JP2017159629A - Inner package and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inner package having a design of a skin conjugated with a substrate with an irregular shape suppressing crumbling ununiformly, where the substrate and the skin are conjugated with nice looking and a manufacturing method therefor.SOLUTION: A member 10 has a substrate 20 and a skin 30 containing a thermoplastic resin for conjugating each other on a boundary surface, the substrate 20 has a sheet shape to which an irregular shape is added, the skin 30 conjugates to a surface of the substrate 20 with following the irregular shape and a heat resistant mesh 40 is inserted to only a part of interlayer between the substrate 20 and the skin 30. The method has a process for conjugating the heat resistant mesh 40 to a part of a non-design surface of the precursor skin which becomes the skin 20, a process for heating a precursor substrate before addition of the irregular shape and a precursor skin to which the heat resistant mesh 40 is conjugated and a process for layering the heated precursor substrate and the precursor skin to which the heat resistant mesh 40 is added to conjugate them integrally with adding the irregular shape.SELECTED DRAWING: Figure 1

Description

  The present invention relates to an interior part and a manufacturing method thereof. More specifically, the present invention relates to an interior part in which a base and a skin are bonded together and a manufacturing method thereof.

  Interior parts having a predetermined uneven shape with interior parts having a skin are often used as interior parts of automobiles, for example, as door trims and instrument panels. Such an interior part is formed by a method in which a heated skin is applied to a substrate provided with a necessary uneven shape while applying pressure using a press. For example, Patent Document 1 below discloses a method for efficiently producing an interior part to which stitch decoration is added using this method.

JP 2014-117835 A

In the method of Patent Document 1, when a heated skin is affixed to a substrate provided with a necessary concavo-convex shape while applying pressure using a press, a nesting provided with protrusions corresponding to the stitches is further provided. Is a method for manufacturing an interior part in which a stitch pattern can be imparted by pushing a thread into the skin.
However, this manufacturing method has a problem that man-hours are required in that a process for pushing in the yarn as described above is required. In addition, there is a problem that it is difficult to manufacture the base body and the skin before being provided with the concavo-convex shape by adopting a more efficient manufacturing method of providing the concavo-convex shape simultaneously with the joining.

For example, when a heated skin is affixed to a substrate provided with a necessary uneven shape while being pressed using a press, the skin is unevenly stretched (and / or developed) according to the uneven shape. This non-uniform stretching is particularly noticeable in a manufacturing method in which a substrate and a skin before being provided with an uneven shape are provided with an uneven shape simultaneously with bonding.
That is, in the epidermis, the portion joined to the concavo-convex convex top, the concave bottom, and the peripheral portion thereof is extended more greatly than the portion joined to the flatter portion. Therefore, for example, when the skin has a pattern, if the skin is to be joined to the substrate by the above-described method, the unevenness is such that the periphery of the uneven top and bottom of the uneven shape is expanded more than the rest. However, there is a problem that the pattern collapses due to stretching. Further, for example, when an outer skin to which a stitch pattern is given by sewing is to be joined to a substrate by the same method as described above, there is a problem that it is difficult to fix the stitch pattern at a target position for the same reason.

  The present invention has been made in view of the above circumstances, and an interior member in which the design of an outer skin bonded to a substrate having a concavo-convex shape is prevented from being disintegrated unevenly, and the substrate and the outer skin are bonded in an attractive manner. And it aims at providing the manufacturing method.

That is, the present invention is as follows.
The interior component according to claim 1 has a base body and an outer skin, both of which contain a thermoplastic resin so as to be bonded at an interface between each other.
The base body has a plate shape with an uneven shape, and the skin is joined to one surface of the base body following the uneven shape,
The gist is that a heat-resistant mesh is interposed only in a part of the interlayer between the base and the skin.
The gist of the interior component according to claim 2 is that in the interior component according to claim 1, the design surface of the skin at the position where the heat-resistant mesh is inserted has a pattern.
An interior part according to claim 3 is the interior part according to claim 2, wherein the pattern is a stitch pattern using a thread.
The gist of an interior component according to claim 4 is that in the interior component according to claim 3, the thread constituting the stitch pattern stitches the skin and the heat-resistant mesh together.
The gist of an interior part according to claim 5 is that in the interior part according to any one of claims 1 to 4, the fiber constituting the heat-resistant mesh is a glass fiber.

The method for manufacturing an interior component according to claim 6 is the method for manufacturing the interior component according to claim 1,
A heat-resistant mesh joining step for joining the heat-resistant mesh to a part of the non-design surface of the precursor skin to be the skin,
A heating step of heating the precursor substrate before the uneven shape is imparted and the precursor skin to which the heat-resistant mesh is bonded;
The precursor substrate, the heat-resistant mesh, and the precursor skin are integrated while superimposing the heated precursor substrate and the precursor skin to which the heated heat-resistant mesh is bonded to give the uneven shape. And a press process for bonding to the gist.
The method for manufacturing an interior part according to claim 7 is the method for manufacturing an interior part according to claim 6, wherein the precursor skin has a pattern on its design surface,
The summary of the heat-resistant mesh joining step is a step of joining the heat-resistant mesh to the non-design surface of the precursor skin in the region having the pattern.
The method for manufacturing an interior component according to claim 8 is the method for manufacturing an interior component according to claim 6, wherein the precursor skin has a stitch pattern using a thread on its design surface,
In the heat-resistant mesh joining step, the heat-resistant mesh is brought into contact with a non-design surface of the precursor skin in a region where the stitch pattern is applied, and the precursor skin and the heat-resistant mesh are stitched together while forming the stitch pattern by sewing. The gist is that it is a step of joining.
The method for manufacturing an interior part according to claim 9 is the method for manufacturing an interior part according to claim 8, wherein the heat-resistant mesh is extended to an edge of the precursor skin,
The gist of the heat-resistant mesh joining step is a step of sewing and joining the precursor skin and the heat-resistant mesh at the edge portion in addition to the sewing for forming the stitch pattern.
The method for manufacturing an interior component according to claim 10 is the method for manufacturing an interior component according to any one of claims 6 to 9, wherein the fiber constituting the heat-resistant mesh is a glass fiber. To do.
An interior part manufacturing method according to claim 11 is the interior part manufacturing method according to claim 1,
A heat-resistant mesh joining step for joining the heat-resistant mesh to a part of the non-design surface of the precursor skin to be the skin,
A heating step of heating the precursor skin to which the heat-resistant mesh is bonded;
A pressing step of superimposing the base body provided with the uneven shape in advance with the precursor skin to which the heated heat-resistant mesh is bonded, and integrally bonding the base body, the heat-resistant mesh, and the precursor skin; The gist is to provide.

In the interior part of the present invention, a heat-resistant mesh is inserted only in a part of the layer between the base and the skin.
For this reason, when the uneven shape is imparted to the substrate, the heat-resistant mesh suppresses the extension of the skin, improves the dimensional stability thereof, and can suppress the uneven design of the skin. Therefore, even if the concavo-convex shape is imparted, it is possible to provide an interior component in which the base and the skin are joined with good appearance. Further, since the heat-resistant mesh is net-like, it is possible to obtain an interior part in which the two are firmly joined even in a portion having the heat-resistant mesh without hindering the joining between the base and the skin.

In the interior part of the present invention, when the design surface of the skin at the position where the heat-resistant mesh is inserted has a pattern, the extension of this pattern is prevented, and the design of the skin is prevented from being broken unevenly, It is possible to make an interior part in which the base body and the skin are joined with good appearance.
In the interior part of the present invention, when the pattern is a stitch pattern using a thread, the stitch pattern is prevented from being stretched, the design of the epidermis is prevented from being broken unevenly, and the base body and the epidermis are beautifully seen. It can be a joined interior part.
In the interior part of the present invention, when the thread constituting the stitch pattern is sewn together with the skin and the heat-resistant mesh, the skin and the heat-resistant mesh are tightly bound by the thread, so that only the skin is stitched. The stitch pattern can be more effectively prevented from being stretched as compared with the case where the pattern is provided. Accordingly, the design of the skin is prevented from being broken unevenly, and the interior part in which the base and the skin are joined with good appearance can be obtained.
In the interior part of the present invention, when the fiber constituting the heat-resistant mesh is glass fiber, the heat-resistant mesh can exhibit excellent heat resistance and dimensional stability, so that the design of the skin is more reliably prevented from being destroyed. Thus, it is possible to provide an interior part in which the base body and the skin are joined with a good appearance.

The method for manufacturing an interior part according to the first invention includes a heat-resistant mesh joining step for joining a heat-resistant mesh to a part of the non-design surface of the precursor skin serving as the skin, and a precursor base before the irregular shape is imparted. The heating process for heating the precursor skin to which the heat-resistant mesh is bonded, the heated precursor substrate, and the precursor skin to which the heated heat-resistant mesh is bonded are superimposed to give an uneven shape, And a pressing step for integrally joining the precursor base, the heat-resistant mesh, and the precursor skin. That is, the precursor skin and the heat-resistant mesh are joined before the heating step.
For this reason, the dimensional stability of the skin in a heating process can be improved. In addition, when joining the precursor substrate to the precursor skin, the heat resistant mesh suppresses the extension of the part where the precursor skin is joined, and the design of the skin of the part is prevented from being unevenly collapsed. The base and the skin can be joined well. Furthermore, since the heat-resistant mesh is mesh-shaped, the bonding between the base and the skin is not hindered, and both of them can be firmly bonded even at a portion provided with the heat-resistant mesh.
In the method for manufacturing an interior part of the present invention, the precursor skin has a pattern on its design surface, and the heat-resistant mesh joining step is a step of joining the heat-resistant mesh to the non-design surface of the precursor skin in the region having the pattern. In this case, the stretch of the pattern where the heat-resistant mesh is bonded is remarkably suppressed, and the design of the skin is prevented from being broken unevenly, so that the base body and the skin can be bonded with a good appearance. Therefore, it is possible to join the base body and the skin with good appearance by suppressing the non-uniform collapse of the design of the skin.

  In the method for manufacturing an interior part according to the present invention, the precursor skin has a stitch pattern using a thread on its design surface, and the heat resistant mesh joining step applies a heat resistant mesh to the non-design surface of the precursor skin in the region where the stitch pattern is applied. In the process of sewing and joining the precursor epidermis and the heat-resistant mesh while forming a stitch pattern by sewing, the threads that make up the stitch pattern are stitched together with the skin and the heat-resistant mesh. Thus, the skin and the heat-resistant mesh are tightly constrained by the thread, and the stitch pattern can be more effectively prevented from stretching compared to the case where the stitch pattern is provided only on the skin. Therefore, it is possible to join the base body and the skin with good appearance by suppressing the non-uniform collapse of the design of the skin.

In the manufacturing method of the interior part of the present invention, the heat-resistant mesh is extended to the end edge portion of the precursor epidermis, and the heat-resistant mesh joining step is further performed at the edge portion in addition to the sewing to form the stitch pattern. In the process where the precursor skin and heat-resistant mesh are joined together by stitching, the skin and heat-resistant mesh are tightly constrained by the thread even at locations other than the stitch pattern, so that the stitch pattern can be stretched more effectively. Can be prevented. In addition, since the heat-resistant mesh is extended to the edge of the precursor skin, the heat-resistant mesh can be fixed by using a restraining frame, so that the stitch pattern can be more effectively prevented from stretching. . From these effects, the substrate and the skin can be joined with a good appearance by suppressing the non-uniform collapse of the design of the skin.
In the method for manufacturing an interior part of the present invention, when the fiber constituting the heat-resistant mesh is glass fiber, excellent heat resistance and dimensional stability can be exhibited. Therefore, it is possible to join the base body and the skin with good appearance by suppressing the non-uniform collapse of the design of the skin.

In the method for manufacturing an interior part according to the second aspect of the invention, a heat-resistant mesh joining step for joining a heat-resistant mesh to a part of the non-design surface of the precursor skin that becomes the skin, and the precursor skin to which the heat-resistant mesh is joined are heated. A heating step, a press step for superimposing a substrate provided with an uneven shape in advance and a precursor skin to which a heated heat-resistant mesh is bonded, and integrally bonding the precursor substrate, the heat-resistant mesh and the precursor skin, Is provided. That is, the precursor skin and the heat-resistant mesh are joined before the heating step.
For this reason, the dimensional stability of the skin in a heating process can be improved. In addition, when joining the precursor substrate and the precursor skin, the heat resistant mesh suppresses the extension of the part where the precursor skin is joined, and the design of the skin of the part is prevented from collapsing unevenly. The base and the skin can be joined well. Furthermore, since the heat-resistant mesh is mesh-shaped, the bonding between the base and the skin is not hindered, and both of them can be firmly bonded even at a portion provided with the heat-resistant mesh.

The present invention will be further described in the following detailed description with reference to the drawings referred to, with reference to non-limiting examples of exemplary embodiments according to the present invention. Similar parts are shown through several figures.
It is the top view and sectional drawing which show typically an example of the interior component of this invention. It is explanatory drawing which shows typically an example of the manufacturing method of the interior component of this invention. It is explanatory drawing which shows typically an example of the manufacturing method of the interior component of this invention. It is explanatory drawing which shows typically the other example of the manufacturing method of the interior component of this invention. It is explanatory drawing which shows the manufacturing method of the conventional interior component typically. It is explanatory drawing which shows the manufacturing method of the conventional interior component typically.

  The items shown here are exemplary and illustrative of the embodiments of the present invention, and are the most effective and easy-to-understand explanations of the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to illustrate the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention. It will be clear to those skilled in the art how it is actually implemented.

[1] Interior Parts Hereinafter, embodiments of the present invention will be described with reference to the drawings.
The interior part (10) of the present invention (see FIG. 1) has a base body (20) and a skin (30), both of which contain a thermoplastic resin so as to be joined at the interface.
Among these, the base body (20) has a plate shape with an uneven shape. The skin (30) is joined to one surface (20a) of the base body (20) following the uneven shape. And the heat-resistant mesh (40) is inserted only in a part of the interlayer between the base body (20) and the skin (30).
Here, FIG. 1 illustrates an interior part 10 as a door trim for an automobile. FIG. 1A is a schematic cross-sectional view of the interior part 10 taken along the line ZZ ′ of FIG. FIG. 1B is a diagram schematically showing a planar form of the interior part 10.

The “base (20)” has a plate shape with an uneven shape. The plate shape means that it has a substantially uniform thickness as a whole. In addition, the base 20 includes a thermoplastic resin so that the base 20 can be bonded to each other at the interface with the skin 30.
The base body 20 may be formed of only a thermoplastic resin, or may be a composite with a material other than the thermoplastic resin.
Examples of the substrate 20 formed only from a thermoplastic resin include an olefin-based foam material obtained by foaming a thermoplastic resin such as a polyolefin resin.
In addition, examples of the composite include a fibrous porous material formed by binding fiber materials such as inorganic fibers (glass fibers and the like) and organic fibers (vegetable fibers and the like) with a thermoplastic resin. The fibrous porous material is a material in which hard fibers such as glass fibers, PET fibers, and vegetable fibers are bound by a thermoplastic resin. For example, after mixing hard fibers and thermoplastic resin fibers, the thermoplastic resin Obtained by melting the fiber. In addition, the polyurethane foam material which has arrange | positioned the thermoplastic resin layer in the joint surface with the skin 30 is mentioned.
Although the kind of thermoplastic resin contained in the base | substrate 20 is not specifically limited, For example, polyolefin, polyester, polyamide etc. are mentioned. These may use only 1 type and may use 2 or more types together.

  The “skin (30)” is joined to one surface 20a of the substrate 20 following the uneven shape of the substrate 20, and a thermoplastic resin is bonded to the skin 30 so as to be bonded to each other at the interface with the substrate 20. include. The skin 30 has a design surface 30a and a non-design surface 30b, and one surface 20a of the base 20 and the non-design surface 30b of the skin 30 are joined. At the time of this joining, since fusion with a thermoplastic resin is used as described above, an adhesive such as a pressure-sensitive adhesive is not required.

This skin 30 may consist of only one layer, or may consist of two or more layers. When it consists of two or more layers, for example, a surface layer (including synthetic leather, woven fabric, etc.) having a design surface 30a and a cushion layer (arranged on the non-design surface 30b side of the surface layer) 30. The cushion layer is an elastic layer disposed on the non-design surface 30 b side of the skin 30. By having the cushion layer, a feeling of elasticity can be given to the tactile sensation from the design surface 30 a side of the skin 30. Although the material which comprises a cushion layer is not limited, For example, a flexible polyurethane foam can be used. In addition, as long as it has sufficient cushioning properties, other soft resin foams, nonwoven fabric sheets, and the like can be used. In addition, if necessary, a nonwoven fabric layer, an air blocking layer or the like can be provided.
Further, when it is difficult to join the base body 20 and the skin 30 by using the surface itself of the surface layer or the cushion layer, it is possible to join the base body 20 and the skin 30 at the interface. A thermoplastic resin layer (for example, disposed on the non-design surface side of the cushion layer) can be provided.

The design surface 30a of the skin 30 can be provided with various patterns. Examples of patterns include stitch patterns (including stitch patterns actually formed by sewing and stitch patterns formed by embossing), wrinkle patterns, and drawing patterns (patterns on which shapes, illustrations, etc. are drawn). It is done. These may use only 1 type and may use 2 or more types together.
Among these, the stitch pattern 55 formed by sewing is a pattern formed by actual sewing using the thread 51. The stitch pattern 55 may be a line pattern or may be a drawing (embroidery) represented by a stitch line. Furthermore, when the stitch pattern 55 formed by such sewing is provided, the thread 51 forming the stitch pattern 55 may be sewn only on the skin 30, or other layers other than the skin 30 may be sewn together. It may be crowded. As a case where the other layers are sewn together, a form in which the skin 30 and the heat-resistant mesh 40 are sewn together can be mentioned.
Such a stitch pattern 55 includes various trim parts such as armrests, upper trims, decorative panels, ornament panels, lower trims, pockets (door trim pockets), quarter trims, and the like. , Side garnish, back door trim and the like.

The “heat-resistant mesh (40)” is a heat-resistant mesh-like layer, and is inserted only in a part of the layer between the base 20 and the skin 30. The base body 20 and the skin 30 are joined by a thermoplastic resin at the interface between them through the mesh of the heat-resistant mesh 40.
The heat resistance of the heat-resistant mesh 40 means the heat resistance against the heating temperature when the base body 20 and the skin 30 are bonded to each other using a thermoplastic resin at the interface. That is, it means having heat resistance that does not melt and decompose at this heating temperature.
Therefore, for example, when the interface between the substrate 20 and the skin 30 is bonded by olefin, it is preferable that the heat-resistant mesh 40 has heat resistance that can maintain a net-like shape at the olefin softening temperature. Similarly, it is preferable that the heat-resistant mesh 40 has heat resistance capable of maintaining a net-like shape at each softening temperature of the polyester when the thermoplastic resin is polyester and the polyamide when the thermoplastic resin is polyamide. .

  The material which comprises the heat-resistant mesh 40 is not specifically limited as long as it has said heat resistance, Various inorganic materials and organic materials can be utilized. That is, the heat-resistant mesh 40 may be a woven mesh obtained by knitting fibers, a non-woven mesh obtained by depositing fibers, or a punching mesh obtained by punching a sheet material. Also good. Of these, woven mesh is preferred. That is, the durability against tearing is high when compared with the nonwoven fabric mesh, and the degree of hindering the bonding between the base 20 and the skin 30 is small when compared with the punching mesh.

Only one of the inorganic material and the organic material described above may be used, or a combination thereof may be used. Among these, examples of the inorganic material include glass, carbon material, metal, and ceramic. These inorganic materials may be used as a fiber or a sheet material. These may use only 1 type and may use 2 or more types together. Examples of the organic material include polyester (polyethylene terephthalate, polybutylene terephthalate, etc.), polyamide (aliphatic polyamide, aromatic polyamide, etc.), polyurethane, rayon and the like. These organic materials may be used as a fiber or a sheet material. These may use only 1 type and may use 2 or more types together.
Of these, glass fiber is preferred. This is because glass fibers have high heat resistance and are difficult to stretch even at high temperatures.

  The mesh shape of the heat-resistant mesh 40 is not limited as long as the base body 20 and the skin 30 can be joined. For example, the opening ratio (area ratio of the opening to the entire mesh) can be 30% or more. . By using a mesh having an opening ratio of 30% or more, sufficient bondability between the base body 20 and the skin 30 can be ensured. The aperture ratio is preferably 40% or more and 80% or less, and more preferably 50% or more and 70% or less. Further, the number of meshes (number of meshes / inch) is not particularly limited, but may be 1 or more, for example. When the number of meshes is 1 or more, it is possible to sufficiently obtain the effect of suppressing the pull-in at the time of forming the skin 30 (the precursor skin 30x at the time of molding). The number of meshes is preferably 3 or more and 8 or less, and more preferably 4 or more and 7 or less.

  The heat-resistant mesh 40 is inserted only in a part between the layers of the base body 20 and the skin 30. That is, the heat-resistant mesh 40 is not inserted on the entire surface between the base 20 and the skin 30. When the heat-resistant mesh 40 is inserted in the entire surface between the base 20 and the skin 30, the skin 30 (precursor skin 30x at the time of molding) is restrained from being stretched at a desired location in the molding, and other portions are replaced instead. It becomes difficult to distribute the extent of expansion such as positive expansion. In other words, in the interior part 10, the heat-resistant mesh 40 is provided only at a desired location between the base 20 and the skin 30 in order to suppress the stretch of the skin 30 at a desired location and extend the other portion instead. It is inserted.

The part between the layers may be any part, but specifically, it is preferably a part where the design surface 30a of the skin 30 has a pattern. Specifically, in FIG. 1, the heat-resistant mesh 40 is disposed so as to cover a portion where the stitch pattern 55 is applied to the skin 30.
Thereby, the expansion | extension of the design surface 30a of the outer skin 30 in the position where the heat-resistant mesh 40 was inserted is suppressed, and shape deformation of this pattern can be suppressed. Thus, from the viewpoint of obtaining the effect of using the heat-resistant mesh 40 more effectively, the interior part 10 has a design on the design surface 30a of the skin 30 at the position where the heat-resistant mesh 40 is inserted. Preferably it is.

The design surface 30a of the skin 30 has various patterns as described above. In particular, in the case of the stitch pattern 55 using the thread 51, the effect of this configuration can be particularly exerted. That is, the stitch pattern 55 is a pattern that is usually applied to a place where the ground pattern is not conspicuous, and it can be said that the distortion of the pattern is so conspicuous that it needs to be applied more accurately to the design. In this configuration, such distortion of the stitch pattern 55 can be effectively suppressed, and the stitch pattern 55 can be provided at a desired location as intended.
The thread 51 constituting the stitch pattern 55 may be applied only to the skin 30 (sewn to only the skin 30), but is formed by sewing the skin 30 and the heat-resistant mesh 40 together. The stitch pattern 55 is preferable. Since the thread 51 is a stitch pattern 55 formed by sewing the skin 30 and the heat-resistant mesh 40 together, the skin 30 and the heat-resistant mesh 40 can be firmly integrated. The action of suppressing distortion can be obtained particularly effectively.

[2] Method for Producing Interior Parts The method for producing interior parts of the present invention is a method for producing the interior part 10 described above, and includes a heat-resistant mesh joining step (R ₁ ), a heating step (R ₂ ), and a pressing step ( R ₃ ) (see FIGS. 2 and 3).
Here, FIG.2 and FIG.3 has shown an example of the manufacturing process of the interior component 10 as a door trim for motor vehicles in the method of this invention, respectively. Among these, FIG. 2 is a diagram schematically showing changes in the cross section (the ZZ ′ cross section in FIG. 3) in each process of the interior component 10, and FIG. 3 is a change in the planar form in each process of the interior component 10. FIG.

The “heat-resistant mesh bonding step (R ₁ )” is a step of bonding the heat-resistant mesh (40) to a part of the non-design surface (30xb) of the precursor skin (30x) (FIGS. 2a to 2b and FIG. 3a to 3b).
The precursor skin 30 x is a material that becomes the skin 30 in the interior part 10. Usually, there is no material change between the precursor epidermis 30x and the epidermis 30, and the configuration of the epidermis 30 described above is provided as the precursor epidermis 30x as it is.
The heat resistant mesh 40 is a mesh material having the configuration described above. The heat-resistant mesh 40 may be disposed or bonded to the surface of the precursor base 20x, but in this method, the heat-resistant mesh 40 is bonded to a part of the non-design surface 30xb of the precursor skin 30x. And since it is joining to a part of precursor skin 30x, it will not join to the other part of precursor skin 30x, and it will be possible to secure an extension to the other part of precursor skin 30x. That is, the degree of extension of the precursor skin 30x can be controlled as desired by the joint location of the heat-resistant mesh 40.

Further, in this method, the precursor epidermal 30x is patterned on the design surface 30Xa (e.g., stitch pattern 55), then a heat mesh bonding step _{R 1} is in the non-design surface 30xb precursor epidermal 30x region having a pattern The step of joining the heat-resistant mesh is preferable. That is, it is preferable to join the heat-resistant mesh 40 to the non-design surface 30xb of the precursor skin 30x so that at least a portion with a pattern is included in the non-design surface 30xb of the precursor skin 30x. Thereby, the expansion | extension of the pattern of the location which joined the heat-resistant mesh 40 can be suppressed, and designability can be hold | maintained.

Furthermore, the precursor epidermal 30x is that if the design surface 30xa having stitch pattern 55 with thread, heat mesh bonding step _{R 1} is heat mesh 40 to the non-design surface 30xb precursor epidermal 30x of the area for receiving a stitch pattern 55 It is preferable to make the process of joining the precursor skin 30x and the heat-resistant mesh 40 together while forming the stitch pattern 55 by sewing using the thread 51 (stitch pattern forming thread).
Thus, when the stitch pattern forming yarn 51 is used and the stitch pattern 55 formed by actual sewing is provided, it is preferable to join the precursor epidermis 30x and the heat-resistant mesh 40 by sewing. As a result, the stitch pattern 55 and the heat-resistant mesh 40 can be reliably integrated, and unintended expansion of the stitch pattern 55 can be prevented. Therefore, the design of the pattern to be applied as the stitch pattern 55 to the precursor skin 30x can be held in the interior part 10 after imparting the uneven shape. That is, for example, the stitch interval formed by the stitch pattern forming thread 51 can be prevented from being increased or decreased unintentionally.

In addition, when the stitch pattern 55 is included, in the heat-resistant mesh joining step R ₁ , in addition to the sewing for forming the stitch pattern 55, the edge portion 30 x c of the precursor skin 30 x and the heat-resistant mesh 40 are connected to the edge portion 30 xc of the precursor skin 30 x. It is preferable that the heat-resistant mesh 40 is joined by the sewing thread 52 so that the heat-resistant mesh 40 extends to the end edge portion 30xc of the precursor skin 30x.
As described above, when the stitch pattern 55 is formed by joining the precursor skin 30x and the heat-resistant mesh 40 by sewing using the stitch pattern forming yarn 51, the end edge 30xc of the precursor skin 30x is further When the heat-resistant mesh 40 and the precursor epidermis 30x are sewn and sewn together using the edge sewing thread 52, the stitch interval of the stitch pattern 55 can be maintained and the misalignment of the stitch pattern 55 can be prevented. The stitch pattern 55 can be placed at a desired position. This is because the region 30xd sandwiched between the stitch pattern forming yarn 51 and the edge sewing thread 52 can be formed while the heat-resistant mesh 40 and the precursor skin 30x are joined. Since this region 30xd is sandwiched between the stitch pattern forming yarn 51 and the edge sewing thread 52, the region 30xd becomes a region where the distance between them is fixed, and the elongation can be suppressed more firmly. Accordingly, the distance from the edge portion 30xc to the stitch pattern 55 can be set on the precursor epidermis 30x before the provision of the uneven shape, and the position of the stitch pattern 55 from the edge portion 30xc set at this time is set after the uneven shape is applied. Can be maintained.

The “heating step (R ₂ )” is a step of heating the precursor base body (20x) before the uneven shape is imparted and the precursor skin (30x) to which the heat-resistant mesh (40) is joined (FIG. 2b to FIG. 2). 2c and FIGS. 3b-3c).
The precursor base 20x before being provided with the concavo-convex shape is usually a plate having a uniform thickness, and is a material to which the concavo-convex shape is provided by shaping and becomes the base 20.
Interior part 10, without passing through the heating step R _2, it is also possible to produce by performing heat pressing, in the method, is produced by performing cold press after preheating. That is, in the heating step R _2, the precursor substrate 20x and progenitor skin 30x (heat mesh 40 is bonded) preheated to soften the thermoplastic resin contained in these precursor substrate 20x and progenitor skin 30x. The heating conditions and the like at this time can be appropriately set depending on the respective materials constituting the precursor base 20x and the precursor skin 30x. Specifically, for example, when the thermoplastic resin commonly contained in the precursor base 20x and the precursor skin 30x is a polyolefin, it is heated to 70 ° C. or higher (the temperature inside the precursor base 20x and the precursor skin 30x). It is preferable to do. The heating temperature is preferably 80 ° C. or higher and 150 ° C. or lower, more preferably 85 ° C. or higher and 130 ° C. or lower, and particularly preferably 90 ° C. or higher and 120 ° C. or lower.

In the “pressing step (R ₃ )”, the heated precursor substrate (20x) and the precursor skin (30x) to which the heated heat-resistant mesh (40) is bonded are superimposed to give an uneven shape. The precursor substrate (20x), the heat-resistant mesh (40), and the precursor skin (20x) are integrally joined (see FIGS. 2c to 2d and FIGS. 3c to 3d). As described above, the joining here is usually obtained by fusing thermoplastic resins contained in the precursor base 20x and the precursor skin 30x. The pressing conditions and the like in this step can be set as appropriate depending on the respective materials constituting the precursor base 20x and the precursor skin 30x.

  Thereafter, in the method of the present invention, the integrated body of the base body 20 and the skin 30 to which the concavo-convex shape is given by pressing is taken out from the press die 92 (see FIGS. 2d to 2e and FIGS. 3d to 3e), Unnecessary parts are removed as necessary (see FIGS. 2e to 2f and 3e to 3f), and the interior part 10 is completed (see FIGS. 5f and 6f).

Thus, in this method, it is a manufacturing method which performs simultaneous provision of uneven | corrugated shape and joining of a base | substrate and a skin. Specifically, so that the uneven shaping and the junction in the pressing step R ₃ are simultaneously performed.
Here, manufacture of interior part 10 'by the conventional method in which the heat-resistant mesh 40 is not utilized is demonstrated using FIG.5 and FIG.6. 5 and 6 show an example of a manufacturing process of an interior part 10 'as a door trim for an automobile in the conventional method. Among these, FIG. 5 is a diagram schematically showing changes in the cross section (the ZZ ′ cross section in FIG. 6) in each step of the interior component 10 ′, and FIG. 6 is a plan view in each step of the interior component 10 ′. It is the figure which showed typically the change of.

In this conventional method (FIGS. 5 and 6), the precursor skin 30x with the stitch pattern 55 applied to the design surface overlaps the non-design surface 30xb and the precursor substrate 20x (see FIGS. 5b and 6b), Heating is performed using a heater 91 (see FIGS. 5c and 6c). Thereafter, the laminated body of the heated precursor substrate 20x and the precursor skin 30x is cold-pressed by a press die 92 (see FIGS. 5d and 6d). The pressing gives an uneven shape, and the precursor skin 30x is joined to the precursor substrate 20x while being stretched to become the substrate 20 and the skin 30. Thereafter, unnecessary portions are cut as necessary (see FIGS. 5e and 6e), and the interior part 10 ′ is completed (see FIGS. 5f and 6f).
In this conventional method, when cold pressing (see FIGS. 5 d and 6 d), the precursor skin 30 x is drawn into the concave bottom 62, so that the stitch pattern 55 has a concave bottom 62 rather than the target position 59. The stitch line tends to be distorted.

  That is, in the conventional method, when providing the uneven shape (deep drawing or the like) to the precursor base 20x, the precursor skin 30x is not accompanied by the heat-resistant mesh 40. It is naturally stretched as needed to follow the uneven shape. For example, the periphery of the concavo-convex concave bottom 62 (the bottom of the concave portion) is stretched so as to be drawn toward the concave bottom 62, and the periphery of the concavo-convex convex top (the top of the convex portion) is directed toward the convex top. It will be stretched to be pulled. Therefore, in particular, the precursor epidermis 30x located between the concave bottom and the convex top tends to have a larger amount of extension than other parts. As described above, it is difficult to uniformly stretch the precursor skin 30x over the entire surface at the time of providing the uneven shape, and naturally nonuniform elongation occurs. For this reason, when the precursor skin 30x has a design such as a pattern, the pattern and the like are similarly unevenly stretched due to the non-uniform elongation as described above, thereby impairing the design.

On the other hand, in the method of the present invention described above (FIGS. 2 and 3), the heat-resistant mesh 40 is joined to the precursor skin 30x. The pre-skin 30x where the heat-resistant mesh 40 is joined is restrained by the heat-resistant mesh 40 so that its elongation is much smaller than other places. That is, by joining the heat-resistant mesh 40 to the precursor skin 30x, the expansion rate of the precursor skin 30x can be partially reduced and the extension of the skin 30 can be controlled. Therefore, for example, if the heat-resistant mesh 40 is not used, it is expected that the heat-resistant mesh 40 is bonded to a portion where the precursor epidermis 30x is expected to be greatly stretched and torn, thereby preventing this tearing or being greatly stretched. By joining the heat-resistant mesh 40 to the place to be formed, the amount of elongation can be suppressed to be equal to the surrounding area, or can be controlled to be smaller than the surrounding area. That is, if desired, the precursor skin 30x as a whole is controlled to have a substantially uniform elongation amount, or the elongation of the precursor skin 30x where the heat resistant mesh 40 is joined is substantially canceled (the heat resistant mesh 40 is changed into the precursor skin 30x). If you sew together). Thus, by controlling the amount of elongation of the precursor epidermis 30x as necessary, the epidermis 30 is excessively thinned or torn, and when the epidermis 30 has a design such as a pattern, the design is maintained. can do.
Thus, in this method, a high quality stitched product can be manufactured in one step. Moreover, since the heat-resistant mesh 40 has a mesh shape, the base 20 and the skin 30 can be fused over the heat-resistant mesh 40, and no separate bonding is required.

Furthermore, in the method of the present invention, the following second embodiment can be obtained. That is, the frame body 70 can be used (see FIG. 4).
Specifically, the precursor skin 30x is fixed to the frame body 70 in a stretched state, and the precursor skin 30x is fixed to the frame body 70 and is put into the press die 92. However, the frame body 70 is placed outside the press die 92. be to position the pressing process R _3, it can be maintained tension precursor epidermis 30x.
And when the edge of the heat-resistant mesh 40 is fixed to the frame 70 together with the edge of the precursor skin 30x, the heat-resistant mesh 40 can be prevented from being drawn into the press die 92 with the provision of the uneven shape. . In particular, when the heat resistant mesh 40 is fixed to the precursor skin 30x using the edge sewing thread 52, the shape of the region 30xd sandwiched between the stitch pattern forming thread and the edge sewing thread is the shape of the area 30xd. It is particularly effective from the viewpoint of maintaining. Furthermore, when fixing the heat resistant mesh 40 to the frame body 70, it is preferable to fix at least two sides of the heat resistant mesh 40 to the frame body 70.

In the manufacturing method of the present invention, in addition to the method described above, a portion of the non-design surface 30xb precursor epidermal 30x as the epidermis, the heat mesh bonding step R ₁ of joining the heat resistant mesh 40, heat mesh 40 There the heating step R ₂ for heating the joined precursor epidermal 30x, overlay and base 20 in advance irregularities is imparted, a precursor epidermal 20x heat mesh 40 is bonded to the heated, a base 20 and heat the mesh 40 and the precursor skin 30 includes a pressing process R ₃ to be joined together, and can be produced interior part 10.

  The foregoing examples are for illustrative purposes only and are not to be construed as limiting the invention. Although the invention has been described with reference to exemplary embodiments, it is to be understood that the language used in the description and illustration of the invention is illustrative and exemplary rather than limiting. As detailed herein, changes may be made in its form within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials and examples have been referred to in the detailed description of the invention herein, it is not intended to limit the invention to the disclosure herein, but rather, the invention is claimed. It covers all functionally equivalent structures, methods and uses within the scope.

The interior parts and the manufacturing method thereof (automobiles, railway vehicles, etc.) of the present invention are widely used as interior parts and their manufacturing methods in various fields such as vehicles, aircraft, ships, and architecture.
Specifically, trim parts such as automobile door trim, armrest, upper trim, decorative panel, ornament panel, lower trim, pocket (door trim pocket), quarter trim; pillar garnish; cowl side garnish (cowl side trim); side Seat system parts such as airbag peripheral parts; Center cluster, register, center box (door), grab door, instrument panel parts such as airbag peripheral parts; center console; overhead console; sun visor; deck board (luggage board) , Under tray; package tray; CRS cover; sheet side garnish; assist grip; passing light lever and the like.

10; interior parts (invention product), 10 '; interior parts (conventional product),
20; substrate, 20a; skin side surface of substrate,
20x: precursor substrate, 20xa: surface to be bonded to the precursor skin of the precursor substrate,
30; skin, 30a; design surface of the skin, 30b; non-design surface of the skin,
30x: Precursor skin, 30xa: Design surface of the precursor skin (surface that becomes the design surface of the skin), 30xb; Non-design surface of the precursor skin (surface that becomes the non-design surface of the skin), 30xc; Edge, 30xd; Stitch The area sandwiched between the pattern forming thread and the edge sewing thread,
35; joined body of precursor skin and heat-resistant mesh,
40; heat-resistant mesh,
51; stitch pattern forming thread; 52; edge sewing thread; 55; stitch pattern (actual position); 59; target position of stitch pattern;
61; part outline (cutting line), 62; deep drawing region,
70; a frame,
91; heater, 92; press die,
R ₁ ; heat-resistant mesh joining process,
R ₂ ; heating step,
R ₃ ; pressing process.

Claims (11)

A substrate and an epidermis, both of which contain a thermoplastic resin so that they are joined together at the interface;
The base body has a plate shape with an uneven shape, and the skin is joined to one surface of the base body following the uneven shape,
An interior part, wherein a heat-resistant mesh is inserted only in a part of a layer between the base and the skin.   The interior part according to claim 1, wherein a design surface of the skin at a position where the heat-resistant mesh is inserted has a pattern.   The interior part according to claim 2, wherein the pattern is a stitch pattern using a thread.   The interior part according to claim 3, wherein a thread constituting the stitch pattern is sewn together with the skin and the heat-resistant mesh.   The interior part according to any one of claims 1 to 4, wherein the fibers constituting the heat-resistant mesh are glass fibers. It is a manufacturing method of the interior component according to claim 1,
A heat-resistant mesh joining step for joining the heat-resistant mesh to a part of the non-design surface of the precursor skin to be the skin,
A heating step of heating the precursor substrate before the uneven shape is imparted and the precursor skin to which the heat-resistant mesh is bonded;
The precursor substrate, the heat-resistant mesh, and the precursor skin are integrated while superimposing the heated precursor substrate and the precursor skin to which the heated heat-resistant mesh is bonded to give the uneven shape. And a pressing process for bonding to the interior part. The precursor epidermis has a pattern on its design surface,
The said heat-resistant mesh joining process is a process of joining the said heat-resistant mesh to the non-design surface of the said precursor skin of the area | region which has the said pattern, The manufacturing method of the interior components of Claim 6. The precursor epidermis has a stitch pattern using yarn on its design surface,
In the heat-resistant mesh joining step, the heat-resistant mesh is brought into contact with a non-design surface of the precursor skin in a region where the stitch pattern is applied, and the precursor skin and the heat-resistant mesh are stitched together while forming the stitch pattern by sewing. The method for manufacturing an interior part according to claim 6, wherein the method is a step of joining together. The heat-resistant mesh is extended to the edge of the precursor skin,
The interior part according to claim 8, wherein the heat-resistant mesh joining step is a step of sewing and joining the precursor skin and the heat-resistant mesh at the edge portion in addition to the sewing for forming the stitch pattern. Production method.   The method for manufacturing an interior part according to any one of claims 6 to 9, wherein the fibers constituting the heat-resistant mesh are glass fibers. It is a manufacturing method of the interior component according to claim 1,
A heat-resistant mesh joining step for joining the heat-resistant mesh to a part of the non-design surface of the precursor skin to be the skin,
A heating step of heating the precursor skin to which the heat-resistant mesh is bonded;
A pressing step of superimposing the base body provided with the uneven shape in advance with the precursor skin to which the heated heat-resistant mesh is bonded, and integrally bonding the base body, the heat-resistant mesh, and the precursor skin; A method for manufacturing an interior part, comprising:

Images