JP5880926B2 - Method for manufacturing vehicle interior material - Google Patents

Description

  The present invention relates to a vehicle interior material.

  As an interior material for a vehicle, for example, one disclosed in Patent Document 1 below is known. Patent Document 1 discloses a vehicle interior material in which a cushion layer (cushion foam) and a skin layer (skin) are laminated on a base material (door panel).

JP 2008-265747 A

  In the above configuration, a skin structure comprising a cushion layer and a skin layer is set in an injection mold, and a base material is integrally formed with the skin structure by injecting a molten resin onto the back surface of the cushion layer. One-piece injection molded products are known. In such a skin-integrated injection-molded product, when the molten resin constituting the base material oozes out to the skin layer, the design property is lowered, and there is a problem in quality. In order to prevent such a situation, for example, a nonwoven fabric is pasted on the back side of the cushion layer. The molten resin is blocked by the non-woven fabric, and the situation of bleeding into the skin layer is suppressed.

  However, in a nonwoven fabric, there is a concern that the molten resin passes through gaps between fibers. In particular, when the base material has a corner and the skin structure is arranged so as to cover the corner, in the vicinity of the corner, the skin structure is curved so as to follow the shape of the corner. It is stretched. Thereby, the clearance gap between the fibers of a nonwoven fabric becomes large (opening), and it becomes easy for molten resin to pass a nonwoven fabric. As a result, the molten resin is likely to exude into the skin layer. It is known that such a situation is particularly likely to occur when the corner radius of curvature is small. This is because if the radius of curvature of the corner portion is small (that is, the corner portion has a sharp shape), the skin structure is further expanded to follow the shape of the corner portion.

  This invention was completed based on the above situations, Comprising: Providing the interior material for vehicles which can suppress more reliably the situation which resin which comprises a base material oozes out into a skin layer. Objective.

  In order to solve the above-described problem, an interior material for a vehicle according to the present invention includes a base material having a plate shape, and a skin structure disposed so as to cover at least a part of a surface on the front side of the base material. The skin structure includes a skin layer constituting a design surface of the skin structure, a cushion layer interposed between the skin layer and the base material, and between the cushion layer and the base material A non-breathable layer interposed and non-breathable; a first adhesive layer interposed between the non-breathable layer and the substrate; and bonding the non-breathable layer and the substrate; and the non-breathable layer And a second adhesive layer that is interposed between the non-breathing layer and the cushion layer.

  In the vehicle interior material of the present invention, the base material, the first adhesive layer, the non-breathable layer, the second adhesive layer, the cushion layer, and the skin layer are laminated in this order. Thereby, the base material is molded by injecting the molten resin to the back side (the side where the base material is disposed) of the first adhesive layer, and at the same time, the base material and the skin structure are bonded via the first adhesive layer. It can be performed. Thereby, the vehicle interior material can be easily molded. In the present invention, a non-breathable layer is interposed between the base material and the cushion layer. With this non-breathable layer, it is possible to suppress the situation where the injected molten resin reaches the cushion layer (and thus the skin layer) during the molding of the substrate, and the situation where the resin oozes out to the skin layer.

  The said structure WHEREIN: The said base material has the main surface part which has a surface of the said base in the said base, and has an at least 1 base material side corner | angular part, The said skin structure covers the said base material side corner | angular part It has a skin side corner portion, and the skin side corner portion has an arc shape when viewed from the front, and a radius of curvature of 0.5 mm or more and 2 mm or less.

  When covering a base material side corner | angular part with a skin structure like this invention, a skin structure is partially expanded according to the shape of the corner | angular part (it is extended). In this respect, since the present invention includes a non-breathable non-breathable layer, the molten resin may pass through the non-breathable layer even when the skin structure including the non-breathable layer is elongated. Absent.

  For this reason, in the present invention, even when the curvature radius in front view of the skin side corner portion is 2 mm or less, that is, when the skin side corner portion is extended more greatly, the situation where the molten resin oozes out to the cushion layer side. It can be surely suppressed and the quality can be made higher. In addition, the front view said here means the state which looked at the skin structure from the design surface side (more specifically, the direction orthogonal to a design surface) of a skin structure.

  ADVANTAGE OF THE INVENTION According to this invention, the vehicle interior material which can suppress more reliably the situation which the molten resin which comprises a base material oozes out to a skin layer can be provided.

The front view which shows the door trim provided with the ornament which concerns on one Embodiment of this invention The perspective view which shows the state which the base material and the skin structure separated in the ornament provided in the door trim of FIG. The perspective view which shows the ornament provided in the door trim of FIG. Sectional drawing which shows the ornament of this embodiment (corresponding to the figure cut | disconnected by the AA line of FIG. 3) The figure which shows the manufacturing method of the ornament of this embodiment (corresponding to the figure cut | disconnected by the AA line of FIG. 3 before base material shaping | molding) The figure which shows the manufacturing method of the ornament of this embodiment (after base-material shaping | molding) Chart showing the results of summarizing the relationship between the radius of curvature R2 and the exudation of molten resin to the skin layer

  An embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a perspective view showing a vehicle door trim 10 including an ornament 20 that is an interior material for a vehicle according to the present embodiment. As shown in FIG. 1, the door trim 10 includes a main board 12 formed in a plate shape from a synthetic resin or the like. The door trim 10 includes a speaker grill 16 and a door pocket 18.

  An opening 12A having a rectangular shape is formed in the upper portion of the main board 12, and an ornament 20 is attached so as to close the opening 12A. A plurality of mounting holes (not shown) are provided in the peripheral portion of the ornament 20, and pins (not shown) are inserted into the mounting holes around the opening 12 </ b> A on the outer surface of the main board 12. A plurality of Then, after the pins provided on the main board 12 are inserted into the mounting holes of the ornament 20, the head is crushed by an instrument such as ultrasonic vibration or a heat trowel (heat caulking), thereby the main board 12 and the ornament 20. Are connected to each other.

  As shown in FIG. 1, the ornament 20 has a substantially rectangular shape in front view, a plate-shaped base material 30, and a skin structure 40 that covers a front side surface 30 </ b> A of the base material 30 (a surface on the vehicle interior side), (See FIG. 2). The base material 30 is made of, for example, a thermoplastic synthetic resin such as polypropylene (polyolefin resin).

  As shown in FIG. 2, the base material 30 includes a main surface portion 31 constituting the front surface 30 </ b> A of the base material 30, and a standing wall portion 33 erected on the back side (outside of the passenger compartment) from the peripheral end of the main surface portion 31. (The side surface of the base material 30 is configured) and a peripheral wall portion 34 extending from the peripheral edge of the standing wall portion 33 along the extending direction of the main board 12. The above-described mounting holes (not shown) are formed in the peripheral wall portion 34, for example.

  The main surface portion 31 has a substantially square shape when viewed from the front, and has four corner portions. Each of these four corners has a circular arc shape when viewed from the front, and among the four corners, the corner on the upper side and the front side of the vehicle (hereinafter referred to as the base material side corner 31A) is another corner. It is assumed that the radius of curvature R1 is smaller. The curvature radius R1 of the base-side corner portion 31A is set, for example, in the range of 0.5 mm to 2 mm. In addition, the front view said here means the state (state of FIG. 1) which looked at the skin structure 40 from the design surface side (more specifically, the direction orthogonal to the design surface) of the skin structure 40.

  As shown in FIG. 3, the skin structure 40 is configured to cover the main surface portion 31, the standing wall portion 33, and the peripheral wall portion 34 in the base material 30. The skin structure 40 is formed by molding the sheet-like material shown in FIG. 2 into a three-dimensional shape that follows the surface shape of the substrate 30. More specifically, as shown in FIG. 3, the skin structure 40 includes a skin main surface part 40 </ b> A covering the main surface part 31, a skin standing wall part 40 </ b> B covering the standing wall part 33, and a skin peripheral wall part 40 </ b> C covering the peripheral wall part 34. At least.

  That is, the skin structure 40 has a skin side corner 41 that covers the base side corner 31A. More specifically, the skin side corner portion 41 is a corner portion of the skin main surface portion 40A and a boundary portion between the skin main surface portion 40A and the skin standing wall portion 40B, and the vicinity of the skin side corner portion 41 is a base material side corner. The three-dimensional shape is formed to cover the portion 31A.

  The skin side corner portion 41 has a shape corresponding to the shape of the base material side corner portion 31A. That is, the skin side corner portion 41 has an arc shape when viewed from the front, and the curvature radius R2 is set to the same value as the curvature radius R1 (in the range of 0.5 mm to 2 mm).

  As shown in FIG. 4, the skin structure 40 is laminated in the order of the skin layer 42, the cushion layer 43, the second adhesive layer 44, the air-impermeable layer 45, and the first adhesive layer 46 from the front side (upper side in FIG. 4). The first adhesive layer 46 adheres to the surface of the base material 30 (the upper surface in FIG. 4).

  The skin layer 42 constitutes the design surface of the skin structure 40, and is formed of, for example, a fabric. The skin layer 42 is not limited to a fabric, and for example, leather, a synthetic resin sheet, a nonwoven fabric, or the like may be used.

  The cushion layer 43 is interposed between the skin layer 42 and the base material 30, and is disposed on the back side of the skin layer 42. The cushion layer 43 is a soft material made of a foam such as slab urethane. The skin layer 42 and the cushion layer 43 are bonded together by, for example, an adhesive or a frame laminating process. The cushion layer 43 is not limited to slab urethane and can be changed as appropriate.

  The non-breathing layer 45 is disposed on the back side (base material 30 side) of the cushion layer 43 via the second adhesive layer 44. That is, the non-breathing layer 45 is interposed between the base material 30 and the cushion layer 43. The non-breathable layer 45 is formed of a non-breathable film made of, for example, PET (polyethylene terephthalate) or nylon.

  The first adhesive layer 46 is for adhering the non-breathing layer 45 and the base material 30, and is interposed between the non-breathing layer 45 and the base material 30. The second adhesive layer 44 is for bonding the non-breathing layer 45 and the cushion layer 43, and is interposed between the non-breathing layer 45 and the cushion layer 43. For the first adhesive layer 46 and the second adhesive layer 44, for example, an olefin resin film (polypropylene or the like) is used.

  Further, as the first adhesive layer 46 and the second adhesive layer 44, modified polypropylene (maleic anhydride-modified polypropylene) or the like may be used, and thereby the adhesiveness with the non-breathing layer 45 can be further increased. In addition, the 1st contact bonding layer 46 and the 2nd contact bonding layer 44 may use resin films other than a polypropylene, for example, may use polyethylene etc.

  Further, a surface modification treatment may be performed on the front side surface (cushion side surface) of the second adhesive layer 44 by corona discharge or the like. Thereby, the adhesiveness with respect to the cushion layer 43 of the 2nd contact bonding layer 44 can be improved. The first adhesive layer 46, the air-impermeable layer 45, and the second adhesive layer 44 are, for example, a laminated body in which the three layers are integrated in a stage before being bonded to the cushion layer 43 by the second adhesive layer 44. Used in the state.

  The first adhesive layer 46 and the second adhesive layer 44 may be made of different materials. However, if the first adhesive layer 46 and the second adhesive layer 44 are made of different materials, the laminate composed of the first adhesive layer 46, the non-breathing layer 45, and the second adhesive layer 44 is likely to curl and be handled. It becomes difficult. For this reason, in order to suppress the situation where the laminated body curls, it is preferable that the first adhesive layer 46 and the second adhesive layer 44 are made of the same material as in the present embodiment.

  Next, the manufacturing method of the ornament 20 of this embodiment is demonstrated using FIG.5 and FIG.6. The ornament 20 is manufactured using a molding die 50 including a core die 51 and a cavity die 52 as shown in FIG. 5, and by injecting molten resin to the back side of the skin structure 40, simultaneously with the molding of the base material 30. The skin structure 40 and the base material 30 are manufactured by an integral molding method.

  As shown in FIG. 5, the core mold 51 is formed with a protrusion 51 </ b> A having a shape corresponding to the back surface shape of the ornament 20, and the cavity mold 52 corresponds to the surface (design surface side) shape of the ornament 20. A recess 52A having a shape is formed. First, as shown in FIG. 5, the core mold 51 and the mold 52 are clamped, and the skin structure 40 is set in the recess 52 </ b> A of the mold 52.

  Thus, a cavity 53 (molding space) for molding the base material 30 is formed between the back surface of the skin structure 40 and the core mold 51. The skin structure 40 is preformed in a shape that matches the shape of the recess 52A (the shape of the base material 30) in the step (preliminary shaping step) prior to setting in the mold 52. Alternatively, the mold cavity 52 may be a vacuum mold, and the skin structure 40 may be molded into the shape of the recess 52 </ b> A by evacuating the cavity mold 52.

  Next, molten resin is injected into the cavity 53 from an injection device (not shown) through a sprue 54 formed in the core mold 51. At this time, as a result of the first adhesive layer 46 being melted by the high-temperature molten resin, the molten resin and the first adhesive layer 46 are bonded. When the molten resin in the cavity 53 is cooled and solidified, the base material 30 is formed. As a result, as shown in FIG. 6, the base material 30 and the skin structure 40 are bonded at the same time as the base material 30 is molded, and the ornament 20 is manufactured.

  And in this embodiment, the non-breathing layer 45 is arranged on the base material 30 side in the skin structure 40. For this reason, when the molten resin is injected into the cavity 53, the non-breathing layer 45 blocks the molten resin (the flow of the molten resin is indicated by the arrow F1 in FIG. 4) toward the skin layer 42 side. For this reason, the situation where the molten resin oozes out to the skin layer 42 can be suppressed. That is, the non-breathing layer 45 is a blocking member that blocks the flow of the molten resin. 5 and 6, the first adhesive layer 46 and the second adhesive layer 44 are not shown.

  As described above, in the ornament 20 of the present embodiment, the skin structure 40 (skin side corner 41) is arranged so as to cover the base side corner 31A of the base 30. As a result, when the skin structure 40 is molded into a three-dimensional shape corresponding to the shape of the base material 30, the skin structure 40 (and thus the non-breathing layer 45) is curved in the vicinity of the skin side corner 41. Stretched.

  For example, when a non-woven fabric is used instead of the non-breathable layer 45, when the non-woven fabric is stretched, the gaps between the fibers constituting the non-woven fabric become larger and the molten resin may pass through the non-woven fabric. However, in the present embodiment, the non-breathable layer 45 having non-breathability is used as a blocking member for blocking the molten resin. If the non-breathable layer 45 has non-breathability, even if it is stretched, the performance of blocking the molten resin does not deteriorate. For this reason, even in the vicinity of the skin side corner portion 41 where the non-breathable layer 45 is extended, the performance of blocking the molten resin does not deteriorate, and the situation where the molten resin oozes out to the skin layer 42 can be more reliably suppressed.

  And the curvature radius R2 of the skin side corner | angular part 41 which covers this becomes small, so that the curvature radius R1 of 31 A of base material side corner | angular parts is small. As a result, in the skin side corner portion 41, the blocking member is extended more greatly. That is, in the conventional configuration using a non-woven fabric or the like as the blocking member, the smaller the curvature radius R1 of the base-side corner portion 31A (the curvature radius R2 of the skin-side corner portion 41) is, the more stained the molten resin into the skin layer 42 is. It becomes easy to take out.

  FIG. 7 is a chart showing the results of summarizing the relationship between the radius of curvature R2 and the leakage of the molten resin into the skin layer 42 when various materials are used as the blocking member. The ornament 20 was formed by the above-described integral molding method using various materials as the blocking member. Then, the ornament 20 (base material 30) was sequentially formed with the curvature radius R2 being gradually reduced, and it was examined how small the curvature radius R2 would be when the molten resin oozed out into the skin layer 42.

  Polypropylene is used as the material of the base material 30. The molding conditions are such that the press pressure by the core mold 51 and the mold mold 52 is 100 tons, the temperature of the molten resin injected into the cavity is 180 ° C., the mold mold 52 and the core mold 51 The temperature is 30 ° C., the mold clamping speed of the mold 52 and the core mold 51 is 10 mm / s, the base material weight is 42 g, the molten resin injection time is 1.37 seconds, and the holding pressure is 0.5 at 200 kg / cm 2. Set in seconds. In addition, the said molding conditions are an example, Comprising: The said molding method is not limited to the value mentioned above.

  (A)-(C) in FIG. 7 is a comparative example using a nonwoven fabric as a blocking member. When (A) wet water punch nonwoven fabric is used as the blocking member, in other words, when the wet water punch nonwoven fabric is interposed between the base material 30 and the cushion layer 43, the radius of curvature R2 is made smaller than 4 mm. Thus, the molten resin oozed out into the skin layer 42.

  Further, when (B) a dry water punch nonwoven fabric is used as the blocking member, when the radius of curvature R2 is made smaller than 8 mm, the molten resin oozes out to the skin layer 42, and the basis weight is larger than (B). When (C) dry water punched nonwoven fabric having a small (high air permeability) was used, when the radius of curvature R2 was made smaller than 10 mm, the molten resin oozed into the skin layer 42.

  (D) in FIG. 7 is the configuration of the present embodiment, and PA6 (nylon 6) is used as the non-breathing layer 45 (blocking member) having zero air permeability. Note that modified PP is used as the first adhesive layer 46 and the second adhesive layer 44. In this case, even if the radius of curvature R2 was 2 mm or less, no leakage of the molten resin to the skin layer 42 occurred.

  FIG. 7E shows the configuration of the present embodiment, in which PET is used as the non-breathing layer 45 and modified PP is used as the first adhesive layer 46 and the second adhesive layer 44. In this case, even if the radius of curvature R2 was 2 mm or less, no leakage of the molten resin to the skin layer 42 occurred.

  FIG. 7F shows a case where PP is used as the non-breathing layer 45 and modified PP is used as the first adhesive layer 46 and the second adhesive layer 44. In this case, the molten resin oozes out into the skin layer 42 when the radius of curvature R2 is 10 mm or more. This is probably because the temperature of the molten resin (180 ° C.) is higher than the melting point of PP, 163 ° C., so that the non-venting layer 45 itself melts and does not sufficiently perform the function of blocking the molten resin.

  According to this result, it is preferable to use a material having a melting point higher than the temperature of the molten resin as the non-breathing layer 45. When the substrate 30 is PP as in this embodiment, the melting point is higher than this. It can be seen that PET and PA6 having a high value are suitable as the material for the non-breathing layer.

  As described above, in the door trim 10 of the present embodiment, the base material 30, the first adhesive layer 46, the non-breathing layer 45, the second adhesive layer 44, the cushion layer 43, and the skin layer 42 are laminated in this order. It has become. As a result, the base material 30 is molded by injecting the molten resin to the back side of the first adhesive layer 46 (the side on which the base material 30 is arranged), and at the same time, the base material 30 and the skin through the first adhesive layer 46. Adhesion with the structure 40 can be performed. Thereby, the ornament 20 can be shape | molded easily. In this embodiment, a non-breathable layer 45 is interposed between the base material 30 and the cushion layer 43. With this non-ventilated layer 45, it is possible to suppress the situation where the injected molten resin reaches the cushion layer 43 (and consequently the skin layer) when the base material 30 is molded, and the molten resin soaks into the skin layer 42 (design surface side of the ornament 20). You can suppress the situation.

  Moreover, the base material 30 has the main surface part 31 which comprises the front side surface in the base material 30, and has at least 1 base material side corner | angular part 31A, and the skin structure 40 covers the base material side corner | angular part 31A. The skin side corner portion 41 has an arc shape when viewed from the front, and the curvature radius R2 can be 0.5 mm or more and 2 mm or less.

  When covering the base material side corner part 31A with the skin structure body 40 having a sheet shape as in the present embodiment, the skin structure body 40 is partially extended according to the shape of the base material side corner part 31A ( Stretched). In this regard, in this embodiment, since the non-breathable layer 45 having a non-breathable property is provided, even if the skin structure 40 including the non-breathable layer 45 is elongated, the non-breathable layer 45 is made of a molten resin. Never pass.

  For this reason, in this embodiment, even if the curvature radius R2 in the front view of the skin side corner portion 41 is 2 mm or less, that is, when the skin side corner portion 41 is extended more greatly, the molten resin is on the cushion layer 43 side. It is possible to surely suppress the situation of oozing out and improve the quality. In other words, according to the configuration of the present embodiment, even a shape with a small radius of curvature R2 can be formed, and the degree of freedom during design can be further increased.

  Moreover, in the case of the structure using the nonwoven fabric as the blocking member as in the prior art, it is necessary to increase the basis weight (weight per unit area) in order to ensure the blocking effect of the molten resin. Specifically, for example, the density of the nonwoven fabric is increased by using fibers having a smaller diameter than usual in order to fill the gaps between the fibers constituting the nonwoven fabric (for example, (A) and (C) in FIG. 7). Fiber diameter (see unit d: denier). For this reason, while the weight of a blocking member increases, the cost concerning material rises. In this regard, according to the configuration of the present embodiment, it is not necessary to increase the basis weight of the non-ventilated layer 45 in order to ensure the effect of blocking the molten resin, and thus an increase in weight and an increase in cost can be suppressed.

<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 said embodiment, although the ornament 20 was illustrated as an interior material for vehicles, it is not limited to this. The door trim 10 can also be exemplified as the vehicle interior material. For example, in the door trim 10, the skin structure 40 may cover a part of the base material constituting the main board 12. Further, the vehicle interior material is not limited to the door trim 10 or its component parts, and can be changed as appropriate. Examples of the vehicle interior material include a pillar garnish and a luggage trim.

  (2) In the above embodiment, the structure in which the skin structure 40 covers the entire surface of the base material 30 is exemplified, but the present invention is not limited to this. It is sufficient that the skin structure 40 covers at least a part of the base material 30. For example, the base material side corner portion 31 </ b> A of the base material 30 may not be covered.

  (3) In the above embodiment, the skin side corner portions 41 having the curvature radius R2 of 0.5 mm or more and 2 mm or less may be provided at a plurality of locations. Moreover, the structure which does not have the skin side corner | angular part 41 whose curvature radius R2 is 0.5 mm or more and 2 mm or less may be sufficient.

DESCRIPTION OF SYMBOLS 20 ... Ornament (vehicle interior material), 30 ... Base material, 31 ... Main surface part, 31A ... Base material side corner, 40 ... Skin structure, 41 ... Skin side corner, 42 ... Skin layer, 43 ... Cushion layer 44 ... second adhesive layer, 45 ... non-breathing layer, 46 ... first adhesive layer, R2 ... radius of curvature

Claims (2)

A base material in the form of a plate,
A skin structure disposed in a form covering at least a part of the front side surface of the base material, and
The skin structure is
A skin layer constituting the design surface of the skin structure,
A cushion layer interposed between the skin layer and the substrate;
A non-breathable layer interposed between the cushion layer and the base material and having non-breathability;
A first adhesive layer interposed between the non-breathing layer and the substrate, and bonding the non-breathing layer and the substrate;
Wherein interposed between the air-impermeable layer and the cushion layer, the a non-breathable layer and the second adhesive layer and the method for producing a vehicle interior material having a for bonding the said cushion layer,
By injecting molten resin to the back side of the skin structure, manufactured by integral molding that bonds the skin structure and the substrate simultaneously with the molding of the substrate,
Wherein the air-impermeable layer, the manufacturing method of a vehicular interior material, characterized that you produced with a high melting point material than the temperature of the molten resin. The base material has a main surface portion that constitutes a front side surface of the base material and has at least one base side corner portion;
The skin structure has a skin side corner that covers the substrate side corner,
2. The method for manufacturing a vehicular interior material according to claim 1, wherein the skin side corner portion has a circular arc shape when viewed from the front, and has a radius of curvature of 0.5 mm to 2 mm.

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