JP2021049682A - Method for manufacturing interior material for vehicle - Google Patents

Abstract

To provide an interior material for a vehicle which can improve a joint strength with a resin member, an interior material for a vehicle having a smooth surface, and an interior material for a vehicle which is light-weight and has high rigidity.SOLUTION: A method for manufacturing an interior material for a vehicle includes: a mat preparation step of creating a mat M in which a foamable resin R1 is coated onto a surface 10A of a first fiber body 10 composed of at least fibers and a second fiber body 20 composed of at least fibers are overlapped on the surface 10A of the first fiber body 10, and the formable resin R1 is arranged therein; and a pressing step of arranging the mat M and a bracket 40 having an uneven part 41 between a pair of molding dies 50 so that the uneven part 41 faces the mat M side, and then heating the mat M while pressing it with the pair of molding dies 50.SELECTED DRAWING: Figure 4

Description

The present invention relates to a method for manufacturing an interior material for a vehicle.

Conventionally, as an interior material for a vehicle and a method for manufacturing the same, those described in Patent Document 1 are known. In the method for manufacturing an interior material (interior base material) for a vehicle described in Patent Document 1, a bracket made of resin and having a large number of protrusions is set in a molding die composed of an upper die and a lower die, and the upper die is formed. It is possible to manufacture an interior base material by setting an interior base material raw fabric made of fiber and resin between the mold and the lower mold, heating it, and pressing and molding it so that the protrusions of the bracket bite into the interior base material raw fabric. It is disclosed.

Japanese Unexamined Patent Publication No. 8-229966

However, in the method for producing an interior material for a vehicle disclosed in Patent Document 1, when the interior base material raw material is pressed by a molding die, the protrusions push in the fibers of the interior base material raw material, and the fibers are pushed in. The resin oozes out on the part. Then, it is considered that the bonding strength between the resin member (bracket) and the base material (interior base material raw material) is lowered, and the resin member may be peeled off from the base material. On the other hand, it is desirable that the surface of the interior material for vehicles is smooth, for example, in order to stretch the skin or improve the design. Further, it is desirable that the interior material for a vehicle is lightweight and highly rigid.

The present invention has been completed based on the above circumstances, and one of the objects of the present invention is to provide an interior material for a vehicle capable of improving the joint strength with a resin member. Another object of the present invention is to provide an interior material for a vehicle having a smooth surface. Furthermore, one of the further purposes is to provide a lightweight and highly rigid interior material for vehicles.

The present invention is a method for producing an interior material for a vehicle, wherein a foamable resin is applied to the surface of at least a first fibrous body composed of fibers, and the surface of the first fibrous body is composed of at least fibers. The mat making step of stacking the second fibrous bodies to create a mat in which the foamable resin is arranged inside, and the mat and the resin member provided with the uneven portion are placed between the pair of molding dies. It is characterized by including a pressing step of heating the mat while pressing the mat with the pair of molding dies after arranging the uneven portions so as to face the mat side.

According to such a method for manufacturing an interior material for a vehicle, in the pressing step, the foamable resin arranged inside the mat can be foamed and impregnated on the outside of the mat (front and back sides of the mat). The foamable resin impregnated on the surface (back surface) side of the resin member side of the mat can bond the mat and the resin member by pressing the fibers against the uneven portion of the resin member while moving the fibers to the back surface side. .. As a result, the fiber and the uneven portion of the resin member can be easily brought into close contact with each other, and the bonding strength of the resin member can be improved. On the other hand, by impregnating the surface (surface) side of the mat opposite to the surface on the resin member side with the foamable resin, the surface of the mat can be imparted with smoothness. Further, since the mat is composed of fibers and foamable resin, it is possible to manufacture a lightweight and highly rigid interior material for vehicles.

Further, in the mat making step, the mat is formed by laminating the second fiber body coated with a foamable resin on the first fiber body so that the back surface thereof faces the front surface of the first fiber body. In the pressing step, the resin member can be arranged so that the uneven portion faces the back surface of the first fiber body in the mat.

According to such a method for manufacturing an interior material for a vehicle, the surface of the second fiber body to which the foamable resin is previously applied in the mat making step becomes the surface of the mat, so that the surface of the mat is further smoothed. Can be done. Further, in the pressing step, the foamable resin applied to the front surface of the second fiber body is impregnated on the back surface side, so that the foamable resin applied to the front surface of the first fiber body moves the fibers to the back surface side. Can be supported. This makes it easier for the foamable resin to press the fibers against the uneven portions of the resin member. Further, by cooling the mat to which the resin member is bonded, the foamable resin for the fiber is compared with the foamable resin high content portion provided on the front surface side and the foamable resin high content portion provided on the back surface side. It is possible to prepare a base material comprising a foaming resin low content portion having a low content of. As a result, it is possible to manufacture an interior material for a vehicle in which the fiber and the uneven portion of the resin member are in close contact with each other in the low foaming resin content portion and the bonding strength of the resin member is improved.

Further, in the above step, the first fiber body may have a smaller basis weight than the second fiber body. According to such a method for manufacturing an interior material for a vehicle, the foamable resin impregnated on the back surface side of the mat makes it easy to move the fibers to the back surface side, and makes it easy to press the fibers against the uneven portion of the resin member.

Further, in the above step, the thickness of the first fiber body can be made smaller than that of the second fiber body. According to such a method for manufacturing an interior material for a vehicle, the foamable resin impregnated on the back surface side of the mat makes it easy to move the fibers to the back surface side, and makes it easy to press the fibers against the uneven portion of the resin member.

According to the present invention, it is possible to provide an interior material for a vehicle capable of improving the joint strength with a resin member. Further, it becomes possible to provide an interior material for a vehicle having a smooth surface. Further, it becomes possible to provide a lightweight and highly rigid vehicle interior material.

Sectional drawing which shows 1st fiber body and 2nd fiber body which concerns on embodiment A cross-sectional view showing an embodiment in which the second fiber body is superposed on the first fiber body. Cross-sectional view showing a mode in which a mat and a resin member are arranged between molding dies in an open state. Sectional drawing which shows the mode which brings the upper mold closer to the lower mold Cross-sectional view showing a molded mold in a closed state Cross-sectional view showing the mode in which the molding die is opened again. Sectional view showing door trim

<Embodiment>
Embodiments of the present invention will be described with reference to FIGS. 1 to 7. In the present embodiment, a door trim (vehicle interior material) 100 mounted on an automobile (vehicle) as a vehicle shown in FIG. 7 and a method for manufacturing the door trim 100 will be described. As shown in FIG. 7, the door trim 100 includes a plate-shaped base material 30 made of fibers and a foamable resin, and a bracket (resin member) 40 made of resin and bonded to the base material 30. .. The material to be bonded to the base material 30 is not limited to the bracket, and may be a member made of a boss or other resin. The upper surface of the base material 30 is the front surface (design surface) 20A, and the lower surface is the back surface 10B. The bracket 40 is joined to the back surface 10B side of the base material 30.

As the fiber of the base material 30, wood fiber obtained by weaving wood or the like, bast plant fiber such as kenaf, inorganic fiber such as glass fiber or carbon fiber, synthetic resin fiber or the like can be adopted. The foamable resin of the base material 30 foams and cures when heated to a predetermined temperature or higher (the foaming reaction and the curing reaction proceed even at room temperature, but when heated to a predetermined temperature or higher, the reaction rate increases. It is a resin (which accelerates significantly). As the foamable resin, for example, one or a combination of one or more of a foamable polyurethane resin, an epoxy-based foamable resin, an olefin-based foamable resin, and the like can be adopted. Of these, a foamable polyurethane resin is preferable. As the material of the bracket 40, a resin such as polypropylene or ABS can be adopted.

The base material 30 is located on the front surface 20A side and is located on the back surface 10B side, and has a low foaming resin content in the fibers as compared with the foaming resin high content portion 31. A low content portion 32 of a sex resin is provided. It can be said that the fibers of the foamable resin low content portion 32 are denser than those of the foamable resin high content portion 31. The bracket 40 includes a concavo-convex concavo-convex portion 41. The uneven portion 41 is provided to increase the bonding area between the bracket 40 and the base material 30 to increase the bonding force. The uneven portion 41 is joined to the foamable resin low content portion 32.

Subsequently, a pair of molding dies 50 as a manufacturing apparatus for manufacturing the door trim 100 will be described. As shown in FIG. 3, the pair of molding dies 50 have a configuration in which a mat-shaped mat M, which will be described later, can be heated while being pressed from above and below. Specifically, the pair of molding dies 50 are arranged above and have a molding surface 51A which is pressed from the surface 20A (the surface of the base material 30 which becomes the surface 20A) side of the mat M to be molded. It is provided with a lower mold 52 which is arranged downward so as to face the upper mold 51 and has a molding surface 52B which is formed by pressing from the back surface 10B (the surface of the base material 30 which becomes the back surface 10B) side of the mat M. The lower mold 52 includes a recessed portion 53 that is recessed to the extent that the bracket 40 can be inserted on the molding surface 52B side.

The upper mold 51 is a movable type that can be moved in the vertical direction with respect to the lower mold 52 by a driving device (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.) (not shown). FIG. 3 shows a state in which the upper mold 51 has moved in a direction away from the lower mold 52 (a state in which the molding mold 50 is open). FIG. 5 shows a state in which the upper mold 51 moves in a direction approaching the lower mold 52 and the mat M is pressed by the molding mold 50 (a state in which the molding mold 50 is closed).

Next, a method of manufacturing the door trim 100 will be described. The method for manufacturing the door trim 100 is roughly classified into a mat making step of making a mat M from the first fibrous body 10 and the second fibrous body 20 as shown in FIGS. 1 and 2, and a mat making step shown in FIGS. 3 to 7. As described above, a pressing step of manufacturing a door trim 100 in which the bracket 40 is joined to the base material 30 by heating the mat M and the bracket 40 while pressing them with a pair of molding dies 50 is included.

As shown in FIG. 1, in the mat making step, a first fiber body 10 composed of fibers (indicated by a plurality of wavy lines) and a second fiber body 20 also composed of fibers are prepared. The first fiber body 10 and the second fiber body 20 have a mat-like shape, and are formed as a non-woven fabric in which fibers are entangled. The fibers constituting the first fiber body 10 and the second fiber body 20 are the same as the fibers used for the above-mentioned base material 30. The first fiber body 10 has a smaller basis weight and a smaller thickness than the second fiber body 20.

Next, the foamable resin R1 is applied to the surface 10A of the first fiber body 10, and the foamable resin R2 is applied to the surface 20A of the second fiber body 20 (these foamable resins R1 and R2 are formed by a plurality of dots. Show). The foamable resins R1 and R2 are the same as the foamable resins used for the above-mentioned base material 30. On the back surface 10B of the first fiber body 10 and the back surface 20B of the second fiber body 20, the foamable resins R1 and R2 are not applied, and the fibers are exposed.

As shown in FIGS. 1 and 2, the mat M is created by superimposing the second fiber body 20 on the first fiber body 10. Specifically, the second fibrous body 20 is laminated on the first fibrous body 10 so that the back surface 20B thereof faces the front surface 10A of the first fibrous body 10. Inside the mat M (that is, between the first fiber body 10 and the second fiber body 20), the foamable resin R1 is arranged so as to be sandwiched between the two fiber bodies 10 and 20. The foamable resin R2 is applied to the surface of the mat M (that is, the surface of the second fiber body 20) 20A. On the back surface of the mat M (that is, the back surface of the first fiber body 10) 10B, the foamable resins R1 and R2 are not applied, and the fibers are exposed.

Next, in the pressing step, as shown in FIG. 3, the mat M and the bracket 40 are arranged between the pair of molding dies 50 in the open state. The mat M is arranged so that its front surface 20A faces the molding surface 51A of the upper mold 51 and its back surface 10B faces the molding surface 52B of the lower mold 52. The bracket 40 is inserted into the recessed portion 53 of the lower mold 52 so that the uneven portion 41 faces the back surface 10B of the mat M.

From this state, as shown in FIG. 4, by gradually bringing the upper mold 51 closer to the lower mold 52, the mat M is pressed together with the bracket 40 by the pair of molding dies 50, and the pair of molding dies 50 are brought to a predetermined temperature. Heat above. Then, the surface 20A side of the mat M is pressed against the molding surface 51A of the upper mold 51 to be molded so as to follow the shape of the molding surface 51A, and the back surface 10B side of the mat M becomes the molding surface 52B of the lower mold 52. By being pressed, it is molded so as to follow the shape of the molding surface 52B.

At this time, the foamable resin R1 arranged inside the mat M is heated and foamed, impregnated in the second fiber body 20 and spreads toward the surface 20A side of the mat M, and impregnated in the first fiber body 10. Then, it spreads toward the back surface 10B side of the mat M. Further, the foamable resin R2 applied to the surface 20A of the mat M is heated and foamed, spreads on the surface 20A side of the mat M, and impregnates the second fiber body 20 toward the back surface 10B side of the mat M. spread. Therefore, the second fibrous body 20 is impregnated with a larger amount of foamable resins R1 and R2 than the first fibrous body 10. The foamable resins R1 and R2 spreading toward the back surface 10B side of the mat M move the fibers toward the back surface 10B side of the mat M, and press the fibers against the uneven portion 41 of the bracket 40 to bring them into close contact with each other.

Then, as shown in FIG. 5, by heating and holding the pair of molding dies 50 in a closed state for a predetermined time, the foaming of the foamable resins R1 and R2 is completed and cured. Then, the mat M is formed as a base material 30 including a foamable resin high content portion 31 located on the front surface 20A side and a foamable resin low content portion 32 located on the back surface 10B side, and the bracket 40 is formed as a base. It is joined to the foamable resin low content portion 32 of the material 30. After cooling the pair of molding dies 50, as shown in FIG. 6, the upper die 51 is separated from the lower die 52 and opened again, so that the base material 30 and the base are formed as shown in FIG. Obtain a door trim 100 with a bracket 40 joined to the material 30.

Subsequently, the effect of this embodiment will be described. In the method for manufacturing the door trim 100 in the present embodiment, the foamable resin R1 is applied to the surface 10A of the first fibrous body 10 made of fibers, and the surface 10A of the first fibrous body 10 is made of a second fiber. A mat making step of stacking the fibrous bodies 20 to create a mat M in which the foamable resin R1 is arranged inside, and a mat M and a bracket 40 having an uneven portion 41 between the pair of molding dies 50. This includes a pressing step of heating the mat M while pressing the mat M with a pair of molding dies 50 after the uneven portion 41 is arranged so as to face the mat M side.

According to such a method for manufacturing the door trim 100, in the pressing step, the foamable resin R1 arranged inside the mat M foams and impregnates the outside of the mat M (the front surface 20A side and the back surface 10B side of the mat M). be able to. The foamable resin R1 impregnated on the back surface (back surface) 10B side of the mat M moves the fibers to the back surface 10B side and presses the fibers against the uneven portion 41 of the bracket 40 to form the mat M and the bracket 40. Can be joined. As a result, the fibers and the uneven portion 41 of the bracket 40 can be easily brought into close contact with each other, and the bonding strength of the bracket 40 can be improved. On the other hand, in the mat M, the surface (surface) 20A on the side opposite to the surface on the bracket 40 side is impregnated with the foamable resin R1 to impart smoothness to the surface 20A of the mat M. Further, since the mat M is composed of fibers and foamable resin, a lightweight and highly rigid door trim 100 can be manufactured.

Further, in the mat making step, the second fibrous body 20 having the foamable resin R2 coated on the front surface 20A is laminated on the first fibrous body 10 so that the back surface 20B of the second fibrous body 20 faces the front surface 10A of the first fibrous body 10. In the pressing step, the bracket 40 is arranged so that the uneven portion 41 faces the back surface 10B of the first fiber body 10 in the mat M.

According to such a method for manufacturing the door trim 100, the surface 20A of the second fiber body 20 coated with the foamable resin R2 in advance in the mat making step becomes the surface 20A of the mat M, so that the surface 20A of the mat M is used. It can be made even smoother. Further, in the pressing step, the foamable resin R2 applied to the surface 20A of the second fiber body 20 is impregnated on the back surface 10B side of the mat M, so that the foamable resin applied to the surface 10A of the first fiber body 10 It can support R1 to move the fiber to the back surface 10B side. As a result, the foamable resins R1 and R2 can easily press the fibers against the uneven portion 41 of the bracket 40. Further, by cooling the mat M to which the bracket 40 is joined, the foamable resin high content portion 31 provided on the front surface 20A side and the foamable resin high content portion 31 provided on the back surface 10B side are compared with each other. It is possible to prepare the base material 30 including the foamable resin low content portion 32 having a low foamable resin content ratio with respect to the fiber. As a result, it is possible to manufacture the door trim 100 in which the fibers and the uneven portion 41 of the bracket 40 are in close contact with each other in the foamable resin low content portion 32 and the bonding strength of the bracket 40 is improved.

Further, the first fiber body 10 has a smaller basis weight than the second fiber body 20. According to such a manufacturing method of the door trim 100, the foamable resins R1 and R2 impregnated on the back surface 10B side of the mat M make it easy to move the fibers to the back surface 10B side, and it is easy to press the fibers against the uneven portion 41 of the bracket 40. Become.

Further, the thickness of the first fiber body 10 is smaller than that of the second fiber body 20. According to such a manufacturing method of the door trim 100, the foamable resins R1 and R2 impregnated on the back surface 10B side of the mat M make it easy to move the fibers to the back surface 10B side, and it is easy to press the fibers against the uneven portion 41 of the bracket 40. Become.

Further, the door trim 100 in the present embodiment includes a base material 30 made of fibers and a foamable resin, and a bracket 40 made of resin and bonded to the base material 30, and the bracket 40 has an uneven shape. The base material 30 includes the uneven portion 41, and the base material 30 includes a foamable resin high content portion 31 and a foamable resin low content portion 32 in which the content of the foamable resin with respect to the fiber is lower than that of the foamable resin high content portion 31. , And the uneven portion 41 is joined to the foamable resin low content portion 32.

According to such a door trim 100, since the base material 30 is composed of fibers and a foamable resin, the door trim 100 is lightweight and has high rigidity. Further, since the uneven portion 41 of the bracket 40 is bonded to the foamable resin low content portion 32 having a low content of the foamable resin with respect to the fiber, the uneven portion 41 of the fiber and the bracket 40 in the foamable resin low content portion 32. And can be brought into close contact with each other, and the joint strength of the bracket 40 can be improved. Further, since the foamable resin high content portion 31 has a higher content of the foamable resin with respect to the fibers than the foamable resin low content portion 32, the surface (back surface) 10B of the base material 30 to which the bracket 40 is joined is used. Can impart smoothness on the opposite surface (surface) 20A.

<Other Embodiments>
The present invention is not limited to the embodiments described by the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention, and further, within the scope not deviating from the gist other than the following. It can be implemented with various changes.

(1) In addition to the above embodiment, the manufacturing process of the vehicle interior material can be changed as appropriate. For example, the mat making step includes a step of making a mat (pre-board) having an adjusted thickness by heating a material obtained by laminating a first fiber body and a second fiber body while pressing the mat into a plate shape. May be good. This makes it possible to provide a method for manufacturing a door trim suitable for transporting and storing a mat.

(2) In addition to the above embodiment, the procedure of the mat making process can be changed as appropriate. In the above embodiment, the first fiber body and the second fiber body are laminated to prepare a mat, but the mat is not limited to this. For example, the first fiber body, the second fiber body, and the third fiber body, which are composed of fibers and each of which is coated with a foamable resin, are layered to create a mat in which the foamable resin is arranged inside. The foamable resin is arranged inside by stacking the first fiber body, the second fiber body, the third fiber body, and the fourth fiber body, which are composed of fibers and each of which is coated with a foamable resin. You may create a mat. That is, the mat may be formed by stacking two or more fiber bodies.

(3) In addition to the above embodiment, the configurations of the first fiber body and the second fiber body can be changed as appropriate.
In the above embodiment, the first fiber body has a smaller basis weight and a smaller thickness than the second fiber body, but the present invention is not limited to this. For example, the first fiber body and the second fiber body may have the same structure such as basis weight and thickness, and may be the same. Further, the foamable resin applied to the surfaces of the first fiber body and the second fiber body may be the same.

(4) In addition to the above embodiment, the mode of impregnating the fiber with the foamable resin in the pressing step can be appropriately changed. For example, in the pressing step, the mat may be impregnated so that the foamable resin spreads uniformly in the thickness direction of the mat by heating the mat while pressing it with a pair of molding dies. Then, it is also possible to prepare an interior material for a vehicle having a base material having a relatively no difference in the content of the foamable resin with respect to the fiber between the front surface side and the back surface side.

(5) In the above embodiment, the door trim is exemplified as the interior material for the vehicle, but the present invention is not limited to this. For example, the interior material for vehicles may be other interior materials for vehicles such as side trims of luggage compartments, roof linings, pillar garnishes, and the like.

(6) The method for manufacturing the interior material for a vehicle exemplified in the above embodiment is not limited to that provided for a vehicle, and may be provided for various vehicles. For example, the above method for manufacturing interior materials for vehicles shall be applied to vehicles such as trains and amusement vehicles as ground vehicles, airplanes and helicopters as flight vehicles, and ships and submersibles as marine and underwater vehicles. Can be done.

10 ... 1st fiber body, 20 ... 2nd fiber body, 30 ... base material, 40 ... bracket (resin member), 41 ... uneven part, 50 ... molding mold, 100 ... door trim (interior material for vehicle), M ... mat

Claims (4)

A foamable resin is applied to the surface of at least the first fiber body composed of fibers, and the second fiber body composed of at least fibers is superposed on the surface of the first fiber body, and the foamable resin is inside. The mat making process to make the arranged mats and
The mat and the resin member provided with the uneven portion are arranged between the pair of molding dies so that the uneven portion faces the mat side, and then the mat is heated while being pressed by the pair of molding dies. A method for manufacturing an interior material for a vehicle, which comprises a pressing step. In the mat making step, the mat is made by laminating the second fiber body coated with a foamable resin on the first fiber body so that the back surface thereof faces the front surface of the first fiber body. And
The method for manufacturing an interior material for a vehicle according to claim 1, wherein in the pressing step, the resin member is arranged so that the uneven portion faces the back surface of the first fiber body in the mat. The method for producing an interior material for a vehicle according to claim 1 or 2, wherein the first fiber body has a smaller basis weight than the second fiber body. The method for producing an interior material for a vehicle according to any one of claims 1 to 3, wherein the first fiber body has a smaller thickness than the second fiber body.

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