JPS63274518A - Production of trim material for vehicle - Google Patents
Production of trim material for vehicleInfo
- Publication number
- JPS63274518A JPS63274518A JP62109380A JP10938087A JPS63274518A JP S63274518 A JPS63274518 A JP S63274518A JP 62109380 A JP62109380 A JP 62109380A JP 10938087 A JP10938087 A JP 10938087A JP S63274518 A JPS63274518 A JP S63274518A
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- soft foam
- laminate product
- thermosetting resin
- solution
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000000463 material Substances 0.000 title claims abstract description 34
- 238000004519 manufacturing process Methods 0.000 title claims description 9
- 239000006260 foam Substances 0.000 claims abstract description 44
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 43
- 229920005989 resin Polymers 0.000 claims abstract description 23
- 239000011347 resin Substances 0.000 claims abstract description 23
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 22
- 238000001035 drying Methods 0.000 claims abstract description 6
- 239000002904 solvent Substances 0.000 claims abstract description 5
- 238000001704 evaporation Methods 0.000 claims 1
- 238000000034 method Methods 0.000 abstract description 15
- 238000000465 moulding Methods 0.000 abstract description 10
- 238000010438 heat treatment Methods 0.000 abstract description 4
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 206010040844 Skin exfoliation Diseases 0.000 description 2
- 239000002313 adhesive film Substances 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
Landscapes
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
【発明の詳細な説明】
〔産業上の利用分野〕
本発明は車両用内装材の製造方法に間し、更に詳細に説
明すると、軟質発泡体の表面に不織布を積層して形成さ
れる車両用内装材の製造方法に関する。[Detailed Description of the Invention] [Industrial Field of Application] The present invention relates to a method for manufacturing a vehicle interior material, and more specifically, to a method for producing a vehicle interior material, a material for a vehicle formed by laminating a nonwoven fabric on the surface of a soft foam. This invention relates to a method for manufacturing interior materials.
従来より、軟質ポリウレタンフォーム等の軟質発泡体に
不織布を接合させて形成される形成天井等の車両用内装
材が存在する。2. Description of the Related Art Conventionally, there have been vehicle interior materials such as molded ceilings formed by bonding a nonwoven fabric to a flexible foam such as flexible polyurethane foam.
第５図及び第６図に示す如く、軟質発泡体１に不織布２
を接合させる手段としては、接着剤３を軟質発泡体１ま
たは不織布２に塗布し、またはホットメルトフィルム等
の熱融着性フィルム４を用いるもの等が存在する。As shown in FIGS. 5 and 6, a nonwoven fabric 2 is attached to a soft foam 1.
As means for bonding, there are methods such as applying an adhesive 3 to the soft foam 1 or nonwoven fabric 2, or using a heat-fusible film 4 such as a hot melt film.
そして軟質発泡体１に適度の剛性を付与させるために熱
硬化性樹脂を含浸させて成形天井を形成している（特公
昭５８−５２４９５号）。In order to impart appropriate rigidity to the soft foam 1, it is impregnated with a thermosetting resin to form a molded ceiling (Japanese Patent Publication No. 58-52495).
然し乍ら、従来の如（、軟質発泡体１と不織布２とを接
着剤３または熱融着性フィルム４を用いて接合させる場
合には、接着剤３の塗布が作業環境を悪化させたり、ま
たは熱融着性フィルム４が高価でコストアップの原因と
なる等の欠点を有し、また作業能率を向上させることが
出来ないものであった・
本発明の目的は軟質発泡体と不織布の接合作業を筒易迅
速に行え、作業環境を悪化させる虞れがなく、また高価
な熱融着性フィルムを用いることがなく経済性に優れ、
更に軟質発泡体と不織布の結合力が強固で剥離する虞れ
がなく、外観の優れた車両用内装材を得ることの出来る
車両用内装材の製造方法を提供するものである。However, when bonding the soft foam 1 and the nonwoven fabric 2 using the adhesive 3 or the heat-adhesive film 4 as in the past, the application of the adhesive 3 may deteriorate the working environment or The fusible film 4 has drawbacks such as being expensive and causing an increase in cost, and also cannot improve work efficiency.The purpose of the present invention is to improve the bonding work of soft foam and nonwoven fabric. It can be easily and quickly carried out, there is no risk of deteriorating the working environment, and it is highly economical as it does not require the use of expensive heat-adhesive films.
Furthermore, it is an object of the present invention to provide a method for producing a vehicle interior material in which the bond between the soft foam and the nonwoven fabric is strong, there is no risk of peeling, and the vehicle interior material has an excellent appearance.
本発明は上述せる問題点に鑑みてなされたもので、軟質
発泡体の表面に不織布を積層し、該不織布の一部をニー
ドル加工により前記軟質発泡体中に埋設し、軟質発泡体
と不織布とを結合させた積層品を形成し、次いで前記積
層品を熱硬化性樹脂溶液中に浸漬し、該積層品に所定量
の熱硬化性樹脂溶液を含浸させ、次いで乾燥工程にて積
層品に含浸する熱硬化性樹脂溶液中の溶剤及び水分を蒸
発させ、次いで前記積層品を加熱プレス成形し、所望形
状の内装材を成形することを特徴とする。The present invention has been made in view of the above-mentioned problems, and involves laminating a nonwoven fabric on the surface of a soft foam, embedding a portion of the nonwoven fabric in the soft foam by needle processing, and combining the soft foam and the nonwoven fabric. are bonded together to form a laminate, then the laminate is immersed in a thermosetting resin solution, the laminate is impregnated with a predetermined amount of the thermosetting resin solution, and the laminate is impregnated in a drying process. The method is characterized in that the solvent and moisture in the thermosetting resin solution are evaporated, and then the laminate is hot press-molded to form an interior material in a desired shape.
〔作用〕
本発明に依れば、軟質発泡体の表面に不織布を積層し、
該不織布の一部をニードル加工により前記軟質発泡体中
に差し込み埋設状態としたので軟質発泡体と不織布とが
強固に絡み合った状態となり、この軟質発泡体と不織布
とが結合して形成された積層品を熱硬化性樹脂溶液中に
浸漬することにより、軟質発泡体と不織布とが熱硬化性
樹脂により結合されて更に強固に結合し、乾燥後加熱プ
レス成形することにより所望形状の内装材を形成するこ
とが出来、ニードル加工により表面が不均一な状態にさ
れた不織布も前記加熱プレス成形により均一な状態に復
元され、外観の優れた内装材を得ることが°出来るもの
である。[Function] According to the present invention, a nonwoven fabric is laminated on the surface of a soft foam,
A part of the nonwoven fabric was inserted into the soft foam by needle processing and embedded, so that the soft foam and the nonwoven fabric became tightly intertwined, and a laminate formed by combining the soft foam and the nonwoven fabric By immersing the product in a thermosetting resin solution, the soft foam and nonwoven fabric are bonded by the thermosetting resin to further strengthen the bond, and after drying, hot press molding is performed to form the interior material in the desired shape. Even non-woven fabrics whose surfaces have been rendered non-uniform by needle processing can be restored to a uniform state by the hot press molding, making it possible to obtain an interior material with an excellent appearance.
以下本発明に係る車両用内装材の製造方法の一実施例を
図面を参照して詳述する。DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the method for manufacturing a vehicle interior material according to the present invention will be described in detail below with reference to the drawings.
第１図乃至第４図には、本発明方法の一実施例の概略が
夫々示されており、本実施例では車両の内装材として天
井材に適用した場合が示されている。まず第１図に示す
如く、スラブウレタン等からなる連続気泡を有する軟質
発泡体１１０表面にポリエステル等からなる不織布１２
を積層し、ニードル針１４を複数突設したニードルバン
チ１３によりニードル加工を施こし、軟質発泡体１１中
に不織布１２の繊維１２ａの一部を差し込み埋設させて
軟質発泡体１１と不織布１２とを結合させたＭｉ層品工
５を形成する。1 to 4 schematically show an embodiment of the method of the present invention, and this embodiment shows a case where the method is applied to a ceiling material as an interior material of a vehicle. First, as shown in FIG. 1, a soft foam 110 having open cells made of slab urethane or the like is covered with a nonwoven fabric 12 made of polyester or the like.
are laminated and subjected to needle processing using a needle bunch 13 having a plurality of protruding needle needles 14, and some of the fibers 12a of the nonwoven fabric 12 are inserted and embedded in the soft foam 11, thereby forming the soft foam 11 and the nonwoven fabric 12. A bonded Mi layer component 5 is formed.
尚本実施例では軟質発泡体１１の表面側に不織布１２を
積層させた場合が示されているが、軟質発泡体１１の表
裏面に不織布１２を積層してニードル加工を施すことも
出来るものである。この場合には軟質発泡体１１をスラ
イスして２枚取りすることも出来、または両面不織布１
２の内装材を得ることが出来るものである。また軟質発
泡体１１と不織布１２とは所定の内装材の大きさに予め
カットしたものを用い、またはローラ等に巻回された長
尺のものを後工程で所定の大きさにカントするものであ
ってもよい。Although this embodiment shows a case where the nonwoven fabric 12 is laminated on the front side of the soft foam 11, it is also possible to laminate the nonwoven fabric 12 on the front and back surfaces of the soft foam 11 and perform needle processing. be. In this case, the soft foam 11 can be sliced into two pieces, or the double-sided nonwoven fabric 1
2 interior material can be obtained. The soft foam 11 and the nonwoven fabric 12 are either pre-cut to the size of the interior material, or long ones are wound around rollers or the like and then canted into the predetermined size in a subsequent process. There may be.
次に、第２図に示す如く、軟質発泡体１１と不織布１２
との結合品である積層品１５をメラミン樹脂、ウレタン
樹脂、尿素樹脂、熱硬化性アクリル樹脂等からなる熱硬
化性樹脂１７溶液中に漫清し、一対の送りローラ１８．
１９間で一次的に積層品１５に含浸した熱硬化性樹脂１
７溶液を絞り、次いで圧縮ローラ２１．２２間で二次的
に積層品１５に含浸した所定量以上の余分な熱硬化性樹
脂１７溶液を絞り取る。Next, as shown in FIG. 2, the soft foam 11 and the nonwoven fabric 12 are
The laminated product 15, which is a bonded product, is soaked in a solution of a thermosetting resin 17 made of melamine resin, urethane resin, urea resin, thermosetting acrylic resin, etc., and then placed between a pair of feed rollers 18.
Thermosetting resin 1 temporarily impregnated into a laminate 15 between 19 and 19
7 solution is squeezed out, and then excess thermosetting resin 17 solution of a predetermined amount or more impregnated into the laminate 15 is secondarily squeezed out between compression rollers 21 and 22.
次いで、加熱乾燥室で積層品１５に含浸した熱硬化性樹
脂１７溶液中の溶剤及び水分を１５０℃〜１６０℃の温
度条件下で５分間乾燥させて蒸発させる。Next, the solvent and moisture in the thermosetting resin 17 solution impregnated into the laminate 15 are dried and evaporated for 5 minutes at a temperature of 150° C. to 160° C. in a heating drying chamber.
次いで第３図に示す如く、内装材の所定の大きさにカッ
トきれた積層品１５を加熱プレス成形機２５の上型２６
及び下型２７間で加熱プレス成形し、所望形状の内装材
３１としての天井材に成形する。この加熱プレス成形に
より、軟質発泡体１１及び不織布１２に含浸した熱硬化
性樹脂１７が硬化し、且つ軟質発泡体１１中に埋設され
た繊維１２ａに含浸した熱硬化性樹脂１７が硬化し、軟
質発泡体１１及び不織布１２が強固に結合された内装材
３１としての天井材が得られる（第４図参照）。Next, as shown in FIG. 3, the laminate 15 cut into the predetermined size of the interior material is placed in the upper die 26 of the hot press molding machine 25.
and a lower die 27 to form a ceiling material as an interior material 31 in a desired shape. By this hot press molding, the thermosetting resin 17 impregnated into the soft foam 11 and the nonwoven fabric 12 is hardened, and the thermosetting resin 17 impregnated into the fibers 12a embedded in the soft foam 11 is hardened, and the soft foam 11 and the nonwoven fabric 12 are hardened. A ceiling material as an interior material 31 in which the foam 11 and the nonwoven fabric 12 are firmly bonded is obtained (see FIG. 4).
以上が本発明に係る車両用内装材の製造方法の一実施例
の方法であるが、斯る方法に依れば、軟質発泡体の表面
に不織布を積層し、該不織布の一部をニードル加工によ
り前記軟質発泡体中に差し込み埋設状態としたので軟質
発泡体と不織布とが接着剤や熱融着性フィルムを用いる
ことなく強固に絡み合った状態となり、この軟質発泡体
と不織布とが結合して形成された積層品を熱硬化性樹脂
溶液中に含浸することにより、軟質発泡体と不織布とが
熱硬化性樹脂により結合されて更に強固に結合し、また
結合作業によって作業環境が悪化する虞れがなく、乾燥
後加熱プレス成形することにより所望形状の内装材を成
形することが出来、ニードル加工により表面が不均一な
状態にされた不織布も前記加熱プレス成形により均一な
状態に復元され、結合力が強固で剥離の虞れがな（外観
の優れた内装材を得ることが出来、また軽量で剛性の優
れた内装材を得ることが出来る車両用内装材の製造方法
を得ることが出来る。The above is an embodiment of the method for manufacturing a vehicle interior material according to the present invention. According to this method, a nonwoven fabric is laminated on the surface of a soft foam, and a part of the nonwoven fabric is subjected to needle processing. Since the soft foam was inserted into the soft foam and embedded, the soft foam and the nonwoven fabric were tightly intertwined without using an adhesive or a heat-fusible film, and the soft foam and the nonwoven fabric were bonded together. By impregnating the formed laminate in a thermosetting resin solution, the soft foam and nonwoven fabric are bonded by the thermosetting resin, resulting in an even stronger bond, and the bonding process may worsen the working environment. The interior material can be molded into the desired shape by hot press molding after drying, and even nonwoven fabrics whose surface has been made uneven by needle processing can be restored to a uniform state by the hot press molding and bonded. It is possible to obtain an interior material for a vehicle that is strong in strength and has no risk of peeling (it is possible to obtain an interior material with an excellent appearance, and it is also possible to obtain an interior material that is lightweight and has excellent rigidity).
第１図乃至第４図は本発明に係る車両用内装材の製造方
法の一実施例の概略を夫々示すもので、第１図は軟質発
泡体と不織布とのニードル加工を示す工程図、第２図は
積層品を熱硬化性樹脂溶液中に浸漬している状態の断面
説明図、第３図は加熱プレス状態の断面説明図、第４図
は内装材として天井材を加熱プレス成形した場合の断面
説明図、第５図及び第６図は従来の軟質発泡体と不織布
との接合状態を示す断面説明図である。
図中、１１・・・軟質発泡体、１２・・・不織布、１２
ａ・・・繊維、１３・・・ニードルパンチ、１４・・・
ニードル針、１５・・・積層品、１７・・・熱硬化性樹
脂、２５・・・加熱プレス成形機、２６・・・上型、２
７・・・下型、３１・・・内装材。
第１図
第２図 第３図
第４図
第５図
第６図
゛ ′口゛1 to 4 each schematically show an embodiment of the method for manufacturing a vehicle interior material according to the present invention. FIG. 1 is a process diagram showing needle processing of a soft foam and a nonwoven fabric; Figure 2 is an explanatory cross-sectional diagram of the laminated product immersed in a thermosetting resin solution, Figure 3 is an explanatory cross-sectional diagram of the hot pressed state, and Figure 4 is a case in which ceiling material is hot press molded as an interior material. FIGS. 5 and 6 are cross-sectional explanatory views showing the state of bonding between a conventional soft foam and a nonwoven fabric. In the figure, 11... Soft foam, 12... Nonwoven fabric, 12
a...Fiber, 13...Needle punch, 14...
Needle needle, 15... Laminated product, 17... Thermosetting resin, 25... Hot press molding machine, 26... Upper mold, 2
7... Lower mold, 31... Interior material. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6
Claims (1)
ニードル加工により前記軟質発泡体中に埋設し、軟質発
泡体と不織布とを結合させた積層品を形成し、次いで前
記積層品を熱硬化性樹脂溶液中に浸漬し、該積層品に所
定量の熱硬化性樹脂溶液を含浸させ、次いで乾燥工程に
て積層品に含浸する熱硬化性樹脂溶液中の溶剤及び水分
を蒸発させ、次いで前記積層品を加熱プレス成形し、所
望形状の内装材を成形することを特徴とする車両用内装
材の製造方法。A nonwoven fabric is laminated on the surface of a soft foam, a part of the nonwoven fabric is embedded in the soft foam by needle processing to form a laminated product in which the soft foam and the nonwoven fabric are bonded, and then the laminated product is immersed in a thermosetting resin solution to impregnate the laminate with a predetermined amount of the thermosetting resin solution, then evaporating the solvent and moisture in the thermosetting resin solution impregnated into the laminate in a drying process, A method for producing an interior material for a vehicle, characterized in that the laminated product is then heated and press-molded to form an interior material in a desired shape.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP62109380A JPS63274518A (en) | 1987-05-02 | 1987-05-02 | Production of trim material for vehicle |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP62109380A JPS63274518A (en) | 1987-05-02 | 1987-05-02 | Production of trim material for vehicle |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPS63274518A true JPS63274518A (en) | 1988-11-11 |
Family
ID=14508775
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP62109380A Pending JPS63274518A (en) | 1987-05-02 | 1987-05-02 | Production of trim material for vehicle |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS63274518A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0822062A1 (en) * | 1996-07-29 | 1998-02-04 | Asahi Fiber Glass Co., Ltd. | Composite substrate for plastic reinforcement, and fiber-reinforced plastic using such composite substrate |
| EP1693497A1 (en) * | 2003-12-08 | 2006-08-23 | Nagoya Oilchemical Co., Ltd. | Stretchable nonwoven fabric |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5852495A (en) * | 1981-09-21 | 1983-03-28 | Nippon Steel Corp | Steel plate for vessel |
-
1987
- 1987-05-02 JP JP62109380A patent/JPS63274518A/en active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5852495A (en) * | 1981-09-21 | 1983-03-28 | Nippon Steel Corp | Steel plate for vessel |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0822062A1 (en) * | 1996-07-29 | 1998-02-04 | Asahi Fiber Glass Co., Ltd. | Composite substrate for plastic reinforcement, and fiber-reinforced plastic using such composite substrate |
| CN1079724C (en) * | 1996-07-29 | 2002-02-27 | 旭玻璃纤维股份有限公司 | Composite substrate for plastic reinforcement, and fiber-reinforced plastic using such composite substrate |
| EP1693497A1 (en) * | 2003-12-08 | 2006-08-23 | Nagoya Oilchemical Co., Ltd. | Stretchable nonwoven fabric |
| EP1693497A4 (en) * | 2003-12-08 | 2008-10-22 | Nagoya Oilchemical | Stretchable nonwoven fabric |
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