JPH0796791A - Manufacture of laying interior material for automobile and laying interior material - Google Patents

Abstract

PURPOSE:To secure an automobile laying interior material being lighter in weight and high in rigidity by pressing and heating an outer layer fiber material subjected to the backing of thermoplastic resin and stacking it so as to be opposed on a honey comb core base material laminated with a low 'metsuke' nonwoven fabric, unitizing them in one, and forming it into the specified form. CONSTITUTION:A honeycomb core 13 is one that is made up of forming a lot of cylindrical projections on a polypropylene resin sheet and covering both sides with the same resin liner, and a nonwoven fabric 14 being 5mm in thickness below 200g/m<2> in 'metsuke' quantity is stuck to the one side. A surface fiber material 11 is made up of applying a backing 12 of low density polyethylene resin on the backside. This surface fiber material is heated from the backside, keeping the backing in a state of being softened intact, and the honeycomb core is also heated, manifesting its plasticity, and a surface provided with the nonwoven fabric is turned upside, then the surface fiber material is stacked, pressed and formed from the upside. Fluff of this nonwoven fabric gets into the backing and stuck, thereby unitizing the surface fiber material and the honeycomb core in one, and when shaping is fixed, it is rapped from the mold and thus a laying material is obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laying interior material laid on a floor panel of an automobile.

[0002]

2. Description of the Related Art Conventionally, carpets are laid on a floor panel as an interior material for interior decoration of automobiles. For example, FIG. 4 shows an example of installation in the luggage room 50.
This kind of carpet is a needle punched carpet, a tufted carpet, a non-woven fabric, or the like, and is formed by providing a backing of a thermoplastic resin on the back surface and shaping it into a shape generally conforming to the floor panel. Although the carpet has a certain degree of hardness, it is a flexible material mainly composed of fibers, and is essentially a laying mode leaning against a floor panel. This laying mode is generally convenient as a method for laying a carpet on a floor panel, but there is a part of the floor panel where such laying mode is not allowed. For example, laying on a recess for storing emergency tires. In this case, since the floor panel has unevenness, the carpet will undulate along with it, and the unevenness of the floor surface is felt through the carpet, which is not preferable. Therefore, a conventional cross-sectional view taken along the line AA ′ of FIG.
As shown in FIG. 6, a method of covering the concave portion with a hard plate 40 having an area larger than the concave portion 21 only and laying the carpet 11 on the concave portion (for example, the actual open sho 62-11).
No. 7178) has been proposed. This overcomes the above-mentioned problems. However, disposing a hard plate as a separate body makes it difficult to take out the tire, looks bad, and causes an increase in weight, which is not preferable.
Furthermore, even when laying on the tool storage recess 22,
Similarly, a hard plate 40 'is used as a lid to lay a carpet, but it is necessary to form a hinge piece in order to make this portion a lid structure that can be opened and closed. In the conventional method, a hard plate is adhered to the back surface of the carpet, and a hinge piece 15 'is formed at the boundary between the part to which the hard plate is adhered and the part without the hard plate.
In order to avoid the peeling of the carpet and the hard plate by repeating the opening and closing operation, it is necessary to adhere the reinforcing non-woven fabric 45 for reinforcement by the method described above, which requires a complicated process.

By the way, as a dimensional relationship between the emergency tire of this kind and the recess for storing the emergency tire, the relationship of (depth of recess> thickness of tire) is usually satisfied, which is a conventional interior material. This is inevitable from the laying mode. However, in a small part of vehicles, there is a relation of (depth of recessed portion <thickness of tire). This is because, for example, in a vehicle with special specifications such as a cold district specification vehicle, it is necessary to use a tire with a thickness greater than that of a normal vehicle, and because the number of mass-produced vehicles with that specification is small, This occurs when the body panel shape is shared with a standard model car. In such a case, the conventional laying manner as described above is no longer possible, and therefore, there is no choice but to accept the inconvenience and lay the carpet.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and in particular, a floor panel for automobiles is stored in a recess for storing emergency tires in a state where a tire having a thickness thicker than the depth of the recess is stored. A method for manufacturing a lightweight and rigid automobile interior laying interior material, which is suitable for laying over the upper surface of the above, and a laying interior interior material.

In the interior material of the present invention, a low basis weight non-woven fabric having a basis weight of less than 200 g / m ² is adhered to the surface of the honeycomb core, and the back surface of the skin fiber material is lined with a thermoplastic resin. So, heat the skin fiber material to soften the lining,
(Or at the same time heating the honeycomb core) This interior material that can be molded while laminating and pressing the nonwoven fabric into the softened lining to integrate them (without using an adhesive), It is lightweight and highly rigid, and especially because it excels in withstand pressure load, it does not cause ripples even if it is laid with a space below. Further, by cutting out the honeycomb core, one side of the hinge mode can be easily formed.

[0005]

[Means for Solving the Problems] The means for solving the problems according to the present invention comprises a basis weight of 200 g / m on at least one side.
^A thermoplastic resin honeycomb core substrate formed by pre-laminating a non-woven fabric of less than ² and a surface fiber material with a thermoplastic resin lining on the back surface are heated until each thermoplastic resin softens, and then the honeycomb core Non-woven fabric for the base material and skin fiber material are laminated so that the linings face each other, and the skin fiber material and the honeycomb core base material are pressed and integrated, and at the same time molded into the required shape. And an interior laying material for automobiles obtained by this production method, and in this laying interior material for automobiles, at least this interior material, of the recess for emergency tire storage of the floor panel laying this interior material The upper surface is a laying interior material for automobiles formed in a convex shape protruding from the general surface, and at least one side included in this interior material is It is a laying interior material for automobiles, which is formed on a hinge piece formed by cutting out a nicam core base material.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of the present invention will be described below with reference to the drawings. FIG. 1 shows a laying interior material 10 of the present invention, which is an outline along a luggage room at a laying position. The honeycomb core 13 is formed by forming a large number of columnar protrusions on a polypropylene resin sheet and further coating both sides with a liner of the same resin. The thickness is 5 mm, the basis weight is 1500 g / m ² , and the nonwoven fabric 14 is adhered to one surface. The non-woven fabric is a mixed fiber non-woven fabric having a basis weight of 100 g / m ² , polypropylene fiber 85% and polyester fiber 15%. The skin fiber material 11 is a plain needle-punched carpet of polyester fiber, and the basis weight is 250 g /
m ² with low density polyethylene resin backing 12
The coating weight is about 250 g / m ² . The integration of the skin fiber material and the honeycomb core and simultaneous molding are performed as follows. First, the surface fiber material is heated from the back surface side (lining side) to put the thermoplastic resin backing into a softened state. Similarly, the honeycomb core made of a thermoplastic resin is also heated so as to exhibit plasticity. Next, with the surface of the honeycomb core to which the non-woven fabric is adhered facing upward, the skin fiber material is overlaid from the upper side, and this is placed in a pair of upper and lower press molding dies and pressed. When the fluff of the non-woven fabric enters into the lining and is fixed, the skin fiber material and the honeycomb core are integrated, and when the shaping shape is fixed, the target laying material is obtained by removing from the mold. You can In the molding of the laid interior material, the upper surface of the recessed portion for storing the emergency tire of the laid position floor panel is formed into a convex shape protruding from the general surface. As shown in FIG. 2, which is a sectional view taken along the line AA ′ of FIG. 1, this is formed by squeezing using the plasticity of the honeycomb core. The size of the convex shape is a circle having a diameter larger than that of the recess for storing the tire, and the height is about 20 to 50 mm. In a further preferred embodiment, in order to form a lid structure capable of opening and closing the upper surface of the tool storage recess, the honeycomb core is linearly cut to form a hinge piece. This is shown in detail in FIG. 3, which is a cross-sectional view taken along the line BB ′ of FIG. 1, and is a linear notch 13a for cutting the honeycomb core in the thickness direction, and this notch is on the upper side of the honeycomb core. The non-woven fabric and the skin fibrous material located in the above position are not reached, and the hinge piece 15 is flexible and excellent in durability due to the skin fibrous material (lining) and the non-woven fabric.

[0007]

The laid interior material of the present invention is lightweight, highly rigid, and
Each formability characteristic is excellent. The skin material and the base material can be integrated and molded at the same time without using an adhesive. In particular,
It is suitable for laying when a concave portion for storing an emergency tire of a floor panel of an automobile is formed into a convex shape and a tire having a thickness thicker than the depth of the concave portion is accommodated in this concave portion. Also, a strong hinge piece can be easily formed.

[Brief description of drawings]

FIG. 1 is a perspective view of a laid interior material of the present invention.

FIG. 2 is a sectional view taken along line AA of FIG.

FIG. 3 is a sectional view taken along line BB of FIG.

FIG. 4 shows a state in which a conventional laying interior material is laid in an automobile.

5 is a sectional view taken along the line CC of FIG.

[Explanation of symbols]

 10 ... Laying interior material 11 ... Skin fiber material 12 ... Backing 13 ... Honeycomb core 13a ... Notches 14 ... Nonwoven fabric 15,15 '... Hinge piece 16 ...・ ・ ・ Convex shape 20 ・ ・ ・ ・ Floor panel 21 ・ ・ ・ Recessed portion for tire storage 22 ・ ・ ・ ・ Recessed portion for tool storage 40, 40 ′ ... Hard plate 45 ・ ・ ・ Reinforcing nonwoven fabric 50 ・ ・ ・・ Car luggage room

Claims (3)

[Claims] 1. A basis weight of 200 g / m on at least one side.
^A thermoplastic resin honeycomb core substrate formed by pre-laminating a non-woven fabric of less than ² and a surface fiber material with a thermoplastic resin lining on the back surface are heated until each thermoplastic resin softens, and then the honeycomb core On an automobile floor panel, characterized in that the nonwoven fabric of the base material and the backing of the skin fiber material are overlapped so as to face each other, and the skin fiber material and the honeycomb core base material are pressed and integrated and simultaneously molded into a required shape. A method for manufacturing a laid interior material for a vehicle to be laid, and a laid interior material for a vehicle obtained by the manufacturing method. 2. The interior laying material for an automobile according to claim 1, wherein at least the interior material has a concave shape for accommodating an emergency tire, which is a convex shape protruding from a general surface of a floor panel on which the interior material is laid. An interior laying material for automobiles, which is characterized by being molded into. 3. The interior laying material for an automobile according to claim 1 or 2, wherein at least one side included in the interior material is formed into a hinge piece formed by cutting out a honeycomb core base material. A featured interior laying material for automobiles.