JP2516809Y2 - Core material structure for automobile interior parts - Google Patents

Description

[Detailed description of the device]

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a core material structure for automobile interior parts such as automobile door trims.

[0002]

2. Description of the Related Art Normally, various interior parts such as door trims and rear corner trims are mounted in the interior of an automobile. The general structure of these interior parts is that they have appropriate shape retention and mounting to the vehicle body panel. Many of them have a laminated structure in which a skin material that provides cushioning and decorative properties is attached to the surface of a core material having rigidity.

The core material for the interior parts is light in weight and has a proper shape-retaining property, the interior parts for automobiles are mass-produced products, and thus the cost is low, and the core material is vacuum-formed. It is preferable that it has air permeability so that it can be attached.

Fiber boards produced by dry papermaking (hereinafter referred to as dry mats) satisfying these requirements
Is mentioned. This dry mat is a fiber mat for hot press molding which is produced by a dry papermaking method using wood fiber fiber, non-wood fiber, thermoplastic resin, and thermosetting resin as raw materials.

Then, as shown in FIG. 8, the dry mat 3 is set in the upper and lower molds 1 and 2 for hot press molding, and the upper and lower molds 1 and 2 for hot press molding are pressurized at a high temperature. As shown in FIG. 9, a molding substrate 4 having a required shape
A door trim is manufactured by molding a sheet, and attaching a skin material to the surface of the molded substrate 4 by vacuum forming or the like.

[0006]

As described above, when the dry mat 3 is thermocompression-molded and used as a core material for a door trim or the like, the dry mat 3 is used in a high expansion rate portion such as an armrest portion 4a of the door trim. If it does, the reinforcement patch is manually attached using an instant adhesive after molding to ensure its function as a core material. Felt is often used, and there is also an attempt to prevent the occurrence of cracks and scales by preliminarily aligning the reinforcing patch with the high expansion rate part of the dry mat and press-integrating it. Air becomes easy to collect by making it so that troubles such as blister and puncture easily occur.

Further, phenol-impregnated paper is also used as a reinforcing patch, but in that case, the breathability is impaired, so that there is a problem that the vacuum attachment of the skin material cannot be performed.

The present invention has been made in view of the above circumstances, and an object of the present invention is to reinforce a high expansion rate portion of a base material on which a dry mat is formed.
The core material structure for automobile interior parts does not cause breakage or scaling on the base material, swelling or puncture due to the reinforcing material, and does not impair the attachment of the skin material and the air permeability. To provide.

[0009]

In order to achieve the above object, the present invention provides a base material formed into a required shape by thermocompressing a dry mat impregnated with a thermosetting resin, and a base material. In a core material structure for an automobile interior part in which a reinforcing material is integrated with a high expansion rate portion of the material, the reinforcing material is obtained by impregnating a high melting point fiber mesh body with a thermosetting resin of the same type as the base material. It is characterized by

The thermosetting resin is preferably a phenol resin, and the reinforcing material is preferably a vinylon fiber mesh body or a stiff fiber mesh body because it has good heat resistance.

Further, the areal density of the reinforcing material is 40 to 100.
The range of g / m ² is preferable, and the surface density is 100 g / m ²
When it exceeds the above value, the residual return force of the reinforcing material is large, and it is difficult to integrate the base material and the reinforcing material, and defects such as floating easily occur.

On the contrary, if the surface density of the reinforcing material is less than 40 g / m ² , the reinforcing effect is small, although it is effective in preventing breakage and scaling.

[0013]

As is apparent from the above construction, since the reinforcing material composed of the fiber mesh body is press-integrated with the high expansion rate portion of the base material, the reinforcing effect of the high expansion rate portion which conventionally causes a decrease in rigidity. Is large and there is no breakage or scaling.

Further, since the reinforcing material is composed of a fiber mesh body, the air permeability of the core material is not impaired, and there is no hindrance when vacuum forming the skin material.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment of a core material structure for an automobile interior part according to the present invention will be described in detail below with reference to the accompanying drawings.

FIG. 1 is a front view showing an automobile door trim to which the core material structure according to the present invention is applied, FIG. 2 is a sectional view showing the structure of the automobile door trim, and FIG. 3 is a core material structure according to the present invention applied to a door trim. Front view showing the door trim core material, FIG. 4 is a sectional view showing the structure of the core material, and FIGS.
FIG. 4 is a cross-sectional view showing a molding process of a door trim core material.

First, referring to FIGS. 1 and 2, an embodiment in which the core material structure according to the present invention is applied to a door trim will be described. The door trim 10 for an automobile is formed into a required shape and has an appropriate shape retention and a vehicle body panel. A core material 20 having attachment rigidity to the core material 20 and a skin material 30 having cushioning and decorative properties are integrally attached to the surface side of the core material 20 by vacuum forming.

By the way, the present invention is characterized by the structure of the core member 20 of these automobile door trims 10.

That is, as shown in FIGS. 3 and 4, the core material 20 is a base material 21 formed by molding a dry mat into a required shape.
And a reinforcing material 22 that is press-integrated with the high expansion rate portion of the base material 21, and in this embodiment, the dry mat M, which is the material of the base material 21, is impregnated with a phenol resin. and with the existing surface density 2 to 2.5 kg / m ^2, reinforcing member 22, 200 ° C. or more decomposition point, consists mesh of fibers having a melting point, in this embodiment, impregnated with phenolic resin A mesh body made of stiff fiber is used, and as the areal density of this mesh body,
It is preferably set within a range of ^{40g / m 2 ~100g / m 2} .

The reason for this is that when the surface density of the mesh body exceeds 100 g / m ² , the residual return force of the mesh body is large, and this residual return force is greater than the adhesive strength between the base material 21 and the reinforcing material 22. This is because there is a problem that floating occurs when it becomes.

On the other hand, when the surface density of the mesh body, which is the material of the reinforcing material 21, is less than 40 g / m ² , there is a certain effect in preventing breakage and scaly, but it cannot withstand a large load. This is because the desired reinforcing effect cannot be obtained.

The inventors of the present invention have a dry mat M of 2.2 kg / m ² and a phenol-impregnated staple fiber mesh body of 40 g / m ^2.
It was found that, when (Surf 30 g / m ² , phenol resin 10 g / m ² ) was used, the 50 kg load could be cleared at this reinforced portion.

Next, the base material 2 will be described with reference to FIGS.
The process of integrating 1 and the reinforcing material 22 will be described.

First, as shown in FIG. 5, when the lower mold 40 for hot press molding and the upper mold 41 for hot press molding are in the mold open state, the dry mat M, which is the material of the base material 21, is placed in the lower mold 40. Set on the mold surface. At this time, the hot press upper and lower molds 40 and 41 are heated to 200 ° C.

Next, as shown in FIG. 6, after placing the reinforcing material 22 on the high expansion rate portion of the dry mat M, the upper die 41 for hot press molding is lowered by a predetermined stroke as shown in FIG. The dry mat M is molded into a desired shape by hot press molding using the hot press molding upper and lower molds 40 and 41 to obtain the base material 21, and the reinforcing material 22 is integrated with the high expansion rate portion of the base material 21.

At this time, the use of the reinforcing material 22 disperses the local force applied to the dry mat M, and promotes the sliding between the dry mat M and the hot press molding upper die 41 by the reinforcing material 22. By this, the base material 21
Problems such as scaling and disconnection are eliminated.

Further, the reinforcing material 22 includes a dry mat M.
Since phenol resin, which is a thermosetting resin of the same type as that of the thermosetting resin impregnated in the base material, is impregnated, the base material 21 and the reinforcing material 22 can be firmly bonded, and at the same time, high strength such as staple and vinylon can be achieved. Since it uses a melting point material, it can withstand high temperatures during hot press molding.

In addition, as described above, since it has a sufficient reinforcing strength and is made of a mesh body, it does not impair the air permeability, so that there is no problem when vacuum-coating the skin material 30.

[0029]

As described above, the core material structure for automobile interior parts according to the present invention has the following special effects.

(1) During hot press molding of a dry mat, a reinforcing material composed of a mesh body of fibers having a high melting point such as soft fibers and vinylon fibers is press-integrated. In this case, no breakage or scaling occurs, sufficient strength is obtained, and swelling or puncture does not occur unlike the conventional reinforcing patch.

(2) Since the reinforcing material is composed of a mesh body of high melting point fibers, it has the effect that the air permeability of the core material is secured and the vacuum attachment of the skin material can be carried out smoothly.

[Brief description of drawings]

FIG. 1 is a front view showing an automobile door trim to which a core structure according to the present invention is applied.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a front view showing a core material of the automobile door trim shown in FIG.

FIG. 4 is a sectional view taken along line IV-IV in FIG. 3;

5 is a cross-sectional view showing a molding step of the core material shown in FIG. 3, showing a state in which a dry mat is set.

FIG. 6 is a cross-sectional view showing a step of setting a reinforcing material, showing a step of forming the core material shown in FIG.

7 is a cross-sectional view showing a hot press molding step of the core material shown in FIG.

FIG. 8 is a sectional view showing a hot pressing process of a dry mat.

FIG. 9 is a sectional view showing a core material of a conventional automobile door trim.

[Explanation of symbols]

 10 Automotive Door Trim 20 Core Material 21 Base Material 22 Reinforcement Material 30 Skin Material 40 Hot Press Molding Lower Mold 41 Hot Press Molding Upper Mold

Claims (3)

(57) [Scope of utility model registration request] 1. A base material (21) formed into a required shape by thermocompressing a dry mat (M) impregnated with a thermosetting resin, and a high expansion rate portion of the base material (21). In a core material structure for an automobile interior part, which comprises an integrated reinforcing material (22), the reinforcing material (22) comprises a high melting point fiber mesh body impregnated with a thermosetting resin of the same type as the base material (21). A core material structure for automobile interior parts characterized by being treated. 2. The thermosetting resin impregnated in the dry mat (M) is a phenol resin, and the reinforcing material (22) is composed of a vinylon fiber mesh body or a soot fiber mesh body impregnated with the phenol resin. The core material structure for an automobile interior part according to claim 1, wherein: 3. The areal density of the reinforcing material (22) is 40 to 100.
The core material structure for automobile interior parts according to claim 1, wherein the core material structure is g / m ² .