JP3042834B2 - Automotive interior parts and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automotive interior part suitable for a roof trim or the like to be installed in a roof panel of an automobile, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In recent years, foamed PPO (abbreviation of polyphenylene oxide) has been demanded for a roof trim for an automobile to be installed in a roof panel of a passenger car, because it is desired to be lightweight and have excellent rigidity and heat resistance. A heat-resistant synthetic resin foam such as a core material or a maleic acid-modified foamed PS (abbreviation of polystyrene) core material is increasingly used as the core material.

FIG. 8 is a partially cutaway perspective view showing a roof trim using a foamed PPO core material.
A cloth skin 3 is attached to the surface of a foamed core material 2 such as foamed PPO. The foamed core material 2 has a skin layer 2b integrated on both sides of a foamed layer 2a. In addition to ensuring shape retention, it has a function of restricting variations in thickness when the foam layer 2a expands.

As a conventional example of a method of manufacturing the roof trim 1, as shown in FIG. 9, a foamed core material 2 and a skin material 3 are overlapped, and the periphery is held by a clamp device 4, and a heater device is provided. After heating to a predetermined temperature by 5 and heat-softening the two, as shown in FIG. 10, they are set in cold press molding dies 6 and 7, and as shown in FIG.
By engaging and pressing the dies 6 and 7, the foam core material 2 and the skin material 3 are integrated to form the roof trim 1 having a required shape.

[0005] The reason why the foamed core material 2 and the cloth skin 3 are heated simultaneously is that, for example, the foamed PPO core material has a high cooling rate after heating and is easily cooled, so that only the foamed core material 2 is heated. This is due to the occurrence of poor molding such as wrinkles and poor adhesion after molding.

[0006]

In order to integrally form the foam core material 2 and the skin material 3 as described above, in particular, foamed PPO
As described above, the core material includes the foam core material 2 and the cloth skin 3.
In fact, the heaters 5 are superimposed and heated to a predetermined temperature at the same time, and the following drawbacks have been pointed out.

That is, when the cloth skin 3 is heated, the pile 3a of the cloth skin 3 is softened, and at the time of press molding, the pile 3a becomes wobbled (so-called reverse hair phenomenon) at a portion rubbed by the dies 6, 7. For example, the pile 3a is inclined in the opposite direction at the vertical wall portion indicated by the reference character A in FIG. 11, giving a sense of incongruity with other parts in appearance and impairing the design.

Therefore, in order to avoid the reverse hair phenomenon of the pile 3a in the cloth outer skin 3, there is a problem in that the molding of the product is greatly restricted and cannot be applied to a molded product having a complicated curved surface.

The present invention has been made in view of the above-mentioned circumstances, and an interior part for an automobile, which is obtained by integrally forming a thermoplastic resin base material such as a foamed PPO core material and a cloth skin by cold press molding, and the like. It is an object of the present invention to provide an automobile interior part which effectively eliminates pile reverse hair on the cloth epidermis, has excellent appearance design, enhances shape flexibility, and can be implemented at low cost, and a method for producing the same. The purpose is.

[0010]

Means for Solving the Problems To achieve the above object, the present invention provides a method for integrally press-molding a thermoplastic resin substrate and a cloth skin by heating and softening the same with a mold for cold press molding of a required shape. In this case, the cloth outer skin is formed so that its pile is inclined in a certain direction.

The interior parts can be applied to a roof trim installed on a roof panel, a door trim installed on a side wall panel, a rear corner trim, a trunk room trim installed on various panels in a trunk room, and the like.

As the thermoplastic resin substrate, foamed PP
In addition to a foamable base material such as an O core material and a foamed PS core material, a PP resin plate, an ABS resin plate, or a composite PP resin plate mixed with an inorganic filler or an organic filler can be used.

On the other hand, tricot,
Various specifications such as jerseys and moquettes can be used, and a cushion material such as polyurethane foam or polyethylene foam can be lined on the back of the cloth skin to enhance the cushioning function. A polyurethane foam and a nonwoven fabric may be laminated.

Further, in the method for manufacturing an automobile interior part according to the present invention, the cloth skin is subjected to a warping process so that the pile of the cloth skin is inclined in a certain direction, and then the raw material of the thermoplastic resin base material is processed. And the cloth skin is heated and softened to a predetermined temperature by a heater device, and then the thermoplastic resin base material and the cloth skin are press-integrated into a required shape by a cold press molding die.

Here, hot roll molding, hot press molding and the like can be applied as the process of applying the cross skin, and the temperature of the hot roll and the hot press mold are set to 130 ° C. or higher, respectively.

The pile inclination angle is preferably 40 ° or less.

Further, regarding the adhesion between the thermoplastic resin substrate and the cloth skin, a hot melt film such as polyethylene is interposed between the two, and the thermoplastic resin substrate and the cloth skin are firmly heat-sealed.

As is apparent from the above structure, in the present invention, the cloth skin is previously subjected to a hot roll forming or a hot press forming so that the pile is inclined in a predetermined direction. Therefore, when the thermoplastic resin base material and the raw material of the resin base material and the cloth skin are superimposed and heated to a predetermined temperature by the heater device, the pile is difficult to stand, and the pile is physically inclined in advance. The pile is difficult to stand even if it is rubbed by the mold if the attachment processing is performed.

Therefore, even if the mold surface shape of the mold is arbitrarily set, the reverse hair phenomenon does not occur in the conventional vertical wall portion, and the pile of the cloth skin is always inclined in a certain direction.

[0020]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective view of a vehicle interior part and a method of manufacturing the same according to the present invention.

FIGS. 1 and 2 are a front view and a sectional view, respectively, showing an automobile roof trim as one embodiment of an automobile interior part according to the present invention. FIGS. 3 to 7 show steps of the method of the present invention. FIG.

1 and 2, a roof trim 10 for an automobile according to the present invention has external dimensions which cover almost the entire surface of a roof panel of a vehicle. The product has a front surface occupant and a passenger side. A concave portion 10a for accommodating an assist grip or the like is formed in each of three places on the passenger seat side and on both sides of a rear seat occupant, respectively.

As shown in FIG. 2, the roof trim 10 is integrally adhered to a foamable base material 20 formed into a required shape and a surface side of the foamable base material 20 to obtain a good surface feel and And a cross skin 30 having a surface appearance.

More specifically, in the present embodiment, the foamable base material 20 is made of a foamed PPO resin.
The skin layer 22 is integrally formed on the back surface of the foam layer 21. The PPO resin in the present embodiment is not pure PPO, but is modified by adding polystyrene in consideration of cost and the like. I have.

With respect to specific values of the foamable base material 20, the basis weight of the foamed layer 21 is 500 to 600 g / m ² ,
The thickness of the skin layer 22 is 0.18 mm,
As will be described in detail in a heating step and a cold press molding step, which will be described later, the total thickness of the foamable base material 20 at the time of the raw fabric.
After heat-softening a 5 mm material and expanding it to 6 to 8 mm, it is compressed by cold press molding to form a foamable base material 2.
The thickness of 0 is set to about 3 to 5 mm.

On the other hand, as the cloth skin 30, cloths of various specifications such as tricot, jersey, moquette and the like may be used. In this embodiment, tricot cloth is used.
In order to enhance the cushioning property, a cushion material 31 such as polyurethane foam is lined on the back surface of the cloth skin 30, and the cloth skin 3 lined with the cushion material 31 is provided.
Although FIG. 2 shows the adhesive layer 32 as an adhesive layer 32 in order to adhere the “0” to the foamable base material 20, a hot melt film such as polyethylene is laminated on the back surface of the cushion material 31 in advance.

The feature of the present invention is that the cloth epidermis 3
It is characterized in that the pile 30a at 0 is hammered so as to be inclined in a certain direction.

That is, in a product using the cloth skin 30, usually, the pile is rubbed against the mold in the deeply drawn portion, so that the direction of the pile in the deeply drawn portion is different from that of the other portions. However, there is a problem that the product appearance gives an unpleasant sensation, and there is a limitation in modeling such as a limitation in a drawn shape of the product. Also, the pile 30a of the cloth skin 30 is inclined in the same direction as the general part, and has excellent appearance and design.

A method of manufacturing the roof trim 10 having the excellent design will be described in detail with reference to FIGS.

First, as shown in FIG.
Is processed by the heat roll 40 so that the pile 30a is inclined in a certain direction.

At this time, the roll temperature of the hot roll 40 is 1
The temperature is set to an arbitrary temperature of 30 to 180 ° C., the roll speed is set to 1 to 5 m / min, the distance between the rolls is set to 0 to 1 mm, and the inclination angle of the pile 30 a is 40調整 Adjust so that it is as follows.

For reference, Table 1 shows the evaluation of hairiness for a conventional example in which the treatment with the hot roll 40 was not performed and the samples of the present invention in which the treatment with the hot roll 40 was performed.

[0033]

[Table 1]

[0034]

[Table 2]

As shown in FIG. 4, the pile 30a of the cloth skin 30 may be formed by hot press molding using hot press dies 50 and 51 as shown in FIG. The time is adjusted to a mold temperature of 130 to 180 ° C. for 10 to 20 seconds.

When the cross-forming of the cloth outer skin 30 by the hot roll forming or the hot press forming is completed in this manner, as shown in FIG. The anti-M and the hot melt film H are overlapped with each other, and the periphery is
In this state, the foamable base material 20 and the cloth skin 30 are heated to a predetermined temperature by being introduced into the heater devices 60 and 61.

At this time, the upper heater 60 is set at 250 ° C.
The lower heater 61 is set at 300 ° C., and the heating time is 40 seconds each.

Next, as shown in FIG.
After the blank M and the cloth skin 30 are softened by heating, they are set in the upper and lower molds 70 and 71 for cold press molding, and the upper mold 70 for cold press is lowered to lower the upper and lower molds 70 and 71.
According to 71, press pressure 25000kgf, press time 20
The molding of the automotive roof trim 10 shown in FIGS. 1 and 2 is completed by clamping the mold for seconds.

At this time, even if there is a deep drawing portion by the upper and lower dies 70 and 71, the cloth skin 30 is previously subjected to a curving process, and the pile 30a is inclined to 40 ° or less, so that the cloth 30a is rubbed with the die. Pile 3 with low resistance at the time
There is no hair of 0a.

Although the above-described embodiment is applied to the automobile roof trim 10 installed in the roof panel, it is installed in a room such as an automobile door trim or a rear corner trim installed in the side wall panel of the vehicle. The present invention can also be applied to applications such as interior parts to be manufactured and a trunk room trim to be installed in a trunk room. In place of the foamable base material 20, a thermoplastic resin plate such as a PP resin plate or an ABS resin plate may be used. it can.

[0041]

As described above, according to the present invention, the following special effects can be obtained.

(1) The automotive interior parts according to the present invention are:
Since the pile on the cloth skin is sewn so that it is inclined in a certain direction, there is no hairiness even in the deep drawing part of the product, and a uniform appearance is obtained over the entire surface of the product, as in the past. There is no discomfort in appearance at the deep drawing portion, and the design is improved.

(2) The automotive interior parts according to the present invention are:
Since the pile on the cloth skin is stiffened so that it is inclined in a certain direction, even if a deep drawn part is set on the product, the deep drawn part does not become bristle, so a complicated curved surface shape For example, the degree of freedom of the shape of the product can be greatly increased.

(3) In the method of the present invention, since it is only necessary to perform a warping process so that the pile in the cloth skin is inclined in a certain direction, the surface appearance is excellent with simple equipment such as hot roll forming and hot press forming. Because interior parts can be mass-produced,
It has the effect of high practical value.

[Brief description of the drawings]

FIG. 1 is a front view of an automobile roof trim showing one embodiment of an automobile interior component according to 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 a hot roll forming step of a cloth skin in the method of the present invention.

FIG. 4 is a cross-sectional view showing a hot press molding step of a cloth skin in the method of the present invention.

FIG. 5 is a cross-sectional view showing one step of the method of the present invention and showing a step of heating the foamable base material and the cloth skin.

FIG. 6 is a cross-sectional view showing one step of the method of the present invention and showing a step of setting a material in a press die.

FIG. 7 is a cross-sectional view showing one step of the method of the present invention and showing a cold press molding step.

FIG. 8 is a partially cutaway perspective view showing a conventional automobile roof trim.

FIG. 9 is a cross-sectional view illustrating a heating step of a foamable base material and a cloth in a conventional roof trim manufacturing method.

FIG. 10 is a cross-sectional view showing a step of setting a material to a mold in a conventional method of manufacturing a roof trim.

FIG. 11 is a cross-sectional view showing a cold press forming step in a conventional roof trim manufacturing method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Roof trim for automobiles 20 Foamable base material 30 Cloth skin 30a Pile 31 Cushion material 40 Heat roll 50,51 Hot press mold 60,61 Heater device 70,71 Cold press molding mold M Raw material H Hot melt film

────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-55-138488 (JP, A) JP-A-6-91772 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B29C 43/00-43/58 B60R 13/00-13/10

Claims (7)

(57) [Claims] 1. An automotive vehicle comprising a thermoplastic resin substrate (20) and a cloth skin (30) heated and softened, and then integrally pressed by a cold press molding die (70, 71) having a required shape. An interior part for an automobile, wherein the cloth outer skin (30) is processed so that its pile (30a) is inclined in a certain direction. 2. The automotive interior part according to claim 1, wherein the thermoplastic resin base material is a foamable resin base material. 3. The automotive interior part according to claim 1, wherein the thermoplastic resin substrate (20) is made of a thermoplastic resin plate such as a PP resin plate or an ABS resin plate. 4. The interior part for an automobile according to claim 1, wherein the cloth skin (30) is lined with a cushion material (31) such as a polyurethane foam or a polyolefin foam on a back surface thereof. 5. A method for manufacturing an interior part for an automobile, comprising forming a thermoplastic resin base material (20) and a cloth skin (30) into a required shape by cold press molding, wherein the pile of the cloth skin (30) is provided. The cloth skin (30) is subjected to a warping process so that (30a) is inclined in a certain direction, and then the raw material (M) of the thermoplastic resin base material (20) and the cloth skin (30) are heated. (60,6
After heat-softening to a predetermined temperature according to 1), the thermoplastic resin base material (20) and the cloth skin (30) are press-integrated into a required shape by a cold press molding die (70, 71). Manufacturing method of interior parts for automobiles. 6. The method for manufacturing an interior part for an automobile according to claim 5, wherein the process of applying the cross-skin to the cloth skin is performed by a hot roll. 7. The method for manufacturing an interior part for an automobile according to claim 5, wherein the cross-cutting of the cloth outer skin is performed by press working with a hot press mold.