JP4767108B2 - Interior materials for vehicles - Google Patents

Description

  The present invention relates to a vehicle interior material used for the purpose of ensuring the flatness of a floor surface of a vehicle and improving sound absorption performance.

  In order to ensure the flatness of the vehicle floor, to improve sound absorption performance, to protect passengers against impacts generated inside and outside the vehicle, or to reduce weight, etc. In addition, it is known that an interior material for a vehicle made of a foamed resin molded body is accommodated in a recess or the like existing there. For example, in Patent Document 1, as shown in FIG. 8, a rigid foam plastic made of a horizontal part 2a corresponding to a floor surface forming a foot of a passenger seat of an automobile and an inclined part 2b laid in front of the foot. The interior material 1 is described in which the interior side of the horizontal part 2a and the inclined part 2b is a flat plate part 2 and the floor side is a projecting structure 3 like a column. This vehicle interior material exhibits a high impact absorption performance with respect to an external impact as well as a reduction in weight of the vehicle interior material.

  By the way, a foamed resin molded body such as a polystyrene resin foam generally has poor sound absorption characteristics and hardly has sound absorption performance by itself. Therefore, when a high sound absorption performance is required for the vehicle interior material for the purpose of improving the comfort in the vehicle, a sound absorbing material such as felt is pasted on the foamed resin molded body by post-processing. On the other hand, when the synthetic resin foam molded product rubs against the vehicle structure, a squealing noise or a frictional noise is generated between the two, which may cause discomfort to the occupant. However, as described above, it is possible to prevent such unpleasant noise from occurring by attaching felt to the back surface of the foamed resin molded body.

Japanese Patent Laid-Open No. 2003-127796

  As in the interior material shown in FIG. 8, the interior side of the vehicle is made of foamed resin and has a structure in which the indoor side is a flat plate portion and the floor frame side has a plurality of protrusions standing from the back surface of the flat plate portion. Even in such a case, as described above, it is necessary to stick felt or the like on the back surface side in order to improve sound absorption and to prevent noise when the bottom surface of the protrusion rubs against the vehicle structure. . When high sound-absorbing performance is required, a felt with a thickness of about 20 mm to 60 mm is conventionally required. However, when a felt with such a thickness is pasted, a decrease in compressive strength due to the felt cannot be ignored. There is a risk of degradation of habitability due to large sinking. Moreover, the operation | work which sticks a felt with an adhesive agent or a double-sided adhesive tape is also needed.

  The present invention has been made in view of the above circumstances, and is a foamed resin that can satisfy sound absorption while satisfying required compression strength and weight reduction, and can also suppress the occurrence of noise. It aims at providing the interior material for vehicles which consists of a molded object.

The vehicle interior material according to the present invention is a vehicle interior material made of a foamed resin molded body and the sound absorbing material, the foamed resin molded body, one or a plurality of projections are formed, the sound absorbing material Is formed with a notch or a through-hole penetrating the sound-absorbing material for the protrusion to be pushed into a position corresponding to the place where the protrusion is formed, and the protrusion is pushed into the notch or the through-hole and foamed. When the resin molded body and the sound absorbing material are incorporated, the bottom surface of the projecting portion is not cut out or protrudes from the through-hole when attached to the vehicle, and the sound absorbing material is elastically deformed so that the bottom surface is partially It is covered .

  In the vehicle interior material according to the present invention, the interior side of the foamed resin molded body is preferably a flat plate, thereby ensuring the flatness of the vehicle floor. In addition, a sound absorbing material is disposed in the foamed resin molded body, and a desired sound absorbing performance can be ensured. On the other hand, the foamed resin molded body has one or a plurality of protrusions penetrating the sound absorbing material, and the dimensions of the protrusions are appropriately set in consideration of the compressive strength required for the vehicle interior material. Thus, it is possible to provide a vehicle interior material that satisfies both impact absorption performance and compressive strength while satisfying weight reduction.

  Furthermore, in the vehicle interior material according to the present invention, the bottom surface of the projection is partially covered with the sound absorbing material when attached to the vehicle. For this reason, it is possible to greatly suppress the occurrence of noise caused by rubbing the bottom surface of the protruding portion, which is a foamed resin, with the vehicle structure without causing deterioration of habitability due to large sinking.

  The method of arranging and fixing the sound absorbing material on the back surface of the foamed resin molded body so as to cover part of the bottom surface of the protrusion when attached to the vehicle is arbitrary, and there is no particular limitation. You may adhere and fix using an adhesive agent. However, considering the work efficiency during installation, prepare a sound-absorbing material with slits at the locations corresponding to the positions of the protrusions, so that the protrusions pass through the slits from the back side of the foamed resin molding. An attachment mode that pushes in is preferable. In this aspect, there is an advantage that the area in which the sound absorbing material covers the bottom surface of the protrusion can be adjusted according to the pushing distance. Furthermore, since the sound absorbing material can be held at a predetermined position only by the frictional force between the sound absorbing material and the side wall of the protrusion, without using other fixing means such as an adhesive, attachment work is easy. In addition, there is an advantage that the foamed resin molded body and the sound absorbing material, which are different materials, can be easily separated and recovered when the vehicle interior material is discarded.

  In a preferred embodiment of the vehicle interior material according to the present invention, the foamed resin molded body is provided with a plurality of through holes. By providing the through hole, the noise on the indoor side can be passed through the through hole and absorbed by the sound absorbing material, so that the sound absorbing performance of the vehicle interior material with respect to the room sound is improved.

  In the present invention, the foamed resin molded body as the interior material body can be molded from any foamed resin, but is preferably a foamed molded body of thermoplastic resin beads. Examples of the thermoplastic resin include polystyrene resins, polyolefin resins (eg, polypropylene resins, polyethylene resins), polyester resins (eg, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate), polycarbonate resins, and the like. .

  Among these, it is preferable to use foamed beads of a styrene-modified polyolefin resin obtained by impregnating and polymerizing a polyolefin-based resin particle with a styrene monomer, particularly a styrene-modified polyethylene resin. The reason for this is that the molded product of the styrene-modified polyolefin resin is superior in dimensional stability and shape retention compared to the polypropylene resin and polyethylene resin, and is less likely to generate dust due to rubbing than the polystyrene resin. In addition, the expansion molding of polyethylene resin beads and polypropylene resin beads has a large dimensional shrinkage ratio, and it is difficult to obtain dimensional accuracy compared to the foam molding of styrene modified polyolefin resin beads. This is because the power is small. When the styrene-modified polyolefin resin is used, the proportion of the styrene component is 40 to 90% by weight, preferably 50 to 85% by weight, and more preferably 55 to 75% by weight.

  When molding a foamed resin molded body constituting a vehicle interior material body, for example, a thermoplastic resin such as the above-described styrene-modified polyethylene resin is impregnated with a foaming agent to form a foamable thermoplastic resin. Prefoamed particles are produced by prefoaming a foamable thermoplastic resin with heated steam or the like within a range of 3 to 70 times. Then, the pre-expanded particles are filled in the mold cavity and foam-molded by steam heating or the like. The expansion ratio at the time of foam molding is 3 to 70 times. Butane, propane or the like can be used as the blowing agent.

  In the present invention, the material constituting the sound absorbing material is not particularly limited, and materials generally used in the field of automobiles can be appropriately used. Specifically, felt (for example, cotton, chemical fibers and other miscellaneous hairs solidified with PET), polyurethane foam, non-woven fabric, recycled materials for vehicle members (pulverized products of urethane, cotton, chemical fibers, etc.) Can be enumerated with PET resin, defibrated fibers, fiber materials made of animals and plants, glass wool, asphalt foam, and the like. Of these, felt, polyurethane foam or non-woven fabric is preferable, and among them, a non-woven fabric made of a high performance batting material (Synsalate (trade name)) is preferable.

  The overall shape of the vehicle interior material according to the present invention is arbitrary and is not particularly limited. For example, the thing of the shape which only forms a horizontal part at the time of installation in a vehicle, or the thing of the shape provided with the inclination part on which a passenger | crew's leg | foot rides on the front-end | tip of a horizontal part as shown in FIG. In the latter case, a plurality of protrusions are erected on the back surfaces of both the horizontal portion and the inclined portion. The shape of the protrusion is also arbitrary, and may be a cylindrical shape or a prismatic shape. In either case, since a space is formed between the protrusions, the sound absorbing material is arranged so as to fill the space. Further, the number of protrusions, the cross-sectional area, and the like are appropriately calculated based on the compressive strength in consideration of the impact absorbing performance required for the vehicle interior material.

  ADVANTAGE OF THE INVENTION According to this invention, the vehicle interior material which consists of a foaming resin molding which can satisfy sound absorption while satisfying required compressive strength and weight reduction, and can also suppress generation | occurrence | production of sound is obtained.

  Hereinafter, the present invention will be described based on embodiments with reference to the drawings. FIG. 1 is a perspective view showing a state before assembling an embodiment of a vehicle interior material according to the present invention. FIG. 2 is a perspective view of a foamed resin molded body used in the vehicle interior material shown in FIG. 3 is a perspective view showing the assembled state of the vehicle interior material shown in FIG. 1 as viewed from the back side, and FIG. 4 is a bottom view showing a part thereof. FIG. 5 is a perspective view showing a state before assembling another form of the vehicle interior material according to the present invention, FIG. 6 is a cross-sectional view showing the state after the assembly of the vehicle interior material shown in FIG. 5, and FIG. It is sectional drawing which shows the state by which the vehicle interior material shown in FIG. 5 is arrange | positioned on the floor frame of a vehicle.

  The vehicle interior material A shown in FIGS. 1 to 4 includes a rectangular foamed resin molded body 10 and a sound absorbing material 20 which are interior material bodies. In this example, the foamed resin molded body 10 is a foamed resin molded body obtained by in-mold foam molding of pre-expanded particles of a styrene-modified polyethylene resin.

  As shown in FIG. 2, the foamed resin molded body 10 has a flat surface 11 on the interior side when it is placed in a vehicle, and a large number of through holes 12 are formed in the thickness direction. As shown in FIG. 1, a plurality (five in the figure) of protrusions 14 are integrally formed on the back side 13 of the foamed resin molded body 10. In the illustrated example, the protrusion 14 has a cross shape in the horizontal cross section, but the horizontal cross sectional shape of the protrusion 14 is arbitrary. Further, the dimensions and the bottom area of each protrusion 14 are appropriately set in consideration of the overload associated with the foamed resin molded body 10.

  The sound absorbing material 20 is formed of a material such as felt, polyurethane foam, or nonwoven fabric, for example. The planar shape of the sound absorbing material 20 is substantially the same as the planar shape of the foamed resin molded body 10. When the foamed resin molded body 10 is assembled, a cross-shaped slit 21 is formed in a portion corresponding to the protrusion 14 of the foamed resin molded body 10 so as to penetrate the thickness direction of the sound absorbing material 20. ing.

  In assembling, the foamed resin molded body 10 molded at the factory is placed with the protrusion 14 side up as shown in FIG. The sound absorbing material 20 is carried thereon, and the sound absorbing material 20 is pushed toward the foamed resin molded body 10 from above in a state where the positions of the protrusions 14 and the slits 21 are matched. Along with the pressing, the cross-shaped slit 21 formed in the sound absorbing material 20 is gradually pushed open with the bottom surface of the protrusion 14 acting as a resistance. 3 and FIG. 4, the region 22 in the vicinity of the slit 21 in the sound absorbing material 20 covers a part of the bottom surface 15 of the protrusion 14 at the time when it is pushed by a predetermined distance. This is the vehicle interior material A.

  In the example shown in FIG. 3, when the foamed resin molded body 10 and the sound absorbing material 20 are laminated without gaps as shown in the figure, the slit vicinity region 22 of the sound absorbing material 20 is the bottom surface of the protrusion 14. 15 is an example, but this is only an example, and depending on the height of the protrusion 14 or the thickness of the sound absorbing material 20, the sound absorbing material 20 causes the bottom surface 15 of the protrusion 14 to be covered. The sound absorbing material 20 is pushed in until it is partially covered, and the pushing is stopped at that position.

  In this state, the sound absorbing material 20 is almost stably integrated with the foamed resin molded body 10 only by the frictional force between the protrusions 14, and the vehicle interior material A is carried out from the factory to an automobile assembly factory or the like. Is done. If the sound absorbing material 20 is easily separated from the foamed resin molded body 10 due to work at the time of unloading or the like, causing inconvenience to the work, the bonding may be further stabilized using an adhesive or the like. However, since the sound absorbing material 20 and the foamed resin molded body 10 are not separated in the state of being incorporated in a vehicle as an interior material, it is desirable not to use an adhesive or the like as much as possible, thereby disposing of the vehicle interior material A. In some cases, it is easy to separate and collect the sound absorbing material 20 and the foamed resin molded body 10 which are different materials.

  Although the vehicle interior material A is not shown, the vehicle interior material A is attached to a required location on the floor frame of the vehicle, and carpets and the like are further spread. In the vehicle interior material A, the indoor side of the foamed resin molded body 10 has a flat plate shape, thereby ensuring the flatness of the vehicle floor. In addition, the sound absorbing material 20 is disposed on the vehicle body side of the foamed resin molded body 10, so that a desired sound absorbing performance can be ensured. Furthermore, the foamed resin molded body 10 has a plurality of protrusions 14 penetrating the sound absorbing material 20, and can satisfy both the impact absorbing performance and the compressive strength while satisfying the weight reduction. In the vehicle interior material A according to the present invention, as described above, the bottom surface 15 of the protrusion 14 is partially covered with the sound absorbing material 20, so that the bottom surface 15 of the protrusion 14 directly contacts the vehicle structure. Therefore, there is little, if any, and therefore, there is no deterioration of the comfort due to large sinking, and the bottom surface 15 of the protrusion 14 made of foamed resin rubs against the vehicle structure. It is possible to greatly suppress the occurrence of sound generation.

  Furthermore, in the vehicle interior material A shown in FIGS. 1 to 4, a large number of through holes 12 are formed in the foamed resin molded body 10, and the noise on the indoor side passes through the through holes 12 to the sound absorbing material 20. Since it is absorbed, the sound absorption performance with respect to room sound is also improved. In addition, although the cross-shaped slit 21 was shown in said example, this is an illustration and the slit 21 should just be a shape comprised by three or more score lines which run to a radial direction.

  5 to 7 show other forms of vehicle interior materials according to the present invention. The vehicle interior material A1 includes a foamed resin molded body 10A, which is an interior material body, composed of a horizontal portion 16 and an inclined portion 17 positioned at the tip of the horizontal portion 16, and the horizontal portion 16 has a cylindrical protrusion. A part 14a and a pedestal 14b on the inclined part 17 are integrally formed on the back side. The sound absorbing material 20A is made of the same material as the sound absorbing material 20, and corresponds to the first portion 23 corresponding to the horizontal portion 16 of the foamed resin molded body 10A and the inclined portion 17 of the foamed resin molded body 10A. And a second portion 24.

  A through hole having a diameter slightly smaller than the diameter of the protrusion 14a is formed in the first portion 23 of the sound absorbing material 20A at a location corresponding to the cylindrical protrusion 14a integrally formed with the horizontal portion 16 of the foamed resin molded body 10A. 25 is formed in the second portion 24 at a position corresponding to the crosspiece-like protrusion 14b integrally formed with the inclined portion 17 of the foamed resin molded body 10A, slightly more than the width of the crosspiece-like protrusion 14b. A narrow notch 26 is formed. Further, as shown in FIG. 6 after assembly, the thickness P1 of the first portion 23 of the sound absorbing material 20A is the height of the cylindrical protrusion 14a integrally formed with the horizontal portion 16 of the foamed resin molded body 10A. The thickness P2 of the second portion 24 is slightly larger than the height h1, and the thickness P2 of the second portion 24 is slightly smaller than the height h2 of the cross-shaped projection 14b integrally formed with the inclined portion 17 of the foamed resin molded body 10A. Big thickness.

  Therefore, as shown in FIG. 5, when the foamed resin molded body 10A is turned upside down and the sound absorbing material 20A is pressed from above and assembled to the foamed resin molded body 10A, the sound absorbing material 20A is formed between the protrusion 14a and the protrusion 14b. It is assembled in a stable state with the friction force between. Then, as shown in FIG. 6 in cross section after assembly, the first portion 23 and the second portion 24 (lower surface side) of the sound absorbing material 20A are composed of the bottom surface 15a and the protrusion 14b of the protrusion 14a. It protrudes downward from the bottom surface 15b.

  As shown in FIG. 7, the foamed resin molded body 10A is attached to a required place on the floor frame 30 of the vehicle, and carpet (not shown) or the like is further spread. Thereby, the sound absorbing material 20A is compressed by the load from above, and the peripheral region 27 of the protrusion 14a and the protrusion 14b in the region protruding downward is the bottom surface 15a of the protrusion 14a and the bottom surface 15b of the protrusion 14b. It is elastically deformed so as to enter below. As a result, the bottom surface 15a of the protrusion 14a and the bottom surface 15b of the protrusion 14b are partially covered with the sound absorbing material 20A.

  In addition, in the vehicle interior material A1 of this form, the periphery of the foamed resin molded body 10A, the protrusions 14a and 14b, the sound absorbing material 20A, and the sound absorbing material 20A that has entered the bottom surface 15a of the protruding part 14a and the bottom surface 15b of the protruding part 14b. The operational effects of the region 27 and the like are such that the foamed resin molded body 10 shown in FIGS. 1 to 4 partially absorbs the foamed resin molded body 10, the protrusions 14, the sound absorbing material 20, and the bottom surface 15 of the protrusions 14. It is easy to know that it corresponds to the function and effect of the vicinity region 22 of the slit 21 in the material 20, and the description thereof is omitted here.

  Although not shown, in the vehicle interior material A1 in the form shown in FIGS. 5 to 7, a part of the bottom surface 15a of the cylindrical protrusion 14a can be covered on the bottom surface side of the through hole 25 formed in the sound absorbing material 20A. The lip may be integrally formed, or a lip capable of covering a part of the bottom surface 15b of the cross-shaped projection 14b may be integrally formed on the bottom surface side of the narrow-width notch 26. In that case, when the sound absorbing material 20A is thinned or the height of the protrusions 14a and 14b is increased and assembled to the foamed resin molded body 10A, the vehicle interior material A1 and the sound absorbing material 20A are assembled. A gap may be formed between the two. In any case, it is preferable to form a through-hole in the thickness direction of the foamed resin molded body 10A, thereby improving the sound absorption performance with respect to room sound as in the case of the vehicle interior material A. It is.

The perspective view which shows the state before the assembly of one form of the interior material for vehicles by this invention. The perspective view which looked at the foaming resin molding used with the vehicle interior material shown in FIG. 1 from the surface side. The perspective view which shows the state after the assembly of the vehicle interior material shown in FIG. The bottom view which shows a part of the state after the assembly of the vehicle interior material shown in FIG. The perspective view which shows the state before the assembly of the other form of the vehicle interior material by this invention. Sectional drawing which shows the state after the assembly of the vehicle interior material shown in FIG. Sectional drawing which shows the state by which the vehicle interior material shown in FIG. 5 is arrange | positioned on the floor frame of a vehicle. The figure which shows an example of the conventional interior material for vehicles.

Explanation of symbols

  DESCRIPTION OF SYMBOLS A ... Interior material for vehicles, 10 ... Foamed resin molding which is interior material main body, 12 ... Through-hole, 14 ... Projection, 15 ... Bottom surface of projection, 20 ... Sound absorbing material, 21 ... Slit, 22 ... Sound absorbing material Area near the slit

Claims (3)

A vehicle interior material comprising a foamed resin molded body and a sound absorbing material,
The foamed resin molded article, one or a plurality of projections are formed,
The sound absorbing material is formed with a notch or a through-hole penetrating the sound absorbing material for the protrusion to be pushed into a position corresponding to the position where the protrusion is formed,
When the protrusion is cut into or pushed into the through hole and the foamed resin molded body and the sound absorbing material are incorporated , the bottom surface of the protrusion does not protrude from the cut or through hole when attached to the vehicle. An interior material for a vehicle , wherein the bottom surface is partially covered by elastic deformation of the material.   The vehicle interior material according to claim 1, wherein the foamed resin molded body has a plurality of through holes.   The vehicle interior material according to claim 1 or 2, wherein the sound absorbing material is any one of felt, polyurethane foam, and nonwoven fabric.

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