JP2003260716A - Method for manufacturing sunshade and its core material for automobile - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve weight reduction and cost reduction of a sunshade of a sunroof for an automobile and to make good use of resources and to contribute to conservation of environment. <P>SOLUTION: In a process for manufacturing an automotive interior trim material by slicing a semirigid urethane foam block 1 into a sheet-like material with a specified thickness, a surface layer part 3 of the block cut down as an end material during slicing is ground into chips with outer diameters of 4-15 mm and 10-30 wt.% urethane resin are added to them and the mixture is filled into a mold and is heated and pressed to remolding a semirigid urethane foam block 12 and the block is sliced again to the sheet-like material with the specified thickness, which is used as a regenerated core material 2a. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile sunshade slidably provided on an automobile sunroof and a method of manufacturing a core material thereof.

[0002]

2. Description of the Related Art A sunshade provided on a sunroof of an automobile has a U-shaped cross-section guide rail that is provided on the upper side of the opening of a ceiling panel. By being slidably loosely fitted, it is slidably supported in the front-rear direction.

By the way, the conventional sunshade has a core plate made of a metal plate made of aluminum or the like, or a synthetic resin plate or a laminated plate having a rigidity equivalent to that of the sunshade, and a skin such as a fabric attached to the inner side surface of the core plate. However, it is difficult to deform, high rigidity, etc., so that it is difficult to reduce the weight and cost.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and it is possible to reduce the weight and cost of the sunshade,
And to achieve high quality. Further, the present invention provides a sunshade for an automobile, which can contribute to resource saving and environmental protection by recycling end materials that have been conventionally discarded when manufacturing a core material, and a method for manufacturing the core material. Is.

[0005]

Therefore, a method of manufacturing an automobile sunshade core material according to the present invention is a process of manufacturing an automobile interior material by slicing a semi-rigid urethane foam block into a plate having a predetermined thickness. In, the surface layer portion of the block cut off as the end material at the time of slicing was crushed into chips having an outer diameter of 4 to 15 mm, 10 to 30 wt% of urethane resin was added to the chips, and the resulting mixture was filled in a molding die and heated and pressed. It is characterized in that a semi-rigid urethane foam block is reshaped and the block is sliced into a plate having a predetermined thickness. Further, the method for producing an automobile sunshade according to the present invention comprises laminating a fiber mat made of synthetic fiber such as glass fiber, carbon fiber, hemp, etc. or natural fiber on both sides of the regenerated core material produced by the above-mentioned method, The surface material such as fabric is laminated on the surface of the fiber mat, and the backing material such as the non-woven fabric is laminated on the other fiber mat, and each of the above layers is formed by sandwiching this multi-layered product with a molding die and heating and pressing. It is characterized by being bonded and shaped into a predetermined three-dimensional shape.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, embodiments of the present invention will be described with reference to the drawings. FIG. 1 shows a process of manufacturing a sunshade core material with only a so-called virgin material. In FIG. 1A, a foaming urethane resin is filled in a molding die and heated.
A block of semi-rigid urethane foam formed into a substantially cubic shape by pressing (density = 0.020 to 0.04
5), the block 1 is sliced into a plate having a predetermined thickness (3 to 10 mm) as shown in FIG. Further, since the surface layer portion 3 of the block cut off as an end material at the time of this slicing is called a skin, it is difficult to use as a core material because it is a non-foaming hard, brittle and indefinite shape. The part 3 is reused through the process described later. The surface layer portion 3 may occur not only on the upper surface of the block 1 but also on the entire surface as shown in the drawing.

Then, a fiber mat made of synthetic fibers or natural fibers such as glass fiber, carbon fiber, hemp or the like is impregnated with a thermosetting resin or a thermoplastic resin in advance, or heat is applied to both surfaces of the core material 2 for bonding. A curable resin or a thermoplastic resin is applied in advance, and the fiber mats 4 and 5 are laminated on both surfaces of the core material 2 as shown in FIG.
A surface material 6 made of a fabric, a needle punched non-woven fabric, a plastic foam laminated knitted fabric, etc. is laminated on the surface of the above, and a polyester nonwoven fabric, a backing material 7 such as paper is laminated on the other fiber mat 5, and this multi-laminated product is As shown in (d), it is sandwiched by the molding dies 8 and 9 and heated and pressed to fuse the respective layers as shown in (e) to form a predetermined three-dimensional shape. The sunshade 10 is formed by trimming this and separating the trim scraps 11 as shown in (f).

Further, the surface layer portion 3 cut off as a scrap material at the time of slicing the block 1 is passed through a crusher as shown in FIGS.
Crush into m chips. Then, 10 to 30% by weight of urethane resin is added thereto, and the mixture is filled in a molding die and heated and pressed to remold the semi-rigid urethane foam block 12 as shown in (i). Then, the block is sliced into a plate having a predetermined thickness to obtain a recycled core material 2a.

The recycled core material 2a is formed into a sunshade through the same manufacturing process as the core material 2. That is, a fiber mat made of synthetic fibers or natural fibers such as glass fiber, carbon fiber, hemp or the like is impregnated with a thermosetting resin or a thermoplastic resin in advance, or the both sides of the regenerated core material 2a are bonded with a thermosetting resin. Applying resin or thermoplastic resin in advance,
As shown in (k), the fiber mats 4 and 5 are laminated on both surfaces of the recycled core material 2, a skin material 6 such as a fabric is laminated on the surface of one fiber mat 4, and the other fiber mat 5 is laminated. A backing material 7 such as a non-woven fabric is polymerized, and this laminated product is sandwiched by molding dies 8 and 9 as shown in (l) and heated and pressed, whereby the above-mentioned layers are formed as shown in (m). Fuse and shape into a predetermined three-dimensional shape, and then trim this,
The sunshade 10 is molded by separating the trim scraps 11 as shown in (n).

The hardness of the recycled core material 2a can be arbitrarily set by changing the finish density by adjusting the size of the chips crushed from the surface layer portion 3 and the amount of urethane resin added. The outer diameter is in the range of 4 to 15 mm, and the urethane resin is added in an amount of 10 to 30% by weight, whereby sufficient rigidity and strength as a sunshade core material can be obtained. The sunshade manufactured from this core material can be light and strong because the fiber mats 4 and 5 are heat-sealed on both sides.

[0011]

As described above, according to the present invention, it is possible to manufacture a sunshade which is significantly lighter in weight and excellent in shape retention as compared with a conventional sunshade using a metal plate or the like as a substrate, and a semi-rigid urethane foam block. By reusing the waste material generated in the process of slicing, it is possible to reduce the manufacturing cost, use resources without waste, and contribute to environmental conservation.

[Brief description of drawings]

FIG. 1 is a process transition diagram showing a method for manufacturing an automobile sunshade according to the present invention.

FIG. 2 is a process transition diagram showing a method for manufacturing an automobile sunshade according to the present invention.

[Explanation of symbols]

1 block 2 core material 2a recycled core material 3 surface layer 4,5 fiber mat 6 skin material 7 Backing material 8,9 Mold 10 sun shade 12 blocks

Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) B29L 31:58 B29L 31:58

Claims (2)

[Claims] 1. In the process of manufacturing an automobile interior material by slicing a semi-rigid urethane foam block into a plate having a predetermined thickness, the surface layer portion of the block cut off as an end material during slicing has an outer diameter of 4 to 4. A semi-rigid urethane foam block is re-molded by crushing it into 15 mm chips, adding 10 to 30 wt% of urethane resin to this, filling it in a mold, and applying heat and pressure. The block is also plate-shaped with a predetermined thickness. A method for producing a sunshade core material for automobiles, which comprises slicing into pieces. 2. The regenerated core material produced by the method according to claim 1 is laminated on both sides with a fiber mat made of synthetic fiber such as glass fiber, carbon fiber, hemp or natural fiber, and the surface of one fiber mat. A fabric or other skin material, and the other fiber mat is laminated with a non-woven fabric or other backing material, and the multi-layered product is sandwiched by a mold and heated and pressed to bond the above layers to each other to form a predetermined solid body. A method for manufacturing an automobile sunshade characterized by being shaped.