JPS6054870B2 - Manufacturing method for vehicle interior materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing an interior material for a vehicle, and particularly to a method of manufacturing an interior material using a vacuum forming mold.

Conventionally, vehicle interior materials such as carpets laid on the floor of a vehicle, ceilings, center pillars, or trunk mats attached to the loop panel side have been made of a thin cushioning material 1 made of foamed urethane, etc., as shown in Fig. 1. , consisting of skins 2 and 3 provided on both sides of this cushioning material 1, and a skin 3 on one side.
For example, a raising treatment 4 is applied to the surface of the .

In order to manufacture such vehicle interior materials, conventional cushioning materials 1
After adhering the skins 2 and 3 to both sides of the sheet using an adhesive or other means, this is placed on a lower press mold, and then molded into the desired shape by pressing with an upper press mold. There is.
However, in the conventional molding method using a press mold, the napping process 4 may fall down due to the press pressure, and the feel and texture of the napping process 4 will deteriorate, and the cushioning material It is necessary to apply the skins 2 and 3 on both sides of the mold, which requires an adhesive, which creates a poor working environment and makes the work complicated.Moreover, an upper mold and a lower mold are required. Therefore, it has the disadvantage that the device becomes large and the cost of the equipment becomes high.

The object of the present invention is to interpose a fine piece between a breathable skin and a non-breathable skin, place it in a vacuum mold, and perform molding by drawing a vacuum from the breathable skin side. At this time, by heating the fine pieces, the fine pieces form a layered body, so that a layered base material is interposed between the breathable epidermis and the non-breathable epidermis, and the fine pieces are formed into a desired shape. The above-mentioned drawbacks can be eliminated by manufacturing an interior material for a vehicle, which will be described in detail below using examples.
FIG. 2 and FIG. 3 are process diagrams showing an embodiment of the method for manufacturing vehicle interior materials according to the present invention. Non-breathable skin 11 made of resin film such as PVC
face each other, and place a chip-like object such as urethane foam between the two.
That is, a member made of a mixture of the cushion chip 12 and the binder 13 is interposed, and the outer peripheral sides of the breathable skin 10 and the non-breathable skin 11 are adhered to each other by means such as adhesive or heat welding. Thus, a base body S is formed, and this is placed on the surface side of the molding surface 15 of the vacuum mold 14 as shown in FIG.

In this case, the air-permeable skin 10 is placed on the side facing the molding surface 15, and vacuuming is performed in this state. Note that at this time, a steam pipe 16 is embedded in the vacuum mold 14,
The mold 14 is heated by the steam passing through the steam pipe 16. Therefore, when the vacuum is drawn, the non-porous skin 11 side is attracted to the molding surface 15 side of the vacuum molding mold 14, so that the entire body S matches the shape of the molding surface 15 due to this suction force. It is formed like this. Then, the binder 13 is heated by the heat of the vacuum mold 14.
Alternatively, since the cushion chips 12 are melted and adhered to each other, a layered body 17 having cushioning properties can be obtained between the skins 10 and 11, and this layered body 17 is placed in the vacuum mold 14. As a result, it is molded and has shape retention properties. Further, the breathable skin 10 is also made of thermoplastic resin, so that it can be softened and hardened to have shape retention properties. Note that when the heating temperature of the mold 14 is high, the inner surface of the non-porous skin 11 melts,
A portion of the melt acts as a binder for the cushion chip 12, making it possible to further enhance the integrity of the cushion chip 12. Therefore, the vehicle interior material thus formed is taken out from the vacuum mold 14 and cooled to form a shape-retaining layered body 17 with a breathable skin 10 and a non-breathable skin 11 on both sides. It is possible to obtain an interior material with a constant wall thickness and rich cushioning properties.
That is, in the process before being molded using the vacuum mold 14, the cushion chips 12 are formed in a state where they are independent of each other. However, by molding while applying heat with the vacuum mold 14, the cushion chips 12 melt together, forming a layered body with rich cushioning properties between the skin 10 and the skin 11. This layered material can be used as a cushion. This makes it possible to manufacture materials that are most suitable for vehicle interior materials. Further, the layered body 17 has shape retention properties and does not lose its shape. Therefore, according to the present invention, since a breath molding die is not used, the cushion chip 12 is not compressed.
Do not damage the second cushion.

Furthermore, even if the surface side of the non-breathable skin 11 is subjected to napping treatment,
Since it is not subjected to excessive pressure, the nap does not fall down, and it is only necessary to stuff the cushion chips 12 etc. into the bag body S, which requires the hassle of gluing the skin on both sides of the cushioning material 1 as in the past. This makes it possible to mass-produce the equipment, simplify the equipment, and lower costs. Note that in the present invention, a melting layer that melts at a low temperature is applied on the inner surface of the non-breathable skin 11 in advance, and this melting layer is melted and bonded to the cushion chip 1.
It may also be used as a binder for 2.

In addition, the breathable skin 10 is not limited to being formed from a cloth material, but may also be made of breathable resin felt, cork material,
Palm etc. may also be used.

Furthermore, in the present invention, as shown in FIG.
Even if the cushion chip 12 is formed into a layered body, the cushion chip 12 can be formed into a layered body, and the skins 10 and 11 can be attached to both sides of the cushion chip 12 by arranging the non-breathable skin 11 thereon and applying vacuum. As explained above, according to the method of manufacturing a vehicle interior material according to the present invention, fine pieces of urethane foam, that is, cushion chips, are placed inside a flat bag made of a breathable skin and a non-breathable skin. A mixture with a binder that adheres to each other is stored, and this bag body is placed on the molding surface of a vacuum molding mold so that the above-mentioned breathable skins face each other, and vacuum is drawn. During this molding, the entire bag body is Since the cushion chips are integrated into a layered body by heating, there is no need for a breath mold as in the past.
The upper mold of the breather does not come into contact with the surface side of the non-breathable epidermis, so even if the napping treatment is applied here, the napping will not collapse, the texture of the napping-treated surface will not deteriorate, and it will adhere to the inside of the epidermis. The binder makes it possible to bond the skin without applying an adhesive, which eliminates the need for an adhesive application process, which degrades the working environment, and eliminates the need for an upper mold and a lower mold, making the equipment easier to use. The cost itself can be lowered, the manufacturing process can be significantly shortened, and mass production can be achieved.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view for explaining a conventional method for manufacturing a vehicle interior material, and FIGS. 2 and 3 are cross-sectional views showing an embodiment of the method for manufacturing a vehicle interior material according to the present invention. FIG. 4 is a sectional view showing another embodiment of the method for manufacturing a vehicle interior material according to the present invention. 10... Breathable epidermis, 11... Non-breathable epidermis, 12... Cushion chip, 13... Binder, 14.
...Vacuum forming mold, ...Steam pipe. 15...molding surface,

Claims (1)

[Claims] 1. A base body consisting of a mixture of fine pieces of foamed urethane and an inverter that adheres the fine pieces to each other is interposed between a breathable skin and a non-breathable skin, and the breathable skin is molded using a vacuum molding mold. The fine pieces were placed in a vacuum forming mold so as to correspond to the surface, and in this state, a vacuum was drawn and almost the entire body was heated to weld the fine pieces together and form a layered body. A method for manufacturing vehicle interior materials.