JP6114505B2 - Interior parts for vehicles - Google Patents

Description

  The present invention relates to a vehicle interior part.

2. Description of the Related Art Conventionally, as a vehicle interior part, a roof trim that forms a ceiling is provided on a vehicle interior ceiling of a vehicle with a proper space inside a vehicle body panel.
As such a roof trim 1, as shown in FIG. 10, for example, a urethane base material 2, and first and second glass fiber layers (on the front side and the back side so as to sandwich the base material 2) ( + Isocyanate adhesive) 3, 4, skin layer 5 laminated on the first glass fiber layer 3 on the front side, that is, the passenger compartment side, and the second glass fiber on the back side, that is, on the body panel (not shown) side. There is one constituted by a heat shielding layer 6 (PET film on which aluminum is deposited) laminated on the layer 4.

Such a roof trim 1 is manufactured through the following manufacturing processes, for example.
First, the base material 2, the first and second glass fiber layers 3, 4, the skin layer 5, and the heat shield layer 6 are laminated to prepare a molding material. An adhesive is applied to the entire front and back surfaces of the first glass fiber layer 3 and the second glass fiber layer 4 in advance in the molding material. Next, hot press molding is performed with the molding material sandwiched between upper and lower molds (not shown). At this time, the back surface of the skin layer 5 is bonded to the surface of the first glass fiber layer 3, and the surface of the heat shield layer 6 is bonded to the back surface of the second glass fiber layer 4. Thereby, all the layers are integrated and the roof trim 1 of a predetermined shape is obtained.

As described above, since the roof trim 1 is formed by stacking various materials in multiple layers, surplus material is generated at the outer edge part that shapes the product. As a processing step, it is necessary to perform a cutting process to remove the marginal material.
As such excision processing, for example, as disclosed in Patent Document 1 as part of terminal processing of interior materials, cutting is performed by a water jet device, a laser device, a cutter, or the like, and then terminal processing is performed by hemming processing.

JP 2000-25050 A

However, in the above-described roof trim 1, the PET film on which aluminum which is the heat shielding layer 6 laminated on the second glass fiber layer 4 on the vehicle body panel side is vapor deposited has a thin PET film with a thickness of 12 μm and an aluminum portion of 0.06 μm. For this reason, when an attempt is made to cut off the surplus material at the outer edge using a water jet device such as that of Patent Document 1, the PET film may peel off and fall off in the vicinity of the cut. Such inconvenience is that when the mold clearance is wide, that is, when the thickness is kept in a predetermined state, the adhesive applied to the glass fiber and the PET film are adhered at the point, so that the cut surface is completely adhered. The parts that are not present are peeled off by the water jet water pressure.
Such an edge is peeled off when loading a cart or handling a product, that is, when attaching various assembly parts (Assembly: urethane chip, harness, harness fixing tape, pad, etc.) to the back side of the roof trim. There is a risk that the end member that has been attached will adhere to a skin layer or the like whose surface has a pattern such as a wrinkle.
Therefore, by suppressing the cutting speed by the water jet, the properties of the cutting site are improved to some extent, but the predetermined processing level has not yet been reached. Furthermore, it is difficult to suppress the manufacturing cost by so-called tact-up.

  The present invention has been proposed in order to improve the above-described problems, and fraying of the outer edge of a product, etc., even after a process of cutting off surplus materials during cutting with a water jet device after molding. An object of the present invention is to provide an interior part for a vehicle that has reached a predetermined processing level as a product.

In order to solve the above-described problem, in the invention described in claim 1, a urethane base material, and first and second glass fiber layers disposed on the front and back surfaces so as to sandwich the base material, The heat insulating layer is composed of a skin layer laminated on the first glass fiber layer on the passenger compartment side and a heat insulating layer laminated on the second glass fiber layer on the vehicle body panel side , and at least in the outer edge portion of the base material In the roof trim, a non-woven fabric containing an adhesive is integrally laminated on the heat-shielding layer as a peeling prevention part for preventing the peeling of
The peeling prevention portion includes a plurality of the nonwoven fabrics from the both side edge portions of the vehicle located at the outer edge portion of the base material toward the central portion, and the nonwoven fabric includes both side edge portions of the vehicle except for the central portion. The thermal barrier layer is provided so as to cover an area along the center, and the central portion where the nonwoven fabric is not interposed is bonded to the second glass fiber layer. It is bonded to the plurality of nonwoven fabrics.

In the invention according to claim 2, the urethane base material, the first and second glass fiber layers disposed on the front and back surfaces so as to sandwich the base material, and the first on the passenger compartment side are provided. It is composed of a skin layer laminated on the glass fiber layer and a heat shield layer laminated on the second glass fiber layer on the vehicle body panel side ,
Peeling prevention part for preventing the peeling of the thermal barrier layer, toward the outer edge of the substrate, formed of crushed write unit the entire thickness is formed so as to gradually become thinner roof trim,
With respect to the cut portion of the side edge portion of the roof trim, from the heat shield layer side, the cutting means is fed to cut off the surplus material at the cut portion, and the heat shield layer becomes the base material by shear stress in cutting . It does not peel from the second glass fiber layer .

  According to the present invention, it is possible to provide an interior part for a vehicle that has reached a predetermined processing level as a product without fraying the outer edge of the product, etc., even after a step of cutting off surplus materials at the time of cutting after molding. Can do.

1 is a plan view of a first embodiment of a vehicle interior part according to the present invention. It is sectional drawing explaining the laminated constitution of the vehicle interior component of 1st Embodiment. It is a figure explaining a raw material preparation process and a press molding process in the manufacturing process of the interior component for vehicles of a 1st embodiment. It is explanatory drawing at the time of performing excision processing with respect to the molded article obtained by the press process shown in FIG. 3, and a molded article. It is a figure which shows the vehicle interior components obtained through the cutting process shown in FIG. It is sectional drawing explaining the laminated constitution of the vehicle interior component of 2nd Embodiment. FIG. 7 is an explanatory plan view showing the arrangement range of the nonwoven fabric as the peeling preventing portion in the layer configuration of the vehicle interior part shown in FIG. 6. It is the figure which showed the press process among the manufacturing processes of the vehicle interior component in 3rd Embodiment. It is a figure explaining the cutting process with respect to the vehicle interior component obtained by the press process shown in FIG. 8, and a vehicle interior component. It is sectional drawing explaining an example of the laminated constitution of the conventional vehicle interior components.

Hereinafter, an embodiment of an interior part for a vehicle according to the present invention will be described and described with reference to the accompanying drawings. Note that the same number is assigned to the same element throughout the description of the embodiment.
The interior part for a vehicle in the present invention includes a laminate of a base material, a skin layer that is provided on the front surface side of the base material and forms a ceiling surface in the vehicle interior, and a heat shield layer provided on the back surface side of the base material. These are manufactured through a press molding process and a cutting process of surplus materials generated during molding.

(First embodiment)
FIG. 1 shows a vehicle interior part 1 (hereinafter, a roof trim 1) according to a first embodiment. The roof trim 1 has a substantially rectangular shape in plan view, and FIG. 1 shows a surface side facing the vehicle body panel. The A side is arranged toward the front window side of the vehicle, and the opposite B side is arranged toward the rear window side. The roof trim 1 is formed and processed into a tray shape in which the central region rises toward the vehicle body panel along the axial direction from the A side to the B side in a shape that follows the shape of the roof panel of the vehicle on which the entire construction is performed. (Described later).
The details of the edge of the roof trim 1 are as follows.
That is, concave end portions 1a and 1a that engage with a front pillar (not shown) of the vehicle are formed at both end portions near the A side of the roof trim 1, and the longitudinal side of the roof trim 1 that is an edge portion of the roof trim is formed. Notched edges 1b and 1b on the side edge of the roof trim that engage with the center pillar (not shown) of the vehicle are formed at substantially intermediate portions of both side edges of the vehicle.

Then, from the center of the edge near the A side of the roof trim 1 to the concave corners 1a and 1a on both sides, the map lamp mounting part 1d and the center between the sun visor arrangement molding parts 1c and 1c, and the center Various assy parts are provided in the region of the region, in addition to a room lamp arrangement molding portion 1e for attaching a room lamp (not shown).

Next, an example of the layer structure of the above roof trim 1 will be given and described with reference to FIG.
As shown in FIG. 2, the roof trim 1 includes a urethane base material 2 and first and second glass fiber layers (+ isocyanate-based adhesive) disposed on the front and back surfaces so as to sandwich the base material 2. Agents) 3 and 4, laminated on the front glass layer 3 on the front side, that is, the first glass fiber layer 3 on the passenger compartment side, and on the second glass fiber layer 4 on the back side, that is, on the body panel (not shown) side. And a heat shielding layer 6 (PET film on which aluminum is deposited).

  The base material 2 consists of foam materials, such as a semi-rigid urethane foam. The first and second glass fiber layers 3, 4 are reinforcing layers that reinforce the roof trim 1, and the skin layer 5 and the first and second glass fiber layers 3, 4 are made of an isocyanate-based adhesive impregnated in the first and second glass fiber layers 3, 4. It also serves as an adhesive layer that adheres the heat shield layer 6 to the substrate 2.

  And between the 1st glass fiber layer 3 and the heat insulation layer 6 of the back surface side of a base material, the peeling prevention part for preventing peeling of the heat insulation layer 6 in the outer edge part 2E of the base material 2 at the time of excision processing As described above, a nonwoven fabric 10 containing an adhesive (described later) is integrally laminated on the heat shield layer 6. That is, the heat shielding layer 6 is bonded to the second glass fiber layer 4 with an isocyanate adhesive via the nonwoven fabric 10.

As the nonwoven fabric 10, various types of nonwoven fabrics such as spunlace, thermal bond, chemical bond, and needle punch can be used.
Spunlace nonwoven fabric is formed by hydroentanglement method and uses the entanglement of fiber material by high-pressure water flow treatment, and the fiber material is highly entangled by high pressure and delicate pressure water to ensure strength. .
The thermal bond non-woven fabric is a sheet in which fibers having different melting points are mixed and softened and melted to bond the fibers together to form a sheet, and an adhesive is not required.
A chemical bond nonwoven fabric is a sheet formed by bonding fibers with a synthetic resin.
Furthermore, a needle punched non-woven fabric is formed by feeding a relatively long short fiber in a certain amount and in a certain direction to form a web, the formed web is superimposed on several layers, and a special needle reciprocates at a high speed in the lamination. The fiber is entangled with fine protrusions of a special needle.
In this case, the nonwoven fabric weight is 15 to 200 g / m ² .

The layer structure of the roof trim 1 according to the first embodiment is as described above, and the roof trim 1 is manufactured through a press molding process and a surplus material cutting process that occurs during molding as described above.
First, in the molding step, a molding die 20 including a first die (upper die) 21 for shaping the skin layer 5 side and a second die (lower die) 22 for shaping the heat shield layer 6 side is used. (See FIG. 3). Then, the base material 2, the skin layer 5, the heat shielding layer 6 laminated on the nonwoven fabric 10, the first and second glass fiber layers 3, 4 are sandwiched between the molding material 7 between the upper mold 21 and the lower mold 22, Hot press molding is performed.
Thereby, the skin layer 5 adheres to the surface of the first glass fiber layer 3, and the heat shield layer 6 adheres to the back surface of the second glass fiber layer 4 through the nonwoven fabric 10. Thereby, the roof trim 1 in which all the layers are integrated can be obtained.
Next, in order to obtain the roof trim 1 as designed by the water jet device, the laser device, the cutter, or the like as the next processing step for the roof trim 1 taken out from the molding die 20, extra material at the edge portion A resection process is performed to remove (see FIG. 4).
In such a cutting process, a shearing stress is applied to the cutting portion of the edge of the roof trim 1 along the cut surface. 2 Since the glass fiber layer 4 is firmly adhered to the back surface, the PET film on which aluminum is deposited is not peeled off by the shearing stress accompanying the cutting process as in the past, and the cutting site has a predetermined edge. Therefore, the roof trim 1 can be manufactured as the designed roof trim 1 (see FIG. 5).

(Second Embodiment)
The layer structure of the roof trim 1 that is an interior part for a vehicle according to the present invention can also be configured as follows.
In the roof trim 1 here, as an anti-peeling portion, an adhesive disposed between the first glass fiber layer 3 and the heat shielding layer 6 on the back surface side of the base material from the outer edge portion of the base material to the vicinity of the outer edge portion. It can be comprised with the nonwoven fabric containing an agent. That is, the peeling preventing portion has a predetermined width dimension (for example, 50 mm or more) from the outer edge portion 2E of the base member 2 of the roof trim 1, that is, from the both side edge portions to the central portion in the width direction along both side edge portions of the vehicle. ) Of the nonwoven fabric 30a, 30b containing an adhesive (see FIG. 6). As shown in FIG. 7, these non-woven fabrics 30 a and 30 b are provided in the roof trim 1 so as to cover regions I and II along both side edges of the vehicle except for the central portion.
Since these nonwoven fabrics 30a and 30b can be comprised with the raw material similar to the nonwoven fabric 10 disclosed by 1st Embodiment, the description is abbreviate | omitted here.

The roof trim 1 of the second embodiment as described above is manufactured through a press molding process and a surplus material cutting process that occurs during molding, as in the roof trim 1 of the first embodiment described above.
In the molding process, a molding die (not shown) is used. That is, the first glass fiber layer 3 and then the skin layer 5 are disposed on the surface of the base material 2 with the base material 2 interposed therebetween, and the second glass fiber layer 4 and then the nonwoven fabrics 30a and 30b are disposed on the back surface of the base material 2. The molding material on which the heat shielding layer 6 is arranged is sandwiched between the upper mold and the lower mold, and hot press molding is performed.
Thereby, the heat shield layer 6 is bonded to the second glass fiber layer 4 at the central portion where the nonwoven fabrics 30a and 30b are not interposed, while the heat shield layers 6 on both side edges of the roof trim 1 are bonded to the nonwoven fabrics 30a and 30b, respectively. By bonding, all the layers can be integrated to obtain the roof trim 1. Next, the roof trim 1 taken out from the molding die is subjected to a cutting process to remove the marginal material by a water jet device, a laser device, a cutter, or the like.
In such a cutting process, a shearing stress is applied to the heat shielding layer 6 on the edge of the roof trim 1, that is, on both sides of the roof trim 1, along the cut surface. Since the thermal barrier layer 6 on the edge side is firmly bonded to the nonwoven fabrics 30a and 30b, the PET film on which the aluminum which is the thermal barrier layer 6 is evaporated does not peel off due to shear stress, and the cut site Are separated to form a predetermined edge, so that the roof trim 1 can be manufactured as a roof trim 1 as designed.

(Third embodiment)
The roof trim 1 that is an interior part for a vehicle according to the present invention can also be configured as follows.
In the roof trim 1 here, the peeling preventing portion for preventing the heat shielding layer 6 from peeling is the outer edge 2E of the base material when the upper die 21 and the lower die 22 are pressed. The crushed portion 40 formed so that the overall thickness gradually decreases toward the surface.
In this case, as shown in FIGS. 8 and 9, for example, as shown in FIGS. 8 and 9, the crushing portion 40 has a thickness of the cutting portion at the edge of the roof trim 1 of about 2 mm. The overall thickness is gradually changed from 2 to 20 mm on the heat shield layer 6 side toward the inner side in the width direction from the cut portion. This changing range is considered from the viewpoints of press working and rigidity. That is, if the change range of the overall thickness is smaller than 2 to 20 mm, the die cutting angle is reduced, and if the change range of the overall thickness is larger than 2 to 20 mm, the rigidity in the vicinity of the edge portion is reduced. In addition, the die cutting angle has a minimum value of 5 degrees in terms of forming the mold. For example, when the total thickness of the product is 20 mm and the product terminal is gradually changed from 2 mm, the extraction angle becomes 5.7 degrees.
Moreover, as thickness of the base material 2, it is 3-20 mm.
Furthermore, the mold clearance is set to 3 to 20 mm from the viewpoint of rigidity and skin adhesion in the product.

  As described above, the roof trim 1 is taken out by pressing by the crushed portion 40 formed so that the overall thickness gradually decreases toward the outer edge portion 2E of the base material 2 as shown in FIG. For the product, the cutting cutter (not shown) from the side of the heat shielding layer 6 where the overall thickness is gradually changed in the range of 2 to 20 mm at the time of cutting with respect to the cutting portion of the edge of the roof trim 1. And the remaining material at the cutting site is removed (see FIG. 9), the heat shield layer 6 will not be peeled off from the base material 2 and the second glass fiber layer 4 due to the shearing stress at the time of cutting. Since the cutting parts are separated so as to form predetermined edges, the roof trim 1 can be manufactured as the roof trim 1 as designed.

  As mentioned above, although this invention was demonstrated using embodiment, the technical scope of this invention is not limited to the range as described in the said embodiment, A various change or improvement can be added to the said embodiment. Is possible. 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 cutting portion of the outer edge in the roof trim naturally includes cutting portions at both ends of the roof trim in the vehicle length direction.

DESCRIPTION OF SYMBOLS 1 Roof trim 1a Recessed corner part 1b Notch edge part 1c Sun visor arrangement | positioning shaping | molding part 1d Map lamp attaching part 1e Room lamp arrangement | positioning shaping | molding part 2 Base material 2E Outer edge part 3 1st glass fiber layer 4 2nd glass fiber layer 5 Skin layer 6 Heat shielding layer 7 Molding material 10 Nonwoven fabric 20 Molding die 21 Upper die 22 Lower die 30a, 30b Nonwoven fabric 40 Crushing part

Claims (2)

A urethane base material;
First and second glass fiber layers disposed on the front and back sides so as to sandwich the substrate; and
A skin layer laminated on the first glass fiber layer on the passenger compartment side;
Consists of a thermal barrier layer laminated to the second glass fiber layer on the body panel side,
In the roof trim, a non-woven fabric containing an adhesive is integrally laminated on the heat shield layer as a peel preventing portion for preventing the heat shield layer from peeling off at least at the outer edge of the base material.
The peeling prevention portion includes a plurality of the nonwoven fabrics from the both side edge portions of the vehicle located at the outer edge portion of the base material toward the central portion, respectively.
The nonwoven fabric is provided so as to cover a region along both side edges of the vehicle except for a central portion,
The heat shield layer is bonded to the second glass fiber layer at a central portion where the nonwoven fabric is not interposed, while the heat shield layers on both side edges are respectively bonded to the plurality of nonwoven fabrics. The characteristic roof trim. Place the first and second glass fiber layers on the front and back sides to sandwich the urethane base material ,
The skin layer is laminated on the first glass fiber layer of the cabin side,
A roof trim base material is formed by laminating a heat shielding layer on the second glass fiber layer on the vehicle body panel side ,
With respect to the cut portion of the side edge portion of the roof trim base material, a cutting means is fed from the heat shield layer side to cut off the surplus material at the cut portion, and toward the outer edge portion of the base material, By forming a squeezed portion that gradually reduces the overall thickness, peeling prevention for preventing the thermal barrier layer from peeling from the base material and the second glass fiber layer due to shear stress in cutting. A method for manufacturing a roof trim , characterized in that the part is constituted .

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