JP4660318B2 - Interior material for vehicle and method for manufacturing the same - Google Patents

Description

  The present invention relates to a vehicle interior material provided in a room of a vehicle such as an automobile and a method for manufacturing the vehicle interior material.

  In general, for example, in a vehicle such as an automobile, a molded ceiling is provided as an interior material on the vehicle interior side of a roof panel constituting a roof. As such a vehicle interior material, for example, as disclosed in Patent Document 1, a reinforcing material made of glass fiber is interposed between a base material made of polyurethane foam and a skin material made of a cloth material, and integrated Molded ones are known. In this product, tricot is used as a skin material corresponding to the design surface of the interior material, and a flexible urethane foam is laminated on the back side of the tricot. By laminating soft urethane foam to the skin material in this way, even if a thin material such as tricot or flat knit is used as the skin material, uneven wrinkles on the surface of the skin material generated by the reinforcing material can be eliminated. In addition, the adhesive such as isocyanate applied to the reinforcing material can be prevented from oozing out into the skin material.

For example, as disclosed in Patent Document 2, in a vehicle interior material in which a reinforcing material made of a fiber is interposed between a base material and a skin material, an adhesive present in the reinforcing material is applied to the skin material. In order to prevent bleeding, a film provided with a bleeding preventing film is known.
JP 2001-301539 A JP 2001-47544 A

  By the way, in recent years, the interior design of vehicles has been diversified. For example, the shape of the part where the sun visor and the assist grip are arranged and the shape set to provide the article storage part on the ceiling protrude into the vehicle interior. In some cases, the shape is so curved. In this case, the shape change of the interior material becomes abrupt. Further, a curtain-type airbag that is deployed to cover the side window in the event of a vehicle collision may be disposed in the vehicle interior. This curtain-type airbag is accommodated on the vehicle body panel side, which is the back side of the interior material, in a folded state before deployment. Similarly, when the shape for accommodating the curtain-type airbag is set as the interior material, the shape change of the interior material becomes abrupt.

  However, in the case where a flexible urethane foam is laminated on the back side of the skin material as in Patent Document 1, when the interior material is heat-molded, when the portion that is tightly curved so as to protrude into the vehicle interior is molded, the skin material is From the flat state before molding, it is tightly curved along the curved portion and is strongly pulled toward the inside of the curved portion. Thus, the flexible urethane foam is compressed by the skin material that is strongly pulled toward the inside of the curved portion. At this time, in the place where the shape change is abrupt as described above, the place where the compressive force of the flexible urethane foam is received becomes extremely thin, and uneven wrinkles due to the reinforcing material occur, or the adhesive oozes out to the skin material. Sometimes. That is, the adhesive applied to the reinforcing material partially penetrates the soft urethane foam and adheres to the skin material, and the soft urethane foam is partially crushed. As a result, the interior material is randomly viewed from the surface. There may be a so-called avatar state in which a depressed portion exists.

  Further, as in Patent Document 2, when a film for preventing the adhesive from bleeding is provided between the reinforcing material and the skin material, noise generated in the vehicle interior is reflected by the film, and the sound absorption performance of the interior material is reduced. It will decline. In addition, an adhesive such as hot melt for bonding such a film and the skin material is also required, which increases the manufacturing cost.

  That is, in the conventional interior material, when there is a place where the shape change is abrupt, the appearance required for the interior material and the sound absorbing performance of noise cannot be achieved at a high level, and the commerciality is low, It was difficult to reduce the manufacturing cost.

  The present invention has been made in view of such a point, and the purpose of the present invention is to prevent the fiber shape of the reinforcing material from appearing on the surface of the skin material even if the interior material has a sharp shape change. In addition to improving the appearance by suppressing the seepage of the adhesive and improving the product quality by reducing the manufacturing cost so that the sound absorption performance of the vehicle interior noise can be sufficiently obtained. is there.

  In order to achieve the above object, according to the first aspect of the present invention, the following means are taken as the invention of the vehicle interior material.

Specifically, a base material made of foam, a reinforcing material made of fibers bonded to the front side of the base material with an adhesive, and a skin material made of a cloth material arranged on the front side of the reinforcing material are predetermined. An interior material for a vehicle that is integrally formed by heat molding at a molding temperature and having a curved portion, and a cushion material made of a nonwoven fabric is provided between the skin material and the reinforcing material. In addition, between the skin material and the cushion material, a film made of a resin material having a melting temperature higher than the molding temperature, and laminated on both front and back sides of the film, the melting temperature is not more than the molding temperature , and A resin material layer made of the same resin material, and the film and the skin material are bonded by a resin material layer laminated on the front side of the film, and the film and the film are laminated by a resin material layer laminated on the back side of the film. Up And the cushion member is bonded, the said film and said resin material layer, a structure in which a large number of through holes are formed.

  According to this configuration, at the time of thermoforming, the reinforcing material, the base material, and the cushion material are bonded by the adhesive, and the resin material constituting each resin material layer is melted to bond the film and the skin material. The film and the cushion material are bonded. Thereby, a base material, a reinforcing material, a cushion material, a film, and a skin material are integrated. At the time of this heat forming, the film does not melt and a shape having a through hole remains.

  At the time of the above heat forming, for example, when a portion that is curved so as to protrude into the vehicle interior is molded, the skin material is strongly pulled toward the inside of the curved portion, and the cushion material is compressed by the skin material and the base material. It will be. At this time, a film is interposed between the skin material and the reinforcing material, and the resin layers on both sides of the film are melted to adhere the film to the reinforcing material and the skin material. Appearance as uneven wrinkles is suppressed. In addition, since the cushion material and the film are arranged between the skin material and the reinforcing material so that the adhesive does not easily pass therethrough, the adhesive can be applied to the skin material even if the amount of the adhesive is somewhat large. Exudation is suppressed. Thereby, the surface roughness of the skin material and the occurrence of avatar are suppressed. And since many through-holes are formed in the said film and resin material layer, the noise in a vehicle interior passes a skin material, a film, and a resin material layer, and is effectively absorbed by a cushion material and a base material. The

In the invention of claim 2, in the invention of claim 1, the film is a nylon film having a thickness of 10 μm or more and 50 μm or less .

In the invention of claim 3, in the invention of claim 1, the cushion material is a nonwoven fabric having a basis weight of 25 g / m ² or more and 100 g / m ² or less.

In the invention of claim 4, in the invention of claim 1, the ratio of the sum of the opening areas of all through holes to the area of the film is 1% or more.

According to a fifth aspect of the present invention, in the first aspect of the invention, the distance between adjacent through-holes in the film is 1.0 mm or more.

In the invention of claim 6, in the invention of claim 1, the inner diameter of the through hole of the film is set to be 0.1 mm or more and 0.5 mm or less.

  According to this configuration, by ensuring a large inner diameter of the through hole of 0.1 mm or more, it is possible to suppress the through hole from being blocked by the adhesive that has oozed into the through hole, It becomes possible to make the through hole open. Further, by setting the inner diameter of the through hole to 0.5 mm or less, it becomes difficult for the adhesive to ooze from the through hole to the skin material.

In order to achieve the above object, in the invention of claim 7 , a base material made of foam, a reinforcing material made of fibers arranged on the front side of the base material, and a front side of the reinforcing material are arranged. A method of manufacturing an interior material for a vehicle having a curved portion and integrated with a skin material made of a cloth material by heating and molding with a molding die at a predetermined molding temperature, the reinforcing material on the front side of the base material A melting temperature lower than the resin material constituting the first film on both the front and back surfaces of the first film made of a resin material And a step of laminating a front side second film and a back side second film made of the same resin material, a step of forming a plurality of through holes in the first film and the second film, and a front side of the cushion material The above first Laminating the film and the second film, laminating the skin material on the front side of the front side second film, and laminating the base material, the reinforcing material, the cushioning material, the first film, the second film and the skin material In such a state, the mold includes a step of heat-molding at a temperature equal to or higher than the melting temperature of the resin material constituting the second film and lower than the melting temperature of the resin material constituting the first film. .

  According to this configuration, the reinforcing material is bonded to the front side of the base material with the adhesive, and the cushion material is bonded to the front side of the reinforcing material with the adhesive. Furthermore, the resin material constituting each second film is once melted and spread between the first film and the cushion material by the heat at the time of molding, and is spread between the first film and the skin material, and then solidified. To do. The resin material constituting the second film bonds the cushion material and the first film, and bonds the first film and the skin material. In this state, the resin material constituting the second film forms resin material layers on both the front and back surfaces of the first film. On the other hand, the first film does not melt by the heat at the time of molding and remains in a shape having through holes. In this way, an interior material is obtained.

  At the time of the above heat forming, the first film is interposed between the skin material and the reinforcing material, and the resin material constituting the second film on both sides of the first film is melted so that the film is applied to the reinforcing material and the skin material. Since it adhere | attaches, it is suppressed that the fiber shape of a reinforcing material appears as an uneven | corrugated wrinkle in a skin material. Since the cushion material and the film are disposed between the skin material and the reinforcing material, it is possible to prevent the adhesive from oozing out into the skin material. Thereby, the surface roughness of the skin material and the occurrence of avatar are suppressed. And since many through-holes are formed in the said film and resin material layer, the noise in a vehicle interior is absorbed effectively with a cushion material and a base material.

In the invention of claim 8, in the invention of claim 7 , the first film is a nylon film, the thickness of the first film before heat forming is 10 μm or more and 50 μm or less, and the thickness of the second film before heat forming The thickness is set to be 10 μm or more and 30 μm or less.

According to the invention of claim 9, in the invention of claim 7 , after the second film is laminated and integrated on both the front and back surfaces of the first film, through holes are simultaneously formed in the first film and the second film. The configuration.

  According to the first aspect of the present invention, the cushion material is interposed between the skin material and the reinforcing material, and the film is interposed between the cushion material and the skin material. In addition, the film and the skin material, and the film and the cushion Since the materials are bonded to each other with the resin material layer, the adhesive can be prevented from oozing out into the skin material, and the surface roughness of the skin material and the occurrence of avatar can be suppressed. Moreover, since the through-hole is formed in the film and the resin material layer, the noise in the vehicle interior can be effectively absorbed by the cushion material and the base material through the skin material, the film and the resin material layer. By these things, while being able to make the appearance of interior material favorable, the sound absorption performance of the noise of a vehicle interior can fully be acquired, and commercial property can be raised, and also manufacturing cost can be reduced. .

According to invention of Claim 2, since the film was made into the nylon film whose thickness is 10 micrometers or more and 50 micrometers or less, cost can be restrained low, ensuring the intensity | strength required at the time of shaping | molding .

According to the invention of claim 3, since the basis weight constituted the cushion material at 25 g / m ² or more 100 g / m ² or less of the nonwoven fabric, it is possible to keep costs low while suppressing uneven wrinkles of the skin material.

According to invention of Claim 4 , since the ratio of the sum of the opening area of all the through-holes with respect to the area of a film was 1% or more, sound absorption performance can fully be obtained.

According to the invention of claim 5 , since the separation distance between adjacent through holes of the film is ensured to be 1.0 mm or more, the strength of the film can be sufficiently obtained.

According to the invention of claim 6 , since the inner diameter of the through hole of the film is set to 0.1 mm or more and 0.5 mm or less, the sound absorption performance is ensured by suppressing the through hole from being blocked by the adhesive. In addition, it is difficult for the adhesive to ooze from the through hole to the skin material, and the appearance can be improved.

According to the invention of claim 7 , the cushioning material can be arranged on the front side of the reinforcing material, and the first film can be arranged on the front side of the cushioning material, and the fiber shape of the reinforcing material appears as uneven wrinkles on the skin material. Can be suppressed. And, since the film and the skin material, the film and the cushion material can be bonded with the resin material constituting the second film, respectively, and further, the cushion material and the film can be arranged between the skin material and the reinforcing material. Surface roughness of the skin material and generation of avatar can be suppressed. Moreover, the noise in the passenger compartment can be effectively absorbed by the cushion material and the base material. As a result, it is possible to obtain an interior material that has a good appearance and has a high merchantability with a sufficient sound absorbing performance for noise in the passenger compartment at low cost.

According to the invention of claim 8 , by setting the thickness of the first film to 10 μm or more, for example, it is possible to ensure the strength that the film does not break during molding, and the thickness of the first film is 50 μm or less. By doing so, the first film is not unnecessarily thick, and the material cost can be suppressed. Further, by setting the thickness of the second film to 10 μm or more, it is possible to obtain the amount of the resin material necessary for bonding the first film and the skin material, and the first film and the cushion material. Moreover, by making the thickness of the second film 30 μm or less, the second film is not unnecessarily thickened, and the material cost is suppressed.

According to the ninth aspect of the present invention, since the second film is laminated and integrated on both the front and back surfaces of the first film and then the through holes are simultaneously formed in these films, the number of manufacturing steps can be reduced. .

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  FIG. 1 shows a molded ceiling 1 as a vehicle interior material according to an embodiment of the present invention as seen from the back side. The molded ceiling 1 is provided on the vehicle interior side of a roof panel (not shown) formed so as to extend in the vehicle longitudinal direction. Although not shown, the molded ceiling 1 is attached with a plurality of places fixed to the vehicle body. A surface facing the vehicle interior side which is the lower surface of the molded ceiling 1 is a surface, and this surface is a design surface of the interior design. Moreover, the surface which faces the vehicle compartment outer side which is the upper surface of the shaping | molding ceiling 1 is made into the back surface.

  Two sun visor disposing portions 2 for disposing sun visors (not shown) for driver seats and front passenger seats are disposed at the front side of the molded ceiling 1 with a gap in the vehicle width direction toward the back side. It is formed to bulge. Between the two sun visor arrangement | positioning parts 2 of the shaping | molding ceiling 1, it forms so that the accommodating part 3 of an article may bulge to the back side. In order to form the sun visor arrangement portion 2 and the storage portion 3, the molded ceiling 1 is set to have a shape that is curved so as to protrude toward the vehicle interior side. is there.

  As shown in FIG. 2, the molded ceiling 1 is provided on the back side of the base material 10, the front side reinforcing material 11 and the back side reinforcing material 12 provided on the front and back sides of the base material 10, and the back side reinforcing material 12. The back material 13, the nonwoven fabric 14 provided on the front side of the front reinforcing material 11, the first film 20 provided on the front side of the nonwoven fabric 14, and the front side resin material layer 30 laminated on both the front and back surfaces of the first film 20, respectively. And the back surface side resin material layer 31 and the skin material 16 provided in the front side of the front side resin material layer 30 are provided. Although details will be described later, the molded ceiling 1 is formed by being heated to about 110 ° C. to 150 ° C. by a molding die 40 as shown in FIG.

  The base material 10 is formed by molding foamed polyurethane into a plate shape. The front reinforcing material 11 is formed of a so-called glass mat formed by molding glass fibers into a mat shape. The back side reinforcing material 12 is configured in the same manner as the front side reinforcing material 11. The front-side reinforcing material 11 and the back-side reinforcing material 12 are bonded to the base material 10 with an adhesive such as isocyanate.

The said nonwoven fabric 14 comprises the cushion material which deform | transforms so that the fiber shape of the front side reinforcement material 11 may be followed. The nonwoven fabric 14 prevents the fiber shape of the front-side reinforcing material 11 from appearing as uneven wrinkles on the surface of the skin material 16. This nonwoven fabric 14 is manufactured by a well-known water needle method. This water needle method is one of the manufacturing methods of the nonwoven fabric 14, and is a method of binding fibers by utilizing the large kinetic energy of the high-speed liquid. According to this method, the fiber is less damaged than the needle punch method using metal, and the resulting nonwoven fabric 14 is less likely to be uneven, and the thickness is uniform and smooth. The thickness of the nonwoven fabric 14 varies depending on the basis weight, and if the thickness of the nonwoven fabric 14 is too thin, the fiber shape constituting the front-side reinforcing material 11 appears on the surface of the skin material 16. In this embodiment, the basis weight is 25 g / m. The thickness of the nonwoven fabric 14 is ensured so that the fiber shape constituting the front-side reinforcing material 11 does not appear on the surface of the skin material 16 as ^two or more. Moreover, the fabric weight of the nonwoven fabric 14 is set to 100 g / m ² or less, whereby the nonwoven fabric 14 does not become unnecessarily thick and material costs are suppressed. Note that the basis weight of the nonwoven fabric 14 is preferably 50 g / m ² or more. By setting the basis weight in this way, the fiber shape of the skin material 16 can be varied even if the thickness of the fibers constituting the front-side reinforcing material 11 varies. The thickness of the nonwoven fabric 14 that does not appear on the surface is ensured. Moreover, the upper limit of the fabric weight of the nonwoven fabric 14 is preferably 70 g / m ² from the viewpoint of suppressing material costs.

  The first film 20 is made of a nylon film. The general melting temperature of nylon is about 190 ° C. to 220 ° C., and the first film 20 is not melted at the temperature at the time of the above-described heat molding. The strength of the first film 20 varies depending on the thickness of the first film 20, and if the first film 20 is too thin, the first film 20 may be broken during heat molding. Thick enough to not break. Moreover, the thickness of the 1st film 20 is set to 50 micrometers or less, and, thereby, the 1st film 20 does not become thick unnecessarily, but material cost is suppressed. Note that the thickness of the first film 20 is preferably 25 μm or more. By setting the thickness in this way, it is possible to prevent the first film 20 from being broken at the time of heat forming. The upper limit of the thickness of the first film 20 is preferably 35 μm from the viewpoint of suppressing material costs.

  The front side resin material layer 30 and the back side resin material layer 31 are composed of a front side second film 21 and a back side second film 22 as shown in FIG. 3 before thermoforming. The front side second film 21 is composed of a film made of polyethylene having a melting temperature lower than that of the resin material constituting the first film 20. The general melting temperature of this polyethylene is about 80-100 degreeC lower than the temperature at the time of thermoforming. The resin material constituting the front side second film 21 spreads between the first film 20 and the skin material 16 when melted at the time of thermoforming, and then cooled and solidified to form the first film 20 and the skin material 16. Glue. In this bonded state, the resin material constituting the front side second film 21 exists as a front side resin material layer 30 instead of a film as shown in FIG.

  If the front-side second film 21 is too thin, the amount of the resin material spreading between the first film 20 and the skin material 16 during heat-molding may be reduced, resulting in incomplete adhesion between the two. The thickness of the two films 21 is set to 10 μm or more so that an amount of the resin material sufficient for complete adhesion can be secured. Moreover, the thickness of the front side 2nd film 21 is set to 30 micrometers or less, and, thereby, the surface side 2nd film 21 does not become unnecessarily thick, but material cost is suppressed. Note that the thickness of the front side second film 21 is preferably 15 μm or more. By setting the thickness in this way, a sufficient amount of the resin material is secured and the first film 20 and the skin material 16 are securely bonded. become. Further, the upper limit of the thickness of the front side second film 21 is preferably 25 μm from the viewpoint of suppressing the material cost.

  Moreover, the said back side 2nd film 22 is the same as the said surface side 2nd film 21, and when the resin material which comprises this back side 2nd film 22 fuse | melts at the time of thermoforming, the 1st film 20, the nonwoven fabric 14, and Then, the first film 20 and the nonwoven fabric 14 are bonded together by cooling and solidifying. The resin material constituting the front side second film 21 and the back side second film 22 may be a resin material having a melting temperature lower than that of the resin material constituting the first film 20, for example, an olefin resin or a nylon resin. It may be.

  The first film 20, the front side second film 21, and the back side second film 22 are laminated before the thermoforming to constitute the intermediate material 15. As shown in FIG. 4, the intermediate member 15 is provided with a large number of through-holes 25 penetrating in the thickness direction at substantially equal intervals. The inner diameter of the through hole 25 is 0.1 mm or more and 0.5 mm or less. By ensuring a large inner diameter of the through hole 25 of 0.1 mm or more, when the adhesive of the reinforcing material 11 oozes out into the through hole 25 or the resin material constituting the second films 21 and 22 is molded. In some cases, the through hole 25 is prevented from being blocked when it melts and enters, and the through hole 25 can be opened. Further, by setting the inner diameter of the through hole 25 to 0.5 mm or less, it is difficult for the adhesive to ooze out from the through hole 25 to the skin material 16.

  The distance Y between the adjacent through holes 25 of the intermediate material 15 is set to 1.0 mm or more. The strength of the 1st film 20 is ensured by ensuring the space | interval dimension of the adjacent through-hole 25 1.0 mm or more, and separating the through-holes 25 mutually. In order to obtain sound absorption performance while ensuring the strength of the first film 20, the distance between the adjacent through holes 25 is preferably 2 mm or more and 3 mm or less.

  Further, the ratio of the sum of the opening areas of all the through holes 25 to the total area of the surface of the intermediate member 15 is 1% or more. This ratio is determined by the inner diameter of the through hole 25 and the distance between adjacent through holes 25, and the upper limit is set to 35% in order to ensure the strength of the first film 20.

  The skin material 16 is composed of a thin cloth material such as tricot or flat knit.

  Next, the point which manufactures the shaping | molding ceiling 1 comprised as mentioned above is demonstrated based on FIG.5 and FIG.6. First, the forming die 40 of the hot press apparatus will be described. The molding die 40 includes an upper die 41 and a lower die 42, an upper molding surface 43 is provided on the lower surface of the upper die 41, and a lower molding surface 44 is provided on the upper surface of the lower die 42. Yes. The upper mold 41 and the lower mold 42 are provided with heating devices (not shown) for heating the upper molding surface 43 and the lower molding surface 44, respectively. Since the warming device is well known in the art, a detailed description thereof will be omitted. By this heating device, the temperature of the upper molding surface 43 and the lower molding surface 44 is heated to a temperature that is equal to or higher than the melting temperature of the second films 21 and 22 and lower than the melting temperature of the first film 20. Yes. Specifically, the temperature of the upper molding surface 43 and the lower molding surface 44 can be arbitrarily set in the range of about 110 ° C to 150 ° C.

  When molding using this molding die 40, as shown in FIG. 5, a back side reinforcing material 12 is disposed on the back side of the base material 10, and an adhesive such as isocyanate is applied. A back material 13 is disposed on the back side. In addition, the front side reinforcing material 11 is arranged on the front side of the base material 10 and an adhesive is similarly applied, and the nonwoven fabric 14 is arranged on the front side of the front side reinforcing material 11.

  On the other hand, after the second films 21 and 22 were laminated on both the front and back surfaces of the first film 20 to form the intermediate material 15, a number of through-hole forming needles protruded from the rolling surface of the roller. A through-hole 25 as shown in FIG. 4 is formed in the intermediate member 15 through a punching device (not shown). The method for forming the through hole 25 is not limited to the above-described method, and may be formed by, for example, punching. In addition, the through hole 25 may become a long hole instead of a perfect circle at the time of molding. In this case, the length in the minor axis direction is the inner diameter of the through hole 25.

  The intermediate material 15 is arranged on the front side of the nonwoven fabric, and the skin material 16 is arranged on the front side of the intermediate material 15.

  Then, after placing the base material 10, the reinforcing materials 11 and 12, the back material 13, the nonwoven fabric 14, the intermediate material 15, and the skin material 16 laminated as described above on the lower molding surface 44, the upper die 41 is moved. The upper die 41 and the lower die 42 are closed as shown in FIG. If it carries out like this, the heat | fever of the upper side molding surface 43 and the lower side molding surface 44 will transmit to the front side 2nd film 21 and the back side 2nd film 22, and the resin material which comprises this 2nd film 21 and 22 will fuse | melt. On the other hand, the shape of the first film 20 remains without melting. Therefore, the resin material constituting the front side second film 21 spreads between the first film 20 and the skin material 16, and the resin material constituting the back side second film 22 is between the first film 20 and the nonwoven fabric 14. Spread with. At this time, since the inner diameter of the through hole 25 of the intermediate material 15 is set to be large at 0.1 mm or more, the molten resin material does not stay at the periphery of the through hole 25 and spread to the center of the through hole 25, It becomes possible to make the hole 25 open.

  When the molten resin material is cooled and solidified, the first film 20 and the skin material 16 are bonded, and the first film 20 and the nonwoven fabric 14 are bonded. The resin material constituting the front side second film 21 remains as the front side resin material layer 30 between the first film 20 and the skin material 16, and the resin material constituting the back side second film 22 is the first film 20 and the nonwoven fabric. 14 remains as the back side resin material layer 31.

  At the time of heat forming, for example, if a portion that is curved so as to protrude into the vehicle interior is formed, the inside of the curved portion (in the direction of arrow T in FIG. 6) when the skin material 16 is bent from the flat state shown in FIG. The nonwoven fabric 14 is compressed by the skin material 16 and the base material 10 by being strongly pulled toward the surface. The skin material 10 and the first film 20, the first film 20 and the nonwoven fabric 14 are bonded by the resin material layers 30 and 31, and the nonwoven fabric 14 and the first film are interposed between the skin material 16 and the front-side reinforcing material 11. Since 20 is arranged and the adhesive is difficult to pass through, even if the amount of the adhesive is somewhat large, the adhesive is prevented from oozing out to the skin material 16. Thereby, the surface roughness of the skin material 16 and generation | occurrence | production of an avatar are suppressed. Since the first film 20 and the resin material layers 30 and 31 are formed with a large number of through holes 25, the noise in the passenger compartment is caused by the skin material 16, the first film 20 and the resin material layers 30 and 31. It passes through and is absorbed by the nonwoven fabric 14 and the substrate 10.

  Therefore, according to this embodiment, since the nonwoven fabric 14 is disposed as a cushioning material between the skin material 16 and the front-side reinforcing material 11, the fiber shape of the front-side reinforcing material 11 is also the skin material even in places where the shape changes rapidly. Appearance as uneven wrinkles on the surface of 16 is suppressed. Further, the skin material 16 and the first film 20, the first film 20 and the nonwoven fabric 14 are bonded by the resin material layers 30 and 31, respectively, and further, the nonwoven fabric 14 and the first film are interposed between the skin material 16 and the front-side reinforcing material 11. Since the film 20 is disposed, the adhesive can be prevented from oozing out into the skin material 16, and the surface roughness of the skin material 16 and the occurrence of avatar can be suppressed. Further, the noise in the passenger compartment can be effectively absorbed by the nonwoven fabric 14 and the base material 10 through the skin material 16, the first film 20 and the resin material layers 30 and 31. By these things, while being able to make the appearance of the shaping | molding ceiling 1 favorable, the sound absorption performance of the noise of a vehicle interior can fully be acquired, merchantability can be improved, and manufacturing cost can be reduced. .

  Since it is possible to suppress the adhesive from seeping out into the skin material 16, the amount of adhesive applied is increased to increase the adhesive strength between the base material 10 and the reinforcing materials 11 and 12, thereby increasing the rigidity of the molded ceiling 1. Can be high. Furthermore, even if the amount of adhesive applied is somewhat large, it is difficult to seep out into the skin material 16, so that it can be increased without strictly controlling the amount of adhesive applied, and the manufacturing process and manufacturing apparatus can be simplified. Can be achieved.

  Moreover, since the 1st film 20 was comprised with the nylon film whose thickness is 10 micrometers or more and 50 micrometers or less, cost can be restrained low, ensuring the intensity | strength required at the time of shaping | molding.

Moreover, since the nonwoven fabric 14 was manufactured by the water needle method, the smooth nonwoven fabric 14 can be obtained and the surface of the skin material 16 can be made smooth. Since the basis weight of the nonwoven fabric 14 is set to 25 g / m ² or more and 100 g / m ² or less, the material cost can be suppressed and the cost can be reduced while suppressing the uneven wrinkles of the skin material 16.

  Moreover, since the ratio of the sum of the opening area of all the through-holes 25 with respect to the area of the 1st film 20 was 1% or more, sound absorption performance can fully be obtained.

  In addition, since the separation distance between the adjacent through holes 25 of the first film 20 is 1.0 mm or more, the strength of the first film 20 can be sufficiently obtained.

  Moreover, since the internal diameter of the through-hole 25 of the 1st film 20 was made into 0.1 mm or more and 0.5 mm or less, it can suppress that the through-hole 25 is obstruct | occluded with an adhesive agent, and can ensure sound absorption performance. In addition, it is difficult for the adhesive to ooze out from the through-hole 25 to the skin material 16, and the appearance can be improved.

  In addition, since the thickness of the second films 21 and 22 before thermoforming is 10 μm or more and 30 μm or less, the amount of the resin material necessary for bonding the skin material 16 and the first film 20 and the nonwoven fabric 14 and the first film The cost can be kept low while obtaining the amount of resin material necessary to bond 20.

  Moreover, since the 2nd films 21 and 22 were laminated | stacked and integrated on both surfaces of the 1st film 20, since the through-hole 25 was simultaneously formed in these films 20, 21, and 22, the through-hole 25 is formed. The process can be simplified and the number of manufacturing steps can be reduced.

  In addition, although this embodiment demonstrated the case where this invention was applied to the molded ceiling 1 of a motor vehicle, this invention can be applied to interior materials, such as a door trim and a pillar trim, for example.

  In this embodiment, the cushion material is the nonwoven fabric 14, but the cushion material may be a fabric material other than the nonwoven fabric. Moreover, you may comprise the reinforcing materials 11 and 12 with a carbon fiber, a vegetable fiber, etc., for example, without using a glass mat.

  As described above, the vehicle interior material according to the present invention is suitable for, for example, a molded ceiling attached to a roof panel of an automobile.

It is the perspective view which looked at the molding ceiling which concerns on embodiment of this invention from the back side. It is sectional drawing of a shaping | molding ceiling. It is sectional drawing of the member which comprises a shaping | molding ceiling. It is a top view of an intermediate material. It is a figure which shows the state which laminated | stacked and arrange | positioned each member which comprises a shaping | molding ceiling on the shaping | molding die of a mold open state. It is a figure which shows the state which closed the shaping | molding die and shape | molded the shaping | molding ceiling.

DESCRIPTION OF SYMBOLS 10 Base material 11 Front side reinforcing material 12 Back side reinforcing material 13 Back surface material 14 Nonwoven fabric (cushion material)
16 skin material 20 first film 21, 22 second film 25 through hole 30, 31 resin material layer 40 molding die

Claims (9)

A base material made of foam, a reinforcing material made of fibers bonded to the front side of the base material with an adhesive, and a skin material made of a cloth material arranged on the front side of the reinforcing material are heated at a predetermined molding temperature. A vehicle interior material that is molded and integrated and has a curved portion,
Between the skin material and the reinforcing material, a cushion material made of a nonwoven fabric is provided,
Between the skin material and the cushion material, a film made of a resin material having a melting temperature higher than the molding temperature, and laminated on both front and back sides of the film, the melting temperature is equal to or lower than the molding temperature , and to each other And a resin material layer made of the same resin material,
The film and the skin material are adhered by the resin material layer laminated on the front side of the film, and the film and the cushion material are adhered by the resin material layer laminated on the back side of the film,
A vehicular interior material, wherein the film and the resin material layer have a large number of through holes. The vehicle interior material according to claim 1,
The vehicle interior material, wherein the film is a nylon film having a thickness of 10 µm to 50 µm. The vehicle interior material according to claim 1,
The vehicle interior material, wherein the cushion material is a nonwoven fabric having a basis weight of 25 g / m ² or more and 100 g / m ² or less. The vehicle interior material according to claim 1,
A vehicle interior material, wherein a ratio of a sum of opening areas of all through holes to an area of a film is 1% or more. The vehicle interior material according to claim 1,
A vehicle interior material, wherein a distance between adjacent through-holes of the film is 1.0 mm or more. The vehicle interior material according to claim 1,
An interior material for a vehicle, wherein the inner diameter of the through hole of the film is 0.1 mm or more and 0.5 mm or less. A base material made of foam, a reinforcing material made of fibers arranged on the front side of the base material, and a skin material made of a cloth material arranged on the front side of the reinforcing material are heated at a predetermined molding temperature by a molding die. A method for manufacturing an interior material for a vehicle having a curved portion and molded and integrated,
Arranging the reinforcing material on the front side of the substrate;
A step of disposing a cushion material made of a nonwoven fabric on the front side of the reinforcing material;
On both sides of the first film made of a resin material, than the resin material constituting the first film melting temperature rather low, and, laminated respectively front second film and the back side second film made of mutually the same resin material Process,
Forming a plurality of through holes in the first film and the second film;
Arranging the first film and the second film on the front side of the cushion material;
Placing the skin material on the front side of the front side second film;
In a state where the base material, the reinforcing material, the cushion material, the first film, the second film, and the skin material are laminated, the first film has a melting temperature equal to or higher than the melting temperature of the resin material constituting the second film. And a step of heat-molding at a temperature lower than the melting temperature of the resin material that constitutes the vehicle interior material manufacturing method. In the manufacturing method of the interior material for vehicles according to claim 7 ,
The first film is a nylon film, and the thickness of the first film before heat molding is 10 μm or more and 50 μm or less,
A method for manufacturing an interior material for a vehicle, wherein the thickness of the second film before heat forming is 10 μm or more and 30 μm or less. In the manufacturing method of the interior material for vehicles according to claim 7 ,
A method for producing an interior material for a vehicle, comprising: laminating and integrating a second film on both front and back surfaces of the first film, and then simultaneously forming through holes in the first film and the second film.

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