JP6853120B2 - Vehicle interior materials and their manufacturing methods - Google Patents

Description

The present invention relates to an interior material for a vehicle in which a resin molded portion is bonded to a molded base material, and a method for manufacturing the same.

Interior materials such as deck side trims are attached to the body panel of automobiles. As the interior material, a base material obtained by press-molding by assembling thermoplastic resin fibers, a base material obtained by foaming a resin material and injection-molding, and the like are used. Since these substrates contain air, they are low in density and lightweight. When a molded portion such as a clip mounting seat is formed by injection molding a molten resin on the back surface of a low-density base material, it is necessary to secure sufficient bonding strength of the molded portion with respect to the back surface of the base material. While increasing the bonding area of the molded portion with respect to the back surface of the base material can increase the bonding strength, the low-density base material may be deformed due to shrinkage of the molded portion cooled after injection molding. Deformation of the base material leads to deterioration of the design of the interior material.

Patent Document 1 discloses a door trim in which a bracket is injection-molded on the back surface of the trim board. The joints of the bracket to the trim board are a linear portion arranged on the outer peripheral edge of the bracket and extending on the base material, and a branch portion protruding from the linear portion on the base material toward the outside of the bracket. It is composed of. This branch is present in order to prevent a decrease in bonding force while reducing the bonding area of the bracket.

Japanese Unexamined Patent Publication No. 2006-21824

However, when a force having a component along the back surface of the trim board is applied to the bracket, the bracket may be peeled off from the base material starting from the tip of the protruding branch portion.
In addition to the door trim, the above-mentioned problems also exist for various vehicle interior materials such as deck side trim and roof trim.

The present invention discloses a novel vehicle interior material in which deformation of a base material and peeling of a molded portion starting from a rib are suppressed, and a new manufacturing method of a vehicle interior material.

The present invention is an interior material for a vehicle including a molded base material containing air and a molded portion of a resin bonded to a part of one surface of the base material.
The molded portion has an embodiment having a main body portion and a regression rib extending from the main body portion along one surface of the base material and turning in a curved shape to return to the main body portion.

Further, the method for manufacturing an interior material for a vehicle of the present invention includes a base material forming step of forming a base material having a required shape including air, and a base material forming step.
A molded portion having a main body portion and a regression rib that extends from the main body portion along one surface of the base material portion, changes its direction in a curved shape, and returns to the main body portion, and is joined to one surface of the base material. A transfer step of transferring the base material to an injection molding mold having a cavity to be formed, and
It has an aspect including an injection step of injecting a resin into the cavity of the injection molding mold in which the base material is arranged.

According to the present invention, it is possible to provide a novel vehicle interior material in which deformation of the base material and peeling of the molded portion starting from the rib are suppressed.

The figure which shows typically the example of the interior of an automobile in a state where the illustration of a side part is omitted. The figure which shows typically the example of the surface which has a molded part in the interior material. The figure which shows typically the example of the molded part bonded to one surface of a base material. FIG. 5 is a cross-sectional view schematically showing an example of a cross section of an interior material at a position where an opening of a main body of a molded portion can be seen. A side view schematically showing an example of a clip. The figure which shows typically the example of another molded part bonded to one surface of a base material. The figure which shows typically the example of another molded part bonded to one surface of a base material. The figure which shows typically the example of another molded part bonded to one surface of a base material. The figure which shows typically the example of another molded part bonded to one surface of a base material. The figure which shows typically the example of another molded part bonded to one surface of a base material. The figure which shows typically the example of the manufacturing method of an interior material. The figure which shows typically the example of injection molding a molded part on one surface of a base material. The figure which shows typically the molded part bonded to the back surface of the base material in the comparative example.

Hereinafter, embodiments of the present invention will be described. Of course, the following embodiments merely exemplify the present invention, and not all of the features shown in the embodiments are essential for the means for solving the invention.

(1) Outline of the technique included in the present invention:
First, the outline of the technique included in the present invention will be described with reference to the examples shown in FIGS. It should be noted that the figures of the present application are diagrams schematically showing examples, and the enlargement ratios in each direction shown in these figures may be different, and the figures may not be consistent. Of course, each element of the present technology is not limited to the specific example indicated by the reference numeral.

[Aspect 1]
As illustrated in FIGS. 3 and 4, the vehicle interior material 1 of the present technology is joined to a molded base material 2 containing air Ar and a part of one surface (for example, the back surface 2b) of the base material 2. A molded portion 3 of the resin R1 is provided. The molding portion 3 has a main body portion 30 and a regression rib 40 that extends from the main body portion 30 along one surface (2b) of the base material 2 and turns in a curved shape to return to the main body portion 30. ..

FIG. 13 schematically shows the back surface of the deck side trim 901 according to the comparative example. In this deck side trim 901, a molding portion 903 by injection molding of molten resin is joined to a part of the back surface 2b of the lightweight base material 2. The molding portion 903 shown in FIG. 13 has a main body portion 30 which is a clip mounting seat, and a plurality of protruding ribs 940 protruding outward along the back surface 2b of the base material from the side surface portion 32 of the main body portion 30. There is. The main body portion 30 has a head portion 31 in which a locking hole 31h connected to a clip insertion port 31o is formed, and a side surface portion 32 that supports the head portion 31.

Each protruding rib 940 has a dead end tip 941. Therefore, when a force Fb having a component along the back surface 2b of the base material is applied to the molding portion 903, the molding portion 903 may be peeled off from the base material 2 starting from the protruding tip 941.

In the molding portion 3 of the above aspect 1, since the rib is connected to the main body portion 30, the deformation of the base material 2 due to the shrinkage of the molding portion 3 after injection molding is suppressed. Further, since the regression rib 40 connected to the main body portion 30 extends from the main body portion 30 along one surface (2b) of the base material 2 and changes its direction in a curved shape to return to the main body portion 30, it is a protruding dead end. There is no tip of. Therefore, even if a force Fb (see, for example, FIG. 4) having a component along one surface (2b) of the base material 2 is applied to the molded portion 3, the regression rib 40 is formed on the one surface (2b) of the base material 2. It is unlikely to be the starting point for peeling of part 3. Therefore, this aspect can provide a novel vehicle interior material in which deformation of the base material and peeling of the molded portion starting from the rib are suppressed.

Here, the base material containing air includes a base material in which fibers are aggregated, a base material made of foamed resin, a base material in which fibers and foamed resin are combined, and the like. A base material in which a skin material or the like is adhered to these materials is also included in the base material containing air.
The resin includes a thermoplastic resin, a cured resin, and the like.
The main body includes a clip mounting seat, a decorative portion, a resin frame attached to an opening of an interior material, and the like.
The appendix of the above aspect 1 is the same as that of the following aspects.

[Aspect 2]
As shown in FIG. 9, the regression rib 40 that extends from the main body portion 30 along one surface (2b) of the base material 2, changes its direction in a curved shape, and returns to the main body portion 30 may have a curved shape without a linear portion. However, as shown in FIG. 3 and the like, the shape may be a combination of a curved line and a straight line. In this embodiment, peeling of the molded portion starting from the rib can be further suppressed.

[Aspect 3]
As shown in FIG. 3 and the like, the return rib 40 extends from the main body 30 in the first direction (for example, the direction DR1) along one surface (2b) of the base material 2 and turns in a curved shape. A first rib (for example, rib 41) returning to the main body portion 30 and a second direction (for example, for example) different from the first direction (DR1) from the main body portion 30 along one surface (2b) of the base material 2. A second rib (for example, a rib 42) that extends in the direction DR2), changes its direction in a curved shape, and returns to the main body portion 30 may be included. In this embodiment, since the regression rib 40 is unlikely to be the starting point of peeling of the molded portion 3 with respect to one surface (2b) of the base material 2 with respect to a force in a wider range, the peeling of the molded portion starting from the rib is further suppressed. can do.
Although not included in the above aspect 3, the case where there is no second rib is also included in the present technology.

[Aspect 4]
As illustrated in FIG. 3 and the like, the molding portion 3 has the first rib (41) and the second rib (42) along one surface (2b) of the base material 2 at a position away from the main body portion 30. ) May have a connecting rib 50. In this embodiment, since the regression rib 40 is unlikely to be the starting point of peeling of the molded portion 3 with respect to one surface (2b) of the base material 2 with respect to a force in a wider range, the peeling of the molded portion starting from the rib is further suppressed. can do.
Although not included in the above aspect 4, the case where there is no connecting rib is also included in the present technology.

[Aspect 5]
As illustrated in FIG. 8 and the like, the molding portion 3 has a crosslinked rib 60 that divides a region A1 surrounded by the main body portion 30 and the regression rib 40 in one surface (2b) of the base material 2. You may. In this aspect, the adhesive strength can be improved while suppressing the deformation of the base material due to the shrinkage of the molded portion after injection molding.
Here, the crosslinked rib 60 may be connected to the first portion P1 of the regression rib 40 and the second portion P2 of the regression rib 40, or may be connected to the main body portion 30 and the regression rib 40.
Although not included in the above aspect 5, the case where there is no crosslinked rib is also included in the present technology.

[Aspect 6]
Further, as illustrated in FIG. 11 and the like, the method for manufacturing the vehicle interior material 1 of the present technology includes a base material forming step ST1, a transfer step ST2, and an injection step ST3. In the base material forming step ST1, a base material 2 having a required shape containing air Ar is formed. The transfer step ST2 includes a main body portion 30 and a regression rib 40 that extends from the main body portion 30 along one surface (2b) of the base material 2, changes its direction in a curved shape, and returns to the main body portion 30. Then, the base material 2 is transferred to an injection molding mold 310 having a cavity CA0 forming a molding portion 3 bonded to one surface (2b) of the base material 2. In the injection step ST3, the resin R1 is injected into the cavity CA0 of the injection molding mold 310 on which the base material 2 is arranged.
As described above, the vehicle interior material 1 in which the molded portion 3 of the resin R1 is bonded to a part of one surface (2b) of the base material 2 having the required shape can be obtained.

In the sixth aspect, when the resin R1 is injected into the cavity CA0, the molded portion 3 having the main body portion 30 and the regression rib 40 is joined to one surface (2b) of the base material 2. Since the return rib 40 extends from the main body 30 and turns in a curved shape and returns to the main body 30, the injected resin R1 is likely to be filled in the cavity (CA2) for the return rib 40. Therefore, the degree of freedom in the shape of the molded portion 3 and the cavity CA0 is high. Further, in the obtained molded product, deformation of the base material 2 and peeling of the molded portion 3 starting from the rib are suppressed. Therefore, this aspect can provide a novel vehicle interior material in which the degree of freedom in the shape of the molded portion is high and the deformation of the base material and the peeling of the molded portion starting from the rib are suppressed.

Here, the resin to be injected includes a molten resin, a curable liquid resin, and the like.

(2) Specific examples of vehicle interior materials of this technology:
FIG. 1 schematically shows the interior of the automobile 100 as an example in a state where the side surface portion is not shown. FIG. 2 schematically shows the back surface 2b of the deck side trim 111 as an example of the vehicle interior material. FIG. 3 schematically shows a clip mounting seat (an example of the main body portion 30) and ribs 40 and 50 as examples of the molded portion. At the bottom of FIG. 3, ribs 41, 50, and 42 are extracted and shown. FIG. 4 schematically shows a cross section of the deck side trim 111 at a position where the opening 33 of the clip mounting seat can be seen as an example of the cross section of the interior material. FIG. 5 schematically shows an example of a clip. In these figures, FRONT, REAR, UP, and DOWN indicate front, back, top, and bottom, respectively. Further, reference numeral D1 indicates a front-rear direction of the automobile 100, reference numeral D2 indicates a vertical direction of the automobile 100, and reference numeral D4 indicates a thickness direction of the interior material 1.

The automobile 100 shown in FIG. 1 is a road-traveling automobile designed and equipped to be used on a road. For example, a metal body panel made of steel plate surrounds the passenger compartment SP1 and the luggage compartment SP2 to surround the vehicle body. Is forming. Further, the automobile 100 shown in FIG. 1 is a wagon type passenger automobile having a rear luggage compartment SP2 connected to the passenger compartment SP1 and having two rows of seats 101 (front seat and rear seat). Of course, automobiles to which this technology can be applied include automobiles other than the two-row seat type such as the three-row seat type, and include so-called station wagons, one-box cars and the like, as well as sedans and the like.

Various interior materials 1 are arranged on the interior (SP1, SP2) side of the vehicle body panel of the automobile 100. On the deck side panel (example of the vehicle body panel) on the side of the luggage compartment SP2, a deck side trim 111 (example of the interior material 1) is installed on the luggage compartment SP2 side. A door trim 112 (example of interior material 1) is installed on the side of the vehicle compartment SP1 on the door panel (example of the vehicle body panel) on the side of the vehicle compartment SP1. Similarly, a pillar trim 113 (example of interior material 1) is installed on the side of the vehicle compartment SP1 on a pillar (example of a vehicle body panel) on the side of the vehicle compartment SP1. Roof trim 114 (example of interior material 1) is installed on the interior (SP1, SP2) side of the roof panel (example of vehicle body panel) above the passenger compartment SP1 and luggage compartment SP2. A rear door trim 115 (example of interior material 1) is installed on the luggage compartment SP2 side of the rear door (Tailgate) 105 located behind the luggage compartment SP2.

In the base material 2 shown in FIGS. 2 to 4, the backing S2b of the skin material S2 is adhered to the surface of the base material main body 10 formed into a required shape having irregularities, and the back surface 2b of the base material 2 (an example of one surface of the base material). ), A resin molding portion 3 is integrally injection-molded. If the skin material adheres to the base material body without backing, the backing can be omitted, and the surface material of the base material may be omitted and the surface of the base material body may be used as the surface of the base material. The molding portion 3 includes a main body portion 30, a regression rib 40, a connecting rib 50, and a crosslinked rib 60 (see FIGS. 8 and 10). The molded portion 3 may be joined to the surface 2a of the base material 2. The molding portions 3 bonded to the base material 2 are shown in the molding portions 3A shown in FIG. 3, the molding portions 3B shown in FIG. 6, the molding portions 3C shown in FIG. 7, the molding portions 3D shown in FIG. 8, and FIG. The molding part 3E, the molding part 3F shown in FIG. 10, and the like are included. As shown in FIG. 2, a plurality of types of molded portions among the molded portions 3A to 3F and the like may be bonded to the base material 2.

The base material body 10 of the base material 2 is a base material containing air Ar such as a base material 10A in which fibers F1 are aggregated, a base material 10B made of foamed resin, and a base material in which fibers and foamed resin are combined. A base material containing a thermoplastic material such as a thermoplastic resin can be used.

As the fibrous base material 10A, a fiber aggregate formed by assembling fibers F1 and containing air Ar, such as a breathable press-formed fiber mat, can be used. The base material 10A may be a fiber aggregate having a multi-layer structure, such as a fiber mat in which a design layer, a shape-retaining layer, and a sound-absorbing layer are laminated.
Fibers F1 for forming the base material 10A include fibers of synthetic resin (including elastomer) such as thermoplastic resin, fibers in which additives are added to synthetic resin, inorganic fibers such as glass fiber and carbon fiber, and plant fibers such as kenaf. , Anti-hair fibers, at least a combination thereof, and the like can be used, and fibers containing thermoplastic fibers such as thermoplastic resin fibers are preferable. As the thermoplastic resin, a polyolefin resin such as polypropylene (PP) resin or polyethylene resin (PE), a polyester resin such as polyethylene terephthalate (PET) resin, a polyamide (PA) resin, an acrylic (PMMA) resin, or the like can be used. .. The fiber F1 may include a main fiber and an adhesive fiber (binder), or may contain a fiber having a conjugated structure such as a core-sheath structure or a side-by-side structure. Further, by mixing inorganic fibers such as glass fibers with thermoplastic fibers, the rigidity of the base material can be increased. The thermoplastic material contained in the base material 10A may be contained in the fiber F1 or may be contained in a material other than the fiber F1.

The thickness Tb (see FIG. 4) of the fibrous base material 10A is preferably 1 mm or more and 8 mm or less, and more preferably 2 mm or more and 7 mm or less, from the viewpoint of being lightweight and obtaining the required rigidity. The basis weight of the base material 10A is preferably ^{450 g / m 2} or more and 1200 g / m ² or less from the viewpoint of being lightweight and obtaining the required rigidity.

As the base material 10B made of foamed resin, a foamed molded product obtained by foaming a resin material and molding so as to contain air bubbles (air Ar) can be used. For example, injection molding can be used for foam molding of the resin material. Further, the base material 10B may have a multilayer structure such as a foamed resin molded product in which a skin layer is left on the surface, a molded product in which a substantially non-foamed layer is laminated on at least one surface of the foamed resin layer, and the like.
As the resin material for forming the base material 10B, various synthetic resins (including elastomers) can be used as long as they contain a thermoplastic material such as a thermoplastic resin, and additives may be added. .. As the thermoplastic resin for forming the base material 10B, polyolefin resins such as PP resin and PE resin, polystyrene (PS) resin, combinations thereof, and the like can be used, and additives such as fillers are included. May be good. For foaming of the resin, physical foaming that dissolves the gas pressurized in the cylinder in the molten resin, chemical foaming that adds a chemical foaming agent and mixes the gas into the molten resin by thermal decomposition or chemical reaction, etc. are adopted. be able to. Foaming agents include volatile foaming agents that generate hydrocarbons such as butane and pentane, organic foaming agents such as azodicarbonamide (ADCA) and hydrazodicarbonamide, and inorganic foaming agents that generate carbon dioxide gas such as ammonium carbonate. , Etc. can be used.

The thickness Tb (see FIG. 4) of the foamed resin base material 10B is preferably 1 mm or more and 8 mm or less, and more preferably 2 mm or more and 7 mm or less, from the viewpoint of being lightweight and obtaining the required rigidity. The basis weight of the base material 10B is preferably ^{450 g / m 2} or more and 1200 g / m ² or less from the viewpoint of being lightweight and obtaining the required rigidity.

The main body portion 30 bonded to the base material 2 includes a clip mounting seat, a decorative portion, a resin frame attached to an opening of an interior material, and the like. The clip mounting seat is a functional portion for mounting a clip 500 (see FIG. 5) for fixing the interior material to a mating member such as a vehicle body panel, and is usually arranged on the back surface of the interior material. The decorative portion is usually a functional portion arranged on the surface of the interior material. The resin frame is used, for example, as a functional portion for fitting a claw of a separate maintenance cover (service cover) that can open and close a maintenance hole (example of opening) provided in the deck side trim.

The clip 500 shown in FIG. 5 has an elastic clip head 501, a dish-shaped seal piece 502, a disk-shaped upper flange 503, a columnar leg portion 504, and a circle in this order from the outside of the vehicle to the interior material side. It has a plate-shaped lower flange 505. The clip 500 is made of resin, for example, and is formed by molding a resin molding material such as a thermoplastic resin. When the lower flange 505 is inserted into the locking hole 31h from the insertion port 31o of the clip mounting seat (30), both flanges 503 and 505 penetrate the hole 31h while sandwiching the head 31 of the clip mounting seat. In this state, the clip 500 is attached to the clip mounting seat (30).

The main body portion 30 shown in FIGS. 2 to 4 has a head portion 31 to which the clip 500 can be attached, and a side surface portion 32 connecting the base material 2 to the head portion 31. Between the head 31 and the base material 2, there is a space SP3 into which the end portion (lower flange 505) of the clip 500 can be inserted. The head 31 has a hole 31h connected to an insertion port 31o at the end (leg 504) of the clip 500, and is arranged along the back surface 2b of the base material 2 with the space SP3 placed therein. The side surface portion 32 is connected to a pair of side wall portions 32a from the back surface 2b of the base material to the edge of the head 31 with the space SP3 interposed therebetween, and from the back surface 2b of the base material to the edge of the head 31 facing the opening 33. It has a back wall portion 32b. The back wall portion 32b is connected from one side wall portion 32a to the other side wall portion 32a. Therefore, the space SP3 is surrounded by the back surface 2b of the base material, the head 31, the pair of side wall portions 32a, and the back wall portion 32b, except for the opening 33 connected to the insertion port 31o.

The ribs 40, 50, 60 shown in FIGS. 2 to 4, 6 to 10 are arranged on the back surface 2b around the main body 30 with respect to the base material 2 formed into a three-dimensional shape. The heights Hr of the ribs 40, 50, 60 from the back surface 2b of the base material (see FIG. 4) are not particularly limited, but are preferably lower than the height Hb of the main body 30 from the back surface 2b of the base material, for example. It can be about 2 to 10 mm. The thickness Tr of the ribs 40, 50, 60 (see FIG. 3) is not particularly limited, but can be, for example, about 1 to 5 mm. In the present application, "Min to Max" means a minimum value of Min or more and a maximum value of Max or less.
In this specific example, it is assumed that all the ribs 40, 50, and 60 have the same height Hr and the same thickness Tr. Of course, the height Hr and the thickness Tr may be changed according to the type of ribs, the height Hr and the thickness Tr may be different between the nearby regression ribs 40, and the height Hr and the thickness Tr may be different between the nearby connecting ribs 50. The height Hr and the thickness Tr may be different, or the height Hr and the thickness Tr may be different between the nearby crosslinked ribs 60. Further, for one rib, the height Hr and the thickness Tr may be changed depending on the part, such as lowering the height Hr or reducing the thickness Tr as the distance from the main body 30 is increased.

The regression rib 40 extends from the main body portion 30 along the back surface 2b of the base material 2, changes its direction in a curved shape, and returns to the main body portion 30. As shown in FIGS. 3, 6, 7 and 9, the region A1 surrounded by the regression rib 40 and the main body 30 on the back surface 2b of the base material is an exposed portion where the back surface 2b is exposed. The regression rib 40 connected to the main body portion 30 can also be expressed as a “circulation rib”, a “U-turn rib”, a “regression rib”, or the like.

The return rib 40 of the molding portion 3A shown in FIG. 3 extends from the left side wall portion 32a to the left side DR1 and turns in a curved shape to return to the side wall portion 32a, and extends from the back wall portion 32b to the upward DR2. It includes a rib 42 that changes its direction in a curved shape and returns to the back wall portion 32b, and a rib 43 that extends from the right side wall portion 32a to the right DR3 and changes its direction in a curved shape and returns to the side wall portion 32a. That is, the number of regression ribs 40 included in the molded portion 3A is three. Since the directions DR1, DR2, and DR3 are different from each other, for example, when the direction DR1 is applied to the first direction, the directions DR2 and DR3 become the second direction, the rib 41 becomes the first rib, and the ribs 42 and 43 become the first rib. It becomes two ribs. When the direction DR2 is applied to the first direction, the directions DR1 and DR3 become the second direction, the rib 42 becomes the first rib, and the ribs 41 and 43 become the second rib. When the direction DR3 is applied to the first direction, the directions DR1 and DR2 become the second direction, the rib 43 becomes the first rib, and the ribs 42 and 43 become the second rib.

Each of the ribs 41, 42, 43 has a straight portion 40b extending linearly in the directions DR1, DR2, DR3 away from the main body 30, a curved portion 40a having a curved shape changed from the straight portion 40b by approximately 180 °, and a curved portion 40a. It has a straight line portion 40b that returns to a straight line from the curved line portion 40a to the main body portion 30. Therefore, each of the ribs 41, 42, and 43 has a shape that is a combination of a curved shape and a linear shape. The curved portions 40a of the ribs 41, 42, and 43 shown in FIG. 3 have the same curvature, but the curvatures of the curved portions 40a may be different between the nearby regression ribs 40.

The connecting rib 50 connects the first rib and the second rib along the back surface 2b of the base material 2 at a position away from the main body portion 30. As shown in FIG. 3, in the back surface 2b of the base material, the region A2 surrounded by the ribs 40 and 50 and the main body 30 is an exposed portion where the back surface 2b is exposed. The connecting rib 50 shown in FIG. 3 includes a connecting rib connecting the rib 41 (example of the first rib) to the adjacent rib 42 (example of the second rib), and a rib adjacent to the rib 42 (example of the first rib). Includes connecting ribs leading to 43 (example of second rib). Each connecting rib 50 has a straight portion 50b that extends linearly in a direction away from the first rib (41 or 42), a curved portion 50a that is curvedly oriented by approximately 90 ° from the straight portion 50b, and this curved line. It has a straight portion 50b that connects the portion 50a to the second rib (42 or 43). Therefore, the connecting rib 50 has a shape that is a combination of a curved shape and a straight shape. The curved portions 40a of each connecting rib 50 shown in FIG. 3 have the same curvature, but the curvatures of the curved portions 40a may be different between the connecting ribs 50.

As in the molding portion 3B shown in FIG. 6, the connecting rib 50 may be omitted depending on the position of joining to the base material 2 and the like.
Further, as in the molding portion 3C shown in FIG. 7, the regression rib 40 may be extended further from the main body portion 30 depending on the position of joining to the base material 2 and the like.

The crosslinked ribs 60 shown in FIGS. 8 and 10 divide a region A1 surrounded by the main body 30 and the regression ribs 40 of the back surface 2b of the base material 2. For example, FIG. 8 shows a molded portion 3D having a crosslinked rib 60 that divides the region A1 surrounded by the regression rib 40 and the main body portion 30 shown in FIG. 7 into regions A3 and A4. Here, the region A3 is an exposed portion surrounded by the ribs 40 and 60 and the main body portion 30 on the back surface 2b of the base material. The region A4 is an exposed portion surrounded by ribs 40 and 60 on the back surface 2b of the base material. Each crosslinked rib 60 is linearly connected from the first portion P1 of the regression rib 40 to the second portion P2 of the regression rib 40 along the back surface 2b of the base material 2 so as to divide the region A1.

The molded portion 3E shown in FIG. 9 has a regression rib 40 without a straight portion 40b. The regression rib 40 is curvedly oriented from the upward DR2 starting from the left side wall portion 32a, extending from the left side wall portion 32a while changing its direction in a curved shape, and returning to the side wall portion 32a. It includes a rib 42 that extends while changing the direction and returns to the back wall portion 32b, and a rib 43 that extends while changing the direction in a curved shape starting from the right side wall portion 32a and returns to the side wall portion 32a. Since the DR1, DR2, and DR3 in each direction are different from each other, when the rib 41 is applied to the first rib, the ribs 42 and 43 become the second rib, and when the rib 42 is applied to the first rib, the ribs 41 and 43 become the second rib. When the rib 43 is applied to the first rib, the ribs 41 and 42 become the second rib. Each rib 41, 42, 43 is formed of a curved portion 40a and has a curved shape.

The connecting rib 50 may have a curved shape without a straight portion 50b or a straight shape without a curved portion 50a.
The crosslinked rib 60 may have a curved shape without a straight portion, or may have a shape obtained by combining a curved shape and a straight shape.

The molding portion 3F shown in FIG. 10 changes the direction of the left side wall portion 32a in a straight line, a curved line that changes the direction by about 180 °, a straight line, a curved line that changes the direction by about 90 °, a straight line, and a direction of about 180 °. It has a return rib 40 that extends in a curved and linear shape and connects to the right side wall portion 32a. Therefore, the number of regression ribs 40 included in the molded portion 3F is one. The molded portion 3F is a crosslinked rib 60 connected from the main body portion 30 to the regression rib 40 along the back surface 2b of the base material 2 so as to divide the region A1 surrounded by the main body portion 30 and the regression rib 40 into a plurality of regions A5. Has a plurality of.

Various synthetic resins (including elastomers) can be used as the resin material for forming the base material body 10 of the molding portion 3 and the base material 2, and additives may be added to facilitate molding. From the viewpoint of properties, a thermoplastic resin material such as a thermoplastic resin is preferable. As the thermoplastic resin, polyolefin resins such as PP resin and PE resin, acrylonitrile butadiene styrene (ABS) resin, combinations thereof, and the like can be used, and additives such as fibers may be contained. When ABS resin or the like having a low coefficient of linear expansion is used as the resin material, shrinkage due to cooling is suppressed and a good base material with less warpage can be obtained. As the fiber, inorganic fiber such as glass fiber or carbon fiber, plant fiber such as kenaf, a combination thereof, or the like can be used.

Further, a foamable resin may be used as the molten resin, and the molded portion 3 or the base material main body 10 may be formed of the foamed resin which is injection-molded so as to contain bubbles. Then, since the limit flow length of the molten resin can be increased by the foaming force of the molten resin, the number of gates can be reduced and the degree of freedom in the shape (design) of the molded portion 3 and the base material body 10 can be improved. Can be done. Further, since the injection pressure can be lowered, when the molded portion 3 is formed, the resin leakage around the gate can be more effectively suppressed, and the deterioration of the interior material such as the skin material can be further effectively suppressed. be able to. Further, since the shrinkage of the injection resin due to cooling is further suppressed, the warp of the base material is also suppressed more effectively.

As the resin material for forming the molded portion 3 and the base material main body 10 with the foamed resin, the above-mentioned various synthetic resins can be used, and additives may be added, and the resin is thermoplastic from the viewpoint of ease of molding. A thermoplastic resin material such as a resin is preferable. Similar to the case of the foamed resin base material 10B, the resin is foamed by physical foaming in which the gas pressurized in the cylinder is dissolved in the molten resin, or by adding a chemical foaming agent to the gas by thermal decomposition or chemical reaction. Chemical foaming, etc., which is mixed with the molten resin can be adopted. As the foaming agent, a volatile foaming agent, an organic foaming agent, an inorganic foaming agent, or the like can be used. As the resin material, a thermoplastic resin such as PP resin is particularly preferably used, and it is preferable to use a resin material to which a filler such as talc is added in an amount of, for example, 15 to 25% by weight. When a filler such as talc is added to the resin material, the filler becomes a core of foaming and the foaming state is improved, so that the warp of the base material is more effectively suppressed.

As the skin material S2, a non-woven fabric, a woven fabric, a knitted fabric, a carpet, a synthetic resin (including an elastomer), rubber, or the like can be used. A backing (lining layer) may be formed on the back surface of the skin material S2. A synthetic resin (including an elastomer) such as a thermoplastic resin can be used for the backing. As the thermoplastic resin, a low melting point thermoplastic resin such as low density polyethylene or ethylene vinyl acetate can be used.

(3) Specific example of manufacturing method of vehicle interior material:
FIG. 11 schematically shows a method of manufacturing the deck side trim 111 as an example of a method of manufacturing the interior material for a vehicle. FIG. 12 schematically shows a state in which the molding portion 3 is injection-molded on the back surface 2b of the base material 2 as an example.

In the production methods shown in FIGS. 11 and 12, a fiber aggregate in which thermoplastic fibers are aggregated on a material sheet S1 (example of a material) for forming the base material 2 (that is, a fiber aggregate containing air Ar) is used. , A thermoplastic resin is used as a resin material for injection molding the base material 2 and the molding portion 3. This manufacturing method includes a base material forming step ST1, a transfer step ST2, and an injection step ST3. In the base material forming step ST1, the material setting step ST1a in which the material sheet S1 before press molding is set in the press molding die 210 (example of the material molding die) and the material sheet S1 before molding are set in the press molding machine 200. The press step ST1b for press molding is included.

In the press molding machine 200 shown in FIG. 11, the upper die 212 and the lower die 214 constituting the press molding die 210 are provided so as to be close to each other and separable from each other. The upper mold 212 is a mold having a mold surface that matches the uneven shape on the luggage compartment SP2 side of the deck side trim 111. The lower mold 214 is a mold having a mold surface that matches the uneven shape of the back surface 2b of the base material 2 except for the molding portion 3. In FIG. 11, the upper mold 212 is a movable type and the lower mold 214 is a fixed type, but the upper mold 212 may be a fixed type and the lower mold 214 may be a movable type, or both types 212 and 214 may be a movable type.

In the first material setting step ST1a, the material sheet S1 to which the required shape is not given is heated above the softening point of the thermoplastic material, preferably above the melting point of the thermoplastic material, and set between the molds 212 and 214. .. Although not shown in FIG. 11, the skin material S2 and the backing or the like may be overlapped on the surface S1a of the material sheet S1 if necessary. In this case, the skin material S2 or the like may be heated as necessary and placed between the molds 212 and 214 so as to be overlapped with the surface S1a side of the material sheet S1 before press molding. Of course, when the material sheet S1 and the skin material S2 and the like are integrated in the original fabric state, they may be heated at the same time.

In the subsequent press step ST1b, at least the material sheet S1 is press-molded into a three-dimensional shape by bringing both molds 212 and 214 close to each other. When the molds 212 and 214 are opened, the three-dimensionally shaped base material 2 can be taken out. When the skin material S2 or the like is stacked, a laminate of the base material main body 10 having a required shape (specifically, the base material 10A in which the fibers F1 shown in FIG. 4 are aggregated) and the skin material S2 or the like can be obtained.
The above is the base material forming step ST1 for forming the base material 2 having a required shape containing air Ar.

In the injection molding machine 300 shown in FIGS. 11 and 12, movable molds 312 and fixed molds 314 constituting the injection molding mold 310 are provided so as to be close to each other and separable from each other. The mold 312 may be a fixed type and the mold 314 may be a movable type, or both molds 312 and 314 may be a movable type. The fixed mold 314 shown in the upper part of FIG. 12 is a master block into which an insert die 315 is fitted. The nesting mold is a partial mold that is used by being fitted into a mother mold, and may be a movable type, which is also called a slide type, or a fixed type. When the nesting mold 315 shown in the upper part of FIG. 12 is used, the nesting mold 315 is placed in the fixed mold 314 at the position shown in the upper part of FIG. 12 before setting the base material 2 having the required shape between the molds 312 and 314. Keep it.

The movable mold 312 is a mold having a mold surface that matches the uneven shape of the deck side trim 111 on the luggage compartment SP2 side. The fixed mold 314 and the nested mold 315 are molds having a mold surface that matches the uneven shape of the back surface 2b of the base material 2. The cavity CA0 for forming the molded portion 3 to be joined to the back surface 2b of the base material is formed by the fixed mold 314 and the nested mold 315. The cavity CA1 for forming the main body 30 and the cavity CA2 for forming the ribs 40, 50, 60 have a shape in which the injection resin R1 is bonded to the back surface 2b of the base material 2. Cavity CA0 is a general term for cavities CA1 and CA2. The cavity CA2 has a regression rib 40 that extends from the main body 30 along the back surface 2b of the base material, turns in a curved shape and returns to the main body 30, and a regression rib along the back surface 2b of the base material at a position away from the main body 30. The shape is matched to the connecting rib 50 that connects the 40s and the crosslinked rib 60 that divides the region A1 surrounded by the main body 30 and the regression rib 40 of the back surface 2b of the base material.

In the transfer step ST2, both molds 212 and 214 of the press molding machine 200 are separated from each other to take out the base material 2 having a required shape, and the base material 2 is transferred between the molds 312 and 314 of the injection molding machine 300 and set. During the transfer from the press molding mold 210 to the injection molding mold 310, the base material 2 cools to become lower than the melting point of the thermoplastic material, and the thermoplastic material is solidified. The temperature of the base material 2 set in the injection molding mold 310 is preferably less than the softening point of the thermoplastic material. The temperature drop of the base material 2 may be a temperature drop due to natural cooling in the atmosphere, or a temperature drop due to forced cooling such as blowing cold air.
The above is the transfer step ST2 for transferring the base material 2 to the injection molding mold 310 having the cavity CA0 forming the molding portion 3.

In the subsequent injection step ST3, both molds 312 and 314 in which the base material 2 set below the melting point of the thermoplastic material, preferably below the softening point is set are closed and molded from the injection device 320 via the gate 316. The molten resin R1 is injected.

In the example shown in FIG. 12, the molten resin R1 injected from the gate 316 into the cavity CA1 for forming the main body flows into the cavity CA2 for forming the rib. Since the cavity for the return rib 40 extends from the cavity CA1 for the main body 30 and turns in a curved shape and returns to the cavity CA1 for the main body 30, the injected resin R1 becomes the cavity for the return rib 40. Easy to fill. If there is a cavity for the connecting rib 50 and a cavity for the crosslinked rib 60, the injected resin R1 is more likely to be filled in the cavity CA2 for the rib. Therefore, the degree of freedom in the shape of the molded portion 3 and the cavity CA0 is high.
As described above, the main body 30 and the ribs 40, 50, 60 were injection-molded, and when the resin R1 solidified, the main body 30 and the ribs 40, 50, 60 were joined to and fixed to the back surface 2b of the base material 2. It becomes a state. Of course, the gate 316 may be in the rib cavity CA2. In this case, the molten resin R1 injected into the cavity CA2 flows into the cavity CA1 for forming the main body.

As described above, the main body portion 30 and the ribs 40, 50, 60 are joined and fixed to a part of the back surface 2b of the base material 2 containing the air Ar.
After that, when both molds 312 and 314 are separated and the nesting mold 315 is removed from the fixed mold 314, the deck side trim 111 having the molding portion 3 of the resin R1 on a part of the back surface 2b of the base material is taken out from the injection molding mold 310. be able to.

When a base material containing a foamed resin base material 10B (see FIG. 4) is used as the base material 2 having the required shape, for example, a resin material (example of the material) is used as a material molding mold for injection molding into the required shape. Is injected and foamed to contain air bubbles (air Ar) (base material forming step ST1), and a foamed molded product (base material containing base material 10B) having a required shape is obtained from the material molding mold. It may be transferred to the injection molding die 310 (transfer step ST2). When the molten resin R1 is injected into the cavity CA0 in the injection step ST3 (the injection step ST3) and the base material 2 is taken out from the injection molding mold 310 together with the molding portion 3 by the molten resin R1, the base material 2 including the base material 10B is formed. A deck side trim 111 to which the molding portion 3 is joined is obtained.

(4) Actions and effects of vehicle interior materials and their manufacturing methods:
The base material 2 of the interior material 1 to be manufactured is lightweight because the base material body 10 having the required shape is at least one of the base material 10A in which the fibers F1 are assembled and the base material 10B made of foamed resin.

Here, assuming that the molded portion 3 does not have ribs 40, 50, 60, the bonding strength of the main body portion 30 is often insufficient with respect to the back surface 2b of the base material because the base material 2 is lightweight. .. When a planar reinforcing portion made of the injection resin R1 is bonded to the back surface 2b of the base material around the main body portion 30, the bonding area of the molded portion 3 to the back surface 2b of the base material increases. The joint can be enhanced. On the other hand, the base material 2 may be deformed due to warpage or wrinkles of the low-density base material 2 due to shrinkage of the planar reinforcing portion of the resin R1 that is cooled after injection molding. Deformation of the base material leads to deterioration of the design of the interior material 1. In this specific example, as shown in FIGS. 2 to 4, 6 to 10, the ribs 40, 50 and 60 are joined to the back surface 2b of the base material so as to extend from the main body 30. Therefore, as shown in FIG. 4, even if a force Fa that separates from the back surface 2b of the base material is applied to the molded portion 3, the molded portion 3 is unlikely to be peeled off from the back surface 2b of the base material. Therefore, in this specific example, it is possible to suppress deformation of the lightweight base material 2 due to shrinkage of the molded part 3 of the resin R1 to be cooled while ensuring sufficient adhesive strength of the molded part 3 with respect to the back surface 2b of the base material. ..

Here, it is compared with the comparative example shown in FIG. In the deck side trim 901 shown in FIG. 13, the molded portion 903 bonded to the back surface 2b of the base material by the molten resin is the main body portion 30 which is a clip mounting seat, and the back surface portion 2b of the base material from the side surface portion 32 of the main body portion 30. It has a plurality of protruding ribs 940 protruding outward along the above. Each protruding rib 940 has a dead end tip 941. Therefore, when the molded portion including the protruding rib is injection-molded, it takes time to fill the cavity with the molten resin. Further, when a force Fb having a component along the back surface 2b of the base material is applied to the molding portion 903, the molding portion 903 may be peeled off from the base material 2 starting from the protruding tip 941.

On the other hand, the regression rib 40 shown in FIGS. 2 to 4, 6 to 10 has no protruding dead end tip and no corner. Therefore, the molten resin is quickly filled in the cavity when the molded portion including the regression rib is injection-molded. Further, since the regression rib 40 extends from the main body portion 30 along the back surface 2b of the base material, changes its direction in a curved shape and returns to the main body portion 30, the shrinkage direction of the resin after injection molding is dispersed, and wrinkles are formed. Occurrence is suppressed. Further, as shown in FIG. 4, even if a force Fb having a component along the back surface 2b of the base material is applied to the molding portion 3, the regression rib 40 is unlikely to be the starting point of peeling of the molding portion 3 with respect to the back surface 2b of the base material. Therefore, this specific example can provide a new vehicle interior material in which deformation of the base material and peeling of the molded portion starting from the rib are suppressed.

Further, when the connecting ribs 50 connect the regression ribs 40 to each other along the back surface 2b of the base material at a position away from the main body 30, the return ribs 40 with respect to the back surface 2b of the base material with respect to a force in a wider range. It is unlikely to be the starting point for peeling of the molded portion 3. Therefore, peeling of the molded portion starting from the rib is further suppressed.
Further, when the crosslinked rib 60 divides the region A1 surrounded by the main body portion 30 and the regression rib 40 of the back surface 2b of the base material, adhesion is performed while suppressing deformation of the base material due to shrinkage of the molded portion after injection molding. The strength can be improved.

(5) Modification example:
Various modifications of the present invention can be considered.
The vehicle interior material to which this technology can be applied may be a door trim 112, a pillar trim 113, a roof trim 114, a rear door trim 115, a trunk interior material, or the like, in addition to the deck side trim 111.
This technique can also be applied to a base material in which a base material 10A in which fibers F1 are aggregated and a base material 10B made of foamed resin are mixed.
Although it is preferable that the molded portion 3 is bonded to the back surface 2b of the base material, the molded portion 3 may be bonded to the surface surface 2a of the base material.

The number of ribs 40, 50, 60 in one molded portion 3 is not limited to the above-described embodiment. For example, the number of regression ribs 40 in one molding portion 3 may be two or four or more. The number of connecting ribs 50 connecting the return ribs 40 to each other is not limited to one, and may be two or more. The number of the crosslinked ribs 60 that divides the region A1 surrounded by the main body portion 30 and the regression ribs 40 may be two, three, or five or more.

(6) Conclusion:
As described above, according to the present invention, it is possible to provide a new technique such as an interior material for a vehicle in which deformation of a base material and peeling of a molded portion starting from a rib are suppressed by various aspects. it can. Of course, the above-mentioned basic actions and effects can be obtained even with a technique consisting of only the constituent requirements according to the independent claims.
In addition, the configurations disclosed in the above-mentioned examples are mutually replaced or the combinations are changed, the known techniques and the respective configurations disclosed in the above-mentioned examples are mutually replaced or the combinations are changed. It is also possible to implement the above-mentioned configuration. The present invention also includes these configurations and the like.

1 ... Interior material,
2 ... Base material, 2a ... Front surface, 2b ... Back surface (example of one surface of the base material),
3 ... Molded part,
10 ... Base material body, 10A ... Base material with aggregated fibers, 10B ... Base material made of foamed resin,
30 ... Main body, 31 ... Head, 32 ... Side, 32a ... Side wall, 32b ... Back wall,
40 ... Regression rib, 40a ... Curved part, 40b ... Straight part, 41, 42, 43 ... Rib,
50 ... connecting ribs, 50a ... curved parts, 50b ... straight parts,
60 ... Cross-linked ribs,
100 ... car, 111 ... deck side trim,
200 ... Press molding machine, 210 ... Press molding mold, 212 ... Upper mold, 214 ... Lower mold,
300 ... Injection molding machine, 310 ... Injection molding type, 312 ... Movable type, 314 ... Fixed type,
315 ... Nested type, 316 ... Gate, 320 ... Injection device,
A1 to A5 ... Area,
Ar ... Air, CA0, CA1, CA2 ... Cavity,
DR1, DR2, DR3 ... direction,
P1 ... 1st part, P2 ... 2nd part,
R1 ... Resin,
S1 ... Material sheet, S1a ... Surface, S2 ... Skin material, S2b ... Backing,
ST1 ... Base material forming process, ST2 ... Transfer process, ST3 ... Injection process.

Claims (6)

A vehicle interior material comprising a molded base material containing air and a resin molded portion bonded to a part of one surface of the base material.
The molded portion is a vehicle interior material having a main body portion and a return rib extending from the main body portion along one surface of the base material, turning in a curved shape and returning to the main body portion. The vehicle interior material according to claim 1, wherein the regression rib has a curved shape or a shape obtained by combining a curved shape and a straight line. The regression ribs are a first rib extending from the main body portion in a first direction along one surface of the base material, turning in a curved direction and returning to the main body portion, and the return rib along one surface of the base material. The vehicle according to claim 1 or 2, comprising a second rib extending from the main body in a second direction different from the first direction, turning in a curved direction and returning to the main body. Interior material. The vehicle interior material according to claim 3, wherein the molded portion has a connecting rib connecting the first rib and the second rib along one surface of the base material at a position away from the main body portion. The vehicle interior according to any one of claims 1 to 4, wherein the molded portion has a crosslinked rib that divides a region surrounded by the main body portion and the regression rib on one surface of the base material. Material. A base material forming process for forming a base material having a required shape including air,
A molded portion having a main body portion and a regression rib that extends from the main body portion along one surface of the base material portion, changes its direction in a curved shape, and returns to the main body portion, and is joined to one surface of the base material. A transfer step of transferring the base material to an injection molding mold having a cavity to be formed, and
A method for manufacturing an interior material for a vehicle, which comprises an injection step of injecting a resin into the cavity of the injection molding mold on which the base material is arranged.

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