JPH0618720B2 - Manufacturing method of automobile interior materials - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing an automobile interior material, and more particularly to a method for producing an automobile interior material having a soft layer.

[Prior Art] Conventionally, as an automobile interior material, in order to make the interior space of the vehicle comfortable, a cushion material or the like that is a soft layer is attached to a skin material to form the interior material. When this interior material is manufactured, a deep undercut part may be formed by separately molding a skin material with a soft layer and a base material, and then joining the two with an adhesive material or the like. There is a problem in that it cannot be processed or cannot be joined. Therefore, various techniques have been proposed in the past.

For example, as shown in FIG. 4, after the skin material 41 in which the soft layer 42 is bonded to the skin 43 is wider and larger than the base material 44 and integrally bonded, the end portion of the skin material 41 is made into a base material by the following processing step. There is a technique in which it is rolled up inside 44 as shown by an arrow and joined by an adhesive, or fixed by a tacker or the like to perform terminal treatment.

Further, as shown in FIG. 5, there is a technique in which a skin material 51 composed of a skin 53 with a soft layer 52 and a base material 54 are mounted on a mold (not shown) and mechanically integrally processed by mold clamping.

[Problems to be Solved by the Invention] In the technique shown in FIG. 4, the base material 44 can be bonded to the skin material 41 when it is made of a material such as ABS resin that is easily bonded. In the case of using an olefin resin, for example, in the case of polypropylene (PP), in order to make the adhesive work effectively, when the adhesive is used, fine unevenness is formed on the bonding surface It is necessary to apply primer treatment to Therefore, there are problems that the number of steps is large and the manufacturing cost is high. There is also a problem in that the shape and the like of the surface of the skin material do not appear clearly due to the pressure generated when joining.

Further, in the technique shown in FIG. 5, the molds can be integrally joined, but if the undercut portion X is deep, there is a problem that a parting line of the mold is generated in the skin material. Further, in each of the above-mentioned techniques, there is a problem that the skin material is crushed due to the joining of the skin material and the base material, and the shape cannot be expressed properly.

An object of the present invention is to provide a method of manufacturing an interior material which can be molded regardless of the material of the base material as long as it is a thermoplastic resin, and moreover, the shape can be surely formed, the width of the design is large, and the number of steps is small. is there.

[Means for Solving the Problems] In order to achieve the above object, the method for manufacturing an automobile interior material according to the present invention has a bubble in one of the molds in at least stamping molding using an upper mold and a lower mold. It is characterized in that a skin material provided with a soft layer is attached, and a thermoplastic resin as a base material is injected into the other mold and the mold is clamped.

Further, as shown in Examples, the skin material having the soft layer is characterized in that it has a crosslinked foamed vinyl chloride resin layer between the skin and the soft layer.

[Operation] In the present invention, the skin material provided with the soft layer is mounted on one mold, and the thermoplastic resin serving as the base material is injected into the other mold and the mold is clamped. Can be joined to and processed at the end. Therefore, it is not necessary to perform the primer treatment or the application of the adhesive so that the adhesive is used. Also, it is not joined with a tacker or the like. Moreover, since the base material can be molded, the skin material and the base material can be joined, and the terminal treatment can be performed at once by stamping molding, the number of manufacturing steps can be reduced. Furthermore, since the interior material is integrally formed by stamping molding, compared to the case where the skin material and the base material are manufactured and attached separately, the shape can be more reliably formed and the interior material for automobiles having a wider design range can be obtained. Obtainable.

Further, as shown in the examples, the skin material provided with the soft layer is configured to have a crosslinked foamed vinyl chloride resin layer between the skin and the soft layer. With such a skin material,
Even if the soft layer is crushed due to pressure and heat applied during molding,
A soft feeling can be maintained by the crosslinked foamed vinyl chloride resin layer. Further, even if the soft layer is compressed or crushed by heat, the compressed or crushed soft layer constitutes a bubble, and thus can have a heat insulating effect.

[Embodiment] An embodiment of the present invention will be described below with reference to the drawings. However, it goes without saying that the members, arrangements, materials and the like described below do not limit the present invention, but are examples of the present invention.

1A to 1E, a pillar as an automobile interior material will be described in this example. The center pillar 1 of this example is formed by joining a base material 2 and a skin material 3 as shown in FIG. 1E.

The skin material 3 is formed by joining a skin 3a made of vinyl chloride and a soft layer 3b having a cushioning property such as polypropylene foam, and is formed in a predetermined shape in advance. And the skin material 3 is, as shown in FIG.
a is formed by being bent inward.

The mold of this example comprises an upper mold 6 and a lower mold 7. The upper mold 6 comprises a fixed mold 6a and a sliding mold 6b, and the upper mold 6 has a concave space in which the skin material 3 can be mounted. The outer cover member 3 is shaped so as to cover the outer cover member 3 to the outer position while leaving a slightly left end of the bent terminal portion 1a. In this way, since the end portion 1a becomes the undercut portion, the upper mold 6
Is a split type.

The lower mold 7 has a convex shape and contacts the upper mold 6 to form a cavity having a predetermined shape.

Next, a manufacturing procedure using the molds 6 and 7 will be described.

First, as shown in FIG. 1A, the skin material 3 is set in the upper mold 6. In this, the split mold 6b of the upper mold 6 is slid by a slide mechanism (not shown), the skin material 3 is mounted on the fixed mold 6a, and then the split mold 6b is slid and set on the upper mold 6. Next, as shown in FIG. 1B, heat is applied to the convex portion of the lower mold 7 to inject a thermoplastic resin (which will become the base material 2) in a moldable state by a supply device (not shown). After injecting the resin,
The upper and lower molds 6 and 7 are pressed to perform stamping molding (see FIG. 1C). Then, as shown in FIG. 1D, the upper and lower molds 6,
Open 7 and take out the molded product. FIG. 1E is a partially enlarged view showing the terminal portion 1a of the interior material 1 molded in this way, and the skin portion 3a and the soft layer 3b constituting the skin material 3 are shown.
Since the resin serving as the base material 2 can cover and press the end portion 1a of the base material 2 into the end portion 1a, no special end treatment is required. Moreover, since stamping molding is used, not only can the mold on the skin material side reliably achieve a predetermined shape, but also the degree of freedom in design can be increased.

2 to 3 show a second embodiment of the present invention.

In this example, as the skin material, a plate-shaped material having a crosslinked expanded vinyl chloride layer 35 laminated between a skin 31 and a polypropylene foam layer 32 as shown in FIG. 3 is used.

This is a PVC or fabric skin 61 as shown in FIG. 6A.
When a skin material 63 made of a laminate of a polypropylene foam 62 and a polypropylene foam 62 is used, in mold stamping, when a base material (not shown) made of a molten resin in a mold is molded,
Since the polypropylene foam 62 is compressed or crushed due to heat, there is a problem that it is extremely difficult to control the temperature of the base resin in the mass production process. To prevent this, as shown in FIG. 6B. Further, a non-woven fabric or a film 64 is laminated to prevent heat from affecting the polypropylene foam 62. However, even in this case, there is a problem that the polypropylene foam layer becomes thin, and therefore it is necessary to manufacture the polypropylene foam layer with a possibility of collapse. Molding in consideration of the prospect like this,
It is not suitable for accurate and uniform shaping in mass production. Further, as shown in FIG. 6C, even when a urethane foam or vinyl chloride chloride 66 is laminated between a PVC (or cloth) skin 61 and a non-woven fabric (film) 65, the same operation as described above is performed. However, there is a problem that it is heavy and loses its softness.

In the present example, the above-mentioned problems do not occur in stamping molding. As shown in FIG. 3A, the skin material 33 of this example is made of PVC or cloth.
1 and a soft layer 32 made of polypropylene foam, a cross-linked expanded vinyl chloride resin layer 35 is laminated to form a plate-like body.

In the molding of this example, as shown in FIGS. 2A to 2C, after the plate-shaped skin material 33 is held by the upper mold 21, the base material 34 is used.
Is filled with a thermoplastic resin in a moldable state by applying heat, and the upper and lower molds 21 and 22 are pressed and tightened.

When the skin material 33 as in this example is used, pressure and heat are applied at the time of molding to compress or crush the soft layer 32 to reduce the thickness of the soft layer 32, but the soft layer 32 has at least bubbles. Therefore, it has a heat insulating effect as compared with the above-mentioned conventional skin material and hardly causes the destruction of the crosslinked expanded vinyl chloride resin layer 35. This crosslinked foamed vinyl chloride resin layer has a good soft feeling. Moreover, the cavity shape of the mold can be accurately formed.

In this example, a plate-shaped skin material was used, but a mold capable of treating the terminal portion as in the first embodiment is used, and a skin material preliminarily molded into a predetermined shape is used. This makes it possible to solve problems such as terminal processing.

[Advantages of the Invention] Since the present invention is configured as described above, a thermoplastic resin can be molded regardless of the material of the base material, and moreover, the shape of the skin material can be surely formed and the design range is wide. It is possible to provide a method for manufacturing an automobile interior material having a small number of steps.

[Brief description of drawings]

FIG. 1 shows a first embodiment of the method of the present invention. FIGS. 1A to 1D are schematic views of the manufacturing process, and FIG. 1E is a partial sectional view of an automobile interior material, FIG. 2 and FIG. FIG. 3 shows a second embodiment, FIGS. 2A to 2C are schematic views of the manufacturing process, FIG. 3A is a partial sectional view of a skin material, FIG. 3B is a partial sectional view of an automobile interior material, and FIG. FIGS. 6 to 6 show a conventional example, FIGS. 4 and 5 are schematic sectional views of an interior material, and FIGS. 6A to 6C are partial sectional views of a skin material. 1 ... Automotive interior material (pillar), 2, 34 ... Base material,
3, 33 ... Skin material, 3a, 31 ... Skin, 3b, 32
...... Soft layer, 6 (6a, 6b), 21 ... Mold (upper mold), 7,22 ... Mold (lower mold), 35 ... Crosslinked foamed vinyl chloride layer.

Claims (3)

[Claims] 1. In stamping molding using at least upper and lower molds, a skin material having a soft layer having bubbles is attached to one of the molds, and a thermoplastic resin as a base material is injected into the other mold. A method for manufacturing an interior material for an automobile, characterized in that the material is clamped with a pressure die. 2. The production of an automobile interior material according to claim 1, wherein the skin material having the soft layer has a crosslinked foamed vinyl chloride resin layer between the skin and the soft layer. Method. 3. The method for producing an automobile interior material according to claim 1 or 2, wherein the thermoplastic resin as the base material is an olefin resin.