JP4435949B2 - Interior material - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an interior material having a soft feeling.
[0002]
[Prior art]
Conventionally, for example, when an interior material constituting an interior wall of a vehicle or the like, for example, a door trim is formed by pasting a skin material on a resin base material, the interior material is configured to realize a soft appearance, a touch, etc. In some cases, an interstitial material such as urethane foam is inserted between the base material and the skin material to form the surface layer portion. The urethane foam and the base material can be integrally formed in a heated state.
[0003]
By the way, it is common that the resin material used for a base material shrink | contracts by being cooled from a heating state. When the resin material for the substrate is heated when the surface layer portion is provided, the substrate 51 is cooled after the formation of the surface layer portion, and the substrate 51 contracts as shown in FIG. As a result, an excess portion is generated in the urethane foam 53, and unevenness and wrinkles are generated on the surface of the skin material 55 of the urethane foam 53. Under the influence of the irregularities and wrinkles of the urethane foam 53, irregularities and wrinkles are generated in the skin material 55, and the appearance is deteriorated. Unevenness and wrinkles are particularly prominent where the surface of an interior material such as a door trim is formed in a concave shape. Since unevenness and wrinkles impair the appearance of the interior material, additional post-processing such as wrinkle removal processing must be performed.
[0004]
[Problems to be solved by the invention]
An object of the present invention is to provide an interior material having a skin layer and an interstitial material on the surface and having a surface layer portion with a good appearance.
[0005]
[Means for Solving the Problems]
In order to solve the above problems, the present invention is an interior material provided with a resin base material, a skin material, and an interstitial material in a laminate, and the interstic material has a density of 0.12 g / cm ³ or more Provided is an interior material characterized by being a foam of 0.30 g / cm ³ or less.
In this interior material, the interposition material constitutes a surface layer portion of the interior material together with the skin material by being interposed between the resin base material and the skin material constituting the interior material. Since the present interstitial material is formed in a foam having the above-mentioned density, it can follow the shrinkage of the base material when integrated with the base material. For this reason, it is an interior material with less unevenness and wrinkles on the surface of the surface layer portion.
[0006]
Moreover, in this invention, it is the said interior material, Comprising: The interior material characterized by providing the protective material between the said intervention material and the said base material can be provided. The protective material can be, for example, a member that prevents the resin material of the base material that is in a softened state when the base material is molded from impregnating inside the foam bubbles. By providing the protective material, it is possible to form a surface layer portion with a better soft feeling.
[0007]
Moreover, the said interior material WHEREIN: The said protective material can be made into a nonwoven fabric. In this laminate, when the foam shrinks following the substrate, the shrinkage is absorbed by the structure of the nonwoven fabric. Therefore, unevenness and wrinkles are hardly generated on the surface provided with the nonwoven fabric.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described in detail with reference to the drawings.
In the interior material of the present invention, an interposition material is provided between the base material of the interior material and the skin material. This intervention material is a foam having a density of 0.12 g / cm ³ or more and 0.30 g / cm ³ or less.
[0009]
The foam can be deformed so as to follow the surface shape of the substrate formed of the resin material. The foam is preferably formed so as to be elastically deformable.
The foam can be formed of polyurethane, polypropylene, polyethylene, or the like. Preferably, a soft polyurethane can be used to obtain a foam having a predetermined elasticity. Moreover, it is preferable that the foam is formed in a continuous foam shape.
[0010]
The foam has a density of 0.12 g / cm ³ or more and 0.30 g / cm ³ or less, preferably 0.18 g / cm ³ or more and 0.30 g / cm ³ or less. If the density of the foam is less than 0.12 g / cm ³ , the shrinkage is attenuated inside the foam even if a force in the shrinking direction is applied to one side of the foam formed into a sheet, and the opposite side of the foam is I cannot follow the contraction. In addition, if the density of the foam is larger than 0.30 g / cm ³ , molding can be performed, but the rigidity of the foam increases and the hardness increases, and the soft tactile sensation obtained by providing the interstitial material cannot be obtained. . Moreover, the foam can be 1.5 mm or more and 5.0 mm or less in thickness, Preferably, it is formed in the sheet form of 2 mm or more and 3 mm or less.
[0011]
The foam can be produced by various known methods. It may be manufactured by foaming to a predetermined density by molding or the like, but after molding a lower density soft foam, it may be hot pressed to increase the density to produce a foam of a predetermined density. good. FIG. 1 shows a method for producing a foam according to the present invention by hot pressing a soft foam block foamed to a lower density.
[0012]
In FIG. 1, the soft foam block 21 shown at the upper end can be manufactured by various known methods. Preferably, after various materials are weighed and mechanically mixed, a soft foam, such as slab urethane, which is continuously foam-cured and formed into a block shape is used. The density of the soft foam block 21, for example, in the case of polyurethane foam, can be used from 0.01 g / cm ³ to of about 0.13 g / cm ^3.
[0013]
The soft foam block 21 is cut so as to be a foam base 22 having a predetermined shape and a predetermined thickness. Typically, it is in the form of a sheet as shown in FIG. The thickness of the soft foam base 22 at this time is determined by the density of the soft foam block 21 and the required density and thickness of the foam 13. For example, when it is desired to obtain a sheet-like urethane foam having a density of 0.18 to 0.30 g / cm ³ and a thickness of 2 to 3 mm from a urethane block having a density of 0.06 g / cm ³ and a urethane foam base material having a thickness of 7 to 8 mm, It is good to cut so that it becomes.
[0014]
Next, the soft foam base material 22 is hot-pressed. Hot pressing can be performed by various known methods. Moreover, you may shape | mold so that the foam after a press may become a predetermined shape by hot press. In FIG. 1, a foam base material 22 formed in a sheet shape is sandwiched between an upper mold 24 and a lower mold 25 and heated and pressurized. By this hot pressing, a urethane foam having the predetermined density and thickness is formed.
[0015]
Since the foam 13 obtained in this way is formed to a predetermined density, when a contraction force acts on one side, the contraction is transmitted to the other side and can contract. For this reason, even when a contracting force acts on one surface side, the surface on the other surface side does not become uneven or wrinkled.
[0016]
The foam 13 may be used for forming the surface layer as it is, but may be formed in advance on the laminate 17 as shown in the lower part of FIG. The laminated body 17 is a member provided with a layer made of another material on at least one side of the foam 13. In FIG. 1, a skin material 11 is provided on one side, and a protective material 15 is provided on the other side.
[0017]
The skin material 11 can be a variety of well-known interior members such as genuine leather, synthetic leather, various woven fabrics, knitted fabrics, and non-woven fabrics, but is preferably a member having elasticity. Shall be knitted.
[0018]
Further, in the present embodiment, a sheet-like protective material 15 for preventing the resin material of the base material for interior from impregnating in the bubbles of the foam 13 on the opposite surface provided with the foam skin material. Was established. The protective material 15 can be various sheets such as a nonwoven fabric.
The protective material 15 can be provided by various bonding methods such as bonding with an adhesive, sewing, and welding. In the laminate 17 of the present embodiment, the skin material 11 and the protective material 15 are integrally provided on the foam 13 by frame lamination. In the frame laminating process, first, one surface of the sheet-like foam 13 is heated and formed in a softened state, and the sheet-like protective material 15 is uniformly pressed by a roller or the like to be joined in a welded state. Next, the other surface of the foam 13 is heated to form a softened state, and the skin material is uniformly pressed against this surface, thereby joining the skin material in the welded state. In this way, a laminate 17 having a three-layer structure can be obtained.
[0019]
In the laminated body 17, since the positional relationship between the skin material 11 and the foam 13, and the foam 13 and the protective material 15 is fixed, the position in the step of forming the surface layer portion on the interior material that constitutes the vehicle interior wall. Deviation can be suppressed. Further, in the process of attaching the surface layer portion, the trouble of adjusting the position of each member can be saved. In addition, management such as storage and transportation can be performed in the state of the laminated body 17.
[0020]
The example which formed the interior material of this invention as an interior material of a vehicle is shown in FIG. FIG. 2 is a view of the interior material (door trim) 1 of the vehicle door as viewed from the vehicle compartment side, and the interior material 1 includes a resin base material 3 on the vehicle compartment side. The base material 3 has a lower base 3a constituting the lower part of the interior material 1 and an upper base 3b constituting the upper part, and an armrest part 5 is formed on the upper part of the lower base 3a.
[0021]
The armrest portion 5 is provided so as to protrude from the base material 3 toward the interior of the vehicle interior, and is formed in a shape that extends long in the front-rear direction of the vehicle body when the interior material 1 is attached to the vehicle body. The top surface 6 of the armrest part 5 is formed in a flat shape for the armrest of the occupant. Further, as shown in FIG. 3, the top surface 6 and the ornament part 4 (upper side of the vehicle interior side surface) formed on the upper base 3b are formed to be continuous with a smooth concave surface. The top surface 6 of the armrest portion 5 and the portion from the top surface 6 to the continuous ornament portion 4 are covered with a single continuous skin material 11. The portion covered with the skin material 11 is provided with a foam 13 which is an intervention material according to the present invention in the lower layer, and is configured as a surface layer portion in the present invention.
[0022]
Below, the method of providing a surface layer part in the base material 3 and obtaining an interior material is demonstrated. Here, the case where the laminated body 17 is used to simultaneously mold the base material 3 constituting the interior material 1 and form the surface layer portion will be described.
First, the laminate 17 is placed at a predetermined portion of a mold for molding the base material 3 so that the skin material 11 faces the mold surface, and is clamped. Next, the base material 3 is molded by, for example, injecting a resin material constituting the base material 3. At this time, the softened resin is filled in the mold without a gap, and in the laminated body 17 portion, the protective material 15 is filled so as to be impregnated, and the protective material 15 is welded. Then, the base material 3 provided with the surface layer part can be obtained by cooling and solidifying the softened resin material and removing the mold.
[0023]
Here, the resin material of the base material 3 heated to a softened state contracts by being cooled after molding. For this reason, as indicated by an arrow in the upper diagram of FIG. At this time, force in the shrinking direction is also applied to the foam 13. Since the foam 13 of the present embodiment is formed at a predetermined density, when a shrinkage force is applied to the surface on the protective material 15 side, the foam 13 is transmitted to the entire inside of the foam 13 and contracts to the skin material 11 side. For this reason, unevenness and wrinkles are not formed on the surface of the foam 13 on the vehicle interior side even after the molding of the base material 3 is finished and cooled.
[0024]
Further, unevenness and wrinkles are not easily formed on the skin material 11 provided along the surface of the foam 13, and a surface layer portion having a beautiful appearance is formed. At this time, if the skin material 11 is a knitted fabric, it is possible to absorb the surplus of the skin material 11 due to the shrinkage of the foam 13 due to the mesh structure, and thus it is easy to suppress the occurrence of irregularities and wrinkles.
[0025]
As shown in FIG. 3, the surface layer portion thus formed is provided in a laminated form on the surface of the base material 3 in the order of the skin material 11, the foam 13 and the protective material 15 from the surface. It is in good contact with the base material 3 formed in (1).
In the state shown in FIG. 3, the foam 13 contracts in a direction along the surface of the base material 3 on the vehicle interior side over the entire thickness direction from the base material 3 side to the vehicle interior side. Therefore, the surface of the foam 13 on the vehicle interior side is in conformity with the shape of the base material 3 on the vehicle interior side, and is not formed with irregularities or wrinkles.
Further, the skin material 11 is disposed along the surface of the foam 13 on the vehicle interior side, has no unevenness and wrinkles, and is formed into a smooth curved surface along the surface shape of the base material 3 on the vehicle interior side. ing.
[0026]
In particular, as shown in FIG. 3, even if the surface on which the surface layer portion is provided is a concave surface, an excess portion is not formed on the vehicle interior side of the foam 13, thereby suppressing the occurrence of unevenness and wrinkles. it can. That is, when the surface layer portion is provided on the base material using the interposing material in the interior material of the present invention, a surface layer portion having a beautiful appearance can be obtained without post-treatment such as wrinkle removal processing.
[0027]
In addition, the method of manufacturing the interior material provided with the surface layer portion is not limited to the above embodiment. Instead of using the laminated body 17, the skin material 11, the foamed body 13, etc., which are separately provided in the molding die, are arranged in a laminated state, and after clamping the mold, a softening resin is injected, etc. May be molded. Alternatively, the laminate 17 may be welded to a predetermined portion of the interior base material that has been molded in advance to an extent that the resin material of the interior base material is softened to form the surface layer portion. In the case of using either a foam or a laminate, it can be carried out by various known methods, but at least the interior material of the passenger compartment provided with the surface layer portion by the method in which the resin member constituting the interior material is heated. To manufacture.
[0028]
In addition, the position which provides a surface layer part, and the shape of a base material are not limited to the said embodiment. The surface layer portion is not limited to a concave surface, and can be provided on a convex portion, a flat surface portion, or a portion having a complicated surface shape.
Further, examples of the interior material include door trims, vehicle parts such as garnishes and safety pads, furniture members, and building materials. It can be a known panel used as a member that covers the inner wall of a vehicle or house, the surface of a device, an article, or the like, or as a member that constitutes the surface itself.
[0029]
【The invention's effect】
In the present invention, it is possible to provide an interior material that has a skin material and an interstitial material on the surface and has a surface layer portion having a good appearance.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a method for manufacturing an intervention material according to an embodiment of the present invention.
FIG. 2 is a perspective view of a vehicle door trim according to an embodiment of the present invention as viewed from the vehicle interior side.
FIG. 3 is a cross-sectional view showing an armrest portion provided with a surface layer portion of the vehicle door trim of FIG. 2;
FIG. 4 is a schematic view showing the appearance of the surface layer part before and after cooling when the laminate of the present embodiment is welded to the base material by heating at the time of molding the base material.
FIG. 5 is a cross-sectional view showing a state immediately after molding and after cooling when a foam is provided between a conventional base material and a skin material and a surface layer portion is formed by heating.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Door trim 3 Base material 4 Ornament part 5 Armrest part 6 Top surface 11,55 Surface material 13,53 Foam 15 Protection material 17 Laminated body 21 Soft foam block 22 Foam base body 24 Upper mold | type 25 Lower mold | type 51 Base material

Claims (3)

A resin base material formed by injection molding , a skin material and an interstitial material are provided in a laminated form, and the skin material and the interstitial material are arranged in a molding die for molding the base material. A foam comprising a flexible polyurethane having a density of 0.12 g / cm ³ or more and 0.30 g / cm ³ or less, wherein the interior material is integrated with the substrate at the same time as the substrate is injection molded. The interior material characterized by being.  The interior material according to claim 1, wherein a protective material is provided between the intervention material and the base material.  The interior material according to claim 2, wherein the protective material is a nonwoven fabric.

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