KR20190087384A - Manufacturing method for vehicle interior material using fiber material, and vehicle interior material manufactured by the method - Google Patents

Abstract

The present invention relates to a manufacturing method of a vehicle interior material using a fiber material and to a vehicle interior material manufactured by the method. A rigid skeleton is formed while greatly reducing the amount of a resin injected by using a light weight fiber material having excellent moldability, thereby realizing weight reduction of the interior material. In addition, even if having no separate skin material attaching process, a skin material, the fiber material and a substrate can be integrally manufactured through only an injection process, thereby simplifying a process.

Description

TECHNICAL FIELD The present invention relates to a method of manufacturing an automobile interior material using a fiber material and an automobile interior material manufactured by the method,

The present invention relates to a method for manufacturing an automobile interior material and an automobile interior material manufactured by the method. More specifically, it is possible to reduce weight while achieving high rigidity by injection molding resin into a fiber material. In the injection molding process, So that the process can be simplified.

In many cases, the interior material to be installed in a car interior is a skin material such as a leather fabric in consideration of aesthetic appearance and contact feeling. That is, the base material to be the skeleton of the interior material is first produced through resin injection, the adhesive agent is applied to the surface of the base material, and then the skin material is adhered to finish. However, there is a problem in that the injection molding process and the skin re-adhering process must be separately performed to complicate the process.

For this purpose, Korean Patent Laid-Open No. 10-2016-0123663 (Oct. 26, 2016, 'Automobile Interior Material Forming Apparatus', hereinafter referred to as 'Prior Art 1') fixes a skin material in a mold, So as to simplify the process.

However, in the prior art 1, since only the resin injection molding is used as the base material of the interior material, there is a problem that the weight of the interior material increases. That is, in recent years, in order to reduce the environmental friendliness and the carbon dioxide, efforts are made to reduce the weight of the vehicle in order to improve the fuel efficiency. Conventional technology 1 is contrary to this tendency.

On the other hand, in Korean Patent Laid-Open No. 10-2014-0057206 (hereinafter referred to as "the manufacture of a vehicle trim component through compression and injection molding", hereinafter referred to as "Prior Art 2"), a lightweight fiber panel And introducing a resin to manufacture a trim component, thereby realizing the rigidity and light weight of the interior material. However, since the inner material manufactured in the prior art 2 also has to wrap the skin material through a separate attaching process, the existing problem of adding the process has been repeated.

The present invention has been conceived 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 manufacturing an injection molding machine, which can realize weight saving of an interior material by using a fiber material having excellent moldability and light weight, The present invention has been made to solve the above problems.

According to an aspect of the present invention, there is provided a method of manufacturing an automobile interior material using a fiber material, the method including: (a) preheating a skin material and a fiber material; (B) placing the preheated skin material and the fiber material on the mold surface in the mold; (C) pressing the skin material and the fiber material located on the mold surface; (D) injecting resin into the surface of the fiber material opposite to the surface on which the skin material is laminated; (E) cooling the injected resin to form a base material, and drawing the interior material in which the skin material, the fiber material, and the base material are integrally formed, from the mold.

The method may further include the step (f) of wrapping the periphery of the skin material and the fiber material around the bottom of the base material.

Also, the mold includes a first mold and a second mold having respective mold surfaces, and a far-end mounting pin for holding the skin material and the fiber material on the mold of either the first mold or the second mold, Wherein the pre-heated skin material and the fiber material are placed on the mold surface by hooking the pre-heated skin material and the fiber material on the far end mounting pin.

In addition, the skin material and the fiber material may have a hook portion protruding outward along the circumference, and a hook hole may be formed in the hook portion into which the far end fitting pin is inserted.

The fibrous material is a natural fiber mixed with a natural fiber and a thermoplastic resin. After the skin material and the fibrous material are preheated through the step (a), the skin material and the fibrous material are separated by the step (b) And the resin is injected through the step (d) while pressing the skin material and the fiber material through the step (c), the thermoplastic resin contained in the fiber material is melted due to the high temperature of the resin, The skin material, the fibrous material, and the substrate may be integrated when cooling is performed through the step (e).

Meanwhile, the present invention includes automobile interior materials manufactured by the above method.

The method of manufacturing an automobile interior material using the fiber material according to the present invention and the automobile interior material manufactured by the method have the following effects.

A rigid skeleton can be formed by using a fibrous material having excellent moldability and light weight and greatly reducing the amount of injected resin, thereby realizing weight saving of the interior material.

In addition, even if there is no separate skin reattaching step, it is possible to manufacture an integrated type of skin material, fiber material, and substrate through the injection process alone, thereby simplifying the process.

1 is a view for explaining a method of manufacturing an automobile interior material according to an embodiment of the present invention.
FIG. 2 is a schematic cross-sectional view of a vehicle interior material manufactured by the process shown in FIG. 1; FIG.
FIG. 3 is a view for explaining another example of an automobile interior material manufactured by the process shown in FIG. 1; FIG.
FIG. 4 is a view for explaining another example of a vehicle interior material manufactured by the process shown in FIG. 1; FIG.
FIG. 5 is a schematic plan view of a skin material and a fiber material applied in the process shown in FIG. 1;
6 is a view for explaining a state in which an interior material manufactured using the skin material and the fibrous material shown in Fig. 5 is mounted on a mounting component; Fig.

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 an embodiment of the present invention. A process for manufacturing the automobile interior material 1 will be described with reference to FIG.

First, the skin material 10 and the fiber material 20 are cut in consideration of the shape and size of the interior material 1 to be manufactured. Of course, it is also possible to prepare the skin material 10 and the fiber material 20 in a sufficient size, and then cut in the subsequent injection molding process or after the injection molding. However, the skin material 10 and the fiber material 20 The loss of raw materials can be prevented.

The skin material 10 may be a natural leather or artificial leather or the like as a portion of the surface of the interior material 1 which is in contact with the user.

The fibrous material 20 is a material replacing a part of the function of the base material 30 constituting the skeleton of the interior material 1, and is a material having an excellent moldability and rigidity as high as that of the resin 70. In this embodiment, a natural fiber in which a natural fiber and a thermoplastic resin are mixed is used as the fiber material 20. Natural fibers include, for example, natural fibers such as kenaf, jute, hemp, flax, sisal, coir, and polypropylene (PP) Inorganic fibers having excellent rigidity and heat resistance such as nitrile-butadiene-styrene (ABS) and polycarbonate (PC) are mixed at a certain ratio, and these fibers are subjected to carding or air- Bonded by punching, and then subjected to preheating, melting, pressing, and cooling to form a sheet. Since the natural fiber is a known material, a detailed description thereof will be omitted.

When the skin material 10 and the fibrous material 20 are prepared by cutting to an appropriate size, they are put into the preheating device 40 as shown in FIG. 1 (a) and preheated. The skin material 10 and the fiber material 20 may be put together in one preheating device 40 and preheated at the same time or may be put into separate preheating devices 40 to be preheated. When the skin material 10 and the fiber material 20 are preheated, they are in a state of stagnation and can be easily deformed according to the shape of the mold surface during the subsequent pressing process.

When the preheating is finished for a predetermined time in the preheating device 40, the skin material 10 and the fiber material 20 are taken out and placed on the mold surfaces 51 and 61 in the molds 50 and 60. [ At this time, the skin material 10 and the fibrous material 20 are placed in a state where they are inserted into the far end mounting pins 52 provided in the molds 50 and 60.

Referring to FIG. 1 (b), examples of the molds 50 and 60 on which the skin material 10 and the fiber material 20 are seated can be confirmed. The mold used in this embodiment includes a first mold 50 and a second mold 60.

The first mold surface 51 and the second mold surface 61 are formed on the surfaces facing each other in the first mold 50 and the second mold 60, respectively. The mold surfaces 51 and 61 have shapes corresponding to the upper surface and the lower surface of the interior material 1 to be manufactured. In this embodiment, the first mold surface 51 is formed on the upper surface , And the second mold surface 61 corresponds to the shape of the lower surface (inner surface) of the interior material 1. In this case,

In addition, a far end mounting pin 52 is provided on the outside of the first mold surface 51 in the first mold 50. The far end mounting pin 52 is for supporting the skin material 10 and the fiber material 20. In the present embodiment, a predetermined number of far end mounting pins 52 are provided on the upper and lower portions of the first mold 50 An installed example is shown.

Here, the far-end mounting pin 52 may be constructed to be drawn out or inserted from the first mold 50 in association with the movement of the second mold 60. When the molds 50 and 60 are opened, the far-end mounting pin 52 is automatically inserted into the first mold 50 in conjunction with the opening operation, The fabric stopper pin 52 is retracted automatically in conjunction with the closing operation when the molds 50 and 60 are closed so that the first mold member 50 and the second mold member 50 can be automatically retracted, (Not shown).

Even if the farthest end fitting pin 52 is retracted and drawn into the first mold 50, the total thickness of the skin material 10, the fibrous material 20, and the base material 30 through the injection Lt; / RTI > When the resin 70 is injected in the state that the far end mounting pin 52 occupies the inner volume of the hooking holes 12 and 22 of the skin material 10 and the fiber material 20, The resin 70 can not be filled, and this portion can be utilized as a mounting hole at a later stage. The hook holes 12 and 22 and the mounting holes will be described later with reference to FIGS. 5 and 6 again.

A resin injection hole 62 is formed at a certain point on the second mold surface 61 in the second mold 60 and a molten resin 70 is injected into the second mold 60 through the resin injection hole 62. [ And the first mold 50, as shown in Fig. Although one resin injection hole 62 is shown in the present embodiment for the sake of convenience, a plurality of resin injection holes 62 may be formed at appropriate positions in an inner portion and an outer portion of the second mold surface 61 have.

When the skin material 10 and the fiber material 20 preheated as shown in FIG. 1 (b) are fitted and fixed in the far end mounting pins 52 provided at the upper and lower portions of the first mold 50, The second mold 60 moves and comes in close contact with the first mold 50 as shown in FIG. The space between the first mold surface 51 and the second mold surface 61 is greater than the sum of the thickness of the skin material 10 and the fiber material 20 because the space in which the resin 70 is to be injected is exaggerated. The second mold 60 is moved in a state where the actual skin material 10 and the fibrous material 20 are positioned between the mold surfaces 51 and 61 to form the first mold 50, The skin material 10 and the fibrous material 20 are pressed between the mold surfaces 51 and 61 so that the skin material 10 and the fibrous material 20 are pressed against the first mold surface 51 and the fibrous material 20, 2 mold surface 61 as shown in FIG.

1 (d), when the molten resin 70 is injected through the resin injection hole 62, the resin 70 is filled in the surface of the fiber material 20 opposite to the surface on which the skin material 10 is laminated It is filled. At this time, the temperature of the molten resin 70 injected into the injection space is very high, and the heat is transferred to the fiber material 20 as it is. Therefore, the thermoplastic resin such as polypropylene contained in the fibrous material 20 is momentarily liquefied due to the high heat of the molten resin 70. The fibrous material 20 and the skin material 10 are strongly pressed by the pressing force caused by the close contact of the molds 50 and 60 and the resin 70 and the fibrous material 20 and the skin material 10 ) Is further increased. As a result, the thermoplastic resin such as polypropylene liquefied in the fiber material 20 is evenly adhered to the skin material 10 by a strong pressing force. That is, the thermoplastic resin of the fiber material 20 liquefied by the heat of the resin 70 functions as an adhesive for bonding the fiber material 20 and the skin material 10.

Thereafter, when the resin 70 is hardened through a predetermined cooling process, the base material 30 is formed corresponding to the shape of the second mold surface 61, and at the same time, the thermoplastic resin of the fiber material 20 is hardened again. That is, since the thermoplastic resin of the fibrous material 20 is hardened while being evenly adhered to the skin material 10 in a molten state, the skin material 10 is strongly adhered to the fibrous material 20 through the cooling process .

When the cooling process is completed, the second mold 60 is released from the first mold 50, and the automobile interior material 1 that has been manufactured as shown in FIG. 1 (e) can be taken out.

1 shows a case where the first mold 50 has the far end fixing pin 52 and the second injection mold 62 has the resin injection hole 62. However, The pins 52 may be provided in the second mold 60 in which the resin injection holes 62 are formed.

2 is a schematic cross-sectional view of the automobile interior material 1 manufactured through the method of manufacturing the automobile interior material described with reference to FIG. Referring to FIG. 2, it can be seen that the interior material 1 manufactured in the manufacturing process according to the embodiment of the present invention forms a layer of the skin material 10, the fibrous material 20, and the substrate 30 from the upper surface have. It is also confirmed that the upper and lower surfaces of the interior material 1 are deformed in a shape corresponding to the shape of the mold surfaces 51 and 61.

2, the thickness of each layer is exaggerated for convenience of explanation, but the thickness of the base material 30 located under the actual fiber material 20 is considerably thin. That is, after the fiber material 20 is preheated, when the resin 70 is injected into the back surface and cooled together, the fiber material 20 has stiffness comparable to that of the substrate 30 formed while the resin 70 is hardened . The fibrous material 20 can replace the function of the base material 30 forming the framework of the interior material 1 so that even if a small amount of the resin 70 is injected to form the base material 30, 1) can have sufficient rigidity.

Therefore, since the lightweight fiber material 20 can replace a substantial portion of the substrate 30, which is an injection molded product of the resin 70, the total weight of the interior material 1 can be greatly reduced.

In addition, as described above, in the present invention, the skin material 10 and the fiber material 20 are preheated simultaneously and then injected into the molds 50 and 60 to inject the resin 70. In the injection molding process Since the skin material 10, the fibrous material 20 and the substrate 30 are closely adhered to each other and then manufactured integrally, a separate step of attaching the skin material 10 is not required. Accordingly, since the manufacturing process is greatly simplified and no separate adhesive is required, the cost of the interior material 1 can be reduced.

3 is a view for explaining another form of the interior material. That is, in the process of FIG. 1, the second mold surface 61 of the second mold 60 is deformed so that the resin 70 is filled only in a certain region of the inner surface of the skin material 10 and the fiber material 20. 3 (a), the skin material 10 and the fibrous material 20 protrude from the periphery of the base material 30 in the finished interior material 1. After the injection molding, 10 and the fibrous material 20 are wrapped around the periphery of the substrate 30, the interior material 1 having the backward wrapping process as shown in FIG. 3 (b) can be manufactured.

Fig. 4 is a view for explaining another embodiment of the interior material. Fig. That is, the shape of the second mold surface 61 of the second mold 60 is modified in the process of FIG. 1 so that the resin 70 is filled only in the peripheral portion 32 and the bottom portion of the fiber material 20. The resin 70 filled in only a part of the bottom of the fiber material 20 serves as a rib 31 to which the manufactured interior material 1 is supported by other parts and the peripheral portion 32 Of the resin 70 plays a role of strengthening the rigidity of the outer portion of the fiber material 20.

In the example shown in Fig. 4, the fiber material 20 replaces most of the surface area of the base material 30, which can enhance the peripheral surface rigidity and the shape of the ribs 31, So that the weight of the interior material 1 is maximized.

FIG. 5 is a schematic plan view for explaining shapes of a skin material and a fiber material used in the manufacturing process of FIG. 1. FIG. 5, the skin material 10 and the fiber material 20 are cut to a predetermined size corresponding to the shape and size of the interior material 1, and a plurality of skin material holding parts 11 and And a fiber material catching portion 21 is protruded. In addition, a skin material holding hole 12 and a fiber material holding hole 22 are formed in the skin re-holding portion 11 and the fiber material holding portion 21, respectively. Each of the hook holes 12 and 22 is a hole into which the far end fitting pin 52 is inserted in the molds 50 and 60.

5, the hook portions 11 and 21 are protruded outward and the far end mounting pins 52 are inserted into the hook holes 12 and 22 formed in the hook portions 11 and 21 When the skin material 10 and the fiber material 20 are placed on the molds 50 and 60, the skin material 10 and the fiber material 20 can be easily aligned.

Of course, depending on the shape of the interior material 1, the hooks 11 and 21 formed with the hook holes 12 and 22 may be cut and removed after injection molding. That is, the hook portions 11 and 21 are used only for the purpose of holding the initial position in the molds 50 and 60. At this time, since the removed portion occupies an extremely small area protruding from the main surface of the skin material 10 and the fibrous material 20, the loss of the raw material is not large.

When the wrapping process shown in FIG. 3 is added, the skin material 10 shown in FIG. 5 and the hooks 11 and 21 having the hook holes 12 and 22 protruded outward in the form of the fiber material 20 are formed Is wrapped around the rear surface of the substrate 30. [ Therefore, if the rearward wrapping process as shown in FIG. 3 is performed, the circumferential surface finish process can be performed without removing the hooks 11 and 21 separately.

Of course, the hook holes 12 and 22 protruding outwardly of the skin material 10 and the fiber material 20 may be used as mounting holes in which the fastening pins 82 are fastened when the fasteners are later engaged with other mounting parts 80. When the base end fixing pin 52 is inserted into the hook holes 12 and 22 and then the resin 70 is injected into the peripheral portion of the fiber material 20 to form the peripheral portion base material 32, Similarly, the through hole 33 is formed in the peripheral portion 32 of the substrate at a position corresponding to the far-end mounting pin 52. That is, the skin reed hole 12, the fiber material hooking hole 22, and the through hole 33 extend straightly.

If the inner material 1 thus manufactured is to be fastened to another mounting part 80, the mounting holes 12, 22 and 33 are positioned on the fastening holes 81 of the fastening part 80, . Therefore, it is not necessary to form a separate mounting hole in the interior material 1. [

Furthermore, when the hook holes 12 and 22 are formed in the outer portion of the center portion of the fiber material 20 and the skin material 10, there is no hole in the center portion of the fiber material 20 and the skin material 10 It is possible to form a completely uneven surface and to be exposed only to the defect portion of the central portion of the fibrous material 20 or the skin material 10 when it is fastened to the other mounting component 80, It can also be used as an interior material (1).

As described above in detail, according to the present invention, a rigid skeleton can be formed while greatly reducing the injection amount of the resin 70 by using the fibrous material 20 having excellent moldability and light weight, Can be realized. In addition, even if there is no separate step of adhering the skin material 10, the skin material 10, the fiber material 20, and the substrate 30 can be integrally formed through only the injection step, thereby simplifying the process.

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.

1: Interior
10: Skin material
11:
12: Cutting edge hole
20: Fiber material
21: Textile hanging part
22: Textile material hook hole
30: substrate
31: rib
32:
33: Through hole
40: Preheating device
50: first mold
51: first mold surface
52: Fabric mounting pin
60: second mold
61: second mold surface
62: resin injection hole
70: Resin
80: Mounting parts
81: fastening hole
82: fastening pin

Claims (1)

(A) a step of putting the skin material and the fiber material into a preheating device to preheat the material;
(B) placing the preheated skin material and the fiber material on the mold surface in the mold;
(C) pressing the skin material and the fiber material located on the mold surface;
(D) injecting resin into the surface of the fiber material opposite to the surface on which the skin material is laminated; And
(E) cooling the injected resin to form a base material, drawing the interior material having the skin material, the fiber material, and the base material integrally formed thereon from the mold; And
(F) wrapping the periphery of the skin material and the fiber material around the bottom of the base material,
The mold includes a first mold and a second mold having respective mold surfaces, and a far-end mounting pin for supporting the skin material and the fiber material is formed on one of the first mold and the second mold In addition,
The step (b) may include positioning the preheated skin material and the fiber material on the mold surface by hooking the pre-heated skin material and the fiber material on the far-
The skin material and the fiber material are formed with hooks protruding outward along the circumference. The hooks are formed with hook holes into which the distal end fixing pins are inserted,
The fiber material is a natural fiber mixed with a natural fiber and a thermoplastic resin,
Wherein the skin material and the fibrous material are pre-heated through the step (a), the skin material and the fibrous material are positioned on the mold surface through the step (b), and the skin material and the fibrous material are When the resin is injected through the step (d) while compressing the fiber material, the thermoplastic resin contained in the fiber material is melted due to the high temperature of the resin and adhered to the skin material, The skin material, the fibrous material and the substrate are integrated,
The resin that is filled only in a part of the fiber material so as to fill the peripheral portion and the bottom portion of the fiber material by deforming the shape of the second mold surface serves as a rib to which the manufactured interior material is supported by other parts , The resin around the fiber material plays a role of reinforcing the rigidity of the outer portion of the fiber material,
When the skin material and the fiber material are compressed through the step (a), the far-end fixing pin is retracted to be drawn into the first mold or the second mold, and the skin material, the fiber material, Wherein a thickness of a total thickness of the substrate to be formed is maintained in a protruding state so that a mounting hole is formed around the skin material, the fiber material and the base material.

Images