JP2021133828A - Vehicular interior material and manufacturing method of the same - Google Patents

Abstract

To provide a vehicular interior material which can increase stiffness while suppressing deterioration of sound absorbing performance, and to provide a manufacturing method of the same.SOLUTION: A vehicular interior material comprises a skin member (21) which constitutes a surface when it is arranged in a vehicle (1) and a raw sheet member (23) which is arranged at the reverse side of the skin member and has a sound absorbing property, with reinforcement members (25a) being added between the skin member and the raw sheet member at predetermined partial areas (A). A manufacturing method of the material includes: a skin member preparation process; a raw sheet member preparation process; a reinforcement member adding process of adding the reinforcement members at the predetermined partial areas between the skin member and the raw sheet member; a raw sheet member arranging process of arranging the raw sheet material at the reverse side of the skin member after the reinforcement member adding process; and a press molding process.SELECTED DRAWING: Figure 3

Description

The present invention relates to an interior material for a vehicle and a method for manufacturing the same, and particularly relates to a technique for maintaining good rigidity and sound absorption.

In a general passenger car, a floor carpet is laid on the part of the floor panel forming the floor plate of the vehicle facing the passenger compartment.
By laying the floor carpet in this way, it is possible to absorb the sound that echoes in the passenger compartment and improve the texture of the feet of the occupants.
However, while increasing the thickness of the floor carpet can improve the sound absorbing performance, there is a problem that the feeling of treading pressure is lowered for the occupant due to the improvement of the cushioning property of the floor carpet.

In other words, the floor carpet has a contradictory property such that the cushioning property can be lowered and the feeling of treading pressure on the occupant can be increased by reducing the thickness, while the sound absorbing performance of the floor carpet is lowered.
Therefore, among the skin members and felt materials (raw fabric members) that make up the floor carpet, a thermoplastic resin is formed as a film layer on the back surface of the skin members, and further needle punching is performed to open holes in the film layer. A technique for forming and increasing rigidity while suppressing deterioration of sound absorption performance has been developed (Patent Document 1).

Japanese Unexamined Patent Publication No. 2016-84104

However, in the technique disclosed in Patent Document 1, it is possible to adopt a so-called Helmholtz type sound absorbing structure in which holes are formed in the film layer by needle punching to improve the sound absorbing property for sound of a specific frequency. However, due to the sound absorbing characteristics of the Helmholtz type sound absorbing structure, there is a problem that a frequency band in which the sound absorbing property is lowered is generated, so that the mode is not necessarily the optimum option.

The present invention has been made in view of such a problem, and an object of the present invention is to provide an interior material for a vehicle capable of increasing rigidity while suppressing a decrease in sound absorption performance and a method for manufacturing the same. be.

In order to achieve the above object, the vehicle interior material and the manufacturing method thereof of the present invention are arranged on the skin member which forms the front surface when laid on the vehicle and the back surface side of the skin member, and has sound absorbing properties. A member is provided, and a reinforcing material is added to a predetermined partial region between the skin member and the raw fabric member.
As a result, by adding a reinforcing material to a predetermined partial region between the skin member and the raw fabric member, the rigidity of the predetermined partial region is increased as compared with the other portion, and the sound absorption by the other portion is increased. It is possible to maintain the sex.

As another aspect, the reinforcing material preferably contains a resin.
As a result, by using a member containing a resin as the reinforcing material, it is possible to optimize the rigidity by lowering the rigidity as compared with the case where a metal is used as the reinforcing material, for example.
As another aspect, it is preferable that the skeleton member is provided between the skin member and the raw fabric member, and the reinforcing material is added to the surface of the skeleton member on the raw fabric member side.

As a result, by adding the reinforcing material to the surface of the skeleton member on the skin member side, it is possible to prevent the reinforcing material from being exposed from the surface of the skin member due to wear deterioration of the skin member or the like.
As another aspect, it is preferable that the predetermined partial area is a position corresponding to the foot portion of the occupant who rides on the vehicle when it is laid on the vehicle.

As a result, by adding a reinforcing material at a position corresponding to the foot of the occupant boarding the vehicle, it is possible to enhance the feeling of treading when the occupant places the foot in a predetermined partial area.
As other embodiments, a skin member preparation step of preparing a skin member that forms a surface when laid on a vehicle, a raw fabric member preparation step of preparing a raw fabric member having sound absorption, and the skin member and the raw fabric member A reinforcing material adding step of adding a reinforcing material to a predetermined partial region between the two, a raw fabric member arranging step of arranging the raw fabric member on the back surface side of the skin member after the reinforcing material adding step, and the above-mentioned After the raw fabric member arranging step, it is preferable to include a press molding step of press-molding the skin member and the raw fabric member into a predetermined shape.

As a result, before the raw fabric member arranging step of arranging the raw fabric member on the back surface side of the skin member, a reinforcing material adding step of adding a reinforcing material to a predetermined partial region between the skin member and the raw fabric member is performed. By doing so, it is possible to add a reinforcing material to a predetermined partial region between the raw fabric member and the skin member.
As another aspect, the reinforcing material preferably contains a resin.

As a result, by using a member containing resin as the reinforcing material, it is possible to easily add the reinforcing material to the raw fabric member as compared with the case where metal is used as the reinforcing material, for example.
As another embodiment, after the reinforcing material addition step, the heating step of heating the skin member and the raw fabric member is included, the reinforcing material has thermoplasticity, and the heating step is the press molding step. It is preferable to do it before.

As a result, the heating step of heating the skin member and the raw fabric member to which the reinforcing material having thermoplasticity is added is performed before the press molding step, so that the raw fabric member is molded at the same time as the press molding step. It is possible to solidify the reinforcing material.
As another aspect, it is preferable that the predetermined partial area is a position corresponding to the foot portion of the occupant who rides on the vehicle when it is laid on the vehicle.

As a result, by adding a reinforcing material at a position corresponding to the foot of the occupant boarding the vehicle, it is possible to enhance the feeling of treading when the occupant places the foot in a predetermined partial area.

According to the vehicle interior material and the manufacturing method thereof of the present invention, since the reinforcing material is added to a predetermined partial region between the skin member and the raw fabric member, a predetermined partial region is compared with the other portion. It is possible to increase the rigidity of the wood and maintain the sound absorption by other parts.
As a result, it is possible to increase the rigidity while suppressing the deterioration of the sound absorption performance of the interior material for the vehicle.

It is a schematic side view of the vehicle in which the floor carpet which concerns on this invention is laid. It is a perspective view of a floor carpet. It is sectional drawing of the I-I cross section in FIG. It is a flowchart which showed the manufacturing process of the floor carpet 13 which concerns on this embodiment. It is sectional drawing of the II cross section in FIG. 2 in the manufacturing process of the floor carpet which concerns on this embodiment. It is sectional drawing of the II cross section in FIG. 2 in the manufacturing process of the floor carpet which concerns on this embodiment. It is sectional drawing of the II cross section in FIG. 2 in the manufacturing process of the floor carpet which concerns on this embodiment. It is sectional drawing of the II cross section in FIG. 2 in the manufacturing process of the floor carpet which concerns on this embodiment. It is sectional drawing of the II cross section in FIG. 2 in the manufacturing process of the floor carpet which concerns on this embodiment. It is sectional drawing of the II cross section in FIG. 2 in the manufacturing process of the floor carpet which concerns on this embodiment. It is sectional drawing of the II cross section in FIG. 2 in the manufacturing process of the floor carpet which concerns on this embodiment. It is sectional drawing of the II cross section in FIG. 2 in the manufacturing process of the floor carpet which concerns on this embodiment.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
With reference to FIG. 1, a schematic side view of the vehicle 1 on which the floor carpet 13 according to the present invention is laid is shown. Vehicle 1 is, for example, a one-box car having a maximum capacity of 7 people. In the vehicle 1, the vehicle interior 11 is formed so as to be covered with the floor panel 3, the roof 5, and the like.

The floor panel 3 is a flat plate member that forms the bottom of the vehicle 1. The roof 5 is a top plate supported by a plurality of pillars 4 extending in the vertical direction of the vehicle.
The vehicle interior 11 is a space in which the occupant 100 is boarded in the vehicle 1. A floor carpet (vehicle interior material) 13 and a plurality of seats 15 are arranged in the vehicle interior 11. The floor carpet 13 is a mat member laid along the upper surface of the floor panel 3. The seat 15 is seated by the occupant 100. The seat 15 is joined to the floor panel 3 so that the lower end thereof sandwiches the floor carpet 13.

Therefore, when the occupant 100 gets into the vehicle interior 11, the occupant 100 sits on the seat 15 with the foot portion 100a placed on the floor carpet 13.
With reference to FIG. 2, a perspective view of the floor carpet 13 is shown. As described above, the floor carpet 13 is laid along the upper surface of the floor panel 3, in other words, is formed so as to have a shape that matches the uneven shape of the floor panel 3. Here, at the position A (predetermined partial area) on the floor carpet 13 where the foot portion 100a of the occupant 100 is placed, a reinforcing portion 25, which will be described later, is formed inside.

With reference to FIG. 3, a cross-sectional view of the II cross section in FIG. 2 is shown. The floor carpet 13 includes a skin member 21 forming the front side, a raw fabric member 23 forming the back side, and a skeleton member 24. Hereinafter, when the floor carpet 13 is laid on the vehicle 1, the upper surface of the floor carpet 13 in the vertical direction of the vehicle is referred to as a front surface, and the lower surface of the floor carpet 13 in the vertical direction of the vehicle is referred to as a back surface.
The skin member 21 has, for example, a PET fiber cloth 21a through which sound can pass, and an infinite number of standing fibers 21b provided so as to extend upward from the cloth 21a in the vertical direction of the vehicle.

The raw fabric member 23 is, for example, a non-woven fabric made of felt, and has a property of absorbing sound, that is, vibration energy of air (hereinafter, also referred to as sound energy) and a cushioning property in the vertical direction. The skeleton member 24 is, for example, a non-woven fabric made of felt similar to the original fabric member 23.
Further, a resin reinforcing portion 25 is mainly formed at the position A between the raw fabric member 23 and the skeleton member 24. The reinforcing portion 25 is a portion formed on the surface of the raw fabric member 23 on the skin member 21 side and having higher rigidity than the skin member 21 and the raw fabric member 23.

The rigidity of the reinforcing portion 25 is increased by solidifying the PE of the liquid PE-containing agent (reinforcing material) 25a containing polyethylene (PE), which is a thermoplastic resin, with the raw material member 23. As a result, the rigidity of the floor carpet 13 at the position A where the foot portion 100a of the occupant 100 is placed can be increased. Therefore, when the occupant 100 places the foot portion 100a at the position A, the PE-containing agent 25a solidified by the raw fabric member 23 disperses the pressure with respect to the raw fabric member 23, so that the degree of collapse of the position A can be reduced. Can be done. Therefore, it is possible to secure the treading comfort at the position A.

Next, the method of manufacturing the floor carpet 13 according to the present embodiment will be described with reference to FIGS. 3 to 12. Here, FIG. 4 shows a manufacturing process of the floor carpet 13 according to the present embodiment in a cross section, and FIGS. 5 to 12 show II in FIG. 2 in the manufacturing process of the floor carpet 13 according to the present embodiment. The cross-sectional view of the cross section is shown.
According to FIG. 4, the method for manufacturing the floor carpet 13 according to the present embodiment includes a preparation step S10, a first forming step S20, a second forming step S30, and a third forming step S40. The preparation step S10 is a step of preparing the materials constituting the floor carpet 13 (FIG. 5). The first forming step S20 is a step of forming a layer (hereinafter, also referred to as a surface layer 13a) above the original fabric member 23 of the floor carpet 13 (FIGS. 6 to 8). The second forming step S30 is a step of applying the PE-containing agent 25a for adding the raw material member 23 to the surface layer 13a formed in the first forming step S20 and then arranging the raw material member 23 on the back surface side of the skeleton member 24. (Figs. 9 and 10). The third forming step S40 is a step of forming along the upper surface of the floor panel 3 of the vehicle 1 (FIGS. 11 and 12). Hereinafter, each of the above steps will be described in detail.

First, in the preparation step S10 (FIG. 5), the skin member 21, the raw fabric member 23, and the skeleton member 24 (only the skeleton member 24 is shown in FIG. 5) are prepared, and the process proceeds to the first forming step S20.
Next, in the first forming step S20, the first basic coating step (FIG. 6), the drilling step (FIG. 7), and the skin member bonding step (FIG. 8) are carried out. First, in the first basic coating step (FIG. 6), the PE-containing agent liquefied by heating is applied to the entire surface of the skeleton member 24 using the basic coating device 31, and then pressure-bonded using the roller 33. .. As a result, a thin film PE layer 24a is formed on the surface of the skeleton member 24. At this time, the roller 33 is at room temperature, and when the skeleton member 24 and the PE-containing agent are pressure-bonded, the heat of the PE-containing agent can be removed and cured.

Next, in the hole-drilling step (FIG. 7), a plurality of holes are made in the PE layer 24a on the surface of the skeleton member 24 by using a hole-drilling device 35 including a plurality of needles. At this time, the hole-drilling device 35 can satisfactorily make holes in the PE layer 24a by heating the needle 35a.
Next, in the skin member bonding step (FIG. 8), the PE layer 24a is heated and melted by a heating device (not shown), the skin member 21 is arranged on the surface side, and the skin member 21 is crimped with a roller 33 similar to the basic coating step. .. By heating the PE layer 24a in this way to melt and crimp it, the skin member 21 and the skeleton member 24 can be bonded to each other via the PE layer 24a. Further, since the roller 33 is at room temperature as in the basic coating step, the heat of the PE-containing agent can be removed and cured when the skeleton member 24 and the PE-containing agent are pressure-bonded.

Next, in the second forming step S30, the second foundation coating step (FIG. 9), the reinforcing material adding step (FIG. 10), and the raw fabric member arranging step (FIG. 10) are carried out. First, in the second basic coating step (FIG. 9), the PE-containing agent 25a is applied to the entire back surface of the skeleton member 24 using the spray coating device 36. The PE-containing agent 25a applied in the second basic coating step is used for adhering the raw fabric member 23 and the skeleton member 24 in the third forming step S40. Instead of coating by the spray coating device 36, a device capable of linearly coating the PE-containing agent 25a may be used to apply the PE-containing agent 25a in a grid pattern.

Next, in the reinforcing material addition step (FIG. 10), the PE-containing agent 25a is further applied to the position corresponding to the position A on the back surface of the skeleton member 24 by using the additional coating device 37. The PE-containing agent 25a added to the back surface of the skeleton member 24 in this reinforcing material adding step is located on the surface where the raw fabric member 23 and the skeleton member 24 meet, and forms the reinforcing portion 25. Although the PE-containing agent 25a is further added by using the additional coating device 37 as the reinforcing material adding step, a sheet-shaped reinforcing material may be arranged. Further, as in the first basic coating step (FIG. 6), a step of pressing the PE-containing agent 25a applied in the reinforcing material adding step onto the skeleton member 24 may be used.

After the reinforcing material addition step, in the raw fabric member arranging step (FIG. 10), the raw fabric member 23 is arranged on the back surface side of the skeleton member 24.
Next, in the third forming step S40, a heating step (FIG. 11) and a forming step (FIG. 12) are carried out. First, in the heating step (FIG. 11), the surface layer 13a and the raw fabric member 23 are heated with hot air using, for example, a heating device 32 (heating step, FIG. 9). By this heating step, the surface layer 13a and the raw fabric member 23 are heated to a temperature (for example, 180 to 260 ° C.) required in the press molding step described later. At this time, since the PE-containing agent 25a is a thermoplastic resin, it is melted by the hot air blown from the heating device 32.

After that, in the forming step (FIG. 12), it is formed by positioning it between the punch 39a and the die 39b of the press machine 39 and pressing it while cooling.
By this cold press molding step, the temperature of the raw fabric member 23 is lowered from the state of being heated in the heating step, and the shape is fixed. As a result, the raw fabric member 23 is formed in a shape that follows the shapes of the punch 39a and the die 39b of the press machine 39, that is, a shape that is laid in the vehicle interior 3 of the vehicle 1 (FIG. 2).

Here, the PE-containing agent 25a applied to the reinforcing portion 25 solidifies as the temperature decreases in the cold press molding step of the heating step. As a result, the rigidity of the reinforcing portion 25 of the floor carpet 13 after molding can be increased.
Further, in the floor carpet 13 formed in this manner, since the reinforcing portion 25 is arranged on the front surface of the original fabric member 23, in other words, on the back surface of the skeleton member 24, the sound absorbing performance of the floor carpet 13 is impaired. Instead, the feeling of treading pressure when the occupant 100 places the foot portion 100a at the position A can be enhanced.

In particular, by arranging the reinforcing portion 25 only in a place where rigidity is required such as position A, the floor carpet 13 as a whole is reinforced while reducing the increase in weight due to the arranging the reinforcing portion 25. Can be done.
As described above, in the vehicle interior material according to the present invention, the skin member 21 which forms a front surface when laid on the vehicle 1 and the original fabric member 23 which is arranged on the back surface side of the skin member 21 and has sound absorption property. , And the PE-containing agent 25a is added to the position A between the skin member 21 and the raw fabric member 23.

Therefore, since the reinforcing portion 25 formed by solidifying the PE-containing agent 25a is formed at the position A between the skin member 21 and the raw fabric member 23, the rigidity of the position A is higher than that of the other parts. And the sound absorption by other parts can be maintained.
Since the PE-containing agent 25a contains PE, which is a resin, the rigidity can be optimized by lowering the rigidity as compared with the case where a metal is used as the PE-containing agent 25a, for example.

The skeleton member 24 is provided between the skin member 21 and the raw fabric member 23, and the PE-containing agent 25a is added to the surface of the skeleton member 24 on the raw fabric member 23 side. It is possible to prevent the reinforcing portion 25 from being exposed from the surface of the skin member 21 due to wear deterioration or the like.
Then, when the original fabric member 23 is laid on the vehicle 1, the PE-containing agent 25a is added to the position corresponding to the foot 100a of the occupant 100 seated on the seat 15 of the vehicle 1, so that the occupant 100 can use the original fabric member 23. It is possible to enhance the feeling of treading when the foot portion 100a is placed at the position A.

A skeleton member 24 having higher sound absorption performance than the raw fabric member 23 is disposed between the skin member 21 and the raw fabric member 23, and the reinforcing portion 25 is formed between the skeleton member 24 and the raw fabric member 23. Since it is arranged between the floor carpet 13 and the floor carpet 13, it is possible to reduce the degree of collapse of the position A by distributing the pressure to the original fabric member 23 without impairing the sound absorbing performance of the floor carpet 13.
Further, in the method for manufacturing an interior material for a vehicle according to the present invention, a skin member preparation step (preparation step S10) for preparing a skin member 21 forming a surface when laid on the vehicle 1 and a sound absorbing raw material member 23 A raw material preparation step (preparation step S10) for preparing the material, a reinforcing material adding step of adding the PE-containing agent 25a to the position A between the skin member 21 and the raw material 23, and a reinforcing material adding step, and then the skin. It includes a raw fabric member arranging step of arranging the raw fabric member 23 on the back surface side of the member 21, and a press molding step of press-molding the skin member 21 and the raw fabric member 23 into a predetermined shape after the raw fabric member arranging step. ..

Therefore, a reinforcing material addition step of adding the PE-containing agent 25a to the position A between the skin member 21 and the raw fabric member 23 before the raw fabric member arranging step of arranging the raw fabric member 23 on the back surface side of the skin member 21. Therefore, the PE-containing agent 25a can be added to the position A between the raw material member 23 and the skin member 21.
Since the PE-containing agent 25a contains PE, which is a resin, the PE-containing agent 25a can be easily added to the raw material member 23 as compared with the case where a metal is used as the PE-containing agent 25a, for example.

Then, after the reinforcing material addition step, a heating step of heating the skin member 21 and the raw fabric member 23 is included, the PE-containing agent 25a is a resin having thermoplasticity, and the heating step is performed before the press molding step. Therefore, the PE-containing agent 25a can be solidified at the same time as the raw fabric member 23 is molded during the press molding process.
Then, a sound absorbing member disposing step of arranging the sound absorbing member on the raw fabric member is provided, and in the preparatory step, a skeleton member 24 having higher sound absorbing performance than the raw fabric member 23 is prepared, and the sound absorbing member disposing step. Is performed after the reinforcing material addition process and before the raw fabric member arranging process. Therefore, the degree of collapse of the position A is reduced by distributing the pressure to the raw fabric member without impairing the sound absorption performance. It is possible to manufacture the floor carpet 13 capable of producing.

This completes the description of the vehicle interior material and the method for manufacturing the vehicle interior material according to the present invention, but the present invention is not limited to the above embodiment and can be changed without departing from the gist of the invention.
For example, in the present embodiment, the floor carpet 13 has been described as an example of the interior material for a vehicle, but it does not have to be a carpet, and the raw fabric member of the interior material such as the head lining that needs to be reinforced. The PE-containing agent 25a may be added to the mixture.

Further, in the present embodiment, the PE-containing agent 25a is added to the raw fabric member 23 by the basic coating device 31, but the raw fabric is coated by applying a liquid or a powdered PE-containing agent is applied to the raw fabric. It may be added by spraying on the member 23.
Further, in the present embodiment, PE is used as the thermoplastic resin, and the liquid PE-containing agent 25a containing the PE is used. However, powders and fibers containing PE, PVA (Poly Vinyl Alcohol), and the like are used. It may be used, or a hot press molding step may be used instead of the cold press molding step by using urethane or the like having a thermosetting resin.

Further, in the present embodiment, the reinforcing portion 25 is located on the surface where the raw fabric member 23 and the skeleton member 24 meet, but the reinforcing material is positioned on the surface of the skeleton member 24 on the skin member 21 side. May be good.

1 Vehicle 13 Floor carpet (interior material for vehicles)
15 Seat 21 Skin member 23 Original fabric member 24 Skeleton member 25 Reinforcing part (reinforcing material)
25a PE-containing agent (reinforcing material)
100 Crew 100a Foot

Claims (8)

The skin member that forms the surface when laid on the vehicle,
It is provided with a raw fabric member which is arranged on the back surface side of the skin member and has a sound absorbing property.
A vehicle interior material in which a reinforcing material is added to a predetermined partial region between the skin member and the raw fabric member. The vehicle interior material according to claim 1, wherein the reinforcing material contains a resin. A skeleton member arranged between the skin member and the raw fabric member is provided.
The vehicle interior material according to claim 1 or 2, wherein the reinforcing material is added to a surface of the skeleton member on the side of the original fabric member. The vehicle interior material according to any one of claims 1 to 3, wherein the predetermined partial area is a position corresponding to the foot of an occupant who rides on the vehicle when laid on the vehicle. The skin member preparation process that prepares the skin member that forms the surface when laid on the vehicle,
The raw fabric member preparation process for preparing the raw fabric member with sound absorption, and
A reinforcing material addition step of adding a reinforcing material to a predetermined partial region between the skin member and the raw fabric member, and
After the reinforcing material addition step, the raw fabric member arranging step of arranging the raw fabric member on the back surface side of the skin member, and the raw fabric member arranging step.
A method for manufacturing an interior material for a vehicle, comprising: a press molding step of press-molding the skin member and the raw fabric member into a predetermined shape after the raw fabric member arranging step. The method for manufacturing an interior material for a vehicle according to claim 5, wherein the reinforcing material contains a resin. After the reinforcing material addition step, the heating step of heating the skin member and the raw fabric member is included.
The reinforcing material has thermoplasticity and is
The method for manufacturing an interior material for a vehicle according to claim 6, wherein the heating step is performed before the press molding step. The vehicle interior material according to any one of claims 5 to 7, wherein the predetermined partial area is a position corresponding to the foot of an occupant who rides on the vehicle when laid on the vehicle. Production method.

Images