JP2786880B2 - Manufacturing method of automotive interior materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a waste binder molding layer formed by combining a mixture of fiber waste and synthetic resin material waste with a binder resin, and integrally bonded to the back surface and the like. The present invention relates to a method for producing an interior material for an automobile, which comprises a low-density foam layer and is used as a floor trim material of an automobile.

[Conventional technology]

Conventionally, as shown in, for example, Japanese Utility Model Publication No. 59-7152, a composite mat material formed by laminating a nonwoven fabric layer on the surface of a sound insulation mat layer made of polyvinyl chloride or the like as a floor trim material laid on the floor of an automobile There is known a device that uses a to improve the effects of vibration isolation, heat insulation, sound insulation, and sound absorption, as well as aesthetics and good stepping comfort.
Further, as the floor trim material, a waste binder molded product obtained by combining a mixture of fiber waste and synthetic resin material waste with a binder resin made of a thermosetting resin or the like is used.

[Problems to be solved by the invention]

The above-mentioned waste binder molded product has a drawback that the specific gravity of the molded product is large due to the high waste density, the processing strength is low, and it is easy to break when bending into a shape corresponding to the installation portion. For this reason, by bonding a reinforcing material made of a low-density foam having a low specific gravity to the back surface of the waste binder molded product via an adhesive to reinforce, the specific gravity of the entire molded product is reduced, and the processing strength is reduced. Although it is conceivable to improve it, in this case, there is a problem that the operation of bonding the above-mentioned waste binder molded product and the reinforcing material made of the low-density foam is complicated, and the production cost is increased.

The present invention has been made in order to solve the above problems, and can easily and inexpensively produce an interior material for automobiles in which a waste binder molding layer and a low density foam layer are integrally joined. An object of the present invention is to provide a method for manufacturing an interior material for an automobile.

[Means for solving the problem]

The present invention provides a method for forming a low-density foam layer in which an engaging portion is provided over the entire joint surface, setting the low-density foam layer in a molding die, and then depositing fiber waste and synthetic resin thereon. By filling the mixture such as material waste and binding the mixture with a binder resin to form a waste binder molded layer, the waste binder molded layer and the low-density foam layer are integrated through the above-mentioned engaging portion. It is intended to be joined to.

[Action]

According to the present invention having the above structure, the waste binder molding layer is molded so as to cover the low-density foam layer provided with the engaging portions, thereby eliminating the need for the bonding operation using an adhesive. An interior material for automobiles comprising a waste binder molding layer and a low-density foam layer integrally joined via a joint portion is manufactured.

〔Example〕

FIG. 1 shows a first embodiment of a method for manufacturing an automobile interior material according to the present invention. To manufacture the automobile interior material, first, in step (a), a projecting ridge having an upwardly extending surface is provided. The low-density foam layer 3 having a thickness of about 10 mm in which dovetail-shaped engaging portions 2 are provided between the ridges 1 and 1 is formed at predetermined intervals. Then, in the step (b), the low-density foam layer 3 is removed from the mold by cooling the low-density foam layer 3 at a temperature of about 80 to 100 ° C. in order to remove shrinkage deformation and the like generated when the low-density foam layer 3 is cooled to room temperature. After heating at the temperature for about 8 hours,
Cool to room temperature again.

Next, in the step (c), after setting the low-density foam layer 3 in the lower mold 4 of the pressure-molding die, a thermosetting resin is added to a mixture 5 obtained by mixing fiber waste and synthetic resin material waste. A mixture of a binder resin material 6 made of a solution or the like is filled on the surface of the low-density foam layer 3. And step (d)
In the above, the pressurizing portion of the upper mold 7 is inserted into the lower mold 4 and the mixture 5 and the like are pressurized at 130 to 150 ° C.
The mixture is heated by supplying a certain amount of steam to cure the binder resin 6, and the mixture 5
To form a waste binder forming layer 8 having a thickness of about 10 mm on the surface of the low-density foam 3 integrally.
At the time of forming this waste binder molding layer 8, the mixture 5 and the binder resin 6 penetrate into the engaging portion 2 of the low-density foam layer 3, and a downwardly extending ridge 9 corresponding to the engaging portion 2 is formed. Therefore, the waste binder molding layer 8 and the low-density foam layer 3 are integrally connected via the engaging portion 2.

Next, in the step (e), the upper mold 7 is released from the lower mold 4 and the lower mold 4 is separated into right and left.
The automobile interior material 10 composed of the waste binder molding layer 8 and the low-density foam layer 3 is taken out from the pressure molding die, and the manufacturing process is completed.

Thus, on the surface of the low-density foam layer 3 provided with the engaging portion 2 on the surface, the waste binder molding layer 8 composed of the mixture 5 such as fiber waste and synthetic resin waste and the binder resin material 6 is formed. Since the waste binder molding layer 8 and the low-density foam layer 3 are integrally connected via the engaging portion 2 by pressure molding, the waste binder molding layer 8 can be formed without using an adhesive or the like. The interior material 10 for automobiles reinforced with the low-density foam layer 2 can be easily manufactured. That is, at the same time as the pressure molding of the waste binder molding layer 8, the ridges 9 of the waste binder molding layer 8 are formed by the material that has entered the engaging portions 2 of the low-density foam layer 3. 9 and the ridges 1 of the low-density foam layer 3 constituting the engaging portion 2 are engaged with each other, so that the joining operation using the adhesive can be performed without using the adhesive. The waste binder molding layer 8 and the low-density foam 3 are mechanically joined to each other.
Can be effectively reinforced.

The low-density foam layer 3 usually has a specific gravity of 0.03.
Since the specific gravity is about 5 and is very small as compared with the waste binder molding layer 8 having a specific gravity of about 0.3 to 0.4, the waste binder molding layer 8 and the low-density foam layer 3 are integrally joined to each other to form an automobile interior. By forming the material 10, the specific gravity of the vehicle interior material 10 can be reduced to a small value.

Further, the low-density foam layer 3 which is liable to undergo shrinkage deformation after molding.
After being formed, the waste binder forming layer 8 which is relatively unlikely to undergo shrinkage deformation is formed by pressure, so that the waste binder forming layer 8 and the low-density foam layer 3 And can be firmly joined. That is, as shown in step (a) of FIG.
After forming the waste binder molding layer 8 having the following, in the step (b), the waste binder molding layer 8 is set in a molding die, and a foaming resin is filled from above to mold the low density foam layer 3 into a mold. However, in this case, in the step (c), when the low-density foam layer 8 is cooled after molding, the internal bubbles are crushed and the low-density foam 3 is contracted and deformed. As a result, the ridge 12 of the low-density foam 3 formed by filling the inside of the engagement portion 11 contracts,
A gap is formed between the low-density foam 3 and the waste binder molding layer 8, whereby a gap is formed between the low-density foam 3 and the engaging portion 11.

On the other hand, as described above, when the low-density foam layer 3 is formed, and then the waste binder forming layer 8 is formed thereon by pressing, when the waste binder forming layer 8 is formed, Since the waste binder molding layer 8 does not shrink and deform, a gap can be prevented from being formed between the engaging portion 2 of the low-density foam layer 3 and the ridge 9 of the waste binder molding layer 8. The joining strength between the waste binder molding layer 8 and the low-density foam 3 does not decrease.

The waste binder molding layer 8 and the low density foam layer 3
The engaging portion 2 of the low-density foam layer 3 constituting the joint portion with
Various deformations are possible without being limited to the above-mentioned dovetail shape. For example, as shown in FIG. 3 and FIG. 5, or as shown in FIG. 5, an engaging portion 2 having a circular hole having an upper portion formed in a lower constriction and a lower portion formed in a lower portion is provided. The material of the waste binder molding layer 8 may be made to enter the inside. In addition, as shown in FIG.
As shown in the figure, an engaging portion 2 composed of a square hole extending downward may be provided, and the material of the waste binder molding layer 8 may enter the engaging portion 2.

FIG. 8 shows a second embodiment of the method for manufacturing an automobile interior material according to the present invention. In this manufacturing method, first, in the step (a), a large number of engaging portions 2 each having a circular through-hole portion or the like are used.
After molding the low density foam layer 3 having
, The lower part of the lower mold 4 of the molding die is filled with a mixture 5 of fiber waste and synthetic resin material waste, and the low-density foam layer 3 is set thereon. Next, in the step (c), after filling the mixture 5 of fiber dust and synthetic resin material dust on the low-density foam layer 3, a binder resin 6 made of a thermosetting foam resin solution or the like is injected from above. I do. The binder resin 6 penetrates through the engagement portion 2 of the low-density foam layer 3 and also into the mixture 5 below the lower mold.

Then, in step (d), after setting the upper mold 7 on the upper part of the lower mold 4, the inside of the mold is heated to cure the binder resin 6, and the mixture 5 is bound by the binder resin. Thus, the low-density foam layer 3
And the scrap binder forming layers 8 and 8 covering both the front and back surfaces thereof are manufactured, and the scrap binder forming layers 8 and 8 are formed on the engaging portions 2 of the low-density foam layer 3. Are connected to each other through the communicating portion 13, whereby the waste binder molding layers 8 and 8 are integrally joined to the front and back surfaces of the low-density foam layer. Even when some gaps are formed between them, there is no possibility that the bonding strength is reduced.

When a foamed resin solution is used as the binder resin 6 for binding the mixture 5 as described above, the binder resin 6 spreads to every corner of the mixture 5 by the expansion action according to the foaming, so that the upper mold 7 Without applying pressure by
The mixture 5 can be effectively combined.

〔The invention's effect〕

As described above, the present invention provides a method of molding a waste binder molding layer on a low-density foam layer provided with an engagement portion, so that the waste binder molding layer and the low-density foam are formed through the engagement portion. Because it was configured to join the body layer integrally,
Without the need for complicated joining work using an adhesive,
The low-density foam layer has the advantage that the waste binder molding layer can be reinforced and an interior material for automobiles having a low specific gravity can be easily and inexpensively manufactured.

[Brief description of the drawings]

FIG. 1 is a first view of a method for manufacturing an interior material for an automobile according to the present invention.
FIG. 2 is a process diagram showing an example, FIG. 2 is a process diagram showing a comparative example for explaining the effect of the method for producing a composite material according to the present invention, and FIGS. FIG. 8 is a process chart showing a second embodiment of the present invention. 2 ... engaging part, 3 ... low density foam layer, 4 ... lower mold (molding die), 5 ... mixture, 6 ... binder resin, 8 ...
… Waste binder molding layer, 10 …… interior materials for automobiles.

Continuation of the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) B29C 43/00-43/02 B29C 43/18-43/20 B29C 65/70, 43/32-43/36 B32B 5 / 00-5/32 B32B 3/00-3/30

Claims (1)

(57) [Claims] 1. A low-density foam layer in which an engaging portion is disposed over the entire joint surface, and the low-density foam layer is set in a molding die. By filling a mixture such as synthetic resin material waste and binding the mixture with a binder resin to form a waste binder molded layer, the waste binder molded layer and the low-density foam layer are formed via the engaging portion. A method of manufacturing an interior material for an automobile, comprising: