JP5774385B2 - Method for manufacturing vehicle interior material - Google Patents

Description

  The present invention relates to a method for manufacturing a vehicle interior material. More specifically, in the present invention, when the holding member is provided on the surface of the base material of the interior material by an injection molding method, it is assumed that the holding member is warped due to shrinkage of the molten resin in the cooling process after molding. The present invention relates to a method for manufacturing an interior material for a vehicle that suppresses warping of a holding member and a base at the periphery of the holding member by recessing a predetermined portion in advance.

  In the vehicle interior material, a holding member such as a side clip or a retainer bracket for attaching the interior material to the vehicle panel is attached to a surface opposite to the vehicle compartment side. Conventionally, this holding member has been bonded and fixed to the interior material surface with an adhesive or the like in the past, but not only requires an adhesive, but also sets the holding member and applies the adhesive. In addition, considerable labor and time are required for holding until cooling after coating. Therefore, a method has been proposed in which resin is directly injected onto the surface of the interior material to mold the holding member, and the surface is joined and fixed to the surface of the interior material.

  For example, a molded body is joined to a base body such as a fiber board by a thermoplastic resin material, and a joint portion has a linear portion extending on the joint surface of the base body, and a branch projecting from the linear portion onto the joint surface. A molded structure formed by a portion is known (for example, see Patent Document 1). Further, there is known a molding method of a resin molded body in which a molding die having a specific cavity is used to mold a resin molded body, and a part of a molten resin is led out and bonded onto a molding target (for example, , See Patent Document 2).

Japanese Patent Laid-Open No. 2006-212824 JP 2006-142746 A

  As described above, the method of injecting resin directly on the surface of the interior material and molding the holding member, for example, the method described in Patent Documents 1 and 2, can simplify the process, The holding member can be joined with sufficient strength. However, particularly in the case of interior materials with relatively low rigidity among various interior materials such as roof trims, the retaining member and the base of the periphery thereof are formed by the shrinkage of the molten resin in the cooling process after molding. May be warped (see FIG. 11, which is a schematic diagram of a partial cross section of the vehicle interior material 101 that has warped).

  The present invention has been made in view of the above-described prior art, and is caused by shrinkage of the molten resin in the cooling process after molding when a holding member is provided on the surface of the base material of the interior material by an injection molding method. An object of the present invention is to provide a method for manufacturing an interior material for a vehicle that suppresses warping of the holding member and its peripheral edge by pre-depressing a predetermined portion of the surface of the base body, assuming warpage of the holding member.

The present invention is as follows.
1. A flexible substrate;
A vehicle interior material manufacturing method comprising: a holding member provided on a surface of the base body for attaching the base body to a vehicle panel;
The holding member includes a seat part joined to the surface of the base body, and a fitting part integrally formed with the seat part, and the planar shape of the seat part is rectangular,
The holding member is formed by injection molding in which a molten resin is poured into the concave portion, with the molding die having the concave portion being in a state where the concave portion is applied to the surface of the base body,
Of the end surfaces of the mold that come into contact with the surface of the base, the tip corresponding to the short side of the seat, which is the end surface for denting the base, is another part corresponding to the long side. More prominent,
The tip is narrow toward the tip,
A vehicle interior characterized in that the injection molding is performed in a state where a portion corresponding to the edge of the holding member of the base body is compressed and deformed in the thickness direction by the tip portion of the molding die. A method of manufacturing the material.
2. The amount by which the base body is compressed and deformed is set such that the amount by which the molten resin shrinks and the base body warps when the molten resin is cooled and the holding member is formed is substantially offset. 1. The manufacturing method of the interior material for vehicles as described in any one of.
3. The holding member includes a seat part joined to the surface of the base body, and a fitting part formed to protrude from the seat part to the side away from the surface of the base body,
The seat section when the seat section is virtually cut by a plane orthogonal to the surface of the base while avoiding the fitting section, has a portion that becomes gradually thinner toward the end. The inclined surface is formed in the concave portion of the mold. Or 2. The manufacturing method of the interior material for vehicles as described in any one of.
4). 2. The inclined surface is formed in the concave portion of the mold so that the entire cross section of the seat portion becomes gradually thinner toward the end. The manufacturing method of the interior material for vehicles as described in any one of.

In the method for manufacturing a vehicle interior material according to the present invention, when the molten resin is injected onto the surface of the base body, it is assumed that the holding member is warped due to the shrinkage of the molten resin in the cooling process after molding, and a predetermined portion of the base surface Is recessed in advance. As a result, a molded body warped in a direction opposite to the warp of the holding member after cooling (after cooling, becomes a holding member) is formed, and the holding member of the holding member after cooling and the base of the periphery thereof is formed. Warpage to the surface side is suppressed. In addition, the time required for forming the holding member can be shortened and productivity can be improved as compared with a method in which a preformed part is bonded to the substrate surface and fixed.
Further, the amount by which the base is compressed and deformed is set so that the amount by which the molten resin contracts and the holding member warps when the molten resin is cooled to form the holding member is substantially offset. In this case, the warp of the holding member and the substrate is further suppressed.
Furthermore, the holding member includes a seat portion joined to the surface of the base body, and a fitting portion formed so as to protrude to a side farther from the surface of the base body than the seat portion, and the seat portion while avoiding the fitting portion. An inclined surface is formed in the concave portion of the mold so that the cross section of the seat portion when virtually cut by a plane orthogonal to the surface of the base has a portion that becomes gradually thinner toward the end. In this case, the warping of the holding member and the substrate can be further suppressed by the synergistic effect of the specific shape of the seat portion and the depression of the predetermined portion of the substrate surface in advance during injection molding. Further, since the cross section of the seat portion gradually becomes thinner toward the end, the volume of the holding member is reduced, and the heat capacity is reduced accordingly. As a result, the time required for cooling is shortened, and the occurrence of dents on the design surface on the passenger compartment side is suppressed.

It is a schematic diagram of a partial cross section of a vehicle interior material including a base and a side clip (holding member) provided on the surface of the base. It is a schematic diagram of a part of a cross section of a vehicle interior material provided with a base body and a side clip provided on the surface of the base body and the surface of a seat portion being an inclined surface. It is a typical perspective view of the side clip of FIG. FIG. 5 is a schematic view of each cross section of a mold for molding a part of a base (for example, a roof trim) and a side clip, and a mold surface having an inclined surface. FIG. 5 is a schematic diagram for explaining a state in which the molding die in FIG. 4 is applied to the surface of the base and a predetermined portion of the base is recessed in the thickness direction. In FIG. 5, it is a schematic diagram for demonstrating the state by which molten resin was inject | poured in the shaping | molding die from the resin injection port. It is a schematic diagram for demonstrating a mode that it was demolded from the state of FIG. 6 and the side clip was formed in the base | substrate surface. It is a model of each cross section of the shaping | molding die for shape | molding a part of a base | substrate (for example, roof trim) and a side clip, and a shaping | molding surface is a flat surface. It is a schematic diagram of a part of a cross section of a vehicle interior material provided with a base body and a retainer bracket (holding member) provided on the surface of the base body and the surface of a seat portion being an inclined surface. FIG. 10 is a schematic perspective view of the retainer bracket of FIG. 9. It is a schematic diagram of a cross section of a part of the vehicle interior material that has warped on the surface side on which the holding member is provided due to the shrinkage of the holding member. Schematic of a partial cross section of the interior material for a vehicle in which the thermoplastic resin blended as the binder melts due to heat at the time of molding the holding member, the binding structure is disturbed, and the design surface on the vehicle compartment side is recessed. FIG.

Hereinafter, the present invention will be described in detail with reference to the drawings.
The items shown here are for illustrative purposes and exemplary embodiments of the present invention, and are the most effective and easy-to-understand explanations of the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to illustrate the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention. It will be clear to those skilled in the art how it is actually implemented.

  The vehicle interior material manufactured by the method of the present invention includes a flexible base and a holding member that is provided on the surface of the base and attaches the base to the vehicle panel. Further, in this manufacturing method, the holding member is formed by injection molding in which a molten resin is poured into the concave portion with the molding die having the concave portion in a state where the concave portion is applied to the surface of the substrate. Further, injection molding is performed in a state where a portion corresponding to the edge portion of the holding member of the base body is compressed and deformed in the thickness direction by a molding die.

  A base body 1 (see FIGS. 1, 2, and 9) of the vehicle interior material 100 has a surface on the vehicle panel side and a surface on the vehicle compartment side when attached to the vehicle, and the holding member 2. Is provided on the surface on the vehicle panel side. The holding member 2 is attached to the vehicle panel, and the vehicle interior material 100 is fixed to the vehicle panel.

[1] Holding Member The “holding member 2” usually includes a seat portion 21 joined to the surface of the base body 1 of the vehicle interior material 100, and a fitting portion 22 formed integrally with the seat portion 21 (FIG. 1-3 and FIGS. Moreover, the fitting part 22 is formed in the form protruded in the side spaced apart from the surface of the base | substrate 1 rather than the seat part 21 (refer FIGS. 1-2 and FIG. 9).

  The holding member 2 is formed on the surface of the substrate 1 by an injection molding method using a molten resin. That is, the molten resin is directly injected onto the surface of the substrate 1 and cooled to form the holding member 2. In such a method, a molten resin is usually injected into a space formed between the inner wall surface of the mold and the substrate surface from an injection molding machine in which movement in the three-dimensional direction is controlled. A required number of holding members 2 are continuously formed at predetermined locations.

  In the “injection molding”, the mold 200 having the recess 3 (see FIGS. 4 to 8) is placed in a state where the recess 3 is in contact with the surface S of the substrate 1, and the molten resin is poured into the recess 3, and then cooled. By doing so, the holding member 2 is formed. At this time, a portion of the substrate 1 corresponding to the edge of the holding member 2 is injection-molded in a state where the portion is compressed and deformed in the thickness direction by the molding die 200 (the substrate surface in FIGS. 5 and 6 is recessed). (See part S1). In this way, by pre-depressing a predetermined portion of the substrate surface, the molded body (which becomes the holding member 2 after cooling) is warped in the opposite direction to that during the cooling process at the time of injection. It becomes. For this reason, even if the molded body warps along with the temperature drop during the cooling process, the holding member 2 can be provided with no warping or at least sufficiently curving after cooling.

The portion of the base body 1 corresponding to the edge of the holding member 2 and compressed and deformed in the thickness direction by the molding die 200 is preferably set by the planar shape of the seat portion 21. For example,
(1) When the planar shape of the seat portion 21 is a rectangle, the edges are opposite short sides,
(2) When the planar shape of the seat portion 21 is a square,
(3) When the planar shape of the seat portion 21 is a circle or an ellipse,
Note that the planar shape of the seat 21 (1) When a shape other than a - (3) by its shape, rather I if the direction of the edge or periphery and predicted that it would most warped, the seat The planar shape of the portion 21 is usually the shape of (1) to (3), but in the present invention, it is the shape of (1).

Furthermore, when the planar shape of the seat portion 21 is the rectangle of (1), the predetermined portion of the base body 1 that is compressed and deformed is discontinuous (only the short side is recessed, and the long side is not recessed). .) In such a case, the end face for recessing the base body 1 among the end faces in contact with the surface S of the base body 1 of the molding die 200 needs to protrude from other places (the moldings of FIGS. 4 to 8 ). (See mold tip 4). On the other hand, when the planar shape of the seat portion 21 is the square of (2), the circle of (3), etc., the predetermined portion to be recessed by compressive deformation of the base body 1 is continuous, and the base body 1 is recessed. It is not necessary to project a part of the end face of.

  Moreover, the front-end | tip part 4 for denting the base | substrate 1 of the shaping | molding die 200 is narrow toward the front-end | tip, ie, the front-end | tip part 4 is sharp (refer FIGS. 4-8). If the tip portion 4 is sharp, the base body 1 can be easily recessed with a small pressing force, can be easily recovered after molding, and the remaining of the recess can be sufficiently suppressed.

  Furthermore, the amount by which the base body 1 is compressed and deformed is not particularly limited as long as the holding member 2 is free of warp or at least sufficiently warped after cooling. In this way, the amount to be recessed is too large or too small, and is set so that the molten resin is cooled and contracted in the process of forming the holding member 2 and the amount by which the holding member 2 warps is substantially offset. It is preferable. Specifically, when the amount by which the base member 1 is compressed and deformed is expressed as a percentage with respect to the amount by which the holding member 2 warps (the estimated amount of the warping amount described below can be used), 80 to 120%. In particular, it is preferably 90 to 110%, more preferably 95 to 105%.

  The amount by which the resin shrinks during the cooling process after the molding described above and the holding member 2 and the base 1 at the periphery thereof warp can be estimated in advance by CAE analysis. In this case, for example, using an analysis program (for example, “Autodesk Moldflow” manufactured by Autodesk), the shape and dimensions of the holding member 2, the type of resin used for molding the holding member 2, and molding conditions during injection molding By performing a simulation based on the above, the amount of warping can be estimated. In this way, the amount of warping is estimated, and this estimated amount and the amount by which the substrate 1 is recessed are approximately the same amount, that is, the amount by which the molten resin contracts to the amount by which the substrate 1 is recessed. Is set to be substantially offset. If it does in this way, it can be easily set as the holding member 2 without a curvature, or at least the curvature was fully suppressed.

  Further, in the present invention, as described above, the holding member 2 is usually formed so as to protrude from the seat portion 21 bonded to the surface of the base body 1 to the side away from the surface of the base body 1 rather than the seat portion 21. The fitting part 22 is provided. Furthermore, the plane 21 perpendicular to the surface S (see FIGS. 1, 2 and 9) of the base 1 is avoided while the seat portion 21 of the holding member 2 avoids the fitting portion 22 [for example, the phantom line (2 in FIG. 3 and FIG. 10). The cross section of the seat when virtually cut by the plane P including the dotted line a)] may be a flat surface (see FIG. 1), or may have a portion that becomes gradually thinner toward the end. Good (see FIGS. 2, 3 and 9, 10).

The above-mentioned “cutting while avoiding the fitting portion 22” means that when the seat portion 21 is virtually cut, the plane P perpendicular to the surface S of the base body 1 is a boundary line between the seat portion 21 and the fitting portion 22. This means that the seat portion 21 is cut in a direction perpendicular to the surface of the base body 1 in contact with or outside the boundary line. The position of this cutting is not particularly limited as long as the fitting portion 22 is avoided, but it is preferable that the plane P is a position in contact with the boundary line between the seat portion 21 and the fitting portion 22. ,
(1) When the planar shape of the seat portion 21 is a rectangle, the virtual line is in contact with the boundary line between the seat portion 21 and the fitting portion 22 and parallel to the long side (see the two-dot chain line a in FIGS. 2 and 9). Is cut along a plane P (see plane P in FIGS. 2 and 9).
(2) When the planar shape of the seat portion 21 is a square, the seat portion 21 is cut by a plane P that is in contact with the boundary line between the seat portion 21 and the fitting portion 22 and includes a virtual line a parallel to one side.
(3) When the planar shape of the seat part 21 is an ellipse, it cut | disconnects by the plane P which contact | connects the boundary line of the seat part 21 and the fitting part 22, and contains the virtual line a parallel to a major axis.
(4) When the planar shape of the seat portion 21 is circular, the plane P includes a virtual line a that is in contact with the boundary line between the seat portion 21 and the fitting portion 22 and has the longest radial length of the cut surface. Cut with.
(5) When the planar shape of the seat portion 21 is a shape other than the above (1) to (4), it is in contact with the boundary line between the seat portion 21 and the fitting portion 22 and the width direction of the cut surface (the seat portion 21). It is assumed that cutting is performed by the plane P including the virtual line a having the longest length in the direction perpendicular to the thickness direction of the first layer.
The seat section is assumed to be a section when the seat section 21 is virtually cut as described in (1) to (5) above.

  It is preferable that the cross section of the seat when the seat 21 is virtually cut has a portion that becomes gradually thinner toward the end. The seat section may have a configuration in which the entire section of the seat section becomes gradually thinner toward the end, or may have a configuration in which a gradually thinned portion and a gradually thickened portion are continuously provided, and a configuration in which the thickness is further repeated. But you can. The seat section is preferably in a form that the structure of the mold is simplified, and that the entire section of the seat section becomes gradually thinner toward the end in terms of ease of molding, for example, It can be set as the holding member 2 in which the surface of the seat part 21 became the inclined surface (refer FIG. 2, 3 and FIG. 9, 10). Moreover, it can also be set as the holding member 2 which has a concave curved surface on the surface of the seat part 21, and can also be set as the holding member 2 which has a convex curved surface on the surface of the seat part 21.

  As described above, if the cross section of the seat has a portion that becomes gradually thinner toward the end, the surface side capable of free shrinkage shrinks in the cooling process after injection molding, and is bonded to the surface of the base 1. Even if the joint surface side that cannot be freely contracted hardly contracts, warpage of the holding member 2 to the surface side is suppressed, and thus warpage of the base 1 at the periphery of the holding member 2 is also suppressed. In this way, in addition to pre-depressing a predetermined portion of the substrate surface during injection molding, the holding member 2 and its peripheral edge can be obtained by forming the seat portion 21 having a portion that becomes gradually thinner toward the end of the cross section. The warp of the substrate 1 can be more sufficiently suppressed.

  Furthermore, if the holding member 2 has a seat section as shown in FIGS. 2, 3, 9, and 10, the seat section has a portion that becomes gradually thinner toward the end. Compared to when the cross-sectional thickness is substantially the same in the length direction (see FIG. 1), the volume of the holding member 2 is reduced and the heat capacity is reduced. Therefore, the temperature can be lowered more quickly after injection molding, and the amount of heat transmitted to the base 1 can be reduced. As a result, the depression in the design surface on the vehicle compartment side (see the depression 1a in FIG. 12), which occurs due to the thermoplastic resin blended as the binder in the substrate 1 being melted and the binding structure being disturbed, is sufficiently suppressed. .

  The raw material resin used for molding the holding member 2 is not particularly limited, and various thermoplastic resins can be used. The thermoplastic resin is not particularly limited. Polyolefin resins such as polypropylene and high-density polyethylene, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyamide resins such as nylon 6 and nylon 66, polymethyl Various thermoplastic resins such as polyacrylic resins such as methacrylate are exemplified.

  Examples of the thermoplastic resin include polyolefin-based resins that are easy to be injection-molded and can be used as the holding member 2 having sufficient strength, particularly polypropylene-based resins such as propylene homopolymers and ethylene / propylene block copolymers. preferable. The thermoplastic resin usually contains various antioxidants, UV absorbers, lubricants, antistatic agents, pigments, fillers, flame retardants, flame retardant aids, and the like. These other components may be used alone or in combination of two or more.

[2] Substrate The “base 1” is the skin layer 12 that forms the design surface on the side of the passenger compartment, the base material layer 11, the skin layer 12 and the base material layer for maintaining the shape of the interior material and imparting strength. 11 and an adhesive film layer 13 having air permeability and functioning as a sound absorbing layer. Further, the air-proofing film is usually laminated on the surface of the base material layer 11 opposite to the skin layer 12 to prevent air and prevent dust and the like from adhering to the surface of the skin layer 12 that is the design surface. The layer 14 and the air barrier film layer 14 are laminated on the surface opposite to the base material layer 11, and are also provided with a nonwoven fabric layer 15 for facilitating handling of the substrate 1 during heating, pressure molding, and the like (FIG. 1, 2 and 9).

  The skin layer 12 can be formed using various woven fabrics, leathers, knitted fabrics, nonwoven fabrics, thermoplastic elastomer sheets, vinyl chloride leathers, and the like. Although the thickness of this skin layer 12 is not specifically limited, For example, it can be set as 0.5-3.0 mm, especially about 1.0-2.0 mm. In addition, the vehicle interior material 100 is usually arranged so that the skin layer 12 faces the vehicle compartment side, and the outer surface of the skin layer 12 becomes the design surface of the vehicle interior material 100.

The base material layer 11 is a layer that supports other layers such as the skin layer 12, and the vehicle interior material 100 has sufficient strength, buffering property, and the like by the base material layer 11. The base material layer 11 only needs to have sufficient rigidity to support the entire vehicle interior material, and the material is not particularly limited. For the formation of the base material layer 11, moldability, physical properties, etc. In view of the above, a nonwoven fabric or a resin foam is often used. The thickness of the base material layer 11 is not particularly limited, but may be 1.0 to 7.0 mm, particularly 2.0 to 4.0 mm, and further 2.0 to 3.0 mm. When the thickness is 1.0 to 7.0 mm, particularly 2.0 to 3.0 mm, the base material layer 11 can sufficiently support other layers such as the skin layer 12. Although not particularly limited weight per unit area of the base material layer 11, 200 to 800 g / ^{m 2,} in particular 300 to 600 g / ^{m 2,} can be further and 400-600 g / ^{m 2.} If the basis weight of the base material layer 11 is 200 to 800 g / m ² , particularly 400 to 600 g / m ² , the vehicle interior material 100 can have a sufficient strength and can be light.

When the base material layer 11 is made of a nonwoven fabric, the nonwoven fabric is not particularly limited. For example, the nonwoven fabric has inorganic fibers and / or natural fibers and a thermoplastic resin that binds at least a part of the entanglement points of these fibers. Can be used.
Examples of the inorganic fiber include glass fiber, carbon fiber, and metal fiber. Of these, glass fibers and / or carbon fibers are preferred. Only one type of inorganic fiber may be used, or two or more types may be used. Examples of natural fibers include plant fibers such as kenaf, hemp, cotton, palm fiber, and here palm fibers, and animal fibers such as silk and wool. Of these, hemp is preferred. Only one type of natural fiber may be used, or two or more types may be used. Furthermore, inorganic fibers and natural fibers can be used in combination. These inorganic fibers and natural fibers are usually fibrillated long fibers.

  The thermoplastic resin is mixed with inorganic fibers and / or natural fibers in the form of fibers, powders, etc., and melts when the formed web is heated and pressurized, and the molten thermoplastic resin allows the inorganic fibers and / or Or the entanglement point of a natural fiber is bound. This thermoplastic resin is not particularly limited, and polyolefin resins such as polypropylene and polyethylene; acrylic resins such as polymethyl acrylate and polymethyl methacrylate; polyamide resins such as nylon-6 and nylon-66; and polyethylene terephthalate Examples thereof include polyester resins. Of these, polyolefin resins, particularly polypropylene resins such as polypropylene homopolymers are preferred. Only one type of thermoplastic resin may be used, or two or more types may be used in combination. In this thermoplastic resin, additives usually used for this type of resin such as an antioxidant, an ultraviolet absorber, a lubricant, and an antistatic agent are blended and contained as necessary.

  Thermally expandable microcapsules can be blended in the nonwoven fabric to be the base material layer 11. In this case, the vehicle interior material 100 can be made lighter by expanding the thermally expandable microcapsules during heating and pressurization in the molding process of the base body 1 of the vehicle interior material 100. Thermally expandable microcapsules usually contain volatile hydrocarbons such as butane and isobutane in the outer shell, and the outer shell contains vinylidene chloride-acrylonitrile copolymer, polyvinyl chloride, polyvinylidene chloride, polyacrylic. It is composed of nitrile or the like.

  The heat-expandable microcapsule is generally spherical with a diameter of 10 to 100 μm, particularly about 20 to 80 μm, and expands 4 to 30 times by heating to a temperature range exceeding the thermal expansion start temperature. The diameter after the body expansion depends on the diameter before the body expansion and the expansion ratio, but is, for example, 40 to 600 μm, particularly 60 to 400 μm. By using such a heat-expandable microcapsule, the base material layer 11 can be reduced in weight, and since it has a porous structure, the vehicle interior material 100 having sufficient sound absorption and the like can be obtained. .

The base material layer 11 can also be formed of a resin foam, particularly a polyurethane foam. The polyurethane foam layer used as the base material layer 11 uses foam raw materials containing polyol, polyisocyanate, crosslinking agent, catalyst, foaming agent, foam stabilizer, etc., foamed by a conventional method, and has a predetermined dimension from the molded slab foam. It can produce by methods, such as cutting out so that it may become. In addition to the various components described above, various additives such as antioxidants, ultraviolet absorbers, fillers, internal mold release agents, flame retardants and the like can be blended in the foam raw material as necessary. .
In addition, the polyurethane foam used for the base material layer 11 is thermosetting, and a dent is not usually produced on the surface of the base body 1 by heat at the time of forming the holding member 2.

  Furthermore, in this base | substrate 1, the air-permeable film layer 14 can be provided in the surface on the opposite side to the surface to which the skin layer 12 of the base material layer 11 is joined (refer FIG.1, 2 and 9). Although this air-blocking film layer 14 is not particularly limited, films made of various synthetic resins such as polyolefin resins such as polypropylene, polyamide resins, polyester resins, and laminated films, for example, polyolefin resin films and polyamide resins It can be formed by a laminated film with a film. Thereby, the ventilation | gas_flowing over the thickness direction of the vehicle interior material 100 is interrupted | blocked or at least suppressed, the dust etc. which adhere to the surface of the skin layer 12 are reduced, and the more excellent design property is maintained. The interior material 100 can be used.

  Moreover, the nonwoven fabric layer 15 can also be provided in the surface opposite to the surface joined to the base material layer 11 of the air-permeable film layer 14 (refer FIG.1, 2 and 9). Although this nonwoven fabric layer 15 is not particularly limited, a thermoplastic resin fiber or powder is blended with inorganic fiber, natural fiber, etc., mixed by needling, etc., heated, pressurized, and entangled with inorganic fiber, natural fiber, etc. Can be formed using a general nonwoven fabric such as a nonwoven fabric bound by a thermoplastic resin. Thereby, it can be set as the base | substrate 1 which is easy to handle at the time of heat-press molding of the base | substrate 1, etc., and when providing the holding member 2, etc., and workability | operativity can be improved.

  The manufacturing method of the vehicle interior material 100 of the present invention is not particularly limited, and can be manufactured by a normal method such as a vacuum forming method. As this vacuum forming method, for example, a sheet preliminarily formed into a desired shape (for example, a fiber board made of a heat-compressed nonwoven fabric, which becomes the base material layer 11) is heated. A method of laminating a multilayer sheet of a skin material (becomes the skin layer 12) and an adhesive film (becomes the adhesive film layer 13) at the same time as vacuum forming is mentioned.

  Further, the vacuum forming method includes a convex drawing vacuum forming method, a concave drawing vacuum forming method, a vacuum forming method using both of these methods, a method of forming by means of plug assist etc. simultaneously with the convex drawing vacuum forming, and upper and lower molds. Various methods such as a vacuum forming method in which vacuuming is performed at the same time as pressing with a mold are included. Moreover, it can also be vacuum-formed using the preformed sheet | seat which laminated | stacked the ventilation stopper film and the nonwoven fabric previously on the fiber board etc. which become the base material layer 11 previously. Thereby, in addition to each above-mentioned layer, the interior material 100 for vehicles which has the ventilation film film layer 14 and the nonwoven fabric layer 15 together can be manufactured.

Hereinafter, the present invention will be specifically described with reference to Examples (see FIGS. 1 to 3 and FIGS. 4 to 8 ).
Example 1
Polypropylene (manufactured by Prime Polymer Co., Ltd., trade name) is applied to a predetermined portion of the surface of the nonwoven fabric layer 15 of the substrate 1 having a thickness of 5.0 mm manufactured by a conventional method using an injection molding machine in which movement in a three-dimensional direction is controlled. “LA880”) was sequentially injected at a temperature of 200 ° C. (set temperature of the cylinder of the molding machine). Further, at the time of injection molding, a molding die in which the surface of the seat portion 21 is a flat surface as shown in FIG. 8 is used, and the seat portion 21 (the planar shape is a rectangle) of the holding member 2 of this molding die. The surface of the nonwoven fabric layer 15 of the base body 1 was pressed and recessed by 2.0 mm with the tip portions corresponding to both short sides. After injection, it was naturally cooled and cooled to room temperature (25 to 30 ° C.), the holding member 2 was formed on the surface of the base 1, and the vehicle interior material 100 was manufactured (see FIG. 1).

  The planar shape of the seat portion 21 of the formed holding member 2 is a rectangle, the seat portion 21 has a long side of 66 mm and a short side of 22 mm, and has a dimension in the long side direction of 19 to 20 mm and a height at a substantially central portion. Is provided with a fitting portion 22 having a shape as shown in FIG. Further, the entire cross section of the seat section (the section when the seat section is virtually cut by the plane P including the two-dot chain line a in the same manner as in FIG. 3 in which the seat section has an inclined surface) is the same thickness. The thickness was 2.0 mm.

Example 2
4 to 7, the mold of the seat portion 21 having an inclined surface is used, and the cross section of the seat portion (the cross section when virtually cut by the plane P including the two-dot chain line a in FIG. 3). The vehicle interior material 100 was manufactured in the same manner as in Example 1 except that the sloped surface gradually decreased from the boundary with the fitting portion 22 toward the end (see FIG. 2). The thickness of the boundary portion between the seat section and the fitting portion 22 was 2.0 mm, and the thickness of the end portion was 0.2 mm.

Comparative Example 1
Other than not having the pointed portion 4 at the tip, a mold having the same structure as in FIG. 8 was used, the surface of the nonwoven fabric layer 15 was not pressed during the injection molding, and the base 1 was not recessed. Were manufactured in the same manner as in Example 1 and evaluated in the same manner. The planar shape of the holding member 2 and the thickness of the seat portion 21 are the same as in the first embodiment.

[1] Evaluation of vehicle interior material The degree of warpage and dent after cooling was evaluated.
(1) Warpage Warpage is such that the side where the planar shape peeled off from the base body 1 is the joint surface with the base body 1 of the rectangular holding member 2 is in contact with the center of the long side on the plane, Evaluation was made based on the distance between the bottom surface and the flat surface at both ends in the long side direction when the bottom surface and the flat surface at both ends in the long side direction were placed at an equal distance.
(2) Recess A recess is a skin layer that becomes a design surface on the vehicle compartment side when the vehicle interior material 100 is cut in the cross-sectional direction at the position where the holding member 2 is provided and the cut surface is observed with an optical microscope. Evaluation was made based on the maximum depth of the recesses formed on the 12 side.

[2] Evaluation Results As a result of the evaluation as described above, the warpage was about 2.0 mm or less in Comparative Example 1 whereas it was 0.5 mm or less in Example 1 (4 in the same manner as in Example 1). When the vehicle interior material 100 was manufactured, warpage was 0.5 mm at the maximum and 0.0 mm at the minimum, and 0.4 mm or less in Example 2 (four vehicle interior materials as in Example 2). When 100 was manufactured, the warp was 0.4 mm at the maximum and 0.0 mm at the minimum. Thus, it turns out that curvature is reduced significantly by denting the predetermined site | part of a base | substrate at the time of injection molding. Further, it can be seen that the warpage can be greatly reduced by making the seat portion 21 having a specific cross-sectional shape while the predetermined portion of the base is recessed at the time of injection molding.

  Further, the recesses were 0.1 to 0.3 mm in Comparative Example 1 (when four vehicle interior materials 100 were manufactured in the same manner as in Comparative Example 1, the recesses were 0.3 mm at the maximum and 0.1 mm at the minimum. In Example 1, 0.0 to 0.2 mm (when four vehicle interior materials 100 were manufactured in the same manner as in Example 1, the dent was 0.2 mm at the maximum and 0.0 mm at the minimum). In contrast, in Example 2, substantially no dent was observed. This is because the volume of the holding member decreases, so that the temperature is quickly lowered after molding, and the amount of heat transmitted to the inside of the substrate is reduced.

  It should be noted that the above description is for illustrative purposes only and is not to be construed as limiting the invention. Although the invention has been described with reference to exemplary embodiments, it is to be understood that the language used in the description and illustration of the invention is illustrative and exemplary rather than restrictive. As detailed herein, modifications may be made in the embodiments within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials, and embodiments have been referred to in the detailed description of the invention herein, it is not intended to limit the invention to the disclosure herein, but rather, the invention is claimed. It covers all functionally equivalent structures, methods and uses within the scope.

  The method for manufacturing a vehicle interior material according to the present invention can be used in the technical field of manufacturing various vehicle interior materials. Examples of the vehicle interior material include a roof trim, a floor trim, and a door trim. The method for manufacturing a vehicle interior material according to the present invention is particularly useful in the technical field of a roof trim, which is a relatively large molded product and has a lower rigidity than other interior materials.

  DESCRIPTION OF SYMBOLS 100; Interior material for vehicles, 101; Interior material for vehicles warped centering on holding member, 102; Interior material for vehicles in which dent was produced in design surface of vehicle interior side, 1; Base, 11; Base material layer , 12; skin layer, 13; adhesive film layer, 14; air-permeable film layer, 15; non-woven fabric layer, 1a; dent generated on the design surface on the passenger compartment side; 2; holding member, 21; Insertion part, 200; mold, 3; recess, 4; tip part of mold, 5; resin injection port.

Claims (4)

A flexible substrate;
A vehicle interior material manufacturing method comprising: a holding member provided on a surface of the base body for attaching the base body to a vehicle panel;
The holding member includes a seat part joined to the surface of the base body, and a fitting part integrally formed with the seat part, and the planar shape of the seat part is rectangular,
The holding member is formed by injection molding in which a molten resin is poured into the concave portion, with the molding die having the concave portion being in a state where the concave portion is applied to the surface of the base body,
Of the end surfaces of the mold that come into contact with the surface of the base, the tip corresponding to the short side of the seat, which is the end surface for denting the base, is another part corresponding to the long side. More prominent,
The tip is narrow toward the tip,
A vehicle interior characterized in that the injection molding is performed in a state where a portion corresponding to the edge of the holding member of the base body is compressed and deformed in the thickness direction by the tip portion of the molding die. A method of manufacturing the material.   The amount by which the base body is compressed and deformed is set such that the amount by which the molten resin shrinks and the base body warps when the molten resin is cooled and the holding member is formed is substantially offset. The method for manufacturing a vehicle interior material according to claim 1. The holding member includes a seat part joined to the surface of the base body, and a fitting part formed to protrude from the seat part to the side away from the surface of the base body,
The seat section when the seat section is virtually cut by a plane orthogonal to the surface of the base while avoiding the fitting section, has a portion that becomes gradually thinner toward the end. The method for manufacturing an interior material for a vehicle according to claim 1, wherein an inclined surface is formed in the recess of the mold. The method for manufacturing an interior material for a vehicle according to claim 3, wherein an inclined surface is formed in the concave portion of the mold so that the entire cross section of the seat portion becomes gradually thinner toward the end.

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