JPS62220304A - Manufacture of base material for interior decoration of vehicle - Google Patents

Abstract

PURPOSE:To enable manufacture of a base without generating deterioration in physical properties and inexpensively, by a method wherein a fiber is made to suck to a molding face by blowing a fleecy woody fiber containing a thermoplastic binder into an enclosed space between both molds and at the same time air vent of the enclosed space is performed on a mold side. CONSTITUTION:A casting space S is formed between both molding faces 1a, 2a by a seal wall 6 by descending a top force 1, fleecy raw materials F are transported through a transport pipe 8 and blowing into the casting space S through each of supply ports 7. In this instance, air is kept sucked through an air passage 4 and each of gas vent holes 3 by driving an air source. Uniformity of suction quantity of the raw materials F is attained by making the raw materials F blown into the casting space S suck to the molding face 2a of a bottom force 2 side. When the raw material in predetermined quantity is sucked, blowing-in of the same is stopped and molding is performed upon performance of mold clamp and fringe cutting by a fringe cutting blade 5 by lowering the top force 1. As the raw materials are molded after a molding form, a change in physical properties is eliminated and an improvement in yield can be attained.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method for producing an automotive interior base material.

(Conventional technology) A conventional manufacturing method will be explained below.

The raw materials conventionally used include fibers such as wood pulp, hemp, cotton, and synthetic fibers, as well as phenols as sizing agents, and thermoplastic substances in predetermined proportions. After passing through the defibration process, a fleece-like mat material having a certain basis weight a is finished in the mat papermaking and fixing process.

This finished mat material is needled or baked for ease of transportation. Needling here refers to the process of piercing the above-mentioned mat material with a needle that moves up and down at high speed, intertwining the internal fibers to make the mat M that is portable and easy to handle. It is. In addition, baking involves blowing hot air onto the mat material and then compressing it, so that the thermoplastic material binds other raw materials together.
Similar to the above, this work is to make the mat M easy to handle.

After completing any of these operations, the material is cut to size and then moved to a molding process. In the molding process, a pair of molds 20a, 20 as shown in FIG.
b is used. Then, the mat M described above is placed in the lower mold 20.
The mold is closed under a predetermined clamping pressure and heating under the conditions set in b.

In this way, the interior material of the desired shape was extracted.

(Problem that the invention attempts to solve) The above method has the following problems.

(1) In the conventional case, needling and baking are performed to make the mat material easier to handle. However, this process is not originally directly involved in the production of interior substrate materials, and is simply carried out for the convenience of transporting the mat when transferring to the next process. be. Therefore, from the perspective of manufacturing the base material, this is an unnecessary process, and the use of such unnecessary processes increases the number of processes in the production line and increases equipment costs.

(2) During the molding process, there are parts of the mat M that are pulled and parts that are gathered together. This is because the mat M is a flat shape with a fixed length, so it is difficult to follow the three-dimensional shape of the molds 20a and 20b. In this case, cracks and fractures occur in the parts that are pulled, and conversely, in the parts where the material is gathered together, the specific gravity increases as the material concentrates, it becomes resinous and becomes brittle, and the physical properties of the surface layer and the underlying layer suddenly change. Changes may cause delamination.

SUMMARY OF THE INVENTION In view of these problems, the present invention aims to provide a method for manufacturing a base material at low cost without causing any deterioration in the physical properties of the molded base material.

(Means for Solving the Problems) In order to achieve the above object, the present invention forms a sealed space between both molds before closing the molding mold, and this sealed space A predetermined meter of fleece-like wood fiber containing a thermoplastic binder agent is blown into the mold, and at the same time, air is removed from the heavy enclosed space on one side of the mold.
The fibers are adsorbed onto a molding surface, and then the mold is closed under prescribed heating to mold into a prescribed shape.

(Example) Hereinafter, an example embodying the present invention will be described in detail with reference to the drawings.

(I) Raw materials In this example, the raw materials shown in Table 1 are used.

The raw materials used in this example are those defibrated into a fleece-like material using a defibrator or the like (fleece-like raw material).

(I[) device The apparatus used in this example is shown in FIG.

In the drawings, reference numerals 1 and 2 indicate a pair of upper and lower molds, each of which has a predetermined molding surface formed on its opposing surfaces.

However, a slight clearance necessary for molding the base material K is set between the molding surfaces 1a and 2a when the mold is closed. Of both molds 1.2, a plurality of gas vent holes 3 are opened in the molding surface 2a on the lower mold 1 side. In this example,
φ3 to φ6 (shoes) are uniformly distributed at a pitch of 20 to 40 am.

Each gas vent hole 3 communicates with an air passage 4 provided laterally inside the lower mold 2. Further, the air passage 4 is connected to an air source (not shown), so that both air suction and air blowing operations are performed at predetermined times.

On the other hand, an edge cutting blade 5 is located near the periphery of the molding surface 1a on the upper mold 1 side.
is provided. Furthermore, a sealing wall 6 is attached downwardly to the outside of the edge cutting blade 5, into which the lower die 2 can be fitted without any gaps.

Therefore, the space formed between the molding surfaces 1a and 2a before molding becomes a sealed space. Raw material supply lowers penetrate this seal wall 6 at a plurality of locations. and,
Each supply lower is connected to a transport pipe 8 for air transporting the above-mentioned fleece-like raw material F, and a predetermined amount of the raw material F is supplied to the above-mentioned mold opening space (hereinafter referred to as raw material injection space S).
It is designed to infuse

(1) Manufacturing process First, the upper mold 1 is lowered to form an injection space S between both molding surfaces 18.2a by the seal wall 6. In this state, the fleece-like raw material F is transported via the transport pipe 8,
Blow into the injection space S through each supply lower. At this time, an air source (not shown) is driven to suck air through the air passage 4 and each gas hole 3. The raw material F injected into the injection space S is adsorbed onto the molding part 2a on the lower mold 2 side, thereby making the adsorption amount of the raw material F uniform.

In this way, when a predetermined amount of raw material has been suctioned, the blowing of the raw material is stopped, and the upper mold 2 is lowered to close the mold and cut the edges with the edge cutting blade 5. However, air suction continues.

The molding conditions of this example are as follows. That is, heating temperature (180-230°C), clamping pressure 10-301g/
d), the pressing time is 15 to 40 (sec).

By the way, gas (mainly water vapor) is generated during molding, but this is forcibly exhausted by the air suction operation described above.

When the molding is completed, the upper mold 2 is returned to its original position, and compressed air (2 to 2
4Kg/cIi) is sent and ejected from each gas vent hole 3. By this, the base material K can be easily taken out, and the stickiness of each gas group hole 3 can be eliminated.

(Effects of the Invention) As explained above, according to the present invention, the following effects are exhibited.

■The number of processes can be reduced because handling and cutting processes are no longer necessary. Further, since the equipment associated with this is not required, the equipment cost is also low.

■Unlike conventional methods, since the raw material is molded according to the molding shape, it is possible to eliminate problems such as cracking or changes in physical properties due to tension or gathering, and improve yield.

[Brief explanation of drawings]

FIG. 1 is a front sectional view of the apparatus according to the method of the present invention, FIGS. 2 to 4 are front sectional views showing the manufacturing procedure of this example, and FIG. 5 is a front sectional view of the apparatus according to the conventional manufacturing method. be. 1.2...Mold 3...Gas vent hole 6...Seal wall 7...Fleece raw material supply port S...Fleece raw material injection space K...Base material

Claims (1)

[Claims] Prior to closing the molding mold, a sealed space is formed between the two molds, and a predetermined amount of fleece-like wood fiber containing a thermoplastic binder is blown into this sealed space. At the same time, on one mold side, the air in the closed space is removed to cause the fibers to be adsorbed to the molding surface, and then the mold is closed under predetermined heating and molded into a predetermined shape. A method for manufacturing interior base materials.