JPS5945130A - Formation of interior member for automobile - Google Patents

Abstract

PURPOSE:To permit the performance of press molding of an expanded interior member having a three-layered structure as well as prevent the loss of elasticity during the press molding period by a method in which surface skin and slab members are pressed to the shape of the top and bottom forces of a cold press, and the end parts of the pressed materials are hot-bonded with the upside of a core member. CONSTITUTION:A core member 2, a slab member 3 plasticized by heating, and a surface skin member 4 are set in a laminated manner on the face 1a of a bottom force 1 of a cold press, and a top force 5 of the cold press is coupled with the bottom force 1 and compressed to cause the surface skin member 4 and the slab material 3 to be deformed along the shape of the force. In the compressed end parts, the thermoplastic resin is extruded and the surface skin member 4, the slab member 3 and the core member 2 are contacted with each. In the parts not compressed, they remain intact. The extruded part of the thermoplastic resin is solidified to form a molding whose each part is integrally combined in the force. Since the thermoplastic resin component is solidified by cooling in the extruded state, the three members are integrally combined by the bonding effect of the resin and the shape corresponding to the compression ratio is kept.

Description

DETAILED DESCRIPTION OF THE INVENTION (1) Field of the Invention The present invention relates to a method for molding an automobile interior material formed by laminating a core material, a foam layer and a skin layer.

(2) Prior art and its problems Molding methods for automobile interior materials with this type of foam layer provided in the middle are: <A) Weld mite method, (B) Bakicomb method, (C) Foaming method. Similar construction methods are known.

(A) The well mite method is a method mainly for forming flat interior materials, in which open-cell low specific gravity foamed urethane slab material is laminated on a core l, and the surface of this slab material is laminated. A skin material such as vinyl chloride is laminated, and this is installed using the weld mite method to form a weld groove pattern on the surface, and the three parts are integrated through the weld weld neck part, that is, the weld groove pattern part. This is something that I told you to be firm.

(B) In the Bakicomb construction method, the foamed Ma J5 is
J: In order to attach the foam layer and the skin material, the foam layer and the skin material are laminated in advance, and this laminated material is formed by vacuum suction to match the curved shape of the core material. It is attached to the core material via adhesive.

Furthermore, in the (C) foaming method, unfoamed resin is injected between a core material that has been previously formed into a required curved surface and a skin material, and then this is foamed in the mold between the core material and skin material. In this method, the above-mentioned skin material is a comb-shaped skin or a spray skin, in which a coating film-like skin is previously formed on the mold surface of the mold by spraying or the like.

However, in method (A) above, the foam layer interposed between the core material and the skin material is extremely thin in order to enable welding between the core material and the skin material. , only those with open cells and low specific gravity can be used, and the finished product has poor cushioning properties, has no waist, easily collapses, and has no so-called tension as a whole.
The appearance is extremely inferior, and due to the problem of the weld mites, the uneven shape on the product surface corresponds to the part crushed by the welding process (1).A curved surface is formed only by the compressive recovery force of the foam layer (1). However, there are problems such as the fact that the curved surface of that part cannot be arbitrarily set.

In addition, in method (B), since the pre-laminated product of the skin material and cushion material is formed into the curved shape of the core H by vacuum, both the foam layer and the skin material respond to the vacuum suction. As a result, the thickness of the cushioning material becomes larger than that of the original material, and this product also lacks cushioning properties after processing. In addition, in this construction method, since a laminated skin is used, when the edge of this is wrapped around the back side of the core material into the fusuma that is attached between it and the core material, the thickness of this part is The layers become extremely thick, resulting in large dimensional errors when assembled to the car body, so it is necessary to peel off the cushioning material from the folded end part and then wrap it around the back side. , which causes extra man-hours.

Furthermore, in method (C), if a spray skin layer or the like is used as the skin material, this molding method itself involves a wet manufacturing process, which not only causes pollution of the working environment, but also extremely high raw material costs. It is expensive, requires many molds such as metal molds or silicone molds, and has drawbacks such as extremely long cycle time for molding, and for this reason, it is only used for relatively high-end products.

(3) Purpose of the Invention The purpose of the present invention is to enable molding of this type of three-layered foam H+J by press molding, and to prevent cell destruction and elasticity of the foam material as described above during punch molding. This was done to prevent loss of sex, etc.

(4) Structure and Effects of the Invention In order to achieve the above-mentioned objects, the present invention provides an automotive product which is formed by laminating a foam layer and a skin layer on the surface of a core material formed into a desired molded product shape. In the interior material 5-, a slab material of a required thickness made of a thermoplastic resin-containing foamed urethane resin is used as the material constituting the foam layer, and this slab material is heated to a temperature higher than the melting point of the thermoplastic resin component contained therein, Next, this slab material is laminated together with the core material and the skin material on the mold surface of the cold press lower mold, and then the cold press upper mold with the required mold surface carved is lowered and engaged on the lower mold. , the skin material and the slab material are compressed in accordance with the mold surface shape of the upper mold, and the compressed end is welded onto the core material, and then, after cooling the slab shed, the upper mold is removed from the lower mold. ! It is characterized by L.

By the above method, the present invention has the advantage of the press molding method that an arbitrary shape can be obtained along the mold surface, and a desired molded product can be obtained by one molding process, and furthermore, the cushion can be partially different. If you want to make a part, etc., you can easily do it accordingly, and if you use vinyl chloride etc. as the skin material, the grain on the surface will not disappear, and it can be used in the most advanced foaming method. This makes it possible to obtain comparable appearance performance.

In other words, in the present invention, the thermoplastic resin contained in the urethane foam resin is once melted at its melting temperature, and this molten resin penetrates into the cells in the remaining components of the urethane foam resin, and in this state, it is pressed. By applying pressure, the thermoplastic resin component becomes impregnated or leached into the cell in a state according to the compression ratio, and in this state, the thermoplastic resin component is cooled to maintain its shape in the compressed area. It solidifies as it is and is fixed again as a urethane resin composition, whereby it is molded while maintaining elasticity equal to or corresponding to the compression ratio of the slab material before press molding.

The present invention has been made based on this knowledge.

(5) Description of Embodiments Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

First, regarding the monthly interest rate, the conventional monthly interest rate can be used for the core material and the skin material.

For example, in the case where the interior material is made of a flat plate, the core material may be a press board trimmed along the shape of the vehicle body panel, or a silk combination of the press board and metal parts. can. In addition, when molding into a curved surface, the outer periphery of a synthetic resin board or a composite resin board containing wood powder is preformed in a separate process using a suitable material for molding along the curved shape. It is possible to use a material that can be trim-cut and a desired curved shape formed on the surface.

Next, as the above-mentioned skin material, a vinyl chloride skin whose surface is textured is most commonly used. In addition, decorative sheets or carpets made of non-woven fabrics, vinyl chloride skins, non-woven fabrics and silk composites of J-Pet can also be used.

As for the composition of the foamed layer, as described above, a slab material of a required thickness made of foamed urethane resin containing thermoplastic resin is used.

More specifically, this slab material is made by blending PVC copolymer etc. into a part of the resin component in the urethane foam, and this PVC copolymer melts during heating as described below. However, the other part, that is, the main component of the foamed urethane resin, maintains its original cell shape in its thermosetting form. In addition, this J: foamed urethane resin may be closed cell, open cell, semi-open cell, etc., but in short, if it is heated once, the thermoplastic component is melted, and then cooled. Any material may be used as long as it maintains its initial elasticity.

Next, the press molding process using the above monthly profits will be explained.

(A) First, each of the above-mentioned materials is trim-cut in advance to an outer shape that corresponds to the shape of the molded product, and if the core material is required to have a curved shape, it is first press-formed (.

(B) Next, the urethane slab material thus trimmed is placed in an infrared heater or the like, and heated to a temperature below the melting temperature of the thermoplastic resin component inside.

In this state, the inside is in a state where the thermoplastic 1:1 resin is molten, but the outer shape is maintained in the state before heating due to the main components R and foam urethane resin.

(C) Next, as shown in FIG. 1] - Ludopu 1 The above-mentioned core material 2 is placed on the mold surface 1a of the lower mold 1, and the slab material which has been heat-plasticized as described above is placed on the top of this core material 2. 3 is laminated, and a skin material 4 is installed on top of this slab material 3 (.

(D> From this state, immediately engage the cold press upper mold 5 onto the lower mold 1.

A mold surface for configuring the surface of the molded product, that is, an uneven portion 5a is formed on the lower surface of the upper mold 5, and as shown in FIG. Both of the slab material 3 are compressively deformed along the shape of the mold surface.

Figure 3 shows the main part of the groove, and the structure of the foamed urethane resin, which is the main ingredient in the slab material 3, is different from the original thickness. It is in a compressed state depending on the distance between the surface and the core material 2, and moreover, in the clear run 20 portion of the mold surface 5a, the cell portion is completely exposed (indicated by the shading of the dots).

The thermoplastic resin portion oozes out from this crushed portion, and the skin material, slab material, and core material 2 come into contact with the leaching of the thermoplastic resin.

In addition, although the parts where pressure has never been applied are in a molten state, the thermoplastic resin component in those parts remains in its original state without leaching out, and a corresponding amount of leaching can be seen in the compressed parts.

Further, in this state a3, since the surface of the skin material 4 is not heated in any way by the mold surface of the upper mold, the grains formed on the surface do not disappear.

(E) Next, over time, the thermoplastic resin component retained in the slab material 3 or the thermoplastic resin component leached onto the surfaces of the skin material 4 and core material 2 solidifies, thereby integrating each part. This means that the molded product can be molded in the mold. After cooling is completed in this manner, the upper mold 5 is moved away from the lower mold and the product is removed from the mold.

In this state, the above-mentioned thermoplastic resin component is leached out due to compression and is subjected to cold JJ], so the adhesive effect of this resin maintains the J: three notes in an integrated state. It sag and is held in a shape according to the compression ratio.

Therefore, the automobile interior 5+4 configured in this manner can be molded into a curved surface according to the mold surface of the cold press mold, and its elasticity can be variably set according to the amount of compression, for example. By using a thicker, low-density urethane cable instead of the conventionally used high-density urethane rope material, a surface feel that corresponds to the compression ratio can be obtained, so It is cheaper than the conventional construction method and can provide the same cushioning properties.Furthermore, the so-called cushioning properties change depending on the compression ratio, so it is possible to It is possible to change the feel in the same process and at the same monthly rate, thereby reducing the number of man-hours and making it possible to reduce the cost.

In addition, if a hot melt film is interposed between the slab material 3 and the core material 2, or between the slab material 3 and the skin material 4, it is possible to perform press molding such as a small one (above) to reduce the gap between each layer during integral molding. Adhesive sclerosis can be further improved.

[Brief explanation of drawings]

1 and 2 are sectional views showing the molding method according to the present invention, and FIG. 3 is an enlarged sectional view of section A in FIG. 2. 1...Cold press lower mold 1a...Mold surface 2...Core material 3...Slab material 4...Skin material 5...・Cold press upper mold 5a... Mold surface patent applicant Kasai Kogyo Co., Ltd. Figure 1

Claims (1)

[Claims] 1) An interior material for an automobile formed by laminating a foam layer and a skin layer on the surface of a core material formed into a desired molded product shape, wherein the foam layer constituent material is a thermoplastic resin. Using a slab material of the required thickness made of foamed urethane resin, this slab material is heated above the melting point of the thermoplastic resin component contained therein, and then this slab material is cored onto the mold surface of a cold press lower mold. After that, a cold press upper mold with a required mold surface carved therein is lowered and engaged with the lower mold, and the skin material and slab material are laminated together with the mold surface shape of the upper mold. 1. A method for molding an interior material for an automobile, characterized in that the slab material is compressed in accordance with the slab material, the compressed end is welded onto a core material, and then, after the slab material is cooled, the upper mold is separated from the lower mold.