colored, a new material is used instead of a recycled material.

On the other hand, the molding die is formed of an upper die 7 and a lower die 8, and has a cavity 9 in which the inner surface of the lower die 8 is excavated into a desired shape. A reinforcing member 11 made of a metal plate is provided upright on the bottom of the cavity 9 via a jig 10. The reinforcing member 11 has a height corresponding to the depth of the cavity 9 while being supported by the jig 10.

A flange 12 circumscribing the side surface of the lower die 8 is formed around the upper die 7, and a fine hole 13 is formed in the flange 12. A semicircular notch 14 (see FIG. 5) is formed in a portion corresponding to the pore 13 at the upper end of the lower die 8. Further, a cutting blade (not shown) for trimming is provided in a portion other than the notch 14 at the upper end of the lower die 8.

Next, a molding method will be described. First, the molding material 1 is heated. In this heating, the materials may be superimposed and then heated together, or the individually heated materials may be superimposed. In this heated state, the nonwoven fabrics 4 and 5 have a high melting temperature, so that the materials do not fuse with each other.

Next, the heated molding material 1 is disposed between the upper mold 7 and the lower mold 8 as shown in FIG. 2, and then the upper mold 7 is lowered as shown in FIG. I do. The molding material 1 has five layers including the skin material 6 and the nonwoven fabric 5 for the same, but since the base material itself is three layers, it is easier than the conventional case where the base material is multi-layered. The handling of the molding material 1 is easy.

Since the cutting blade (not shown) is provided at the upper end of the lower mold 8 as described above, the periphery of the molding material 1 can be trimmed simultaneously with the mold clamping. Since trimming can be performed at the stage of mold clamping before inserting a needle nozzle 15 described later for blowing air, reliable trimming can be performed without being hindered by the needle nozzle 15. In addition, since the mold clamping causes a mold clamping pressure to be applied to the molding material 1, the olefin resin sheets 2, 3 and the skin material 6, which have been heated and softened, enter the gaps between the nonwoven fabrics 4, 5, and are trimmed. The rims are fused to each other.

After clamping, as shown in FIG.
3, the needle nozzle 15 is inserted, and the tip is inserted between the two olefin resin sheets 2 and 3. At this time, since the notch 14 is formed at the upper end of the lower die 8 corresponding to the needle nozzle 15, the mold clamping pressure is weakened only at that portion, and the olefin resin sheets 2, 3 at that portion are formed.
The melting force between them becomes weaker, and the needle nozzle 15 can be easily inserted between them.

Then, air is blown between the two olefin resin sheets 2 and 3 from the inserted needle nozzle 15. Then, the two olefin resin sheets 2 and 3 are closely adhered to the inner surfaces of the upper mold 7 and the lower mold 8, respectively, and are thermoformed. In particular, the lower olefin resin sheet 3 is hollow while expanding toward the lower mold 8. The part 16 is formed. At the same time, the softened lower olefin resin sheet 3 is
Wrap one. Even if the olefin resin sheet 3 wrapping the reinforcing material 11 abuts on the upper olefin resin sheet 2 (nonwoven fabric 4), there is a cavity 9 as an air passage before and after the reinforcing material 11 as shown in FIG. Therefore, the air from the needle nozzle 15 also flows into the space on the opposite side of the reinforcing member 11. Therefore, the olefin resin sheet 3 completely covers the reinforcing member 11 except for the trace 17 of the jig 10 (see FIG. 7) due to the pressure of the air flowing around the reinforcing member 11.

When the thermoforming of the olefin resin sheets 2 and 3 is completed, the blowing of air from the needle nozzle 15 is stopped.
After returning the inside of the mold to the atmospheric pressure, the needle nozzle 15 is pulled out. A trace of the needle nozzle 15 is slightly removed but remains thin, so that there is not much problem in appearance. Then, open the upper mold 7 and the lower mold 8,
The interior part 18 is taken out.

The obtained interior part 18 has a three-layer structure of two olefin resin sheets 2 and 3 and one polyester nonwoven fabric 4 as a base material. It is advantageous. Further, since the olefin resin sheet 2 provided with the skin material 6 is not exposed to the outside, an inexpensive recycled material can be used, and also in this respect, the cost can be reduced.

Further, in the interior part 18, since the reinforcing member 11 wrapped with the olefin resin sheet 3 is provided in the hollow portion 16, the rigidity of the hollow portion 16 is improved. In addition, since the tip of the reinforcing material 11 wrapped by the olefin resin sheet 3 is in contact with the upper olefin resin sheet 2 (nonwoven fabric 4), the reinforcing material 11 becomes a "stretch material" and the rigidity of the hollow portion 16 is reduced. Further improve. Further, since the reinforcing member 11 faces the inside of the hollow portion 16, there is no change in the appearance of the hollow portion 16, which is advantageous in appearance.

Furthermore, since the nonwoven fabric 4 sandwiched between the upper and lower olefin resin sheets 2 and 3 is provided in the hollow portion 16 in a cross-linked state, when the hollow portion 16 is going to deform, The nonwoven fabric 4 is pulled, producing a reaction force against it. Therefore, the sectional rigidity of the hollow portion 16 is improved, and the deformation is suppressed.

Further, in this embodiment, since the nonwoven fabric 5 is interposed between the olefin resin sheet 2 and the skin material 6 with the expectation of its air permeability, air can be held in the nonwoven fabric 5. An air pocket 19 (illustrated by an imaginary line in FIG. 6) can be prevented from being generated between the skin material 6 and the olefin resin sheet 2. Therefore, the surface of the skin material 6 becomes flat, and the appearance and the touch are improved.

FIGS. 8 to 10 show a second embodiment of the present invention. In the second embodiment, the needle nozzle 15
Instead of being inserted between the two olefin resin sheets 2 and 3, instead of being inserted from the lower olefin resin sheet 3,
Needle nozzle 15 between two olefin resin sheets 2 and 3
Is to be positioned. for that reason,
As shown in FIG. 10, a projection 21 is formed on the upper end of the lower mold 20, and a pore 22 corresponding to the pore 13 of the upper mold 7 is formed on the projection 21. Further, an air vent hole 23 is formed near the insertion portion of the needle nozzle 15 in the upper die 7.

In the second embodiment, the upper die 7 and the lower die 20
When the is tightened, the convex portion 21 of the lower mold 20 strongly presses the lower olefin resin sheet 3, so that a step portion 24 is formed on the olefin resin sheet 3. The needle nozzle 15 has a fine hole 13,
22 and is inserted toward the step 24 so that the step 24
(Olefin resin sheet 3), the tip of the needle nozzle 15 is located between the two olefin resin sheets 2, 3. In particular, since the upper olefin resin sheet 2 is sucked and fixed from the air vent hole 23, the tip of the inserted needle nozzle 15 is positioned between the two olefin resin sheets 2 and 3 as positioned in advance. Will do.

If the tip of the needle nozzle 15 is located between the two olefin resin sheets 2 and 3, the remaining interior parts can be obtained by blowing air from the needle nozzle 15 as in the first embodiment. Is obtained. In the interior part obtained in the second embodiment, the trace of the removal of the needle nozzle 15 remains only in the lower olefin resin sheet 3 and does not remain in the joining portion of the two olefin resin sheets 2 and 3. This is suitable for products whose appearance is important. Other configurations and operational effects are the same as those of the first embodiment, and therefore, common portions are denoted by the same reference numerals, and redundant description will be omitted.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a molding material according to a first embodiment.

FIG. 2 is an exploded sectional view showing a molding material and a mold.

FIG. 3 is a cross-sectional view showing a state where a molding material is clamped and trimmed.

FIG. 4 is a cross-sectional view showing a state in which air is blown from a needle nozzle.

FIG. 5 is a side view showing a part into which needle nozzles of an upper die and a lower die are inserted.

FIG. 6 is a cross-sectional view of the interior component taken out of the mold.

FIG. 7 is a sectional view taken along the line SA-SA shown in FIG. 6;

FIG. 8 is a sectional view showing a state in which the needle nozzle according to the second embodiment is inserted into a step portion.

FIG. 9 is a sectional view showing a state in which air is being blown out from a needle nozzle.

FIG. 10 is a side view showing a portion into which needle nozzles of an upper die and a lower die are inserted.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Molding material 2, 3 Olefin resin sheet 4, 5 Nonwoven fabric 6 Skin material 7 Upper die 8, 20 Lower die 11 Reinforcement material 14 Notch 15 Needle nozzle 16 Hollow part 18 Interior parts 19 Air pocket 23 Air vent hole 24 Step part

 ────────────────────────────────────────────────── ─── Continuing from the front page (72) Inventor Ichiro Yuzawa 33 Onna, Atsugi-shi, Kanagawa Pref. In-house F-term (reference) 3D023 BA01 BB07 BC00 BD02 BE07 BE31 4F100 AK03A AK03C AK41B AT00D BA03 BA04 BA10A BA10D BA13 DB00 DG15B EC032 EC051 EJ202 EJ422 GB08 GB31 4F208 AA03 AA24 AC03 AD05 AD08 MC12 AG03 MB03 MG04 MG11 MH06 MJ05 MJ22 MJ23 MW02 MW23 MW26

Claims (11)

[Claims] 1. A hollow portion is defined by recessing at least one of the mating surfaces of two thermoformed impermeable olefin resin sheets, and the olefin is located between the two olefin resin sheets. An interior part comprising a polyester nonwoven fabric having a melting temperature higher than a melting temperature of a resin. 2. The interior part according to claim 1, wherein the non-woven fabric of polyester is arranged in a hollow portion in a cross-linked state. 3. The interior part according to claim 1, wherein a skin material is provided in a laminated state on an outer surface of at least one olefin resin sheet. 4. The interior part according to claim 3, wherein the skin material is non-permeable, and a non-woven fabric made of synthetic resin and having good air permeability is interposed between the skin material and the olefin resin sheet. Interior parts characterized by: 5. The interior part according to any one of claims 1 to 4, wherein the interior part of the olefin resin sheet forming a hollow portion is wrapped with the olefin resin sheet, and An interior part, wherein a reinforcing material facing the inside of the hollow portion is provided. 6. The interior part according to claim 5, wherein a tip of the reinforcing material wrapped by the olefin resin sheet is in contact with a facing surface of the hollow part. 7. A molding material having a three-layered base material is formed by interposing a polyester nonwoven fabric having a melting temperature higher than the melting temperature of the olefin resin between two olefin resin sheets. After heating the material, the mold is placed between a pair of molds provided with a cavity having a desired shape, the mold is clamped, and a mold clamping pressure is applied to the olefin resin sheet. Air is blown by inserting a needle nozzle between the two olefin resin sheets, and at least one of the mating surfaces of the two olefin resin sheets is depressed while the two olefin resin sheets are closely adhered to the inner surface of the mold and thermoformed. A method for manufacturing an interior component, wherein a hollow portion is defined by forming the hollow portion. 8. The method for manufacturing an interior part according to claim 7, wherein a cutout is formed at a position corresponding to the needle nozzle on a surface of one of the molds on which the olefin resin sheet is pressed. Interior parts manufacturing method. 9. The method of manufacturing an interior part according to claim 7, wherein trimming is performed around a molding material simultaneously with mold clamping. 10. The method for producing an interior part according to claim 7, wherein a step is formed on one of the olefin resin sheets at the time of mold clamping.
A method for manufacturing an interior part, comprising inserting a needle nozzle into the step to position the tip of the needle nozzle between two olefin resin sheets. 11. The method for manufacturing an interior part according to claim 10, wherein an air vent hole is formed near an insertion portion of a needle nozzle in at least one of the molds, and a corresponding olefin resin sheet is sucked from the air vent hole. A method for producing an interior part, characterized by comprising: