JP2004058303A - Method for manufacturing interior finishing base material and interior finishing base material manufactured by the method - Google Patents

Method for manufacturing interior finishing base material and interior finishing base material manufactured by the method Download PDF

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JP2004058303A
JP2004058303A JP2002216480A JP2002216480A JP2004058303A JP 2004058303 A JP2004058303 A JP 2004058303A JP 2002216480 A JP2002216480 A JP 2002216480A JP 2002216480 A JP2002216480 A JP 2002216480A JP 2004058303 A JP2004058303 A JP 2004058303A
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Japan
Prior art keywords
thermoplastic resin
base material
skin material
web layer
solidified
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JP2002216480A
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Japanese (ja)
Inventor
Masayuki Shimomukai
下向　正之
Kazuhiro Tawada
多和田　和広
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Takanichi Co Ltd
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Takanichi Co Ltd
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Priority to JP2002216480A priority Critical patent/JP2004058303A/en
Publication of JP2004058303A publication Critical patent/JP2004058303A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/14—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps
    • B29C43/146—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps for making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C43/183—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an interior finishing base material with a skin material having a sufficient rigidity and an excellent light weight property, and to provide the interior finishing base material manufactured by the method. <P>SOLUTION: The method for manufacturing the interior finishing base material comprises a primary pressurizing step of pressurizing and compressing by clamping molds 10a, 10b so that the molds, 10a, 10b become smaller in thickness than a final product to pressurize to compress and a secondary pressurizing step of cooling to solidify a thermoplastic resin by openings the molds 10a, 10b so as to form a thickness of a final product. A fiber web layer 1 manufactured by this method is made of a low density layer having many cavity parts 3 therein, and the skin material 2 is integrally adhered to the surface in which the thermoplastic resin is melted and solidified. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は十分な剛性を有しており、しかも軽量性にも優れた表皮材付きの内装基材の製造方法およびその方法により製造された内装基材に関するものである。
【０００２】
【従来の技術】
例えば、自動車等に用いられる内装基材として、図６に示されるように、麻等の長繊維と熱可塑性繊維とを混合した繊維ウェブ層３０を加熱後、冷間プレス成形したものや、熱可塑性樹脂が付着している長繊維からなる繊維ウェブ層３０を熱間プレス成形したものが知られている。
【０００３】
このような内装基材は、繊維どうしを熱可塑性繊維で融着した構造であり、内部に多数の空洞部があるため軽量化を図れるという利点を有しているものの、繊維どうしが点接触の状態で絡んだ状態であり、十分な剛性を得ることはできないものであった。従って、一定値以上の剛性を確保しようとすると、全体の繊維密度を高くする必要があり、重量的に重くなるという問題点があった。
一方、内装基材の表面には表皮材を貼り合わせるのが普通であるが、成形上、型クリアランスを小さくする必要性から結果的には基材厚さが薄くなって十分な剛性を確保することができないという問題点や、成形時の熱と圧力により表皮材が大きなダメージを受けてしまうという問題点があった。
【０００４】
【発明が解決しようとする課題】
本発明は上記のような従来の問題点を解決して、表皮材に大きなダメージ与えることなく繊維ウェブ層上に強固に貼り合わせることができる内装基材の製造方法を提供すること、また繊維ウェブ層全体が低密度で軽量性に優れており、しかも十分な剛性と厚みを有している内装基材を提供することを目的として完成されたものである。
【０００５】
【課題を解決するための手段】
上記の課題を解決するためになされた本発明は、所定形状のキャビティを有する一対の成形型間に、予備加熱して熱可塑性樹脂を溶融状態とした繊維ウェブ層と表皮材とをセットし、次いで、成形型を最終製品の厚みよりも小さい厚みとなるように型締めして加圧圧縮する１次加圧工程と、前記熱可塑性樹脂が固まる前に成形型を最終製品の厚みとなるように開いて熱可塑性樹脂を冷却固化する２次加圧工程の２段階の加圧処理を施すことを特徴とする内装基材の製造方法と、この方法により製造され、熱可塑性樹脂を含浸させた繊維ウェブ層の表面に表皮材を一体に貼着した内装基材であって、前記繊維ウェブ層は各繊維間に熱可塑性樹脂が十分に含浸・固化されているとともに、内部に多数の空洞部が形成された低密度な層からなり、一方、表皮材は繊維ウェブ層の表面に溶出・固化した熱可塑性樹脂により一体的に貼着してあることを特徴とする内装基材である。
【０００６】
【発明の実施の形態】
以下に、図面を参照しつつ本発明の好ましい実施の形態を示す。
図面は、本発明を自動車の内装基材に適用した場合を示すものであり、図１において、１は熱可塑性樹脂を含浸させた繊維ウェブ層、２はその表面に一体に貼着された表皮材である。
そして本発明で得られる内装基材では、前記繊維ウェブ層１は各繊維間に熱可塑性樹脂４が十分に含浸・固化されているとともに、内部に多数の空洞部３が形成された低密度な層からなり、一方、表皮材２は繊維ウェブ層１の表面に溶出・固化した熱可塑性樹脂４により一体的に貼着した構造となっている。
このような構成とすることにより、繊維ウェブ層１の内部に無数の空洞部３があって低密度で軽量性に優れているとともに、繊維ウェブ層１を構成する各繊維間に熱可塑性樹脂４が十分に含浸・固化して十分な剛性を確保し、更に表面には表皮材２が熱可塑性樹脂の固化により一体的に貼着された有用性の高い内装基材とすることができるのである。
【０００７】
前記繊維ウェブ層１を構成する繊維としては、麻、木質、木綿、竹、パルプ等の天然繊維や、ガラス繊維、炭素繊維等の無機繊維や一般的な有機繊維を用いることができ、これらの一種または二種以上を任意に選択することができる。これらの天然繊維、無機繊維、有機繊維の合計は、重量％で３０〜７０％とし、残部を熱可塑性樹脂とするものが好ましい。特に、基材剛性の観点からは熱可塑性樹脂を重量％で４０〜６０％とするのが好ましい。
また、このような繊維を用いて繊維ウェブ層１を形成し、あるいは必要に応じてニードルパンチを行い繊維が絡合した繊維ウェブ層１を形成する。
【０００８】
熱可塑性樹脂としては、ポリプロピレン樹脂、ポリエチレン樹脂、ポリスチレン樹脂、ＡＳ樹脂、ＡＢＡ樹脂、ウレタン樹脂等を用いることができる。この熱可塑性樹脂は、具体的には繊維状のものとして前記繊維ウェブ層１に混入させることができる。混入量としては、前述したように重量％で３０〜７０％、好ましくは４０〜６０％の範囲である。
【０００９】
表皮材２としては、繊維編織物、不織布やこれらとポリウレタン発泡体、ポリプロピレン発泡体との積層品等を用いることができる。ただし、繊維編織物や不織布は前記熱可塑性樹脂の融点よりも高い融点を有する繊維からなるものを用いる。
【００１０】
次に、このような内装基材の製造方法について説明する。
先ず、図２に示されるように、所定形状のキャビティを有する上下一対の雌雄型からなる成形型１０ａ、１０ｂ間に、予備加熱して熱可塑性樹脂を溶融状態とした繊維ウェブ層１と表皮材２とをセットする。なお、１１は表皮材２を固定するクランパーである。
この時、成形型１０ａ、１０ｂの型温度は、熱可塑性樹脂が固化可能な１０〜６０℃程度の温度に調節しておく。また、表皮材２として、キャビティ意匠面の形状に予備成形したものを使用することもできる。この予備成形は成形型１０ａ、１０ｂ内であっても、また外部の成形型によるものであってもよい。
【００１１】
次いで、図３に示されるように、成形型１０ａ、１０ｂを最終製品の厚みよりも小さい厚みとなるように型締めして加圧圧縮する１次加圧工程を施す。
この１次加圧工程は、熱可塑性樹脂の融点以上で分解温度以下の温度範囲で行うものであり、繊維ウェブ層１と表皮材２をキャビティに沿って所定形状とするとともに、繊維ウェブ層１を構成する天然繊維、無機繊維、有機繊維に熱可塑性樹脂を含浸させて繊維どうしの接着力を高めるものである。そして、この加圧圧縮は１．５〜４ＭＰａの強い圧力で行われ、表皮材２にダメージを与えないように所定の圧力値に達したら直ちに終了して次工程へ移る。
【００１２】
次いで、図４に示されるように、前記熱可塑性樹脂が固まる前に成形型１０ａ、１０ｂを最終製品の厚みとなるように開いて熱可塑性樹脂を冷却固化する２次加圧工程を施す。
この２次加圧工程は、熱可塑性樹脂が凝固してしまう前に成形型１０ａ、１０ｂを最終製品の厚みとなるように開くことで、繊維の復元力により厚み方向に膨張させ基材の厚みを確保するものである。これにより、繊維ウェブ層１は内部に多数の空洞部３が形成されて低密度な層となり、しかも繊維ウェブ層を構成する各繊維間には熱可塑性樹脂が十分に含浸・固化して高剛性な層となる。この結果、簡易なハニカム構造体となって、十分な軽量化と剛性の確保ができることとなる。また、これと同時に表皮材２も熱可塑性樹脂の接着力でもって繊維ウェブ層１の表面に強固に貼着一体化されることとなる。
なお、この２次加圧工程は１次加圧工程に比べて熱および圧力とも低いため、表皮材２に与えるダメージが小さく表皮材２の損傷を極力抑えることが可能となり、また耐熱性の低い安価な表皮材の使用も可能となる。
【００１３】
なお図示のものでは、図２〜４に示されるように、成形型１０ｂ側の基台１２上に高さの異なるエンドブロック１２ａ、１２ｂが設けられており、該エンドブロック１２ａ、１２ｂの上端面のいずれかを、成形型１０ａ側の基盤１３に設けられたガイド柱１３ａの下端面に当接させることにより前記１次加圧工程と２次加圧工程の位置決めを行うように構成されている。即ち、１次加圧工程の場合はエンドブロック１２ａの上端面とガイド柱１３ａの下端面を当接させ、一方、２次加圧工程の場合はエンドブロックを矢印方向へスライドさせてエンドブロック１２ｂの上端面とガイド柱１３ａの下端面を当接させるのである。ただし、成形型１０ａ側のプレス機構に位置決め手段を設ければ、上記のようなエンドブロックを必要としないことは勿論である。
【００１４】
このようにして得られた内装基材は、熱可塑性樹脂を含浸させた繊維ウェブ層１の表面に表皮材２を一体に貼着した内装基材であって、前記繊維ウェブ層１は各繊維間に熱可塑性樹脂４が十分に含浸・固化されているとともに、内部に多数の空洞部３が形成された低密度な層からなり、一方、表皮材２は繊維ウェブ層１の表面に溶出・固化した熱可塑性樹脂４により一体的に貼着した構造である。従って、繊維ウェブ層１は十分な剛性を確保しているうえに、多数の空洞部３を有して密度が低く内装材全体の軽量化を大幅に改善することができるものである。また、熱可塑性樹脂が浸透固化して形成された構造であり層間剥離を起こしにくく、更には表皮材２も一体化しているので剥がれにくいものとなる。
また、１次加圧工程と２次加圧工程の２段階の加圧処理を施すようにしたので、表皮材への熱および圧力のダメージが小さくなり、表皮材の損傷を極力抑えることが可能となるとともに、耐熱性の低い安価な表皮材の使用も可能となるという利点もある。
【００１５】
なお、前記繊維ウェブ層１の構造について説明すると、図５（ａ）の拡大断面図に示されるように、例えば天然繊維（ケナフ）１ａと無機繊維（カーボン繊維）１ｂとが絡合されていて、熱可塑性樹脂（ポリプロピレン）４が各繊維１ａ、１ｂ間に十分に含浸した状態となっており、また所々には空洞部３が形成された構造となっている。この結果、繊維ウェブ層１は十分な剛性と軽量性を満足できることとなる。
これに対し、同一の繊維と熱可塑性樹脂からなるが、本発明のような１次加圧工程と２次加圧工程の２段階の加圧処理を施さない場合には、図５（ｂ）の拡大断面図に示されるように、各繊維１ａ、１ｂは点状に分散した熱可塑性樹脂４により連結された構造となっており、剛性の確保ができないものとなる。
【００１６】
【実施例】
麻繊維２５重量％、カーボン繊維２５重量％、ポリプロピレン繊維５０重量％を混合した繊維ウェブ層（目付量：１２００ｇ／ｍ２）と、ポリプロピレン繊維からなる織物とポリプロピレン発泡体からなるクッションとを積層し予備成形するとともに表皮材を、２５℃に温度調整した成形型内にセットした。次いで、２．５ＭＰａの圧力で型締めして加圧成形した後、成形型を直ちに型クリアランスを最終製品の厚みである４．２ｍｍまで開き、型温度を２５℃としてその状態で２５秒間加圧・冷却処理を施した。
その後、成形品を成形型より取り出し内装基材とした。得られた内装基材は、多数の空洞部が形成された低密度な層からなり、表面に表皮材が一体的に貼着されたもので、従来に比べて十分な軽量化を達成するものであった。
なお、同様の繊維ウェブ層と表皮材を用いて、２段階の加圧処理を施さず最初から型クリアランスを最終製品の厚みである４．２ｍｍとして成形したものと強度の比較を測定した結果、本発明のものは１．５倍以上の強度が得られていることが確認できた。
【００１７】
【発明の効果】
以上の説明からも明らかなように、本発明は表皮材に大きなダメージ与えることなく繊維ウェブ層上に強固に貼り合わせることができる内装基材の製造方法を提供すること、また繊維ウェブ層全体が低密度で軽量性に優れており、しかも十分な剛性と厚みを有している内装基材を提供することができるものである。
よって本発明は従来の問題点を一掃した内装基材の製造方法およびその方法により製造された内装基材として、産業の発展に寄与するところは極めて大である。
【図面の簡単な説明】
【図１】本発明によって得られる内装基材を示す断面図である。
【図２】本発明の製造工程を示す断面図である。
【図３】本発明の１次加圧工程を示す断面図である。
【図４】本発明の２次加圧工程を示す断面図である。
【図５】（ａ）は本発明の繊維ウェブ層を示す拡大説明図、（ｂ）は比較例の繊維ウェブ層を示す拡大説明図である。
【図６】従来例を示す断面図である。
【符号の説明】
１　　　繊維ウェブ層
２　　　表皮材
３　　　空洞部
４　　　熱可塑性樹脂
１０ａ　成形型
１０ｂ　成形型[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for producing an interior substrate with a skin material having sufficient rigidity and excellent lightness, and an interior substrate produced by the method.
[0002]
[Prior art]
For example, as shown in FIG. 6, as an interior base material used for an automobile or the like, a fibrous web layer 30 obtained by mixing a long fiber such as hemp and a thermoplastic fiber is heated and then cold-pressed. There is known a fiber web layer 30 made of long fibers to which a plastic resin is adhered, which is subjected to hot press molding.
[0003]
Such an interior base material has a structure in which fibers are fused with thermoplastic fibers, and has the advantage of being able to reduce the weight because there are a large number of cavities inside, but the fibers have point contact. It was in a tangled state and could not obtain sufficient rigidity. Therefore, in order to secure a rigidity equal to or higher than a certain value, it is necessary to increase the overall fiber density, and there is a problem that the weight becomes heavy.
On the other hand, it is common to attach a skin material to the surface of the interior base material, but due to the need to reduce the mold clearance on molding, the base material thickness is eventually reduced and sufficient rigidity is secured. There is a problem that it cannot be performed, and a problem that the skin material is greatly damaged by heat and pressure during molding.
[0004]
[Problems to be solved by the invention]
The present invention solves the conventional problems as described above, and provides a method for producing an interior base material that can be firmly bonded onto a fiber web layer without significantly damaging a skin material, The present invention has been completed for the purpose of providing an interior base material in which the entire layer has a low density and is excellent in lightness and has sufficient rigidity and thickness.
[0005]
[Means for Solving the Problems]
The present invention has been made to solve the above problems, between a pair of molds having a cavity of a predetermined shape, preheated to set a fiber web layer and a skin material in a molten thermoplastic resin, Next, a primary pressurizing step of clamping and pressing and compressing the mold so as to have a thickness smaller than the thickness of the final product, and a step of bringing the mold into the thickness of the final product before the thermoplastic resin solidifies. A method for producing an interior base material, which is subjected to a two-stage pressure treatment of a secondary pressure step of cooling and solidifying the thermoplastic resin by opening the thermoplastic resin, and a thermoplastic resin produced by this method and impregnated with the thermoplastic resin. An interior substrate in which a skin material is integrally adhered to a surface of a fiber web layer, wherein the fiber web layer is sufficiently impregnated and solidified with a thermoplastic resin between fibers, and has a large number of hollow portions inside. Consists of a low-density layer with , The skin material is an interior base material, characterized in that are integrally bonded by a thermoplastic resin eluted and solidified on the surface of the fiber web layer.
[0006]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
The drawing shows a case where the present invention is applied to an interior substrate of an automobile. In FIG. 1, 1 is a fibrous web layer impregnated with a thermoplastic resin, and 2 is a skin integrally adhered to the surface thereof. Material.
In the interior base material obtained according to the present invention, the fiber web layer 1 has a low density in which the thermoplastic resin 4 is sufficiently impregnated and solidified between the fibers, and in which a large number of hollow portions 3 are formed. On the other hand, the skin material 2 has a structure integrally adhered to the surface of the fibrous web layer 1 with the thermoplastic resin 4 eluted and solidified.
With such a configuration, the countless hollow portions 3 are provided inside the fibrous web layer 1 so that the fiber web layer 1 is excellent in low density and light weight, and the thermoplastic resin 4 is provided between the fibers constituting the fibrous web layer 1. Is sufficiently impregnated and solidified to secure sufficient rigidity, and the surface material 2 can be a highly useful interior base material integrally adhered to the surface by solidification of the thermoplastic resin. .
[0007]
As the fibers constituting the fibrous web layer 1, natural fibers such as hemp, wood, cotton, bamboo, and pulp, inorganic fibers such as glass fibers and carbon fibers, and general organic fibers can be used. One or more types can be arbitrarily selected. The total of these natural fibers, inorganic fibers, and organic fibers is preferably 30 to 70% by weight, and the remainder is preferably made of a thermoplastic resin. In particular, from the viewpoint of the rigidity of the base material, the content of the thermoplastic resin is preferably set to 40 to 60% by weight.
Further, the fiber web layer 1 is formed using such fibers, or if necessary, needle punching is performed to form the fiber web layer 1 in which the fibers are entangled.
[0008]
As the thermoplastic resin, polypropylene resin, polyethylene resin, polystyrene resin, AS resin, ABA resin, urethane resin and the like can be used. This thermoplastic resin can be mixed into the fibrous web layer 1 as a fibrous material. As described above, the mixing amount is in the range of 30 to 70% by weight, preferably 40 to 60% by weight.
[0009]
As the skin material 2, a fiber knitted or woven fabric, a nonwoven fabric, or a laminate of these with a polyurethane foam or a polypropylene foam can be used. However, the fiber woven fabric or the nonwoven fabric is made of a fiber having a melting point higher than the melting point of the thermoplastic resin.
[0010]
Next, a method for manufacturing such an interior base material will be described.
First, as shown in FIG. 2, a fibrous web layer 1 having a thermoplastic resin in a molten state by preheating and a skin material between a pair of upper and lower molding dies 10a and 10b having a cavity of a predetermined shape. Set 2 In addition, 11 is a clamper for fixing the skin material 2.
At this time, the mold temperatures of the molds 10a and 10b are adjusted to a temperature of about 10 to 60 ° C. at which the thermoplastic resin can be solidified. Further, as the skin material 2, a material preformed in the shape of the cavity design surface can be used. This preforming may be in the molds 10a and 10b or by an external mold.
[0011]
Next, as shown in FIG. 3, a first pressurizing step is performed in which the molds 10a and 10b are clamped and pressurized and compressed so as to have a thickness smaller than the thickness of the final product.
This primary pressurizing step is performed in a temperature range not lower than the melting point of the thermoplastic resin and not higher than the decomposition temperature, and the fiber web layer 1 and the skin material 2 are formed into a predetermined shape along the cavity. The natural fiber, the inorganic fiber, and the organic fiber constituting the above are impregnated with a thermoplastic resin to increase the adhesive force between the fibers. This pressurization and compression is performed at a strong pressure of 1.5 to 4 MPa. When the pressure reaches a predetermined pressure value so as not to damage the skin material 2, the process is immediately terminated and the process proceeds to the next step.
[0012]
Next, as shown in FIG. 4, before the thermoplastic resin is hardened, the molds 10a and 10b are opened to the thickness of the final product, and a second pressurizing step of cooling and solidifying the thermoplastic resin is performed.
In this secondary pressing step, the molds 10a and 10b are opened so as to have the thickness of the final product before the thermoplastic resin is solidified, thereby expanding in the thickness direction by the restoring force of the fiber, thereby increasing the thickness of the base material. Is to ensure. As a result, the fiber web layer 1 becomes a low-density layer with a number of hollow portions 3 formed therein, and the thermoplastic resin is sufficiently impregnated and solidified between the fibers constituting the fiber web layer to achieve high rigidity. Layer. As a result, a simple honeycomb structure is obtained, and sufficient weight reduction and rigidity can be ensured. At the same time, the skin material 2 is also firmly adhered and integrated on the surface of the fiber web layer 1 by the adhesive force of the thermoplastic resin.
In addition, since the heat and pressure are lower in this secondary pressurization step than in the primary pressurization step, damage to the skin material 2 is small, and damage to the skin material 2 can be suppressed as much as possible, and heat resistance is low. Inexpensive skin materials can also be used.
[0013]
2 to 4, end blocks 12a and 12b having different heights are provided on the base 12 on the side of the molding die 10b, and upper end surfaces of the end blocks 12a and 12b. Is brought into contact with the lower end surface of the guide column 13a provided on the base 13 on the side of the molding die 10a, thereby performing the positioning in the primary pressing step and the secondary pressing step. . That is, in the case of the primary pressing step, the upper end face of the end block 12a is brought into contact with the lower end face of the guide column 13a, while in the case of the secondary pressing step, the end block is slid in the direction of the arrow to close the end block 12b. Is brought into contact with the lower end surface of the guide column 13a. However, if positioning means is provided in the press mechanism on the side of the molding die 10a, it goes without saying that the end block as described above is not required.
[0014]
The interior base material thus obtained is an interior base material in which a skin material 2 is integrally adhered to the surface of a fibrous web layer 1 impregnated with a thermoplastic resin, and the fibrous web layer 1 is made of each fiber. The thermoplastic resin 4 is sufficiently impregnated and solidified in between, and comprises a low-density layer in which a number of cavities 3 are formed. On the other hand, the skin material 2 elutes on the surface of the fiber web layer 1. This is a structure integrally adhered by the solidified thermoplastic resin 4. Accordingly, the fibrous web layer 1 has sufficient rigidity and has a large number of hollow portions 3 so that the density is low and the weight of the entire interior material can be significantly reduced. Further, the structure is formed by the permeation and solidification of the thermoplastic resin, so that delamination hardly occurs. Further, since the skin material 2 is also integrated, the peeling is difficult.
In addition, since the two-stage pressurization process of the primary pressurization process and the secondary pressurization process is performed, heat and pressure damage to the skin material is reduced, and damage to the skin material can be minimized. In addition, there is an advantage that an inexpensive skin material having low heat resistance can be used.
[0015]
The structure of the fiber web layer 1 will be described. For example, as shown in an enlarged sectional view of FIG. 5A, natural fibers (kenaf) 1a and inorganic fibers (carbon fibers) 1b are entangled. The structure is such that the thermoplastic resin (polypropylene) 4 is sufficiently impregnated between the fibers 1a and 1b, and the cavity 3 is formed in some places. As a result, the fiber web layer 1 can satisfy sufficient rigidity and lightness.
On the other hand, when the same fiber and the thermoplastic resin are used but the two-stage pressing process of the first pressing process and the second pressing process as in the present invention is not performed, FIG. As shown in the enlarged cross-sectional view, the fibers 1a and 1b have a structure in which the fibers 1a and 1b are connected by the thermoplastic resin 4 dispersed in a point-like manner, and rigidity cannot be secured.
[0016]
【Example】
A fibrous web layer (basis weight: 1200 g / m 2 ) in which 25% by weight of hemp fiber, 25% by weight of carbon fiber and 50% by weight of polypropylene fiber are mixed, a woven fabric made of polypropylene fiber and a cushion made of polypropylene foam are laminated. The preform was formed, and the skin material was set in a molding die whose temperature was adjusted to 25 ° C. Then, after the mold is clamped at a pressure of 2.5 MPa and press-molded, the mold is immediately opened with the mold clearance to 4.2 mm, which is the thickness of the final product, and the mold is pressurized for 25 seconds at 25 ° C. at that temperature. -Cooling treatment was applied.
Thereafter, the molded product was taken out of the molding die and used as an interior substrate. The resulting interior base material consists of a low-density layer with a large number of cavities formed, and a skin material is integrally adhered to the surface, achieving a sufficient weight reduction compared to the past. Met.
In addition, the same fiber web layer and skin material were subjected to a two-stage pressurization treatment without applying a two-stage pressure treatment. From the beginning, the mold was molded to a thickness of 4.2 mm, which is the thickness of the final product. It was confirmed that the material of the present invention had a strength 1.5 times or more.
[0017]
【The invention's effect】
As is clear from the above description, the present invention provides a method of manufacturing an interior base material that can be firmly bonded onto a fiber web layer without significantly damaging the skin material, and the entire fiber web layer is provided. It is possible to provide an interior base material having low density, excellent lightness, and sufficient rigidity and thickness.
Therefore, the present invention greatly contributes to industrial development as a method of manufacturing an interior base material that has eliminated the conventional problems and an interior base material manufactured by the method.
[Brief description of the drawings]
FIG. 1 is a sectional view showing an interior substrate obtained by the present invention.
FIG. 2 is a cross-sectional view illustrating a manufacturing process of the present invention.
FIG. 3 is a cross-sectional view showing a primary pressurizing step of the present invention.
FIG. 4 is a cross-sectional view showing a secondary pressurizing step of the present invention.
5A is an enlarged explanatory view showing a fiber web layer of the present invention, and FIG. 5B is an enlarged explanatory view showing a fiber web layer of a comparative example.
FIG. 6 is a sectional view showing a conventional example.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Fiber web layer 2 Skin material 3 Hollow part 4 Thermoplastic resin 10a Mold 10b Mold

Claims (4)

所定形状のキャビティを有する一対の成形型間に、予備加熱して熱可塑性樹脂を溶融状態とした繊維ウェブ層と表皮材とをセットし、次いで、成形型を最終製品の厚みよりも小さい厚みとなるように型締めして加圧圧縮する１次加圧工程と、前記熱可塑性樹脂が固まる前に成形型を最終製品の厚みとなるように開いて熱可塑性樹脂を冷却固化する２次加圧工程の２段階の加圧処理を施すことを特徴とする内装基材の製造方法。Between a pair of molding dies having a cavity of a predetermined shape, a fibrous web layer and a skin material in which the thermoplastic resin has been preheated and melted are set, and then the molding dies have a thickness smaller than the thickness of the final product. A first pressurizing step in which the mold is clamped and pressure-compressed, and a second pressurization in which the thermoplastic resin is cooled and solidified by opening the mold so as to have the thickness of the final product before the thermoplastic resin is hardened. A method for producing an interior base material, comprising performing a two-stage pressure treatment in a process. １次加圧を熱可塑性樹脂が固化可能な温度範囲で、かつ表皮材にダメージを与えないように短時間で行う請求項１に記載の内装基材の製造方法。The method for producing an interior base material according to claim 1, wherein the primary press is performed in a temperature range in which the thermoplastic resin can be solidified and in a short time so as not to damage the skin material. 表皮材として、キャビティ意匠面の形状に予備成形したものを使用する請求項１または２に記載の内装基材の製造方法。The method for producing an interior base material according to claim 1, wherein a material preliminarily molded into the shape of the cavity design surface is used as the skin material. 熱可塑性樹脂を含浸させた繊維ウェブ層の表面に表皮材を一体に貼着した内装基材であって、前記繊維ウェブ層は各繊維間に熱可塑性樹脂が十分に含浸・固化されているとともに、内部に多数の空洞部が形成された低密度な層からなり、一方、表皮材は繊維ウェブ層の表面に溶出・固化した熱可塑性樹脂により一体的に貼着してあることを特徴とする請求項１または２または３の方法により製造された内装基材。An interior substrate in which a skin material is integrally adhered to the surface of a fibrous web layer impregnated with a thermoplastic resin, wherein the fibrous web layer is sufficiently impregnated and solidified with a thermoplastic resin between fibers. It consists of a low-density layer in which a number of cavities are formed, while the skin material is integrally adhered to the surface of the fibrous web layer by a thermoplastic resin eluted and solidified. An interior substrate manufactured by the method according to claim 1.
JP2002216480A 2002-07-25 2002-07-25 Method for manufacturing interior finishing base material and interior finishing base material manufactured by the method Pending JP2004058303A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2737987A3 (en) * 2012-06-21 2014-08-06 Faurecia Innenraum Systeme GmbH Method and device for producing an internal trim lining
US9821509B2 (en) 2013-07-29 2017-11-21 Faurecia Innenraum Systeme Gmbh Method and device for producing an interior covering part

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2737987A3 (en) * 2012-06-21 2014-08-06 Faurecia Innenraum Systeme GmbH Method and device for producing an internal trim lining
US9821509B2 (en) 2013-07-29 2017-11-21 Faurecia Innenraum Systeme Gmbh Method and device for producing an interior covering part

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