JP2002036401A - Mounting material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve designing characteristics of door trims wherein a decorative member is arranged so as to fit a corner part of each door trim by molding a sharp corner part on each base composed of a vegetable material. SOLUTION: An upper door trim 10 is provided with an upper base 11, and an upper skin material 13 composed of a soft elastic material and stretched on a surface of the upper base 11. On the upper base 11, the sharp corner part 11e is molded, and a thin part 11f is molded on a lower end of a side part 11b adjacent to the corner part 11e. When the upper base 11 is molded by heating and compressing, the thin part 11f is pressed more thinly than other parts so that an uncured binder is pushed out from the thin part 11f and that at least a part of it reaches the corner part 11e to fill the inside of the corner part 11e. Thereafter, the binder is cured and the dense sharp corner part 11e is molded on the upper base 11.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface covering material in which a skin material is adhered to a substrate made of a vegetable material, and more particularly to a surface covering material for decorating an inner surface of a vehicle or the like and an outer surface of furniture or the like.

[0002]

2. Description of the Related Art A surface trim for decorating an inner surface of a vehicle or the like or an outer surface of furniture or the like includes, for example, an automobile door trim as shown in FIG. 1. Conventionally, as shown in FIG. It is composed of base materials 1 and 4 made of vegetable material, and skin materials 3 and 6 made of soft elastic material adhered to the surfaces of the base materials 1 and 4, respectively. The base materials 1 and 4 are obtained by impregnating a fibrous or powdery fine plant material with a binder made of a thermosetting resin that binds the plant material to a predetermined thickness. It is molded by heating and compressing into a predetermined shape. Pad materials 2 and 5 made of a soft elastic material are lined with the skin materials 3 and 6, respectively.

[0003]

When the corner 1a is formed on the substrate 1 made of the vegetable material, the corner 1a of the substrate 1 is formed.
When the radius of curvature is set to be small, the vegetable material also contains fibrous materials, so it is difficult to spread to the tip of the corner when compressed, so that the amount of the vegetable material and the binder near the tip is reduced. Since the amount of the binder near the surface of the corner is not sufficient, there is a problem that the strength of the corner of the substrate, particularly the tip, is reduced. In order to prevent this, the radius of curvature of the corner 1a of the substrate 1 has to be set so large that the plant material can sufficiently reach the tip. Also,
As described above, in a corner portion having a small radius of curvature, a thick fibrous vegetable material may be broken because it is excessively bent. Since this broken end is not bonded to other plant material or is weakly bonded even if bonded, it returns to the original state by the reaction force after molding, so that it protrudes from the surface of the base material 1, There was a problem that it would be an obstacle to the adhesion of the skin material. In order to prevent this, the radius of curvature of the corner 1a of the substrate 1 has to be set so large that the fibrous plant material does not break.

[0004] Since the skin material 3 backing the pad material 2 is previously adhered to the base material 1 on which the corner portion 1a having a large radius of curvature is formed by a vacuum forming method, the corner portion having a large radius of curvature is provided. The pad material 2 in contact with 1a was crushed, and the radius of curvature of this portion (the corner 3a of the door trim) was larger than that of the corner 1a of the base material 1. When the decorative member 7 is attached to the corner 3a of the door trim with the edge of the upper surface 7a abutting, a flat surface comes into contact with a curved surface having a large radius of curvature. A relatively large gap S was formed at the joint of the member 7 and the same surface between the door trim and the decorative member 7 was lost, and the design of the door trim was impaired.

Accordingly, an object of the present invention is to provide a surface covering material having good design even if a decorative member is attached to the corner of the surface covering material by forming a sharp corner on a substrate made of a vegetable material. Is to do.

[0006]

SUMMARY OF THE INVENTION The present invention relates to a method of impregnating a fine plant material such as fibrous or powdery material with a binder made of a thermosetting resin for binding the plant material. The base material formed by heating and compressing into a predetermined shape after being deposited to a thickness, and a covering material including a skin material made of a soft elastic material adhered to the surface of the base material. And a thin portion formed in the vicinity of the corner and formed so that the binder before being cured at the time of heat compression is extruded at least to the corner.

[0007] According to this, when the vegetable material impregnated with the binder is heated and compressed, the corners of the base material are compressed into a predetermined pointed shape, while the thin portions of the base material are more compressed than other parts. The binder before being hardened and hardened is extruded from the thin portion, and a part of the binder reaches at least a corner of the base material and fills the inside of the corner. Thereafter, the corners formed on the base material by the curing of the binder become dense and sharp. Further, even if a thick fibrous plant material is excessively bent and broken, the broken end is buried and hardened in the hardened binder and does not protrude from the surface of the base material.

[0008]

According to the present invention, the corners formed on the base material made of vegetable material are dense and sharp,
When a skin material made of soft elastic material is attached to the base material,
Although the skin material adhered to the sharp corner is crushed and the surface of the skin material becomes a curved surface, the radius of curvature of the corner of the surface material can be made sufficiently smaller than the radius of curvature of the corner of the conventional surface material. When the upper surface edge of the decorative member is abutted on the corner of such a decorative material, the flat surface comes into contact with a curved surface having a sufficiently small radius of curvature. Can be made sufficiently small.
Therefore, the same surface of the decorative material and the decorative material can be maintained, and the design of the decorative material can be improved.

Furthermore, even if a thick fibrous plant material is excessively bent and broken, the broken end is embedded in the hardened binder and solidified, so that it protrudes from the surface of the base material. I will not do it. Therefore, since the surface of the corner portion of the base material is a smooth surface, when a skin material is adhered to the base material by a vacuum forming method or the like, the surface of the corner portion of the surface material may also be a smooth surface without unevenness. it can.

[0010]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front view of a vehicular door trim according to an embodiment of the present invention applied to a vehicular door trim. FIG. 1 is a front view of a vehicular door trim. FIG. 2 is a sectional view taken along line 2-2 of FIG. 1.

As shown in FIG. 1, the door trim for a vehicle includes upper and lower door trims 10 and 20 formed in a predetermined shape and a decorative member 30 for decorating the door trim by combining the door trims 10 and 20.

The upper door trim 10 is, as shown in FIG.
An upper base material 11 and an upper skin material 13 made of a soft elastic material (for example, polypropylene) adhered to the surface of the upper base material 11 are provided. The upper base material 11 is formed by heating and compression molding a fine plant material such as a chip, a fiber, or a powder impregnated with a binder made of a thermosetting resin (for example, a phenol resin) as described later. As shown in FIG. 3, it is composed of a generally U-shaped section having an upper portion 11a, a side portion 11b and a lower portion 11c, and a hanging portion 11d extending downward from the lower portion 11c. Side 11
A corner 11e (which may be acute, right or obtuse) formed by b and the lower portion 11c is formed to have a sharp pointed shape with a small radius of curvature. At the lower end of the side portion 11b near the corner 11e, a thin portion 11f thinner than other portions is formed. The thickness of the other parts is, for example, 2.3 to 2.5 mm,
The thickness of the thin portion 11f is, for example, 1.2 to 1.5 mm. The upper skin material 13 is lined with an upper pad material 12 made of a soft elastic material (for example, foamed polypropylene).

Although the above-mentioned plant material uses wood as a raw material, it is not limited to this, and any plant material can be used. For example, plants (eg, kenaf) may be used. May be paper made from plant material.

The lower door trim 20 has the same structure as the upper door trim 10, and as shown in FIG. 2, a lower substrate 21 formed of a fine plant material in a predetermined shape, and a surface of the lower substrate 21. Is provided with a lower skin material 23 made of a soft elastic material (for example, polypropylene). The lower skin material 23 is also lined with a lower pad material 22 made of a soft elastic material (for example, foamed polypropylene).

The decorative member 30 is formed of a synthetic resin or the like in a predetermined shape. As shown in FIG. 2, the decorative member 30 is arranged such that the side surface of the decorative member 30 is flush with the side surface of the upper door trim 10, and The upper edge 31 is brought into contact with the corner 10 a of the upper door trim 10, and is fixedly fastened to the upper and lower door trims 10 and 20 by screws 32. Note that a woodgrain design is applied to the side surface of the decorative member 30.

A method for manufacturing the above-described door trim will be described. First, a method of manufacturing the upper door trim 10 will be described. First, in molding the upper base material 11, the above-described plant material is impregnated with a binder made of a thermosetting resin that binds the plant material. After being deposited to a thickness of, for example, 15 mm, it is heated and compressed.
At this time, the corner portion 11e is compressed into the predetermined pointed shape, while the thin portion 11f is squashed thinner than other portions, and the binder before being hardened is extruded from the thin portion 11f, and a part of the binder is extruded. At least the corner 11e is reached and the inside of the corner 11e is filled. Thereafter, the corners 11e formed on the upper base material 11 by the curing of the binder become dense and sharp. Furthermore, even if a thick fibrous plant material is excessively bent and broken, the broken end is embedded in the hardened binder and solidified. The surface of the corner portion 11e of the upper base material 11 becomes smooth without protruding.

Next, an upper skin material 13 previously lined with an upper pad material 12 is adhered to the upper base material 11 thus formed by a vacuum forming method. At this time, the upper pad material 12 that comes into contact with the sharp corner 11e is crushed, and the surface of the upper skin material 13 (that is, the surface of the upper door trim 10) corresponding to this portion is curved, but the corner of the upper door trim 10 is curved. 10
The radius of curvature a (for example, R1 to 1.5 mm) can be made sufficiently smaller than the radius of curvature (R8 to 9 mm) of the corner portion of the conventional door trim. Further, since the surface of the corner 11e of the upper base material 11 is a smooth surface, the corner 1e of the upper door trim 10 is formed.
The surface of Oa can be a smooth surface without irregularities.

In parallel with this, a lower door trim 20 is manufactured. The method is the same as that of the upper door trim 10. A lower substrate 21 is formed, and a lower pad material 22 is previously lined with the lower substrate 21. The lower skin material 23 thus obtained is attached by a vacuum forming method to manufacture the lower door trim 20.

The decorative member 30 is fastened together with the screws 32 to the upper and lower door trims 10 and 20 thus manufactured.
At this time, since the upper edge 31 of the decorative member 30 is abutted and attached to the corner 10a of the upper door trim 10, the flat surface comes into contact with a curved surface having a sufficiently small radius of curvature. That is, the gap S generated at the joint between the upper door trim 10 and the decorative member 30 can be made sufficiently small. Therefore, the same surface property of the upper door trim 10 and the decorative member 30 is maintained, and the design of the door trim can be improved.

In the above embodiment, the present invention is applied to a door trim formed by combining upper and lower door trims 10 and 20 formed separately from each other, but the present invention can also be applied to a door trim originally formed integrally. .

Further, in the above embodiment, the surface covering material according to the present invention is applied to the door trim for an automobile, but it is formed by heating and compression molding a fine vegetable material impregnated with a binder made of a thermosetting resin. The present invention can also be applied to a surface decoration material made of a base material, for example, a surface decoration material for decorating the inner surface of a vehicle other than the door trim (interior material of the vehicle), a surface decoration material for decorating the outer surface of furniture and the like.

[Brief description of the drawings]

FIG. 1 is a front view of a door trim according to an embodiment of the present invention.

FIG. 2 is a partially enlarged sectional view taken along line 2-2 of FIG.

FIG. 3 is a partially enlarged cross-sectional view of the upper substrate shown in FIG. 1, taken along line 2-2.

FIG. 4 is a partially enlarged sectional view corresponding to FIG. 2 of a conventional door trim.

[Explanation of symbols]

10: upper door trim, 11: upper substrate, 11a: upper part, 1
1b: side portion, 11c: lower portion, 11d: hanging portion, 11e ...
Corner, 11f Thin part, 12 Upper pad material, 13 Upper skin material, 20 Lower door trim, 21 Lower substrate, 22 Lower pad material, 23 Lower skin material, 30 Decorative member, 31 Upper edge, 32 ... screws.

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (reference) // B29K 103: 00 B29K 103: 00 B29L 31:58 B29L 31:58 F term (reference) 3D023 BA01 BB08 BD03 BE03 BE06 BE16 BE31 4F100 AJ02H AK01A AK07 AK33 AR00B BA02 CA23A DB01 DB08 DD01 DE01A DG01A DH00A DJ01 EJ82A GB33 GB81 HB00 JB13A JK07B JL01 4F204 AA01 AA36 AC02 AC04 AD08 AG03 AH26 AH51 FF01 F08 FB01 F08 FB01

Claims (1)

[Claims] 1. A fibrous or powdery fine plant material impregnated with a binder made of a thermosetting resin that binds the plant material is deposited to a predetermined thickness, and then heated. In a base material compressed and molded into a predetermined shape, and in a covering material including a skin material made of a soft elastic material adhered to the surface of the base material, the base material has a sharp corner, And a thin part formed in such a manner that the binder before being cured during the heating and compression is extruded at least to the corner.