JP5505699B2 - Interior material for vehicle and method for manufacturing the same - Google Patents

Description

  The present invention relates to a vehicle interior material and a method for manufacturing the same.

  As a vehicle interior material used for automobiles and the like, those described in Patent Document 1 are known. This is a molded ceiling attached to the indoor surface side of the roof panel, and has a two-layer structure of a panel-side base material having a desired uneven shape and an indoor-side base material having a flat surface shape. A plurality of hollow portions are formed between the concave portion provided on the roof panel side of the panel-side base material and the indoor-side base material, thereby enhancing the heat insulating property of the molded ceiling. Moreover, each hollow part is demarcated because the panel side base material is joined to the indoor side base material. This molded ceiling is used by being mounted along the indoor surface side of the roof panel and appropriately cut.

JP 2006-36089 A

  By the way, the interior material for a vehicle such as the above-described molded ceiling is mounted along the shape of the vehicle interior and is used in a curved shape depending on the part, so that it is necessary to ensure a certain strength or more. However, according to the above-described configuration of the molded ceiling, each concave portion is only connected by a flat plate-like connecting portion, so that the connecting portion is easily bent and has a disadvantage that the strength in the bending direction is low as the molded ceiling. .

  This invention is completed based on the above situations, Comprising: It aims at providing the interior material for vehicles which can improve rigidity, and its manufacturing method, ensuring heat insulation. .

  The present invention is a vehicle interior material in which a sheet molded body is bonded to one surface side of a base material, and the sheet molded body includes a plurality of bulged portions rising from the base material and the adjacent bulged portions. A base portion of the side wall of the base plate, and a connecting portion constituting an adhesive surface to the base material. A cross-linked portion that is retreated is formed, and the cross-linked portion is formed by joining the side wall surfaces of the adjacent bulging portions to each other.

  According to such a configuration, since the adjacent side wall surfaces of the bulged portion of the sheet molded body are joined to each other by the bridging portion, the rigidity in the bending direction of the vehicle interior material can be improved. This bridging portion is provided integrally with the sheet molded body, and can easily improve rigidity without adding a separate reinforcing member, thereby reducing the material cost as an interior member for a vehicle and thus contributing to weight reduction of the entire vehicle. It is possible. Moreover, since the edge part by the side of the base material of a bridge | crosslinking part exists in the position retreated with respect to the adhesive surface to the base material of a connection part, when a bridge part is not formed, for example, so that a bulging part may be divided Compared with the case where a grid-like connection part is formed, the adhesion area with the base material can be reduced, and the heat insulation can be improved. In other words, since air has a lower thermal conductivity than materials (for example, synthetic resins) that make up vehicle interior materials, more air is interposed between the base material and the sheet molded body, so that the sheet is formed on the base material. By reducing the contact area of the body, the heat insulation by the sheet molded body can be enhanced.

  Moreover, this invention is a manufacturing method of the interior material for vehicles formed by adhere | attaching a sheet molded object on the one surface side of a base material, Comprising: The said sheet molded object is adjacent to the several bulging part which stands up from the said base material. A heating step of heating a resin sheet which is a material of the sheet molded body, and the sheet in the heated state is formed from a metal mold. When the sheet is placed on a mold and shaped along the molding surface of the molding die, the bridges are formed by welding the sheets that could not follow the molding surface to each other. And a molding step.

  According to such a manufacturing method, a sheet having a bridging portion can be easily obtained by devising the shape of a molding die, for example, without changing the production process in the case of molding an outer base material having no bridging portion. It is possible to form a molded body. In addition, since the bridging portion is formed by welding two sheets to each other, the thickness thereof is thicker than that of other parts made of at least one sheet, and the bridging portion is formed. The rigidity of the part can be improved. In addition, since the bulging portions are connected to each other by welding the side wall surfaces of the adjacent bulging portions, it is possible to form a vehicle interior material having high bending direction rigidity.

  In the method for manufacturing an interior material for a vehicle, in the molding step, a flow groove is formed on the adhesive surface side of the base material by welding the sheets that could not follow the surface shape of the molding surface to each other. The flow grooves circulate through the internal spaces of the bulging portions, and after the forming step, the base material is placed on the sheet molded body, and the swell is passed through the flow grooves. It is desirable to provide a pressing step of pressing the base material against the sheet molded body in a state where gas is pressed into the exit portion.

  The vehicle interior material of the present invention secures the heat insulating property of the vehicle interior material by providing a bulging portion in the sheet molded body by a hollow portion generated between the bulging portion and the base material. It is important to secure as much volume as possible. However, in the pressing step of pressing the base material and the sheet molded body, the volume of the hollow portion decreases due to the base material entering the bulging portion of the sheet molded body and the hollow portion being crushed, and as a vehicle interior material There is a possibility that the heat insulating property is lowered. On the other hand, according to the method for manufacturing an interior material for a vehicle of the present invention, the base material is pressed in a state where a gas is press-fitted into the bulging portion of the sheet molded body through a flow groove and the bulging portion is pressurized from the inside. Since it can be pressed, it is possible to ensure heat insulation without the hollow portion being crushed by the base material being pushed into the bulging portion.

  The molding step preferably comprises a vacuum molding step of molding the sheet molded body by sucking air from a suction port formed on the molding surface of the molding die.

  ADVANTAGE OF THE INVENTION According to this invention, the interior material for vehicles which can improve rigidity, ensuring heat insulation, and its manufacturing method can be provided.

1 is a side view of a vehicle to which a vehicle interior material according to an embodiment of the present invention is applied. Perspective view of vehicle interior material Top view of vehicle interior materials AA sectional view of FIG. BB sectional view of FIG. Perspective view of a molding die for molding a sheet molded body Top view of mold CC sectional view of FIG. DD sectional view of FIG. Sectional drawing which showed the suction state of the formation process in CC cross section of FIG. Sectional drawing which showed the suction state of the formation process in the DD cross section of FIG. Sectional drawing which showed the press process in the DD cross section of FIG.

<One Embodiment>
An embodiment of the present invention will be described with reference to FIGS. Each drawing conceptually shows the structure and manufacturing method of the vehicle interior material 10 of the present embodiment, and does not represent an accurate dimensional relationship.
The vehicle interior material 10 manufactured according to the present embodiment is applied to a ceiling material that is mounted on the vehicle interior side of the roof panel 51 of the automobile 50 shown in FIG. This vehicle interior material 10 has a structure in which a base material 20 disposed on the vehicle interior side and a sheet molded body 30 attached to the base material 20 and disposed on the roof panel 51 side are laminated, Although not shown, the side surface of the base material 20 on the vehicle interior side is covered with a skin material. Hereinafter, the base material 20 side will be described with respect to the sheet molded body 30, and the roof panel 51 side will be described below.

  The upper base material 20 in the vehicle interior material 10 shown in FIG. 2 is made of a synthetic resin, and blends, for example, PP (polypropylene) and fibers (natural fibers, glass fibers, or carbon fibers). The adhesive surface with the sheet molded body 30 is substantially flat and has a plate shape as a whole.

  The sheet molded body 30 is formed of a resin material such as PP and has a thickness of about 0.3 mm. As shown in FIG. 2, the main structure is that a plurality of bulging portions 31 bulged so as to protrude toward the opposite side (lower side) to the base material 20 side by vacuum forming, and adjacent bulging portions. And a connecting portion 32 that connects the standing wall 31a that forms the side wall of 31. The bulging portions 31 are arranged in parallel, the top portion 31 b is a flat and substantially square shape, and the standing wall 31 a is formed so as to rise substantially perpendicular to the base material 20. The connection part 32 connects the base end part of the standing wall 31a of the adjacent bulging part 31, and has comprised the planar view lattice shape which divides the bulging part 31 as shown in FIG. Of the connecting portion 32, a flat bottom surface having a cross shape in plan view is an adhesive surface 32 a that is bonded to the substrate 20.

  Now, a bridging portion 33 is formed at a substantially central portion in the width direction of the standing wall 31a by joining the wall surfaces of the adjacent standing walls 31a connected by the connecting portion 32. As will be clarified from the manufacturing method described later, the bridging portion 33 is formed by welding the materials that could not follow the groove provided in the molding die in the vacuum forming process while trying to follow the molding surface. Therefore, the upper end portion has a concave shape on the lower side (the top portion 31 b side of the bulging portion 31) with respect to the bonding surface 32 a of the connecting portion 32. Thereby, compared with the case where the bridge | crosslinking part 33 is not formed in the adhesion surface 32a to the base material 20, the adhesion area for the width | variety of the bridge | crosslinking part 33 will be reduced.

  In a state where the sheet molded body 30 is bonded to the base material 20, a substantially rectangular parallelepiped hollow portion 11 is formed between the bulging portion 31 and the base material 20 as shown in FIGS. 2 and 4. As shown in FIG. 4 and FIG. 5, the hollow portion 11 is adjacent to each other by a flow groove 12 that is formed between the upper end portion of the bridging portion 33 and the base material 20 by being recessed with respect to the bonding surface 32 a. The parts 11 communicate with each other.

Next, a method for manufacturing the vehicle interior material 10 will be described.
The vehicle interior material 10 of the present embodiment is based on a heating process for heating a PP sheet 35 that is a material of the sheet molded body 30, a molding process for molding the sheet by vacuum molding, and a sheet molded body 30. It is manufactured by a pressing process for crimping the material 20. First, the mold structure used in the molding process will be described.

  As shown in FIGS. 6 and 7, the first mold 40 for molding the sheet molded body 30 has a plurality of molding recesses 41 in parallel for molding the bulging portion 31 of the sheet molded body 30 on the molding surface. Is provided. At four corners of the bottom surface 42 of each molding recess 41, suction ports 43 for evacuation are opened. A bridging portion forming groove 44 having the same depth as the bottom surface 42 is formed at a substantially central position in the width direction of each side wall of the forming recess 41. In the present embodiment, the height of the side wall of the molding recess 41 is, for example, 8 mm, and the width of the bridging portion forming groove 44 is, for example, 5 mm.

Next, each manufacturing process will be described.
First, in the heating step, the sheet 35 is softened by a heating plate (not shown) disposed on both surfaces of the sheet 35. Subsequently, in the molding step, the sheet 35 in a softened state as shown in FIGS. 8 and 9 is placed on the molding surface of the first mold 40, and from the suction port 43 that opens to the first mold 40. The sheet molded body 30 is vacuum-formed by suction with a vacuum pump or the like. Thereby, the sheet | seat 35 is shaped along the molding surface of the 1st metal mold | die 40, as shown in FIG.10 and FIG.11. At this time, the portion of the sheet 35 disposed in the bridging portion forming groove 44 cannot follow the molding surface, and the facing portions 35 are welded together to form the bridging portion 33. In addition, since this bridge | crosslinking part 33 is formed by welding while being vacuumed from the suction port 43 provided in the four corners of the bottom face 42 of the 1st metal mold | die 40, the upper end part was shaped along the molding surface. It has a concave shape so as to be pulled downward from the bonding surface 32a (see FIG. 11).

  The formed sheet compact 30 is continuously released from the first mold 40 without being released. By placing the substrate 20 on the sheet molded body 30 and clamping the second mold 45 and the first mold 40 disposed on the side opposite to the sheet molded body 30 side of the substrate 20. Then, the base material 20 is pressed against the adhesive surface 32a of the sheet molded body 30 (see FIG. 12). At the same time as the mold clamping, a gas such as air is press-fitted into the hollow portion 11 formed between the bulging portion 31 and the base material 20 through the flow groove 12 formed by the recess on the upper side of the bridging portion 33. Is done. Accordingly, the bulging portion 31 is maintained in a shape along the molding surface, and the base material 20 cannot enter the bulging portion 31 by being compressed, so that the volume of the hollow portion 11 is reduced. The base material 20 is crimped | bonded with respect to the sheet molded object 30 without doing. Then, the vehicle interior material 10 is obtained by releasing the sheet molded body 30 from the first mold 40.

  As described above, in the vehicular interior material 10 according to the present embodiment, the bulging portion 31 of the sheet molded body 30 is joined by the bridging portion 33 so that the surfaces of the adjacent standing walls 31a are joined to each other. Compared with the case where each bulging part is formed independently without being formed, the rigidity in the bending direction can be improved. In addition, the flow groove 12 is naturally formed between the bridging portion 33 and the base material 20 by forming a shape in which the upper end portion of the bridging portion 33 is recessed with respect to the bonding surface 32 a of the connecting portion 32. Thereby, compared with the case where it forms in a grid | lattice form so that the adhesion surface of a connection part may surround the bulging part circumference | surroundings, the adhesion area with respect to the base material 20 of the sheet molded object 30 can be suppressed, for example. By suppressing the adhesion area of a resin such as PP having a higher thermal conductivity than that of air, the heat conduction through the sheet molded body 30 can be suppressed, and the heat insulation effect can be enhanced. In addition, the volume of the flow groove 12 is increased between the sheet molded body 30 and the base material 20 in addition to the hollow portion 11 by reducing the adhesion area to the base material due to the formation of the bridging portion 33. Similarly, the heat insulation in the vehicle interior material 10 can be enhanced.

  Moreover, according to the manufacturing method of the vehicle interior material 10 according to the present embodiment, the bridging portion 33 of the sheet molded body 30 is formed on the side wall of the molding concave portion 41 of the first mold 40 that is a molding die. Therefore, it is not necessary to add a reinforcing member in order to improve the rigidity in the bending direction. Furthermore, since it is not necessary to change the manufacturing process, and it is not necessary to change the material and amount of the sheet 35 as a material, it is possible to improve the rigidity of the vehicle interior member 10 at a low cost.

  In addition, when the sheet molded body 30 is bonded to the base material 20 by providing the sheet molded body 30 with the bridging portion 33, the flow groove 12 communicating with the hollow portion 11 is naturally formed. Since the sheet molded body 30 and the base material 20 can be pressed through the flow grooves 12 while a gas such as air is pressed into each hollow portion 11, the base material 20 is a bulging portion of the sheet molded body 30. It is possible to prevent entry into 31. Thereby, it is possible to prevent the bulging portion 31 forming the hollow portion 11 or the base material 20 disposed to face the bulging portion 31 from being crushed in the pressing step and reducing the volume of the hollow portion 11. Therefore, the heat insulation performance obtained by providing the hollow part 11 between both members can be maintained reliably.

  Further, since the bridging portion 33 is formed by welding two sheets facing each other, the material 35 is compared with the top portion 31b of the bulging portion 31 formed from another sheet 35, for example. As a result, the strength of the bridging portion 33 is increased. Thereby, not only a bending direction but the rigidity as the vehicle interior material 10 can be improved. Further, since the bridging portion 33 is provided on the side wall of the bulging portion 31 along the mold drawing direction, it is convenient for releasing from the first mold 40.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.

  (1) In the above-described embodiment, the bulging portion 31 is a quadrangular column, but is not limited thereto, and may be a polygonal column such as a hexagonal column. An example is a honeycomb structure. The top 31b may be a substantially truncated polygonal pyramid that is a polygon such as a quadrangle or a hexagon. Among them, in particular, if the shape of the top portion 31b of the bulging portion 31 is a hexagon, the rigidity of the bulging portion 31 can be increased. Further, if the bulging portion 31 is formed in a weight shape, the rigidity can be improved similarly, and a draft can be secured in the mold, so that the mold can be held better.

  (2) In the above-described embodiment, the sheet molded body 30 is molded by vacuum molding. However, the present invention is not limited to this. For example, the sheet molded body 30 may be molded by pressure molding.

DESCRIPTION OF SYMBOLS 10 ... Vehicle interior material 11 ... Hollow part 12 ... Flowing groove 20 ... Base material 30 ... Sheet molded object 31 ... Swelling part 31a ... Standing wall 31b ... Top part 32 ... Connection part 32a ... Adhesive surface 33 ... Bridging part 35 ... Sheet 40 ... first mold 41 ... molding recess 42 ... bottom face 43 ... suction port 44 ... bridge forming groove 45 ... second mold 50 ... automobile 51 ... roof panel

Claims (4)

An interior material for a vehicle in which a sheet molded body is bonded to one side of a base material,
The sheet molded body includes a plurality of bulging portions that rise from the base material, and a connection portion that connects a base end portion of a side wall of the adjacent bulging portion and constitutes an adhesive surface to the base material. ,
A part of the side wall of the bulging portion is a bridging portion in which an end of the side wall on the base material side is retreated with respect to the adhesive surface .
In the bridging portion , the vehicle interior material is characterized in that the side wall surfaces of the adjacent bulging portions are joined in contact with each other. A method for manufacturing an interior material for a vehicle in which a sheet molded body is bonded to one surface side of a substrate,
The sheet molded body includes a plurality of bulging portions rising from the base material, and a bridging portion in which side wall surfaces of the adjacent bulging portions are joined to each other,
A heating step of heating a resin sheet as a material of the sheet molded body;
When the sheet in a heated state is placed on a molding die and the sheet is shaped along the molding surface of the molding die, the sheets that could not follow the molding surface are welded together. And a molding step in which the bridging portion is formed. It is a manufacturing method of the interior material for vehicles according to claim 2,
In the molding step, the sheets that have not been able to follow the surface shape of the molding surface are welded together to form a flow groove on the adhesive surface side with the base material, and the flow groove is the bulging portion The internal spaces of each other are distributed.
After the molding step, the base material is placed on the adhesive surface side of the sheet molded body, and the base material is pressed against the sheet molded body in a state where gas is pressed into the bulging portion through the flow groove. A method for producing an interior material for a vehicle, comprising a pressing step of pressing.   The said shaping | molding process consists of the vacuum forming process which attracts | sucks air from the suction port formed in the shaping | molding surface of the said metal mold | die, and shape | molds the said sheet molded object, The Claim 2 or Claim 3 characterized by the above-mentioned. Manufacturing method for vehicle interior materials.

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