JPS61154922A - Manufacture of trim for automobile - Google Patents

Abstract

PURPOSE:To coat a laminated skin material simultaneously with the forming of a formed base material from a thermoplastic synthetic resin sheet by a method wherein the thermoplastic synthetic resin sheet and the laminated skin material are set between molds for synthetic resin deep draw forming. CONSTITUTION:The thermoplastic synthetic resin sheet 2, consisting of the polypropylene resin sheet of stamp forming grade, which is having the melting temperature of 140 deg.C, is set on a male mold side among the molds 1, 1 so as to face it while the laminated skin material 4 is set on a female mold so as to face it. The laminated skin material 4 consists of a skin 5, a cushion layer 6 having continuous voids and a polyamide resin series hot-melt film 7 having melting temperature of 150 deg.C. When the molds 1, 1 are clamped under a condition that the thermoplastic synthetic resin sheet 2 is heated to 140 deg.C and softened, the sheet 2 is formed by deep draw forming and the formed base material 120 having a necessary configuration is obtained. Simultaneously, the laminated skin material 4 is adhered to the surface of the formed base material 20 in molten condition still through the non-molten film 7 on the rear surface thereof under a condition that the cushion layer 6 thereof is compressed.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a manufacturing method for automobile interior materials that can easily mass-produce highly decorative automobile interior materials such as automobile door trims, center pillars, and garnishes. It is something.

(Prior art) Automotive interior materials such as automobile door trims with enhanced decorativeness include a laminated skin material in which a cushion layer made of synthetic resin foam is laminated to the surface of a molded base material. Such automobile interior materials are usually coated with a laminated skin material on a pre-prepared molded base material by means such as vacuum forming.

(Problems to be Solved by the Invention) However, when such a manufacturing method is used, the step of molding the molded base material and the step of covering the molded base material with the laminated skin material are performed separately, which is time-consuming. In addition, molds and other equipment costs are high, making it difficult to mass-produce at a low cost.In addition, if the cushioning layer of the laminated skin material is impregnated with adhesive during the coating process of the laminated skin material, the cushion layer will be damaged. There are a number of problems, such as the bubbles being crushed and a soft feel not being achieved.

(Means for Solving the Problems) The present invention was completed with the aim of producing an automobile interior material that solved the above-mentioned problems. A laminated skin material made by laminating a cushion layer having continuous pores and a film having a melting point higher than the melting temperature of the thermoplastic synthetic resin plate material is placed between molds for deep drawing of the synthetic resin to form the thermoplastic synthetic resin. The laminated skin material is applied to the surface of the molded base material made of the thermoplastic synthetic resin plate material by pressure molding at a high temperature that is higher than the melting temperature of the equipment and lower than the melting temperature of the film, and the film on the back side is melted by the molded base material. It is characterized in that the coating is integrated with the surface while being adhered to it during molding.

In the present invention, the thermoplastic synthetic resin plate material used as the material for the molding base material is preferably one that can be easily processed by stamping under heating, so a polyolefin resin plate material such as stamping grade polypropylene resin is used. A fabric or non-woven fabric that is soft to the touch and breathable should be used as the outer skin.In particular, if the molding base material has large irregularities, the outer skin will stretch and the appearance will be impaired if the stitch opening is large, so use a small opening. Preferably. In addition, since the cushion layer with open cells needs to have excellent breathability as well as cushioning properties, a synthetic resin foam having countless open pores is preferable, and in particular, the thermoplastic synthetic resin board material is The most suitable polyurethane foam is a polyurethane foam that has a heat-resistant temperature that does not melt when pressure-molded.Secondly, the film should have a melting point higher than that of the thermoplastic synthetic resin board, but in addition to having high elongation, it also has a molding base. A synthetic resin film made of a material that is easily adhered to the surface of the material during melt molding, such as a polyamide hot melt film with a heat resistance temperature of 140° C. or higher, is optimal.

(Example) Next, the present invention will be explained in detail with reference to illustrated process diagrams. (1) and (1) are a pair of molds for deep drawing of synthetic resin, and nuclear molds (1) and (11 As shown in Fig. 1, a stamping molding grade polypropylene resin sheet with a melting temperature of 140°C is placed as a thermoplastic synthetic resin plate material (2) so that it faces the male side of the mold (11, (1)). Also, the laminated skin material (4) is set facing the female mold side between the molds (11, +1) with its edges clamped by clamps (3), (3). The laminated skin material (4) includes a skin (5) made of fabric, a cushion layer (6) made of polyurethane foam having continuous pores and having excellent pressure resilience, and a film (7) with a melting temperature of 150°C. A polyamide resin-based true melt film with a thickness of 60 to 100 μm is laminated using a well-known lamination method. During molding, a thermoplastic synthetic resin plate material (2) is heated using a heating device such as an infrared heater. By heating and softening the material to 140°C and operating a 150-ton press to press the molds (1) and (l) as shown in Figure 2, a thermoplastic synthetic resin plate material (
2) is deep-drawn into the molded base material (20) into the desired shape at a high pressure of about 20 kg/cal per unit area, and at the same time, the laminated skin material (4) is formed with the cushion layer (6) in a compressed state. A film on the back side that will not be melted (
7) to adhere to the surface of the molded substrate (20) which is still in a molten state. When the mold is opened, the compressed laminated skin material (4) itself has continuous pores, and the skin (5) is also fibrous and breathable, so air enters and gradually The product is restored to its original thickness, and a product (30) with a soft feel and excellent decorative properties is obtained as shown in FIG. Note that whether or not to apply an adhesive to the surface of the thermoplastic synthetic resin plate material (2) in advance is optional depending on the material of the laminated skin material (4) and other conditions.

(Effects of the Invention) As is clear from the above description, the present invention is capable of simultaneously covering the laminated skin material when molding a molding base material from a thermoplastic synthetic resin plate material, which not only simplifies the manufacturing process but also eliminates the need for molds and other materials. Equipment costs can be significantly reduced, and since the film on the back side of the laminated skin material prevents adhesive or molten resin from migrating and impregnating the cushion layer during the coating process of the laminated skin material, it is possible to Even if the cushion layer collapses once, the air permeability of the skin and cushion layer allows the compressed cushion layer to properly return to its original shape when the pressure is released, resulting in a product with a soft feel and excellent decorative properties. This method has the following advantages and contributes greatly to the development of the industry as a manufacturing method for automobile interior materials that solves the problems of conventional methods.

[Brief explanation of the drawing]

1 and 2 are process explanatory diagrams of the method of the present invention, and FIG. 3 is a partially cutaway perspective view of a product obtained by the present invention. (1): Mold, (2): Thermoplastic synthetic resin board, (4):
Laminated skin material, (5): skin, (6); cushion layer, (
7): Film. Figure 2

Claims (1)

[Claims] A laminated skin material made by laminating a thermoplastic synthetic resin board material, a cushion layer having a fibrous skin with continuous pores, and a film having a melting point higher than the melting temperature of the thermoplastic synthetic resin board material is used for deep drawing processing of the synthetic resin. A laminated skin material is formed on the surface of the molded base material made of the thermoplastic synthetic resin plate material by setting it between molds and pressure-molding it at a high temperature that is higher than the melting temperature of the thermoplastic synthetic resin plate material and lower than the melting temperature of the film. A method for manufacturing an interior material for an automobile, characterized in that the film on the back side is adhered to the surface of the molding base material during melt molding and is integrally coated with the film.