JP5943350B2 - Interior material for vehicle and method for producing interior material for vehicle - Google Patents

Description

  The present invention relates to a vehicle interior material and a method for manufacturing a vehicle interior material, and more particularly to a terminal processing technique for a vehicle interior material.

  2. Description of the Related Art Various types of terminal processing techniques have been proposed in the past for vehicle interior materials, in which an end formed at an outer edge or an opening is folded back to the back side of the vehicle interior material (see, for example, Patent Document 1).

  FIG. 7A is a diagram for explaining the basic configuration of the vehicle interior material. The vehicle interior material 100 is, for example, a vehicle ceiling material, and includes an interior material body 101 that interiors the ceiling surface of the passenger compartment. Have. The interior material main body 101 is formed by laminating a base material 102 made of a foam molded body such as urethane foam, a skin material 103 provided on the front side of the base material 102, and a back material 105 provided on the back side of the base material 102. . The back material 105 has a three-layer structure in which an inner layer made of a homopolymer polypropylene film, an intermediate layer made of a copolymer polypropylene film, and an outer layer made of spunlace are sequentially laminated from the base material 102 side.

  A so-called hemming method is generally used for terminal processing in the interior material body 101. In the hemming method, the end portion 106 of the interior material body 101 is heated and softened from the back surface material 105 side, and then the end portion 106 is disposed in the direction indicated by the arrow (10) as shown in FIG. Fold back to the back of the material body 101. The folded portion 107 is in contact with the spun lace of the back material 105, but since the intermediate layer made of a low-melting-point copolymer polypropylene melts, the folded portion 107 has the overlapping back material 105 welded together. And fixed.

  Incidentally, the end portion 106 of the vehicle interior material 100 may be required to have higher rigidity. For example, when the sunroof opening is provided in the interior material body 101, a reinforcing material is installed so as to surround the opening, and the rigidity of the end portion 106 that forms the sunroof opening is increased by the installed reinforcing material.

  In such a case, conventionally, as shown in FIG. 7C, after the end portion 106 is subjected to terminal treatment by a hemming method, the reinforcing material 108 is fixed to the back surface material 105 with an adhesive 111 such as hot melt. The rigidity of the end portion 106 was increased by pressing the folded portion 107 with the reinforcing material 108.

JP 2002-86600 A

  However, in the end portion 106 subjected to the terminal treatment by the hemming method, the width W of the end portion 106 and the thickness t of the end portion 106 are likely to fluctuate. Therefore, the reinforcing material 108 can be accurately positioned with respect to the end portion 106. difficult. For this reason, the position of the reinforcing material 108 varies and the appearance around the end portion 106 is not good.

  Moreover, even if the adhesive 111 protrudes from the edge 112 of the reinforcing material 108, the appearance is deteriorated. As a countermeasure, generally, the adhesive 111 is not applied in the vicinity of the edge 112 of the reinforcing material 108. However, in this case, the unbonded range of the reinforcing material 108 is widened, so that the rigidity of the end portion 106 is sufficiently increased. I can't.

  It is also possible to use a so-called kiss-cut method, in which a part of the base material is cut while leaving the skin material, and after fixing the reinforcing material to the base material, the end portion of the skin material is folded and bonded. However, in this method, since it takes time and effort to peel off the substrate, productivity is lowered.

  The present invention has been made in view of such circumstances, and an object of the present invention is to improve the appearance and rigidity of the end portion of the interior material body, and to obtain high productivity, and an interior material for a vehicle. It is in providing the manufacturing method of material.

The present invention is grasped by the following composition.
(1) The vehicle interior material of the present invention has an interior material body formed by laminating a base material, a skin material provided on the front side of the base material, and a back material provided on the back side of the base material. In the interior material for a vehicle, the reinforcement material is formed by folding back an end portion of the interior material body to the back side of the interior material body with a reinforcing material fixed to the back surface material and an edge of the reinforcement material as a base point. And a folded portion fixed to the head.

  According to this configuration, the end portion of the interior material body is folded back with the edge portion of the reinforcing material as a base point, so that the folded portion is accurately positioned with respect to the reinforcing material. Thereby, the appearance of an edge part can be improved. In addition, since the edge of the reinforcing material is covered by the folded portion, there is no concern that the adhesive protrudes from the edge of the reinforcing material, and the adhesive strength of the reinforcing material can be increased by ensuring a wide bonding range of the reinforcing material. it can. As a result, the rigidity of the end portion can be increased, and the material cost can be reduced and the weight can be reduced by reducing the thickness of the reinforcing material by the amount corresponding to the increased rigidity. Furthermore, since it is not necessary to peel off the base material, productivity can be improved as compared with the technique using the kiss cut method.

(2) In the vehicle interior material of the present invention, in the configuration of (1), the reinforcing material is made of a material that can be welded to the back material, and the back material is the reinforcing material in the folded portion. It is characterized by being welded to the material.

  According to this configuration, the folded back surface material can be welded to the reinforcing material at the same time as the folded portion is formed. Thereby, the process for fixing a folding | returning part to a reinforcing material can be reduced, and productivity can be improved more.

(3) The method for manufacturing a vehicle interior material according to the present invention includes an interior material obtained by laminating a base material, a skin material provided on the front side of the base material, and a back material provided on the back side of the base material. In the method of manufacturing a vehicle interior material having a main body, a fixing step of fixing a reinforcing material to the back material, a heating step of softening an end portion of the interior material main body from the back material side, and the reinforcing material A folding step in which the end of the interior material body is folded back to the back side of the interior material body with the edge portion of the interior material as a base point, and then the back material is welded to the reinforcing material at the folded back portion. Features.

  According to this configuration, the end portion of the interior material body is folded back with the edge portion of the reinforcing material as a base point, so that the folded portion is accurately positioned with respect to the reinforcing material. Thereby, the appearance of an edge part can be improved. In addition, since the end portion is folded after the reinforcing material is fixed to the back surface material, the edge portion of the reinforcing material is covered by the folded portion. Therefore, there is no concern that the adhesive protrudes from the edge of the reinforcing material, and the adhesive strength of the reinforcing material can be increased by ensuring a wide bonding range of the reinforcing material. As a result, the rigidity of the end portion can be increased, and the material cost can be reduced and the weight can be reduced by reducing the thickness of the reinforcing material by the amount corresponding to the increased rigidity. Furthermore, since it is not necessary to peel off the base material, productivity can be improved as compared with the technique using the kiss cut method. Further, since the back material is welded to the reinforcing material in the folding process, the process for fixing the folded part to the reinforcing material can be reduced, and the productivity can be further increased.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the interior material for vehicles which improves the appearance and rigidity of the edge part of an interior material main body, and can obtain high productivity can be provided.

It is a top view of the interior material for vehicles of the embodiment concerning the present invention. It is sectional drawing which shows the layer structure of an interior material main body. It is the sectional view on the AA line of FIG. It is a figure explaining a fixing process. (A) is a figure explaining a setting process, (b) is a figure explaining a heating process, (c) is a figure explaining a folding process. It is a figure which shows the modification of the vehicle interior material, and is a figure corresponding to FIG. It is a figure explaining the edge part of the conventional vehicle interior material, (a) is a figure which shows a basic composition, (b) is a figure which shows the edge part which terminal-processed (a) by the hemming method, (c) (B) is a figure which shows the edge part which installed the reinforcing material in (b).

(Embodiment)
DESCRIPTION OF EMBODIMENTS Hereinafter, a mode for carrying out the present invention (hereinafter referred to as “embodiment”) will be described in detail with reference to the accompanying drawings. The same number is attached | subjected to the same element through the whole description of embodiment.

(Overall structure of vehicle interior materials)
As shown in FIG. 1, the vehicle interior material 10 according to the embodiment is a vehicle ceiling material that is attached to the inner surface side (vehicle compartment side) of the vehicle roof panel, and the interior material main body that interiors the ceiling surface of the vehicle interior. 20 The interior material main body 20 has a rectangular shape in plan view, and includes a front end portion 21 and a rear end portion 22 formed along the vehicle width direction, and left and right side end portions 23 formed along the vehicle front-rear direction. And have. An opening 25 is provided in the center of the front portion of the interior material body 20. This opening 25 is provided corresponding to the sunroof provided in the roof panel. In this example, the opening 25 is formed in a rectangular shape that is long in the vehicle width direction.

(Layer structure of interior material body)
As shown in FIG. 2, the interior material body 20 includes a base material 26, a front surface side fiber layer 27 provided on the front side of the base material 26, a back side fiber layer 28 provided on the back side of the base material 26, and a front side. A skin material 31 provided on the fiber layer 27 side and a back material 32 provided on the back side fiber layer 28 side are laminated.

  The base material 26 is comprised with the foaming molding etc. which were represented by urethane foam. The front-side fiber layer 27 and the back-side fiber layer 28 are made of fiber materials such as glass mats, and are reinforcing layers that reinforce the interior material body 20. Moreover, the front surface side fiber layer 27 and the back surface side fiber layer 28 may have a function of bonding the skin material 31 and the back surface material 32 to the base material 26.

  The skin material 31 forms a ceiling surface in the passenger compartment, and is made of a breathable material such as a nonwoven fabric, a woven fabric, or a knit. On the other hand, the back surface material 32 is made of a non-breathable material and stops the flow of air from the passenger compartment to the back side of the interior material body 20, thereby preventing dust and the like from adhering to the surface of the skin material 31.

  Such a back surface material 32 can be constituted by a multilayer structure. In this example, an inner layer (for example, a film made of homopolymer polypropylene) 33 made of a synthetic resin having a normal melting point, an intermediate layer (for example, a film made of copolymer polypropylene) 35 made of a synthetic resin having a low melting point, and an outer layer (for example, a film made of homopolymer polypropylene) The back material 32 is formed of a three-layer structure of spun lace) 36.

(Configuration of end and reinforcement)
As shown in FIG. 3, the interior material body 20 has an end portion 40 that forms the periphery of the opening 25, and the vehicle interior material 10 has a reinforcing material 50 that reinforces the end portion 40. The end portion 40 is subjected to a terminal treatment by a hemming method, and a bent portion 42 (portion indicated by a range A2) connected to a base portion 41 (portion indicated by a range A1) of the interior material body 20 and a folded portion 43 connected to the bent portion 42. (Part indicated by range A3).

  The reinforcing member 50 is a plate-like member and is disposed so as to surround the periphery of the opening 25. The entire lower surface of the reinforcing material 50 is fixed to the upper surface of the back material 32 by an adhesive (for example, hot melt) 51.

  The reinforcing material 50 can be made of various materials, but here is made of a material that can be welded to the back surface material 32. For example, with respect to the back material 32 mainly composed of a polypropylene film, the reinforcing material 50 is made of a polypropylene resin containing glass fiber, and the back material 32 and the reinforcing material 50 are made of the same material. In addition, by configuring the back material 32 and the reinforcing material 50 with the same material, the reinforcing material 50 can be fixed to the back material 32 using an ultrasonic welding method instead of the adhesive 51.

  The bent portion 42 is a portion that forms the periphery of the opening 25 at the end portion 40. The bent portion 42 is curved into an arbitrary shape (here, a semicircular shape) and covers the edge 52 on the end 40 side of the reinforcing member 50. The folded portion 43 is formed by folding the end portion 40 with the edge 52 of the reinforcing material 50 as a base point, and is fixed to the upper surface of the reinforcing material 50.

(Manufacturing method of vehicle interior materials)
Next, the manufacturing method of the interior material for vehicles is demonstrated based on FIG. 4, FIG.
The vehicle interior material manufacturing method includes a preparation process for preparing the interior material body 20, a fixing process for fixing the reinforcing material 50 to the interior material body 20, and heating for softening the end portion 40 of the interior material body 20. A process and a folding process in which the end portion 40 of the interior material body 20 is folded and welded to the reinforcing material 50.

  First, in the preparation process, as shown in FIG. 4, a product using a laser cutting device or the like is applied to the interior material body 20 in which the base material 26, the skin material 31, and the back surface material 32 formed into a predetermined shape are laminated. A trim cut process is performed along the outer shape and a hole 61 is formed for forming the opening 25 (see FIG. 1).

  In the fixing step, the reinforcing material 50 is fixed to the back material 32 of the interior material body 20 using the adhesive 51 (arrow (1)). At this time, the edge portion 52 of the reinforcing member 50 is arranged at a position separated from the periphery of the hole 61 by a distance L commensurate with the formation of the bent portion 42 (see FIG. 3) and the folded portion 43 (see FIG. 3).

  In the setting step, as shown in FIG. 5A, the interior material main body 20 to which the reinforcing material 50 is fixed is set on the receiving base 62 (arrow (2)). At this time, in a state where the end portion 40 corresponding to the distance L protrudes from the receiving base 62, the skin material 31 side of the interior material body 20 is placed on the receiving base 62.

  In the heating step, as shown in FIG. 5B, the hot air nozzle 63 and the hot air shielding plate 65 are moved closer to the back surface material 32 side of the end portion 40 (arrow (3)), and other than the end portion 40 in the interior material body 20. While the part is shielded by the hot air shielding plate 65, hot hot air is applied to the end 40 from the hot air nozzle 63. Thereby, the edge part 40 is heated and softened from the back material 32 side. At this time, in the end portion 40, the intermediate layer 35 (see FIG. 2) composed of a low melting point synthetic resin such as a film made of copolymer polypropylene is melted.

  In the folding step, the hot air nozzle 63 is retracted (arrow (4)), and the block 66 is approached from the skin material 31 side toward the softened end portion 40 (arrow (5)). And by this block 66, the edge part 40 is bend | folded to the back side of the interior material main body 20 (arrow (6)). Further, the hot air shielding plate 65 is retracted, and the block 66 is moved to the reinforcing member 50 side (arrow (7)) as shown in FIG. Then, after the end portion 40 is folded back to the back side of the interior material body 20 with the edge portion 52 of the reinforcing member 50 as a base point by the block 66, the back surface member 32 is pushed onto the upper surface of the reinforcing member 50 at the folded portion 43. Hit (arrow (8)). At this time, in the folded portion 43, the outer layer 36 (see FIG. 2) such as a spun lace contacts the upper surface of the reinforcing material 50, but the intermediate layer 35 (see FIG. 2) made of a copolymer polypropylene film or the like is melted. Therefore, the back surface material 32 is welded to the reinforcing material 50 at the folded portion 43.

(Effect of embodiment)
The effects of the vehicle interior material 10 and the manufacturing method thereof according to the embodiment described above will be described.

  In the present embodiment, the end 40 is folded back with the edge 52 of the reinforcing member 50 as a base point. On the other hand, the position of the base point of the folded portion 43 can be adjusted by adjusting the gap between the hot air shielding plate 65 and the block 66. However, in this case, since it is difficult to stabilize the position of the base point of the folded portion 43, the form of the end portion 40 is likely to vary. In this respect, according to the present embodiment, since the end portion 40 is folded back with the edge portion 52 of the reinforcing member 50 as a base point, the folded portion 43 can be accurately positioned with respect to the reinforcing member 50. Thereby, the appearance of the edge part 40 can be improved.

  In the embodiment, since the end portion 40 is folded after the reinforcing member 50 is fixed to the back surface member 32, the edge portion 52 of the reinforcing member 50 is covered by the folded portion 43. Therefore, there is no fear that the adhesive 51 protrudes from the edge portion 52, and the adhesion range of the reinforcing material 50 can be increased by securing a wide bonding range of the reinforcing material 50. As a result, the rigidity of the end portion 40 can be increased, and the material cost can be reduced and the vehicle interior material 10 can be reduced in weight by reducing the plate thickness of the reinforcing member 50 by the increased rigidity. . Furthermore, since it is not necessary to peel off the base material 26, productivity can be improved compared with the technique using a kiss cut construction method.

  Further, since the folded back portion 32 can be welded to the reinforcing material 50 at the same time as the folded portion 43 is formed in the folding step, the process for fixing the folded portion 43 to the reinforcing material 50 can be reduced, and productivity can be reduced. Can be further enhanced.

  Therefore, according to this embodiment, the appearance and rigidity of the end portion 40 of the interior material body 20 can be improved, and the productivity can be increased.

(Variations of vehicle interior materials)
Next, a modification of the vehicle interior material will be described with reference to FIG. In addition, the same code | symbol is attached | subjected to the element which is common in the edge part 40 (refer FIG. 3) mentioned above, and the overlapping description is abbreviate | omitted.

  As shown in FIG. 6, in the vehicle interior material 10 </ b> B, the end portion 40 </ b> B of the interior material body 20 </ b> B has a rising portion 45 that rises obliquely with respect to the base portion 41. The reinforcing member 50 </ b> B that reinforces the end portion 40 </ b> B includes a horizontal portion 53 located on the base 41 side, and an inclined portion 55 that continues to the horizontal portion 53 and is inclined along the rising portion 45. The folded portion 43 is welded to the inclined portion 55 after being folded back to the back side of the interior material main body 20B with the edge portion 52 of the inclined portion 55 as a base point.

  Also in the vehicle interior material 10B configured as described above, the same effect as that of the vehicle interior material 10 (see FIG. 3) described above can be obtained, and the appearance and rigidity of the end portion 40B of the interior material body 20B can be increased. And high productivity can be obtained.

  As mentioned above, although this invention was demonstrated using embodiment, it cannot be overemphasized that the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above-described embodiments. Further, it is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

  For example, in the embodiment, the example in which the terminal processing technology according to the present invention is applied to the end portion that forms the opening for the sunroof is shown, but the terminal processing technology according to the present invention is the front end portion 21 (see FIG. 1). Further, the present invention can be applied to each end portion of the vehicle ceiling material such as the rear end portion 22 (see FIG. 1) and the left and right side end portions 23 (see FIG. 1).

  Moreover, although the example which applied this invention to the ceiling material for vehicles was shown in embodiment, this invention is applicable to various interior materials for vehicles, such as a vehicle door trim other than the ceiling material for vehicles.

DESCRIPTION OF SYMBOLS 10 Vehicle interior material 10B Vehicle interior material 20 Interior material main body 20B Interior material main body 26 Base material 31 Skin material 32 Back surface material 40 End part 40B End part 43 Turn-up part 50 Reinforcement material 50B Reinforcement material 52 Edge

Claims (3)

A base material, a surface side fiber layer provided on the front side of the base material, a skin material provided on the surface side fiber layer side, a back side fiber layer provided on the back side of the base material, and a back side fiber layer side In an interior material for a vehicle having an interior material body formed by laminating a back material provided ,
The back material is composed of an inner layer of a homopolymer polypropylene film from the base material side, an intermediate layer made of a low melting point copolymer polypropylene film, and an outer layer of spunlace,
Reinforcing material composed of polypropylene resin containing glass fiber, and fixed to the back material;
A folded portion that is formed by folding an end portion of the interior material main body back to the back side of the interior material main body from the edge of the reinforcement material as a base, and is connected to a bent portion that is continuous to the interior material main body, and is fixed to the reinforcement material, I have a,
The vehicle interior material, wherein the reinforcing material is provided beyond the folded portion on the opposite side to the bent portion . The back surface member is in the folded portion, a vehicle interior material according to claim 1, characterized in that it is welded to the reinforcing member. A base material, a surface side fiber layer provided on the front side of the base material, a skin material provided on the surface side fiber layer side, a back side fiber layer provided on the back side of the base material, and a back side fiber layer side In the method for manufacturing an interior material for a vehicle having an interior material body formed by laminating a back material provided ,
From the base material side, an inner layer of a film made of homopolymer polypropylene, an intermediate layer made of a low melting point copolymer polypropylene film, and a backside material composed of an outer layer of spunlace are made of a polypropylene resin containing glass fiber. A fixing step for fixing the constituted reinforcing material;
A heating step of heating and softening the end of the interior material body from the back material side;
Starting from the edge of the reinforcing material, the end of the interior material main body is folded back to the back side of the interior material main body, and the back material is used as the reinforcing material in the folded portion that is continuous with the folded portion that is continuous with the interior material main body. and the folding step of welding, only including,
In the fixing step, the reinforcing material is provided so as to exceed the folded portion on the side opposite to the folded portion,
In the heating step, a hot air is applied to an end portion of the interior material body while shielding a portion other than the end portion of the interior material body with a hot air shielding plate .

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