JP2894668B2 - Manufacturing method for automotive interior parts - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing interior parts for automobiles requiring sound absorbing performance such as roof trim for automobiles.

[0002]

2. Description of the Related Art For example, an automobile roof trim installed on a ceiling surface of an automobile interior preferably has a sound absorbing function for reducing the sound pressure in the interior of the automobile in addition to a decorative function. As shown in FIG. 7, the roof trim 1
A skin material 3 is integrally attached to a surface of a core material 2 made of a porous base material.

As a method of forming the roof trim 1, as shown in FIG. 8, a skin material 3 on which a hot melt film is laminated is set on a mold surface of a lower mold 4a for press molding, and a core material 2 is formed. Heated by the heater device 5, the hot melt film laminated on the skin material 3 is melted by the heat of the core material 2, and the engagement between the cold press molding upper mold 4b and the cold press molding lower mold 4a is clamped. Then, the roof trim 1 is completed by integrally forming the roof trim 1 into a required shape.

As shown in FIG. 9, both the core material 2 and the skin material 3 are heated by separate heater devices 5 and 6, and the core material 2 and the skin material are placed in upper and lower dies 4a and 4b for cold press molding. 3 and integrated by press molding,
There is also a method of forming the roof trim 1.

[0005]

However, in order to provide the roof trim 1 with desired sound absorbing performance, the core material 2
In the method shown in FIG. 8, for example, when the clearance between the press dies 4a and 4b is set to 10 mm or more, the press pressure is greatly reduced. As a result, there has been a problem that the bonding strength between the core material 2 and the skin material 3 becomes insufficient, and defects such as floating and peeling of the skin material 3 are likely to occur.

[0009] Similarly, in the method shown in FIG. 9, although the adhesiveness is somewhat improved, it is still not sufficient, and defects such as peeling and floating of the skin material 3 cannot be fundamentally solved. .

The present invention has been made in view of such circumstances, and achieves good sound absorbing performance in a method of manufacturing an automobile interior part having a sound absorbing performance, which is made of a laminated body such as a core material skin material. Therefore, it is an object of the present invention to provide a method for manufacturing an automobile interior part that can sufficiently increase the adhesive strength between the core material and the skin material even when the thickness of the core material is set to be large.

[0008]

In order to achieve the above-mentioned object, the present invention provides a molded nonwoven fabric core material having a large thickness for providing sound absorption, and a breathable material for providing decorativeness on the product surface. In a method for manufacturing an automobile interior part having a skin material, a molded non-woven fabric core material, a gas permeable hot melt film, and a gas permeable skin material are sequentially laminated, and a hot air is blown for a predetermined time while the peripheral edge is clamped, so that the lamination is integrated. Press-forming in which the heat-integrating step of forming the laminate and the laminated body integrated in the above-described step are set in a cold press forming die having a required mold surface shape, and low-pressure press forming is performed with a large clearance between the dies. And a process.

[0009] As a material of the core material of the molded nonwoven fabric, a high melting point ultrafine synthetic fiber and a heat-fusible fiber having a function as a binder are mixed and dispersed in a mat shape, and needling or hot air processing is performed. Use the integrated one.

The synthetic fibers may be appropriately selected from thermoplastic synthetic resin fibers such as nylon, polyacrylonitrile, polyacetate, polyethylene terephthalate, and the like, and the heat-fusible fibers may be polyethylene, polypropylene, wire or the like. May be appropriately selected from polyester, polyamide and the like.

The basis weight of the nonwoven fabric core material for molding is 800 to
2000 g / m ² is desirable.

Further, as the air permeable hot melt film, a non-woven fabric type hot melt film such as low melting point polyethylene and polyamide is used.

For the purpose of reinforcing the rigidity of the molded nonwoven fabric core,
A phenol resin impregnated mesh may be interposed between the air permeable hot melt film and the air permeable skin material. The phenol resin impregnated mesh is obtained by impregnating a fiber mesh such as vinylon, glass fiber, and suffix with a phenol resin. , Mainly contributing to the reinforcement function and the improvement of the handling of the mat.

As the breathable skin material, a nonwoven fabric or a cloth with urethane is used.

[0015]

As is clear from the above configuration, the molded nonwoven fabric core material, the air-permeable hot melt film, the phenolic resin-impregnated mesh body, and the air-permeable skin material all have air-permeability. By the melting action of the hot melt film, each material can be heated and integrated.

Therefore, since the respective materials are integrated before press molding, even if low pressure pressing is performed with a large clearance between the upper and lower press dies, the core material and the skin material are not separated. It has sufficient adhesive strength.

[0017]

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

FIGS. 1 and 2 are a perspective view and a sectional view, respectively, showing an automotive roof trim manufactured by applying the method of the present invention. FIGS. 3 to 5 show the method of the present invention applied to a method of manufacturing a roof trim. FIG. 6 is a cross-sectional view showing each step, and FIG. 6 is a cross-sectional view showing a modified example of an automobile roof trim manufactured by applying the method of the present invention.

In FIG. 1 and FIG. 2, an automobile roof trim 10 installed on a ceiling surface in an automobile interior comprises a molded nonwoven fabric core material 11 having a sound absorbing performance, a gas permeable hot melt film 12, and a phenol resin impregnated mesh body 13. , And a breathable skin material 14. The excellent sound absorbing performance of the molded nonwoven fabric core material 11 can greatly contribute to a reduction in the sound pressure in the passenger compartment.

In this embodiment, fibers obtained by mixing 50 to 80 parts by weight of a polyester fiber as the molded nonwoven fabric core material 11 and 20 to 50 parts by weight of a low melting point polyethylene fiber as the heat fusion fiber are scattered in a mat form by a card method. And adjusted to a basis weight of 800 to 2000 g / m ² , needling,
A nonwoven fabric mat formed by heating with hot air is used.

As the air-permeable hot melt film 12, a low melting point polyethylene film is used. As the phenol resin-impregnated mesh, a mesh of vinylon fibers impregnated with a phenol resin is used. As the skin material 14, a cloth laminated with urethane is used.

Next, an embodiment of a manufacturing process of the automobile roof trim 10 shown in FIGS. 1 and 2 will be described with reference to FIGS.

First, as shown in FIG. 3, a molded nonwoven fabric core material 11, a gas permeable hot melt film 12, a phenol resin impregnated mesh body 13, and a gas permeable skin material 14 are laminated in this order, and the periphery is clamped by a clamp device 20. Clamped by
Heating is performed in the hot air circulator 21.

The heating conditions were as follows: hot air temperature 200
Heating is performed at 60 ° C. for 60 seconds.

Then, in this heating step, the gas permeable hot melt film 12 is melted, and the molded nonwoven fabric core material 11, the phenol resin impregnated mesh body 13, and the gas permeable skin material 14 are firmly heated and integrated.

Thereafter, as shown in FIG. 4, the integrated laminated body M is set on the mold surface of the lower mold 30 for cold press molding, and the upper mold 31 for cold press molding is lowered. As shown in (1), the clearance between the upper and lower dies 30, 31 is set to be large (10 mm in the present embodiment), and cold press forming is performed to press-mold the roof trim 10 into a required shape.

At this time, even if the thickness is set to maintain the sound absorbing performance, the pressing pressure is set low because the molded nonwoven fabric core material 11 and the breathable skin material 14 are firmly integrated in the heating step. Even if the air-permeable skin material 14 does not peel off, there is no occurrence of defects such as floating.

Further, in addition to maintaining good adhesive strength between the molded nonwoven fabric core material 11 and the air permeable skin material 14, the work of setting the laminate M in the press molds 30, 31 is also performed by positioning the laminate M at a predetermined position. Since the setting operation is merely performed, there is an additional effect that the setting operation can be simplified and the operation efficiency is improved.

As described above, according to the present embodiment, by using a gas permeable material, the molded nonwoven fabric core material 11 and the gas permeable skin material 14 can be integrated in advance in the heating step with hot air, Even if the clearance between molds is set large in order to maintain good sound absorption performance in molding, there is no peeling or floating between the molded nonwoven fabric core material 11 and the permeable skin material 14, and strong adhesive strength can be expected. In addition, there is an effect that interior parts having good sound absorption performance can be efficiently mass-produced.

The phenol resin impregnated mesh 13
Has a function of complementing the shape retention of the molded nonwoven fabric core material 11.

Next, the one shown in FIG.
In this embodiment, the air-permeable hot melt film 1 is provided on both sides of the molded nonwoven fabric core material 11.
2, the phenolic resin-impregnated mesh body 13 is integrated. According to this embodiment, there is an advantage that the handling characteristics and the dimensional stability of the molded nonwoven fabric core material 11 are further improved.

[0032]

As described above, according to the method for manufacturing an automobile interior part according to the present invention, the following special effects can be obtained.

(1) The core material and the skin material can be firmly integrated in the heating step by blowing hot air in a state where the materials having air permeability are laminated, so that the sound absorbing performance can be enhanced in the pressing step. Even when low-pressure pressing with a large clearance between the molds is performed, the bonding strength between the core and the skin is sufficiently ensured. The problem can be effectively solved, and there is an effect that it is possible to mass-produce interior parts having excellent sound absorption performance.

(2) Since each material having air permeability is integrated by a heating step, the laminate is subjected to cold press molding. Therefore, it is necessary to set each material in a press mold as in the conventional case. In addition, the process of setting the material in the press die can be simplified, and the operability is improved.

[Brief description of the drawings]

FIG. 1 is a perspective view of a roof trim for an automobile manufactured by applying the method of the present invention, as viewed from the indoor side.

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

FIG. 3 is a cross-sectional view showing one step of the method of the present invention and showing a step of heating and integrating the materials.

FIG. 4 is a cross-sectional view showing one step of the method of the present invention and showing a step of setting a laminate to a press die.

FIG. 5 is a cross-sectional view showing one step of the method of the present invention and showing a cold press forming step.

FIG. 6 is a cross-sectional view showing the configuration of another embodiment of a roof trim for an automobile manufactured by applying the method of the present invention.

FIG. 7 is a cross-sectional view showing a configuration of a conventional roof trim.

FIG. 8 is an explanatory view showing a conventional method of forming a roof trim.

FIG. 9 is an explanatory view showing a conventional method of forming a roof trim.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Roof trim for automobiles 11 Molded nonwoven fabric core material 12 Air permeable hot melt film 13 Mesh body impregnated with phenol resin 14 Air permeable skin material 20 Clamping device 21 Hot air circulation machine 30 Lower die for cold press molding 31 Upper die for cold press molding M Lamination body

──────────────────────────────────────────────────続 き Continuation of the front page (51) Int.Cl. ⁶ identification code FI B29L 31:58 (58) Investigated field (Int.Cl. ⁶ , DB name) B29C 43/18-43/20 B29C 43/36 -43/42 B29B 11/14-11/16 B32B 5/02-5/28 B60R 13/02

Claims (2)

(57) [Claims] 1. An automotive interior part comprising a molded nonwoven fabric core material (11) set thick to provide sound absorption and a breathable skin material (14) for imparting decorativeness to the product surface. In the method of manufacturing, the molded nonwoven fabric core material (11), the air permeable hot melt film (12), and the air permeable skin material (14) are sequentially laminated, and hot air is blown for a predetermined time while the peripheral edge is clamped, so that the lamination is performed integrally. And a lamination (M) integrated in the above step are set in a mold (30, 31) for cold press molding having a required mold surface shape, and a large clearance between the molds is set. And a press forming step of performing low-pressure press forming. 2. A phenolic resin-impregnated mesh body (13) is interposed between a permeable hot melt film (12) and a permeable skin material (14).
A method for producing an automobile interior part according to the above.