JP2003260718A - Method for manufacturing automotive interior trim material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an automotive interior trim material such as an automotive molded ceiling, a sunshade and a deck board, in which resources can be used without waste and manufacturing cost is reduced and industrial wastes being the origin of the environmental disruption can be decreased. <P>SOLUTION: The method for manufacturing the automotive interior trim material comprises slicing a semirigid urethane foam block 1 to a specified thickness to form a sheet-like core material 2, laminating the core material with fiber mats 4 and 5 comprising a synthetic fiber or a natural fiber such as a glass fiber, a carbon fiber and a hemp, laminating surface layer materials 6 and 7 thereon, placing this between molds 8 and 9, heating and pressing it to fuse these layers and then, trimming this multi-layered laminated product. In this method, a surface layer part 3 of the semirigid urethane foam block cut down as an end material during slicing the core material is ground and wastes 11 of trimming generated during trimming are also ground and these are mixed together at a specified ratio and 10-30 wt.% urethane resin are added therein and the mixture is heated and pressed by molds 18 and 19 to mold it into a required shape. <P>COPYRIGHT: (C)2003,JPO

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing interior materials for automobiles such as molded ceilings, sunshades and deck boards of automobiles. 2. Description of the Related Art When manufacturing interior materials for automobiles such as molded ceilings and sunshades using semi-rigid urethane foam as a core material, first, a block of semi-rigid urethane foam is molded, and the block is formed into a predetermined size. However, the surface part cut off at this time is called a skin, and it is difficult to use as a core material because it is a non-foamed hard and brittle, so it has been conventionally discarded Was. [0003] A fiber mat made of synthetic fibers or natural fibers such as glass fiber, carbon fiber, and hemp is laminated on the core material of the semi-rigid urethane foam, and a surface layer material is laminated.
After sandwiching this with a press die and heating and pressing to fuse the above layers, trimming the multi-layered product produces an interior material for automobiles. Since different materials are firmly adhered and integrated, separation is difficult and recycling is difficult, and they have conventionally been disposed of. [0004] By the way, the above-mentioned industrial waste has been conventionally incinerated or landfilled.
Since resources could not be used effectively and the environment could be destroyed, it was necessary to quickly establish countermeasures. In view of the above, the present invention is intended to contribute to resource saving and environmental conservation by recycling the above-described surface layer portion and trim scraps which have been conventionally discarded when manufacturing automotive interior materials. In order to achieve the object, a method for manufacturing an interior material for an automobile according to the present invention is to form a plate-shaped core material by slicing a semi-rigid urethane foam block to a predetermined thickness. A fiber mat made of synthetic fiber such as glass fiber, carbon fiber, hemp, polypropylene fiber, or natural fiber or a mixed fiber thereof is laminated on a core material, and a surface layer material is laminated. In the method for manufacturing an interior material for an automobile in which the above layers are trimmed by applying pressure, the surface portion of the semi-rigid urethane foam block cut off as an end material at the time of slicing the core material is used. While pulverizing, trim chips generated during the trimming are pulverized, mixed at a predetermined ratio, added with a urethane resin in an amount of 10 to 30% by weight, and filled in a molding die. It is characterized by forming into a required shape by filling, heating and pressing. Next, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a process of manufacturing a molded ceiling. FIG. 1 (a) shows a semi-rigid urethane foam formed into a substantially cubic shape by filling a foaming urethane resin into a mold and heating and pressing the mold. Block (density = 0.02)
0 to 0.045), and the block 1 is sliced into a plate shape having a predetermined thickness (3 to 10 mm) as shown in FIG. Further, the surface layer portion 3 of the block, which is cut off as an end material at the time of slicing, is reused to manufacture a deck board through a process described later. A fiber mat made of a synthetic fiber such as glass fiber, carbon fiber, hemp or the like or a natural fiber is impregnated with a thermosetting resin or a thermoplastic resin in advance, or both sides of the core material 2 are bonded with heat for bonding. A curable resin or a thermoplastic resin is applied in advance, and the fiber mats 4 and 5 are laminated on both sides of the core material 2 as shown in FIG.
A skin material 6 made of a fabric (a cloth), a needle-punched nonwoven fabric, a plastic form laminate knitted fabric, or the like is laminated on the surface of the above, and a backing material 7 such as a polyester nonwoven fabric or paper is polymerized on the other fiber mat 5, and this laminated product is As shown in (d), the layers are sandwiched by the molds 8 and 9 and heated and pressed to fuse the respective layers as shown in (e) to form a predetermined three-dimensional shape. Is trimmed and the trim ceiling 11 is formed by separating the trimming waste 11 as shown in FIG. Next, the surface layer portion 3 cut off as an end material at the time of slicing the block 1 and the trim waste 11
A method of manufacturing a deck board using the method will be described with reference to FIGS. As shown in FIGS. 2 (g) and 2 (h), the surface layer portion 3 and the trim waste 11 are first pulverized into chips having an outer diameter of 4 to 15 mm by passing through a pulverizer. Then, a urethane resin is added in an amount of 10 to 30% by weight, filled in a molding die, and heated and pressed to form a deck board substrate 12a, 12b, 12c having a required shape as shown in (i).
Is molded. On the other hand, as shown in FIG. 3 (j), both sides of fiber mats 13 and 14 made of synthetic fiber such as glass fiber, carbon fiber, hemp, polypropylene fiber, or natural fiber or a mixed fiber thereof are provided on both surfaces. Adhesive film 1
5 respectively, and these are mounted on the deck board substrate 12.
a, 12b, and 12c, a skin material 16 made of a carpet, a fabric (fabric), a needle-punched nonwoven fabric, a plastic form laminate knit, or the like is laminated on the front side of one fiber mat 13;
A backing material 17 such as a polyester nonwoven fabric or paper is laminated on the back side of No. 4, and this multi-layered product is molded as shown in FIG.
By sandwiching and heating and pressurizing by 19,
As shown in (l), the respective layers are fused to form a predetermined three-dimensional shape, and this is trimmed to obtain (m)
The deck board 20 is formed as shown in FIG. Note that the deck board substrates 12a, 12a
The hardness of b, 12c can be arbitrarily set by changing the mixing ratio of the surface layer portion 3 and the trim debris 11, the size of the pulverized chips, the amount of urethane resin added, and changing the finished density. The size of the tip is outside diameter 4-1
The range is 5 mm, and the added amount of the urethane resin is 10 to 30.
By setting the weight%, rigidity suitable for deck board substrate,
Strength is obtained. The deck board 20 manufactured on the basis of the deck board substrate is lightweight and strong because the fiber mats 13 and 14 are heat-sealed on both sides. Also,
By making the width of the deck board substrates 12a, 12b, 12c narrower than the fiber mats 13, 14, the skin material 16, and the backing material 17, the end of the deck board 20 is formed by the molds 18, 19. As shown in FIG. 4, the edges of the deck board substrates 12a, 12b and 12c are wrapped in a bag-like shape when the fiber mats 13 and 14, the skin material 16 and the backing material 17 are adhered to each other. This prevents the deck board substrate from collapsing and ensures the required rigidity as a product. In addition, this skin material 1
Surface materials such as 6, backing material 17 and the like can be attached later. As described above, according to the method of manufacturing an interior material for an automobile according to the present invention, a semi-rigid urethane foam block is sliced to a predetermined thickness to form a plate-shaped core material, and the core material is formed on the core material. A fiber mat made of glass fiber, carbon fiber, hemp, polypropylene fiber, or other synthetic fibers or natural fibers or a mixture of these fibers is laminated, and the surface layer material is laminated. This is sandwiched by a press mold and heated and pressed. After fusing the above layers, in the method for manufacturing an automotive interior material for trimming this multi-layered product, the surface layer portion of the semi-rigid urethane foam block cut off as an end material when slicing the core material is pulverized. Trim chips generated during the trimming are pulverized, mixed at a predetermined ratio, added with a urethane resin in an amount of 10 to 30% by weight, filled in a molding die, and heated.
Since it is formed into a required shape by pressurizing, there are beneficial effects such that resources can be used without waste, manufacturing costs can be reduced, and industrial waste that has been a source of environmental destruction can be reduced.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a process transition diagram of a method for manufacturing an automobile interior material according to the present invention. FIG. 2 is a process transition diagram of the method for manufacturing an automotive interior material according to the present invention. FIG. 3 is a process transition diagram of a method for manufacturing an automobile interior material according to the present invention. FIG. 4 is a sectional view of an edge of an automobile interior material manufactured according to the present invention. [Description of Signs] 1 Semi-rigid urethane foam block 2 Core material 3 Surface portion 4,5 Fiber mat 6 Skin material 7 Backing material 8,9 Mold 10 Molded ceiling 11 Trim chips 12a, 12b, 12c Deck board substrates 13,14 Fiber mat 16 Skin material 17 Backing material 18, 19 Mold 20 Deck board

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (Reference) B29K 105: 26 B29K 105: 26 B29L 31:58 B29L 31:58

Claims (1)

Claims: 1. A semi-rigid urethane foam block is sliced to a predetermined thickness to form a plate-like core material, and a glass fiber, carbon fiber, hemp, polypropylene fiber or the like is synthesized with the core material. After laminating fiber mats made of fibers or natural fibers or a mixture of these fibers, the surface layer material is laminated, this is sandwiched by a press mold, and the above layers are fused by heating and pressing, and then the multi-layer is laminated. In the method for manufacturing an automotive interior material for trimming a product, while crushing a surface layer portion of a semi-rigid urethane foam block cut off as an end material at the time of slicing the core material, crushing trim waste generated at the time of the trimming, Are mixed in a predetermined ratio, and a urethane resin is added in an amount of 10 to 30% by weight, and the mixture is filled in a mold and heated.
A method for producing an interior material for an automobile, comprising forming into a required shape by pressing.