JPS5973938A - Preparation of interior panel for vehicle - Google Patents

Abstract

PURPOSE:To obtain the titled interior panel such as a trim panel with good appearance having soft feeling or gorgeousness, good in adhesiveness and generating no tear or no crack to cloth, by adhering special stitch cloth to a fibrous compression molding body. CONSTITUTION:Stitch cloth 30 prepared by compounding 10-50% of a low m.p. polyester fiber with a m.p. of 110-200 deg.C in a polyester fiber with a m.p. of 260 deg.C is superposed on a fibrous mat shaped layer 28 with bulkiness containing thermosetting synthetic resin. In this state, the laminated structure is clamped under pressure between a bottom force 2 having a protruded part 3 and top force 6 having a recessed part 7 under such a condition that a molding temp. is 120- 220 deg.C, pressure is 10-60kg/cm<2> and a press clamping time is 30sec-2min to obtain an objective interior panel 11 wherein a cloth layer 10 is adhered to a compression molding body 9 comprising a fibrous layer body.

Description

[Detailed Description of the Invention] The invention relates to a method of manufacturing an interior panel for a vehicle, such as a trim panel having a material covered on one side facing a single room. .

Generally, door trims (hereinafter referred to as trim plates) for automobile interiors are molded in order to widen the space in a single room. The material used for the molded trim is polypropylene alone, polypropylene mixed with wood flour, polypropylene mixed with waste paper, or polypropylene mixed with inorganic fibers. However, the molded trim plate did not have a soft feel and lacked luxury. In addition, a sheet with vinyl chloride leather adhered to the surface of a fibrous compression molded product (hereinafter simply referred to as core), or a polyethylene foam or urethane foam inserted between the vinyl chloride leather and the core to make it soft. There are some that have added a sense of texture, but all of them have the disadvantage of the coldness of the leather surface. In addition, in order to eliminate the coldness, there are cases where adhesives are glued to the core,
This product had the disadvantage that it was difficult to conform to the shape of uneven parts with a small radius of curvature in the trim, the adhesion was insufficient, and cracks occurred when used, making it impossible to obtain a product with good workmanship. .

The object of the present invention is to eliminate the conventional drawbacks of trim temporary, which involves stitching cloth (also referred to as stretch cloth) on the core. ), it can give a soft feel and luxury, and the adhesion of the stitch cloth is sufficient even on uneven parts with a small radius of curvature of the trim board, and the stitch cloth does not tear or crack. An object of the present invention is to provide a method for manufacturing a trim plate for an automobile door. Another object of the present invention is to provide a method for producing a vehicle interior panel that can be given a soft feel and luxury by adhering stitch cloth and has good adhesive properties.

The method for manufacturing a vehicle interior panel according to the present invention includes (a)
The first method is to overlap the mat-like shoulder body to obtain the core and the stitched cloth and press them together at the same time. There are two manufacturing methods, a second method in which the stitch cloth is molded and bonded together, and the first manufacturing method will be explained first.

The invention related to the first method is to manufacture an interior panel for a vehicle in which a resin is bonded to a fiber core. This is a method of manufacturing an interior panel for a vehicle, in which a shoulder body is used, a stitch cloth is used for the housing, and these are simultaneously pressed and molded using a mold. The shoulder body used to obtain this core is made of a bulky layered material made by mixing about 20 to 50% of thermosetting synthetic resin powder or fibers with fibers such as wood pulp, vegetable fibers, and synthetic fibers, so-called fleece. is used.

The stitched cloth is made of 100% polyester, which is made by stitching a polyester staple nonwoven fabric using a polyester binder with polyester filaments. This item is regular polyester fiber (259 yen per piece)
~266°C) with a low melting point (melting point 110°C ~ 200°C)
) polyester fibers are self-stitched at 10 to 50%, and the size is 14 cm and 50 to 500 f. In addition, the date amount is 200 to 65 from the texture as an interior board.
A value of about 0f is desirable. The low-melting point polyester fibers used in stitch cloth have a high elongation when heated, so they fit well into irregularities with a small radius of curvature, while the high-melting point polyester fibers have high shape retention, making them extremely convenient for thermoforming. .

Note that if the stitch cloth contains a lot of polyester fibers with a low melting point, it will melt during heat molding, and the cut cloth will be used to mold the specified shape of vehicle interior panels such as dash boards. A heating device is used which consists of a convex mold having a shape and a concave mold having four molded parts. To form the interior board, the shoulder body and stitch cloth are overlapped and heated and formed at the same time. In addition, when forming the stitch cloth, the concave molding concave portion is made to have a necessary clearance with respect to the convex molding convex portion. When stacking stitch cloth on the shoulder body and bonding the stitch cloth to the shoulder body, that is, the core, at the same time as forming the stitch cloth, it is necessary to interpose a urethane-based or nylon-based adhesive fi1 on the joining surface of the two, or to use a saturated polyester adhesive on the stitch cloth. Apply a type of adhesive and use the adhesive. In addition, the thermosetting resin such as phenol in the shoulder body is 4
It is not necessary to use an adhesive for those containing 0 to 50%. When applying the stitch cloth to the shoulder body and gluing the stitch cloth to the carcass at the same time as forming the shoulder body, the pressing conditions are: molding temperature of approximately 150 to 220°C, pressure of approximately 40 to 60 k
ti/d, and the pressing time is approximately 60 seconds to 2 minutes.

Further, the invention relating to the second method is, when producing an interior panel for a vehicle in which a carcass is bonded to a compression-molded carcass made of fiber, a thermosetting synthetic resin is applied to the carcass. Using a core pre-molded in a convex mold and a concave mold with a shoulder part made of fibers, the material is made of polyester fiber with a melting point of approximately 260°C and a melting point of approximately 11°C.
0-200°C low melting point polyene 7-/I/m fiber approx. 10
Using a stitch cloth containing ~50%, these were molded in convex and concave molds having molding surfaces similar to those of the carcass at a temperature of approximately 120 to 200°C and a pressure of approximately 10 to 40 kg. /d, a method for manufacturing vehicle interior panels in which pressing is performed with a trowel for a pressing time of about 60 seconds to 1 minute. The pre-formed core is formed by molding the aforementioned fleece at a temperature of about 180-22
0℃, pressure about 60~60kl, clamping time about 60 seconds~2
It can be pressed in minutes or wet molded.

The core produced by wet molding is made by beating and defibrating wood valve waste paper, adding a small amount of thermosetting resin to it, making a valve suspension liquid, placing a pre-forming mold into the liquid, and applying a vacuum to the surface of the pre-forming mold. After allowing a predetermined amount of valves to adhere, they are removed, inserted into a hot press mold, and press-molded.

Then, the core is placed on a predetermined convex mold of the mold, a stitch cloth of the same composition as that described above is placed on top of the core, and then a concave mold is placed on top of this stitch cloth and pressed to form the predetermined interior decoration. Get a board. Note that the four concave molded parts overlapping the convex molded parts are designed to have a clearance with respect to the convex molded convex part as required during mold matching.

When adhering the stitch cloth to the core, a urethane-based or nylon-based adhesive is used on the joint surfaces of the two, or a saturated polyester adhesive is applied to the stitch cloth.

The adhesion conditions for the core formed (fleece) and stitch cloth, or the core formed by wet molding and stitch cloth, are as described above (molding temperature approximately 120~200 m
"C, pressure approximately 10-40 kg/cd, clamping time approximately 60
However, under these bonding conditions, the more desirable conditions are the molding temperature of 120 to 120 seconds for bonding with a core seven-stitch cloth molded in seven lines.
180'c, pressure of about 10 to 30 kq/c and clamping time of about 60 seconds to 1 minute. For adhesion of the core and stitch cloth by wet method, it is preferable that the molding flow rate is 120 to 18 D'C1, the pressure is 10 to 301 g/d, and the pressing time is about 30 seconds to 1 minute.

Thus, it goes without saying that the vehicle interior panels formed by both methods of the present invention are formed into a predetermined shape, and stitch crosses on uneven areas with a small radius of curvature do not cause cracks or damage. There is no problem, and there is no lifting due to poor adhesion.
It is uniformly bonded, maintains the texture of stitched cloth, and has a good texture and luxurious feel.

Next, embodiments of the present invention will be described with reference to the drawings.

Example 1 60 parts by weight of wood bulb (hereinafter simply abbreviated as parts) and coarse wool (consisting of 40 parts of cotton fiber and 60 parts of chemical fiber).
40 parts of phenolic resin and 50 parts of phenolic resin were placed in a hopper feeder and dropped onto a conveying machine at a constant rate, and the mixture was continuously transferred by 1 cm.Then, the mixture was applied to a fleece making machine to make a fleece machine with a thickness of 30 pieces. Fabric weight 1.8 kq/n? Fleece 8.

On the other hand, a hot press mold 1 made of metal is prepared. This mold 1 consists of one lower mold 2 and two upper molds 4, 6, a first and a second, and a molding convex portion 6 of the lower mold 2 and each upper mold 4.
A predetermined trim plate shape of an automobile door is formed by forming the molding recesses 5 and 7 (B) and (e). Molding recess 5 of first upper mold 4
1 is smaller than the clearance when fitting into the molding convex portion 6 of the lower mold 2, and in this example, it is set to 2.50. Second upper mold 6
The molding part 7 has the same shape as the molding part 5 of the first upper mold 4, but the clearance when fitting into the molding convex part 5 of the tooth mold 2 is large, and in this example, the clearance is 5.0 mm. It is being done.

Then, the fleece 8 is inserted between the molding convex part 6 of the lower mold 2 and the molding recess 5 of the first upper mold 4 and molded (the molding conditions are mold temperature 210°C, pressure 50 ktj~, clamping (The time is 60 seconds.) After molding, the fiber core 9 with a thickness of 2.5 mm is molded into the predetermined shape of the trim plate.
get. This core 9 had a density of 0.721A, a maximum bending load of 5, and a bending elastic modulus of 15000 kQ/d.

Next, the core 9 is placed on the molding convex part 6 of the lower mold 2, and the outer surface 9A of the core 9 is coated with moss (not shown) using adhesive KR-3.
After spraying 01 (manufactured by Koyo Sangyo KK, trade name, water-based vinyl urethane adhesive) at a rate of 100yβ, a stitch cloth 10 is placed on the core 9 so as to break the core 9. The stitch cloth 10 has a basis weight of 20
0yβ, stitch composition is chain tricot GaN 1g
e/Course'=50150, and low melting point (1
10°C) Melting point 26 containing 50% polyester fiber
Unitika Stitch Bond "Olivia" (manufactured by Unitika KW, trade name), which is made of 100% polyester fiber at 0°C, was used.

After that, the molding part 7 of the second upper mold 6 is pressed and heat-sealed (the pressing conditions are mold temperature: 120°C, pressure: 20k).
g/d, pressing time 30 seconds). Then release the pressure,
The mold is removed to obtain a trim plate 11 having a predetermined uneven shape and having a stitch cloth 10 adhered to one side of the core 9. The molded trim plate 11 has no sharp parts of the glued stitch cloth 10 and adapts well to irregularities with a small radius of curvature, and even in the heat test of leaving it at 85°C for 72 hours, the stitching remained intact. The cloth 10 was in good condition with no lifting or shrinkage at all.

Example 2 A core 9 obtained by pressing the fleece 8 in Example 1 is prepared. On the other hand, Unitika Stitch Bond ``Olivia'' Stitch Croix, 20, is coated with polyester adhesive (saturated copolymerized polyester resin UR) on the entire one side.
:3230, manufactured by Unitika KK, product name) (not shown).

), and a polyethylene sheet 22 made of foamed polyethylene having a foam density of 0.05 f/cd and having a thickness of 2 layers is laminated thereon to obtain a stitch cloth 26 with polyethylene.

Next, the prepared core 9 is positioned and placed on the molding convex portion 3 of the lower mold 2, and the entire outer surface of the core 9 is coated with the above-mentioned polyester adhesive (saturated polyester resin U E3).
2'30) (not shown) is applied, and a stitch cloth 23 with polyethylene is placed on this core 9. After that, the molding recess 7 of the second upper mold 6 is positioned above the stitch cloth 26 with polyethylene, and the mold temperature is set to 12.
Clamping is carried out under the conditions of 0°C, pressure of 15 Icy/d, and clamping time of 60 seconds. Then, the pressure is released and the mold is removed to obtain a predetermined trim plate in which the molded stitch cloth 26 with polyethylene is adhered to the core 9 (see FIG. 6).

The polyethylene-coated stitch cloth 26 is adhered to the uneven portions of the core 9 in a well-blended state, and the polyethylene-coated stitch cloth surface of the trim plate has the soft feel of cloth and the stiffness of polyethylene, and It had a luxurious feel.

Example 6 60 parts of wood pulp, 60 parts of coarse hair, 4 parts of phenolic resin
0 parts to a thickness of 50ttt by the same means as in Example 1.
ttt, fleece 28 with a basis weight of 1.8#.

On the other hand, as stitch cloth 30 for adhesion, the basis weight is 2001/nl, the stitch composition is chain cord, G
auge/Course = 85/2'l,
Unitika Tesochibond "Olivia" (manufactured by Unitika mK, trade name) is prepared, which is made of 100% polyester fiber with a melting point of 260°C and containing 10% of low melting point (180″C) polyester fiber. Thus, the lower mold 2 in Example 1 and the second upper mold 6 were prepared, the fleece 8 was placed on the molding convex part 6 of the lower mold 2, and then stitch black/c60 was applied on the fleece 8. After positioning the molding recess 7 side of the second upper mold 6, it is pressed (pressing conditions are molding degree 190'', C1 pressure 40 kti/d, pressing time 20
seconds). After that, the pressure is released, the mold is removed, and the core 9
A trim plate having a predetermined uneven shape and having a stitch cloth 60 adhered to one side thereof is obtained (see FIG. 6). The fleece 28 is mixed with phenol resin and melted during heating and pressing, so the fleece 28 and stitch cloth 50 are glued together in the molded state, forming a trim plate of a predetermined shape. is formed. The molded trim plate has no sharp parts of the glued stitch cloth 20, and it conforms well to irregularities with a small radius of curvature, and even in a heat resistance test where it was left at 85°C for 72 hours, the stitch cloth 6
There is no floating or deformation of the 0, and it can withstand practical use.

Example 80 parts of wood pulp and 20 parts of waste paper were beaten in a pulper and defibrated in a refiner, and water-soluble phenol/I
/ Add 2 parts of resin to make a pulp suspension with a solids content of 5%. A preforming mold (not shown) having suction holes on the surface is submerged in this suspension, and suction is applied from the back side of the molding mold to form a layer of pulp on the surface of the preforming mold. After deposition, the pulp layer is removed to obtain a pre-tin molded product (not shown). (llii molded products have a moisture content of 80%,
The thickness is 7 mat.

Next, the pre-molded product (not shown) is placed in the lower mold 62 of the molding 1 equipped with the steam extraction hole 36, and heated to 200°C.
The upper mold 4, which has been heated to 300 kg/cd, is heat-pressed for about 6 minutes at a pressure of about 30 kg/cd. The wet molded core 69 is dry and has a thickness of 2.5 mm, a density of CJ-68fA, a maximum bending load of 4 ky, and a bending modulus of 16,500 kg/
A trim plate 11 having a predetermined uneven shape is obtained by adhering 7 pieces of cloth 10 to one side of a core 39 using cl. The recurved trim plate 11 has no sharp parts of the stitch cloth 10, and fits well even on irregularities with a small radius of curvature.
Even in a heat resistance test in which the stitch cloth 10 was left at 72 hours at °C, the stitch cloth 10 showed no lifting or shrinkage and was good.

[Brief explanation of the drawing]

1 to 6 show a first embodiment of the present invention, in which FIG. 1 is a clear view of the lower mold and the first upper mold, and FIG. 2 is an explanation of the second upper mold. Fig. 6 is an explanatory diagram of forming a core from fleece, Fig. 4 is an explanatory diagram of gluing the core]-this stitch cloth, Fig. 5 is an explanatory diagram of the clamped part of the trim plate, FIG. 6 is a perspective view of the molded trim plate. 7 and 8 show a second embodiment, in which FIG. 7 is an explanatory diagram showing the structure of a polyethylene stitch cloth, and FIG. 8 is an explanatory diagram of the forming process. FIG. 9 is an explanatory diagram showing the molding process of the sixth embodiment, and FIG. 10 is an explanatory diagram showing the molding process of the sixth embodiment.
It is an explanatory view showing a molding process of example J1. 1... Molding mold 2.32... Lower mold 6.
...Molding convex part 4.6...Top mold 5.7...
・Molding recess 8...fleece 9.69...(
Fiber compression molded body) Core 10, 20.30...
・Stitch cloth 11...trim board 22
...Polyethylene sheet 66...Steam vent hole application Person: Nippon Sekisoe Shiba Co., Ltd. Agent
Person Patent Attorney Oka 1) Hidehiko 2'3 Figure 8 Part 9E Figure 10

Claims (2)

[Claims] (1) When manufacturing an interior panel for a vehicle in which a material is adhered to a compression molded body made of a fiber material, the peripheral body is made of a bulky fiber material containing a thermosetting synthetic resin. A mat-like surrounding body is used, and the material is a polyester fiber having a melting point of about 260°C and a melting point of about 110 to 20°C.
Using stitch cloth blended with 10-50% of low melting point polyester fibers at 0°C, they were molded in a mold consisting of convex and concave molds at a temperature of approximately 120-220°C and a pressure of approximately 10-60 kQ/d. A method for manufacturing a vehicle interior panel, characterized in that the pressing is performed for a pressing time of approximately 60 seconds to 2 minutes. (2) When manufacturing an interior panel for a vehicle in which a material is adhered to a compression-molded body made of a fiber material, the circumferential body contains a thermosetting synthetic resin and is made of a layered fiber material. A fibrous compression molded body is used which has been pre-molded in a convex mold and a concave mold.
Stitch cloth blended with about 10 to 50% of low melting point polyester fibers at 200°C was molded at a temperature of about 120°C in convex and concave molds having molding surfaces almost similar to those of the surrounding body. ~220°C1 pressure approx. 10~5
1. A method for manufacturing a vehicle interior panel, characterized by pressing at a pressure of 0 kg/d for a pressing time of approximately 60 seconds to 4 minutes.