KR101925296B1 - Manufacturing method of automobile interior material having stitch shape implemented - Google Patents

Abstract

The present invention relates to a method for manufacturing an automobile interior material having a stitch shape according to the content of a blowing agent. According to the present invention, a base material layer, a foam layer, and a skin layer are integrally formed And a portion of the skin layer is removed to expose the foam layer to the outside of the skin layer, thereby realizing a stitch shape at a time, thereby realizing the luxury of the automobile interior material.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an automobile interior material having a stitch shape according to a foaming agent content,

The present invention relates to a method for manufacturing an automobile interior material, and more particularly, to a technique for integrally manufacturing a base layer, a foam layer, and a skin layer while simultaneously realizing a synthetic stitch shape.

In general, the surface of various parts used as an automobile interior material such as an instrument panel, a floor console, or an arm rest is provided with a luxurious image in the interior of a vehicle, Various skin materials and so-called skin materials are applied to give a more comfortable atmosphere to the passengers by imparting a soft touch to portions where contact is expected.

The most popular way of applying skin to the skin is by wrapping a piece of leather on a core (substrate) that retains its shape. In this case, the texture of the fabric and the stitch line sewing the fabric can be exposed to give a more luxurious feeling. However, it is applied only to some luxury cars due to a considerable amount of manual and fabric materials.

For this reason, a plastic sheet is used as a skin material, and an automotive interior material to which foamed foam is applied to improve cushion performance is also used.

However, in the conventional foamed lining material, since a separate skin material is first prepared for application of the skin material and then a foam layer is formed between the substrate and the skin material, there is a disadvantage in that the work process is complicated and the stitch shape is difficult to implement .

On the other hand, Korean Patent No. 10-0695788 (Mar. 3, 2007 'Skin Structure for Automobile Interior Materials') relating to automobile interior materials to which a skin material is applied is known.

Disclosure of the Invention The present invention has been conceived in order to solve the problems of the prior art as described above, and it is an object of the present invention to provide a method of forming a skin layer, a foam layer and a skin layer by integrally forming a base layer, And a part of the foam layer is exposed to the outside of the skin layer by removing a part of the foam layer.

According to another aspect of the present invention, there is provided a method of manufacturing an automobile interior material having a stitch shape according to the present invention, comprising the steps of: (a) spraying and applying a stock solution of a skin to a lower mold having a hot wire at a specific position on an inner surface thereof; (B) a step of injecting a foaming stock solution into a lower mold to which a stock solution of the skins has been applied, (c) placing a substrate on the foaming stock solution, pressing the substrate with an upper mold, (D) integrally forming a base layer, a foam layer having foamed foamed raw material foam, and a skin layer having foamed foamed skin by foaming the raw liquid and the skin stock solution, and heating the heat ray provided to the lower mold, (E) removing a portion of the layer at a high temperature to expose the foam layer through a removed portion of the skin layer to thereby realize a stitch shape, The skin layer and the foam layer are made of the same raw material but the content of the foaming agent in the skin layer is made smaller than the content of the foaming agent in the foam layer.

In the method of manufacturing an automobile interior material according to the present invention, a polyurethane resin is sprayed onto a lower mold and foamed together with the foam layer, instead of using a plastic skin material that is manufactured in advance, so that the base layer, the foam layer, It can be made in one piece at once.

In addition, a part of the skin layer is removed through a hot wire provided on the lower mold or a contact tip provided in the skin removing device to expose the foam layer to the outside of the skin layer, so that the foam layer exposed due to the color difference between the skin layer and the foam layer By making the shape of the stitch line stand out, it is possible to realize the luxury of the automobile interior material. In this case, since the stitch-like embodying work is not performed in a separate process but is performed in a process of integrating the foam layer and the skin layer, the entire process can be simplified.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view for explaining a method for manufacturing an automobile interior material according to a first embodiment of the present invention; FIG.
Fig. 2 is a view for explaining an automobile interior material manufactured by the manufacturing method shown in Fig. 1; Fig.
3 is a view for explaining a method of manufacturing an automobile interior material according to a second embodiment of the present invention.

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. However, some configurations which are not related to the gist of the present invention may be omitted or compressed, but the configurations omitted are not necessarily those not necessary in the present invention, and they may be combined by a person having ordinary skill in the art to which the present invention belongs. .

1 is a view for explaining a method of manufacturing an automobile interior material according to a first embodiment of the present invention. Referring to FIG. 1, in order to manufacture an automobile interior material, the inner surface of the lower mold 40 is sprayed with the skin stock solution 10a (S105).

Here, the lower mold 40 includes a base layer 30, a foam layer 20, and a skin layer 10, which are exposed to the surface of the skin layer 10, which constitute an interior material (a product to be produced in the present invention) And has an inner surface shape corresponding to the shape. Particularly, in the present invention, a groove 42 is formed in a portion where stitches are formed so that the stitches protrude from the surface of the interior material 1, and a heat ray 41 is embedded in each groove 42.

The skin stock solution 10a sprayed on the inner surface of the lower mold 40 is a raw material for forming the skin layer 10 serving as a skin material. As the skin stock solution 10a, a hard polyurethane resin may be used. That is, the hard polyurethane resin is sprayed on the inner surface of the lower mold 40 by a spraying method through a spray gun or the like. The thickness of the skin stock solution 10a applied to the inner surface of the lower mold 40 is considerable, but the actual skin stock solution 10a is very thinly coated with a thickness of 0.1 mm to 1 mm. Therefore, the skin stock solution 10a is applied evenly at a portion where the grooves 42 are formed, substantially uniformly corresponding to the shape of the grooves 42.

Thereafter, the foaming stock solution 20a is injected into the lower mold 40 to which the skin stock solution 10a is applied. The foaming stock solution 20a refers to a raw material for forming the foam layer 20, and a flexible polyurethane resin can be used. On the other hand, the skin stock solution 10a and the foam stock solution 20a are different in color so as to be visually distinct, and when the foam layer 20 is exposed to the outside of the skin layer 10 at a later time, . For example, the skin stock solution 10a uses a dark system color such as black, and the foam stock solution 20a uses a light system color such as light gray.

Thereafter, a preformed base material 30 is set by injection molding a polypropylene resin on the foaming stock solution 20a and the upper portion of the base material 30 is pressed by the upper mold 50 to form the foamed stock solution 20a and the skin The raw liquid 10a is foamed. When the raw foaming liquid 20a and the skins raw liquid 10a are foamed for a certain period of time under a specific temperature and pressure atmosphere, the foaming layer 20 is formed by foaming of the foaming raw liquid 20a and the foaming of the raw skins 10a The base layer 30, the foam layer 20 and the skin layer 10 are integrated while the skin layer 10 is formed.

That is, in the present invention, polyurethane resin as the skin stock solution 10a is applied to the lower mold 40 by spraying the foam stock solution 20a and the foaming liquid 20a, instead of forming the foam layer 20 after the fabric or the plastic skin material is prepared in advance The foaming layer 20 and the skin layer 10 can be integrally formed at one time, thereby simplifying the manufacturing process.

At this time, soft polyurethane resin was used as the foaming stock solution 20a as the raw material of the foam layer 20 and rigid polyurethane resin was used as the skins stock solution 10a as the raw material of the skin layer 10 . Therefore, the bubbles formed in the foam layer 20 are relatively large, so that they can function as a cushion for absorbing shock, and the bubbles formed in the skin layer 10 can function as a skin material having a very soft touch have.

A predetermined cooling process is performed to heat the heat ray 41 provided in the groove 42 of the lower mold 40 to heat the skin layer 10 to heat the skin ray 10a, 41 is melted and removed at a high temperature (S125). At this time, since the heat ray 41 is formed only at the portion corresponding to the groove 42, only the skin layer 10 applied to the groove 42 is removed by high temperature. Thereafter, the product 1 is taken out from the molds 40 and 50 (S130).

Fig. 2 is a view for explaining an automobile interior material manufactured by the manufacturing method shown in Fig. 1. Fig. That is, FIG. 2 (a) is a schematic cross-sectional view of the automobile interior material, and FIG. 2 (b) is a view from above of the automobile interior material.

Referring first to FIG. 2 (a), an automobile interior material manufactured by the manufacturing method according to an embodiment of the present invention is integrally formed with a base layer 30, a foam layer 20, and a skin layer 10. The base layer 30 maintains the shape of the parts, the foam layer 20 functions as a cushion for absorbing the impact, and the skin layer 10 functions as a skin material having soft touch.

Here, a part of the skin layer 10 is removed by the heat ray 41 provided on the lower mold 40. A part corresponding to the groove 42 of the lower mold 40 is protruded outward from the finished product 1 by the part where the recess 42 is formed in the lower mold 40. [ The portion 10b protruding from the skin layer 10 is removed at a high temperature so that the portion 20b formed in the foam layer 20 corresponding to the groove 42 is exposed on the skin layer 10. [

Since the skin layer 10 and the foam layer 20 have different colors of raw materials, the exposed portion of the foam layer 20 is significantly different from the color of the other skin layers 10. Although the color of the raw material of the skin layer 10 and the foam layer 20 may be different from each other, the same raw material is used, the content of the foaming agent is relatively small in the skin layer 10, It is possible to make the color difference according to the difference in the foaming ratio.

The lower mold 40 is provided with recesses 42 and heat lines 41 at regular intervals along virtual stitch lines. Therefore, the line of the foam layer 20 exposed on the surface of the skin layer 10 as shown in FIG. 2 (b) is similar to the stitch line of the actual sewed fabric, so that the interior material can be sophisticated. Particularly, the foam layer 20 protruding outside the skin layer 10 has a shape similar to that of an actual stitch protruded, so that the stitch line can be reproduced more realistically.

In the above description, an example is described in which the base stock 30 is coated with the stock solution 10a, and then the base stock 30 is set after the base stock 20a is injected. However, It is also possible to inject the foaming stock solution 20a between the base material 30 and the applied skin stock solution 10a. An opening (not shown) is formed in the upper mold 50. A hole (not shown) is formed in the base 30 at a position corresponding to the injection port of the upper mold 50, The raw foil 20a is injected through the hole of the base 30 and the base 30 and the lower mold 20a through the hole of the base 30. [ 40 to the skin stock solution 10a.

It is also possible to apply the spinning liquid 10a to the lower mold 40 by spraying method, then apply the foaming raw liquid 20a by the spraying method, and then set the substrate 30.

3 is a view for explaining a method of manufacturing an automobile interior material according to a second embodiment of the present invention. Referring to FIG. 3, first, a spinning solution 10a is sprayed on the inner surface of a lower mold 60 to apply automobile interior material.

Here, the lower mold 60 is divided into a stationary mold 61 and a movable mold 62. In other words, the stationary mold 61 is located outside the stitch line and the movable mold 62 is located inside the stitch line. Therefore, the groove 63 is formed at the position where the stitch line is formed in the movable mold 62. [ However, in this embodiment, the groove 63 of the movable mold 62 is not provided with a heat wire. The movable mold 62 is designed to be detachable from the stationary mold 61.

Subsequently, the foamed raw liquid 20a is injected into the lower mold 60 to which the raw skins 10a have been applied S310, the previously prepared substrate 30 is set, (70) so that the foam stock solution (20a) and the skin stock solution (10a) are foamed. When the raw foaming liquid 20a and the skins raw liquid 10a are foamed for a certain period of time under a specific temperature and pressure atmosphere, the foaming layer 20 is formed by foaming of the foaming raw liquid 20a and the foaming of the raw skins 10a The base layer 30, the foam layer 20 and the skin layer 10 are integrated while the skin layer 10 is formed.

After completion of the foaming process of the foam stock solution 20a and the skin stock solution 10a, a predetermined cooling process is performed and the movable mold 62 is separated from the stationary mold 61 and then the skin removing device 80 And moves the movable mold 62 between the removed fixed molds 61.

The skin removing device 80 is provided with a contact tip 81 at a position corresponding to a portion of the skin layer 10 protruded and formed by the groove 63 of the movable mold 62. And a heating means is built in the end portion of the contact tip 81. [ The heating means may be realized as a metallic hot wire or a CNT heating element.

Therefore, when the contact tip 81, which generates a high temperature by entering the skin removing apparatus 80, contacts the protruded molded portion of the skin layer 10, the contact portion is melted and removed. Thereafter, the product 1 is taken out from the molds 60 and 70 (S335).

In this embodiment, a separate skin removing device 80 is used to remove the skin layer 10 to realize the stitch line. That is, if the entire lower mold 40 is integrally formed as shown in FIG. 1 and a heat ray 41 is provided on a part of the inner surface of the lower mold 40, heat is generated near the groove 42 when the heat ray 41 is operated. There is a possibility that the skin layer 10 in a large area which is unintentionally transferred due to conduction may be removed.

3, the skin layer 10, the foam layer 20, and the base layer 30 are integrally formed through the lower mold 60 including the stationary mold 61 and the movable mold 62 Thereafter, the movable mold 62 of the portion where the stitch line is to be formed is removed, heat is applied by contacting the thin contact tip 81, heat is not conducted around the protruded portion of the skin layer 10, The skin layer 10 can be removed only by the high temperature.

As described in detail above, in the present invention, the polyurethane resin is sprayed onto the lower molds 40 and 60 and foamed together with the foam layer 20, instead of using a plastic skin material that is manufactured in advance, The foam layer 30, the foam layer 20, and the skin layer 10 can be integrally formed at one time.

A part of the skin layer 10 is removed through the contact tip 81 provided in the heating wire 41 or the skin removing device 80 provided in the lower mold 40 to remove the foam layer 20 from the skin layer 10, It is possible to realize the high quality of the automobile interior material by making the exposed foam layer 20 have the shape of the stitch line due to the color difference between the skin layer 10 and the foam layer 20. At this time, since the stitch-like embodying work is not performed in a separate process but is performed together in the process of integrating the foam layer 20 and the skin layer 10, the entire process can be simplified.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, And additions should be considered as falling within the scope of the claims of the present invention.

≪ Embodiment 1 >
1: Finished product (interior material)
10: skin layer
10a: Skin stock solution
10b: the part to be removed
20: foam layer
20a: foaming stock solution
20b: exposed part
30: substrate layer (substrate)
40: Lower mold
41: Heat line
42: groove
50: upper mold
≪ Embodiment 2 >
1: Finished product (interior material)
10: skin layer
10a: Skin stock solution
20: foam layer
20a: foaming stock solution
20b: exposed part
30: substrate layer (substrate)
60: Lower mold
61: Fixed mold
62: Moving mold
63: groove
70: Upper mold
80: Epidermal removal device
81: Contact tip

Claims (1)

(A) spraying and applying a stock solution of a skin to a lower mold provided with a hot wire at a specific position on the inner surface;
(B) injecting a foaming stock solution into a lower mold having the skin stock solution applied thereto;
(C) placing the substrate on the foaming stock solution;
The base material is pressurized with an upper mold to foam the foaming stock solution and the skin stock solution in a specific temperature and pressure atmosphere to form a foam layer in which the foam stock solution is foamed and a skin layer in which the foam stock solution is foamed integrally (d); And
(E) heating the hot wire provided in the lower mold to remove a portion of the skin layer at a high temperature, thereby exposing the foam layer through the removed portion of the skin layer to realize a stitch shape,
Characterized in that the skin layer and the foam layer are made of the same raw material but the content of the foaming agent in the skin layer is made smaller than the content of the foaming agent in the foam layer so as to produce a stitch- .

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