JPS61241136A - Interior part for automobile and manufacture thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to automobile interior parts such as a roof trim, a door trim, and a sun visor, and a method for manufacturing the same.

(Prior art) Conventional automobile interior parts are manufactured by forming a base material such as resin felt or wood board into a predetermined shape, and then attaching a skin layer to this base material using an adhesive. .

(Problems to be Solved by the Invention) The above manufacturing method has poor productivity because it requires two steps: molding the base material and adhering the skin layer.

Furthermore, the automobile interior parts obtained by this method were heavy.

(Means for Solving the Problems) The present invention has been made to solve the above problems.
The gist thereof lies in an automobile interior product characterized in that a foamed resin layer is interposed between a base material and a skin layer, and the foamed resin layer fixes the base material and the skin layer.

Another gist of the present invention is that the base material, the unfoamed foamable resin layer, and the skin layer are laminated in this order and then heated and pressurized using a molding die to perform molding and foaming. The present invention provides a method for manufacturing automobile interior parts, characterized by integrating a resin foam layer and a skin layer.

(Example) Hereinafter, as an example of the method of the present invention, an automobile roof trim and a method for manufacturing the same will be described with reference to FIGS. 1 and 2.

10 in FIG. 1 is a base material. The base material 10 is relatively lightweight (
500g/m2 or less) of fiber material 11. Examples of the fiber material 11 include glass fiber, polyamide fiber, carbon fiber, silicon carbide fiber, vegetable fiber such as linen and cotton, and cellulose wits. Note that the fiber material 11 may include a relatively thick mat-like material, a cloth-like material made of woven fibers,
A paper-like material formed without knitting fibers is used. Examples of paper-like materials include Kraft paper made of cellulose fibers. Furthermore, materials in which different types of fibers are mixed or materials in which different types of fiber materials are laminated are also used.

Prior to the molding described below, a powder of a foamable curable resin, such as a foamable phenol resin, is applied to the base material 10 and heated at a predetermined temperature to form a B-stage (uncured, unfoamed) film. A foamable resin layer 20 having a shape or a plate shape is formed.

Reference numeral 30 in FIG. 1 is a skin layer, and this skin layer 30 is constructed by laminating a thermoplastic resin film 33 and nonwoven fabrics 31 and 32 disposed on both sides thereof. The nonwoven fabrics 31 and 32 are made of polypropylene, nylon, polyester, or the like.

The nonwoven fabric 32 on the front side may be plain like the nonwoven fabric 31 on the back side, but it may be decorated with prints, crests, printed raising, etc. For example, a polyethylene film or the like is used as the resin film 33. The nonwoven fabric 31t32 and the resin film 33 may be simply laminated and not integrated with each other before molding, or may be bonded together with an adhesive, climbed onto a knee V-lench punch, or may be integrated by extrusion of the resin film 33. The nonwoven fabrics 31 and 32 may be applied to both sides of the resin film 33, which is sometimes in a softened state, and then integrated by applying pressure.

Next, a skin layer 30 is applied to the base material 10 provided with the foamable resin layer 20.
are laminated, and this is heated and pressurized using a molding die 40 to be molded. Specifically, the molding die 40 includes a lower mold 41 and an upper mold 42 that moves up and down with respect to the lower mold 41. The lower mold 41 has a molding recess 41a formed therein, and the upper mold 42 has a molding protrusion 42a formed therein. Then, the upper mold 42 is lowered, and the laminate is molded into a route 7 trim shape between the molding recesses 41a and 42a.

The foamable resin layer 20 is foamed and hardened by the heating during the molding, and as a result, a resin foam layer 21 is formed between the base material 10 and the skin layer 30 as shown in FIG. Also,
Since the base material 10 is made of the fiber material 11 and the back side of the skin layer 30 is made of the nonwoven fabric 31h, the foamable resin layer 2
A part of the resin material, ie, the phenolic resin, of the fiber material 11 penetrates into the fiber material 11 and into the nonwoven fabric 31, and as a result, the fiber material 11. The resin foam layer 21 and the nonwoven fabric 31 are integrated. Incidentally, the permeated phenol resin is added to the fiber material 11 above. Almost no foaming occurs within the nonwoven fabric 31.

Moreover, even if the skin layer 30 is simply a lamination of the nonwoven fabric 31.32 and the resin film 33, the heat generated by the foaming softens the resin film 33 and entangles it with the nonwoven fabric 31.32. Non-woven fabric 31
．． 32 and resin film 33 are integrated.

The 7 enol resin of the foamable resin layer 20 is the resin film 3
3 prevents penetration. For this reason, the nonwoven fabric 3 on the front side
2, the phenol resin does not penetrate into the material, and problems such as impairing the appearance, loss of decorative effect, and hardening of the surface due to the phenol resin seepage do not occur.

Furthermore, since the front side of the skin 30 is made of the nonwoven fabric 32, deep drawing can be performed. That is, if the front side is made of woven fabric, the stitches will stretch during deep drawing, resulting in poor appearance, but non-woven fabric does not cause such inconvenience.

The Ru7 trim shown in FIG. 2 manufactured by the above method has a three-layer structure in which the fiber material 11 impregnated with phenol resin, the nonwoven fabric 31, and the resin foam layer 21 are integrated, and is light and rigid. Moreover, the resin foam layer 21 has heat insulation and sound insulation functions. Moreover, as mentioned above, since there is no phenol seeping into the nonwoven fabric 32 on the front side, the appearance is good.

It has a tactile and highly decorative quality.

In addition, if the nonwoven fabric 32 on the front side where the phenol resin does not permeate is made thicker, a product with a better feel can be obtained, and if the nonwoven fabric 31 on the back side where the phenolic resin permeates is made thicker, a product with higher rigidity can be obtained.

A specific experimental example based on the above method will be explained.

As the fiber material 11 of the base material 10, a paper-like glass fiber of 70 g/m2 is used. A powder of foamable phenolic resin is applied at 330 g/m2 onto this fiber material 11, and then heated at 100±5° C. for 10 minutes to form a B-stage foamable resin layer 20. In addition, the epidermal layer 30
The nonwoven fabric 31 on the back side is a 100 g/m2 polypropylene nonwoven fabric, and the resin film 33 is 50 g/m2.
A polypropylene nonwoven fabric of 150 g/m 2 is used as the nonwoven fabric 32 on the front side. These nonwoven fabrics 31, 32 and resin film 33 are simply laminated and not integrated.

Then, the fiber material 11 provided with the foamable resin layer 20 and the skin layer 30 are laminated, and the molding die 40 is used to heat the fiber material 11 at a temperature of 1.
70'C1 was molded at a pressure of 5 kg/ca+2 and a press time of 1.5 minutes. The resulting Ru 7 trim had good appearance and feel, with no 7 enol resin seeping out on the surface, and was lightweight and rigid.

Furthermore, an experimental example in which a door trim was manufactured using a method similar to the above method will be described. As the fiber material 11 of the base material 10,
A cross-shaped Lasnor resin powder of 150 g/m 2 is applied at 400 g/m 2 , and then a B-stage foamable resin layer 20 is formed.

In addition, the nonwoven fabric 31 on the back side of the skin layer 30 is 150 g/m
Using the polypropylene nonwoven fabric of No. 2, the resin film 33
A 50 g/m 2 polyethylene film is used as the material, and a 300 g/m 2 polypropylene nonwoven fabric is used as the nonwoven fabric 32 on the front side. As a result of molding under the same molding conditions as in the experimental example of the Ru7 trim above, the appearance and feel were good, with no 7 enol resin seeping out on the surface, and
A light and rigid door trim was obtained.

FIG. 3 shows another embodiment of the method of the present invention, in which the base material 10A
is constructed by laminating a fiber material 15 and a nonwoven fabric 16 on the back side thereof. Further, the foamable resin layer 20 is formed on the fiber material 15 in the same manner as in the method described above. Epidermal layer 3
The OA is constructed by laminating a resin film 33 and a nonwoven fabric 32 on the front side. Then, molding, foaming, and integration are performed simultaneously in the same manner as described above, and the seven enol resins of the foamed resin layer 20 permeate into the nonwoven fabric 16 and the fiber material 15 on the side shown in FIG. It has an integrated three-layer structure and is lightweight and rigid. Further, the phenol resin is blocked by the resin film 33 and does not seep into the nonwoven fabric 33 on the front side, so that the appearance etc. are not impaired.

The present invention is not limited to the above embodiments, and various embodiments are possible. For example, as a base material, a wood board made of wood fibers hardened with a 7-enol resin, or a resin felt made of vegetable fibers such as cotton hardened with a 7-enol resin can also be used. Further, the present invention can be applied to interior parts such as sun visors in addition to the above-mentioned roof trim and door trim of automobiles.

(Effects of the Invention) As explained above, since the automobile interior part of the present invention has a resin foam layer between the base material and the skin layer, it can be made lightweight and exhibits heat insulation and sound insulation functions. I can do it. Furthermore, according to the method of the present invention, the skin can be fixed to the base material side without using adhesives, and the manufacturing process can be reduced because the base material, foamed resin layer, and skin layer are integrated at the same time as molding. can improve productivity.

[Brief explanation of the drawing]

Fig. 1 is a sectional view illustrating an embodiment of the method of the present invention;
The figure is a cross-sectional view of the route 7 trim manufactured by the method shown in Figure 1.
FIG. 3 is a sectional view illustrating another embodiment of the method of the present invention, and FIG. 4 is a sectional view of a route 7 trim manufactured by the method of FIG. 3. 10. IOA... Base material, 11.15... Fiber material,
16... Nonwoven fabric, 20... Unfoamed foamable resin layer,
21...Resin foam layer, 30.3OA...Skin layer, 1
5, 31° 32... Nonwoven fabric, 33... Resin film, 40... Molding mold

Claims (10)

[Claims] (1) An automobile interior product characterized in that a foamed resin layer is interposed between the base material and the skin layer, and the foamed resin layer fixes the base material and the skin layer. (2) The automobile interior component according to claim 1, wherein the base material has a fiber material impregnated with the resin material of the resin foam layer. (3) Claims characterized in that the base material includes a fiber material impregnated with the resin material of the resin foam layer, and a nonwoven fabric impregnated with the resin material disposed on the back side of the fiber material. Automotive interior parts according to item 2. (4) The automobile interior component according to claim 1, wherein the skin layer includes a resin film and a nonwoven fabric disposed on the front side thereof. (5) The skin layer includes a resin film, a nonwoven fabric disposed on the front side thereof, and a nonwoven fabric impregnated with the resin material of the resin foam layer disposed on the back side. Automotive interior parts described in scope item 4. (6) With the base material, unfoamed foamable resin layer, and skin layer laminated in order, heat and pressure is applied using a molding mold to perform molding and foaming, and at the same time, the base material, foamed resin layer, and skin layer are laminated in order. A method for manufacturing automobile interior parts, characterized by integrating the above. (7) The method for manufacturing an automobile interior part according to claim 6, wherein the base material has a fiber material. (8) Claim 7, characterized in that the base material has a fiber material and a nonwoven fabric disposed on the back side thereof.
The method for manufacturing the automobile interior parts described in Section 1. (9) The method for manufacturing an automobile interior part according to claim 6, wherein the skin layer includes a resin film and a nonwoven fabric disposed on the front side thereof. (10) Manufacture of an automobile interior component according to claim 9, wherein the skin layer includes a resin film, a nonwoven fabric placed on the front side of the skin layer, and a nonwoven fabric placed on the back side of the skin layer. Method.