JP5574540B2 - Interior parts for automobiles and their manufacturing methods - Google Patents

Description

  The present invention relates to an automotive interior part used as, for example, a trunk floor board and a manufacturing method thereof, and more particularly, to reduce the weight, reduce the cost, and improve the rigidity of such an automotive interior part. is there.

  As this type of automobile interior part, for example, a load bearing board for automobiles disclosed in Patent Document 1 is known. The load bearing board for automobiles in the literature 1 has a structure in which a thermoplastic foam core layer is sandwiched between a first fibrous base material and a second fibrous base material (see FIG. 2 of the literature 1).

  However, when the load bearing board for automobiles of Patent Document 1 is used as, for example, a trunk floor board, a thermoplastic foam core layer is included in the trunk floor board constituent material, so that the interior temperature of the vehicle becomes high. There is a problem that the rigidity of the trunk floor board itself decreases, and the deformation of the trunk floor board becomes large in a state where luggage is placed. Although this problem can be solved by increasing the weight and thickness of the trunk floor board, this solution causes another problem of increasing the cost and weight of the trunk floor board due to the increase in weight and thickness.

  The above-mentioned problems are not limited to trunk floor boards, but generally occur in automobile interior parts used under the same conditions as trunk floor boards.

JP 2008-222208 A

  The present invention has been made to solve the above-described problems, and an object of the present invention is to reduce the weight, reduce the cost, and improve the rigidity of an automotive interior part used as, for example, a trunk floor board. It is an object of the present invention to provide an automotive interior part and a method for manufacturing the same.

In order to achieve the above object, an automotive interior part according to the present invention is formed by joining a thermosetting semi-rigid urethane core layer and a thermoplastic resin member made of a thermoplastic resin sheet or thermoplastic resin fiber. The semi-rigid urethane core layer is an automotive interior part, and is formed by slicing a block-like material produced by reaction / foaming of the raw material , so that the cell in the surface of the layer is a cell in the layer. The bubble cell on the surface of the layer communicates with the outside through the bubble cell inside the layer, and the thermoplastic resin member and the semi-rigid urethane core layer are joined to each other. In part, the thermoplastic resin member and the semi-rigid urethane core layer are bonded by a part of the thermoplastic resin member entering the cell of the surface of the semi-rigid urethane core layer. And wherein the Rukoto.

A method for manufacturing an automotive interior part according to the present invention is an automotive interior part formed by joining a thermosetting semi-rigid urethane core layer and a thermoplastic resin member made of a thermoplastic resin sheet or thermoplastic resin fiber. A manufacturing method, wherein the manufacturing method includes a step of heating the thermoplastic resin member, a step of setting the semi-rigid urethane core layer and the heated thermoplastic resin member in a molding die, and the molding die. A step of pressure-bonding the semi-rigid urethane core layer in the mold and the heated thermoplastic resin member, and the semi-rigid urethane core layer is a block made by reaction / foaming of the raw material by consisting of those obtained by slicing the Jo was foamed cells of the layer surface has a magnitude equivalent to the layer inside the foamed cells, and foamed cells are foamed cells inside the layer of the layer surface In the form of communicating with the outside through the air, the air in the bubble cell on the surface of the semi-rigid urethane core layer is discharged to the outside through the bubble cell inside the semi-rigid urethane core layer during the pressure bonding. , The phenomenon that a part of the thermoplastic resin member enters the bubble cell on the surface of the semi-rigid urethane core layer is promoted, and the thermoplastic resin member and the semi-rigid urethane core layer are integrated by an anchor effect due to the penetration. It is characterized by doing so.

  In the present invention, the following effects (1) to (3) are achieved by adopting the above configuration.

  (1) For example, when a trunk floor board is produced by applying the interior parts for automobiles and the manufacturing method thereof according to the present invention, the trunk floor board has a semi-rigid urethane core layer constituting the trunk floor board because it is a thermosetting resin. Because there is little deformation even when the luggage is placed when the inside of the car gets hot, there is no need to increase the plate thickness to prevent deformation, so lightweight and low-cost trunk floor boards and other automotive interior parts Can be provided.

  (2) The semi-rigid urethane core layer is configured such that the bubble cells on the surface of the layer communicate with the outside through the bubble cells inside the layer. It can be discharged to the outside through the bubble cell inside the layer. Thereby, for example, when a semi-rigid urethane core layer and a thermoplastic resin member are joined by pressure bonding, a phenomenon in which a part of the thermoplastic resin member enters the bubble cell on the surface of the semi-rigid urethane core layer is promoted. Due to the anchor effect due to penetration, the thermoplastic resin member and the semi-rigid urethane core layer can be firmly bonded and integrated. In addition, the air pool that can be generated at the interface between the thermoplastic resin member and the semi-rigid urethane core layer is reduced, so that the adhesion at the interface is increased and the thermoplastic resin member and the semi-rigid urethane core layer are bonded to each other. Since the force is further improved, it is possible to obtain a final product such as a trunk floorboard having high rigidity and other automotive interior parts.

  (3) Since the semi-rigid urethane core layer and the thermoplastic resin member are firmly integrated with each other by the anchor effect described above, these bonding steps can be eliminated, and trunk floor boards and other automotive interior parts Simplification of the manufacturing process and further cost reduction can be achieved.

(A) is sectional drawing which is one Embodiment of the interior component for motor vehicles based on this invention, (b) is an enlarged schematic diagram of the A section, (c) is a semi-rigid urethane core layer before joining a thermoplastic resin member The enlarged schematic diagram of the surface vicinity.

  Hereinafter, the best mode for carrying out the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 1A is a cross-sectional view showing an embodiment of an automotive interior part according to the present invention, FIG. 1B is an enlarged schematic view of part A, and FIG. 1C is a view before joining a thermoplastic resin member. It is an enlarged schematic diagram of the surface vicinity of the semi-rigid urethane core layer.

  The automobile interior part 1 shown in FIG. 1A is used as, for example, a trunk floor board of an automobile, but is not limited to this application. This automotive interior part 1 has a structure in which a thermosetting semi-rigid urethane core layer 2 and a sheet-like thermoplastic resin member 3 made of a thermoplastic resin sheet or thermoplastic resin fiber are joined.

  In the joint structure, the semi-rigid urethane core layer 2 has a bubble cell B1 on the surface of the layer substantially equal in size to the bubble cell B2 inside the layer (requirement 1), and the bubble cell on the surface of the layer. B1 is configured to communicate with the outside through the bubble cell B2 inside the layer (requirement 2). As an example of the form of communication to the outside, the bubble cell B1 on the surface of the semi-rigid urethane core layer is opened to the outside through the bubble cell B2 inside the same layer adjacent to the cell (not shown). ).

  At the joint P between the thermoplastic resin member 3 and the semi-rigid urethane core layer 2, a part of the thermoplastic resin member 3 enters the bubble cell B1 on the surface of the semi-rigid urethane core layer as shown in FIG. The thermoplastic resin member 3 and the semi-rigid urethane core layer 2 are combined and integrated by the anchor effect due to this penetration.

<< Method for obtaining semi-rigid urethane core layer 2 satisfying the above (Requirement 1) >>
The semi-rigid urethane core layer 2 is prepared by reacting and foaming a polyol and an isocyanate in a container to produce a block-like product, and slicing the produced block-like product with a predetermined thickness into a sheet shape.

  By the way, the surface of the block-like material is a skin layer including a large number of fine bubble cells. On the other hand, in the block-like product, the portion other than the skin layer has a tissue structure including many bubble cells larger than the fine bubble cells in the skin layer. In the present embodiment, the semi-rigid urethane core layer 2 is obtained by slicing a portion below the skin layer of the block-like material into a sheet shape.

  For this reason, there is no skin layer on the surface of the semi-rigid urethane core layer 2 obtained by the slicing. The surface of the obtained semi-rigid urethane core layer 2 is in a state in which the internal structure of the block-like material is directly exposed to the outside by slicing, that is, the bubble cell inside the block-like material larger than the fine cell in the skin layer is on the surface. The organization structure is directly exposed. Therefore, in the semi-rigid urethane core layer 2 obtained by slicing, the bubble cell B1 on the surface of the layer and the bubble cell B2 on the inside of the layer have substantially the same size (requirement 1). It satisfies.

<< Method for obtaining semi-rigid urethane core layer 2 satisfying (Requirement 2) >>
In the present embodiment, when the block-shaped material is produced, the blending ratio (parts by weight) of the polyol and isocyanate, which are the materials of the block-shaped material, is set to 100: 150 to 170, so that (Requirement 2) The semi-rigid urethane core layer 2 that satisfies the above is obtained.

  By the way, in the blending ratio, if the blending ratio of isocyanate is increased, the semi-rigid urethane core layer 2 becomes harder and its rigidity is improved, but the individual cell cells B1 and B2 of the semi-rigid urethane core layer 2 are independent. End up. For this reason, the effect of the above-mentioned open cell that air in the bubble cell B1 on the surface of the same layer is discharged outside through the bubble cell B2 inside the same layer does not occur, and a part of the thermosetting resin member 3 is half It becomes difficult to enter the bubble cell B1 on the surface of the hard urethane core layer, and the anchor effect described above cannot be effectively exhibited. Therefore, in this embodiment, the blending ratio of polyol and isocyanate is set to the above ratio.

<< Method to Make Part of Thermoplastic Resin Member 3 Easily Enter Bubble Cell B1 on the Surface of Semi-Rigid Urethane Core Layer >>
In the present embodiment, by setting the diameter of the bubble cell B1 on the surface of the semi-rigid urethane core layer to any dimension within the range of 0.1 to 1 mm, a part of the thermoplastic resin member 3 is the semi-rigid urethane core. It is made easy to enter the bubble cell B1 on the surface of the layer. In addition, the diameter of this bubble cell B1 of 0.1-1 mm is larger than the diameter of the fine bubble cell in the skin layer demonstrated previously. Since the bubble cell B1 on the surface of the semi-rigid urethane core layer and the bubble cell B2 inside the layer are approximately the same size, if the diameter of the bubble cell B1 on the surface of the same layer is 0.1 to 1 mm, Similarly, the diameter of the bubble cell B2 is 0.1 to 1 mm. The density of the semi-rigid urethane core layer 2 is preferably 0.01 to 0.05 g / cm ³ .

  Since the bubble cell B1 on the surface of the semi-rigid urethane core layer is larger than the fine cell of the skin layer as described above, a part of the thermoplastic resin member 3 bites into the cell B1 on the surface of the semi-rigid urethane core layer. The anchor effect described above is greater than the anchor effect caused by, for example, a part of the thermoplastic resin member biting into the fine cell of the skin layer.

  Further, in the present embodiment, when the thermoplastic resin member 3 and the semi-rigid urethane core layer 2 are joined, the thermoplastic resin member 3 is heated to any temperature within the range of 180 ° C. to 220 ° C. to make the semi-rigid urethane. By pressure-bonding to the core layer 2, a part of the thermoplastic resin member 3 can easily enter the bubble cell B1 on the surface of the semi-rigid urethane core layer.

  The semi-rigid urethane core layer 2 in the present embodiment is obtained by slicing a block-like material into a sheet as described above, and has a flat plate shape, for example, a flat automotive interior such as a trunk floor board. In the case of producing a part, the semi-rigid urethane core layer 2 is not heated, only the thermoplastic resin member 3 is heated, and the semi-rigid urethane core layer 2 and the thermoplastic resin member 3 are pressed by a press machine or the like. That's fine. On the other hand, when producing an uneven interior part for an automobile, the semi-rigid urethane core layer 2 is also heated, and the heated semi-rigid urethane core layer 2 and the heated thermoplastic resin member 3 are overlapped and press-molded. Can be done.

<< Method for Manufacturing Interior Parts for Automobile (First Example) >>
Next, a method for manufacturing the automobile interior part 1 shown in FIG. 1 will be described. Here, an example of manufacturing a flat automotive interior part 1 such as a trunk floor board will be described. This type of flat automotive interior part 1 can be manufactured by the following steps 1 to 3.

(Process 1)
Step 1 is a step of preparing two sheet-like thermoplastic resin members 3 made of thermoplastic resin sheets or thermoplastic resin fibers and heating them. As described above, the heating temperature is any temperature within the range of 180 ° C to 220 ° C. This is because a part of the thermoplastic resin member 3 can easily enter the bubble cell B1 on the surface of the semi-rigid urethane core layer.

(Process 2)
In step 2, the semi-rigid urethane core layer 2 and the two sheets heated with the semi-rigid urethane core layer 2 interposed between the two thermoplastic resin members 3 heated as described above (sandwich form). This thermoplastic resin member 3 is set in a mold. As described above, the semi-rigid urethane core layer 2 set here has the bubble cell B1 on the surface of the layer substantially the same size as the bubble cell B2 inside the layer, and the bubble on the surface of the layer. It is assumed that the cell B1 communicates with the outside through the bubble cell B2 inside the layer.

(Process 3)
Step 3 is a step of crimping the semi-rigid urethane core layer 2 in the mold and the two heated thermoplastic resin members 3 with the molding die. The final product of the trunk floor board is the one that has been crimped.

  As described above, the bubble cell B1 on the surface of the semi-rigid urethane core layer communicates with the outside through the bubble cell B2 inside the same layer. The air in the cell B1 is discharged to the outside through the bubble cell B2 in the same layer.

  Thereby, the phenomenon that a part of the thermoplastic resin member 3 enters the bubble cell B1 on the surface of the semi-rigid urethane core layer as shown in FIG. 1B is promoted, and the thermoplastic resin member is obtained by the anchor effect due to such penetration. 3 and the semi-rigid urethane core layer 2 are firmly bonded and integrated. In addition, since the air pool that can be generated at the boundary surface between the thermoplastic resin member 3 and the semi-rigid urethane core layer 2 is reduced, the adhesiveness of the boundary surface is increased, and the thermoplastic resin member 3 and the semi-rigid urethane core layer are increased. 2 further improves the final strength of the trunk floorboard.

<< Method for Manufacturing Interior Parts for Automobile (Second Embodiment) >>
In the automobile interior part manufacturing method (first embodiment) described above, the thermoplastic resin member 3 and the semi-rigid urethane core layer 2 are integrated only by the anchor effect. It is also possible to adopt a method for achieving the integration by combining the effect and the adhesive effect by the adhesive. When this method is adopted, an additional step of interposing an adhesive between the thermoplastic resin member 3 and the semi-rigid urethane core layer 2 is provided between the step 1 and the step 2. Good.

  The present invention is not limited to the embodiments described above, and many modifications can be made by those having ordinary knowledge in the art within the technical idea of the present invention.

1 Automotive interior parts (trunk floor boards, etc.)
2 Semi-rigid urethane core layer 3 Thermoplastic resin member B1 Bubble cell B2 on the surface of semi-rigid urethane core layer B2 Cell cell inside the semi-rigid urethane core layer Joint between semi-rigid urethane core layer and thermoplastic resin member

Claims (4)

An automotive interior part formed by joining a thermosetting semi-rigid urethane core layer and a thermoplastic resin member made of a thermoplastic resin sheet or thermoplastic resin fiber,
The semi-rigid urethane core layer is formed by slicing a block-like material produced by reaction / foaming of the raw material, so that the bubble cell on the surface of the layer has the same size as the bubble cell inside the layer. And the bubble cell on the surface of the layer is in a form communicating with the outside through the bubble cell inside the layer,
In the joint portion between the thermoplastic resin member and the semi-rigid urethane core layer, a part of the thermoplastic resin member enters the bubble cell on the surface of the semi-rigid urethane core layer, so that the thermoplastic resin member and the Automotive interior parts characterized by being bonded to a semi-rigid urethane core layer.   The raw material consists of polyol and isocyanate,
  By setting the blending ratio of the polyol and the isocyanate to 100 parts by weight: 150 to 170 parts by weight, the bubble cell on the surface of the layer is configured to communicate with the outside through the bubble cell inside the layer.
  The interior part for automobiles according to claim 1. A method for producing an interior part for an automobile, comprising joining a thermosetting semi-rigid urethane core layer and a thermoplastic resin member comprising a thermoplastic resin sheet or thermoplastic resin fiber,
The manufacturing method includes:
Heating the thermoplastic resin member;
Setting the semi-rigid urethane core layer and the heated thermoplastic resin member in a mold;
A step of crimping the semi-rigid urethane core layer in the mold and the heated thermoplastic resin member by the molding die,
The semi-rigid urethane core layer is formed by slicing a block-like material produced by reaction / foaming of the raw material, so that the bubble cell on the surface of the layer has the same size as the bubble cell inside the layer. And the bubble cell on the surface of the layer is in a form communicating with the outside through the bubble cell inside the layer,
During the crimping, the air in the bubble cell on the surface of the semi-rigid urethane core layer is discharged to the outside through the bubble cell inside the semi-rigid urethane core layer, so that a part of the thermoplastic resin member becomes the semi-rigid An interior part for an automobile characterized in that the thermoplastic resin member and the semi-rigid urethane core layer are integrated with each other by accelerating the phenomenon of entering into the bubble cell on the surface of the urethane core layer, and the anchor effect due to the penetration. Manufacturing method.   The raw material consists of polyol and isocyanate,
  By setting the blending ratio of the polyol and the isocyanate to 100 parts by weight: 150 to 170 parts by weight, the bubble cell on the surface of the layer is configured to communicate with the outside through the bubble cell inside the layer.
  The manufacturing method of the interior component for motor vehicles of Claim 3 characterized by these.

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