KR20210036280A - Interior parts for vehicle and method for manufacturing thereof - Google Patents

Abstract

An interior part for vehicles according to one aspect of the present invention comprises a real material layer and a decorative unit inserted into the real material layer so that a part is exposed on the surface of the real material layer, wherein the real material layer comprises any one selected from a surface material layer, a non-woven fabric layer and a combination thereof. Therefore, it is possible to prevent deformation such as shrinkage or expansion in the surface material layer during the manufacturing process.

Description

Automobile interior material and its manufacturing method {INTERIOR PARTS FOR VEHICLE AND METHOD FOR MANUFACTURING THEREOF}

The present invention relates to a vehicle interior material and a method of manufacturing the same.

In general, as interior and exterior materials of automobiles, resin molded parts are used in console boxes of automobiles, panels of instrument panels, cast irons, etc., and resin molded products are widely used in home appliances such as cases and covers such as electronic rice cookers.

In particular, various control units and convenience devices are installed in the dashboard and audio decks, gear transmission units, airbags, door locks, and window openings and closing units that are mounted around the driver's seat and passenger's seat inside a vehicle. In the gap between the exterior of the device and the interior material, an interior material finishing panel is installed to finish the interior material, and this interior material is an important factor in determining the appearance of the interior of the vehicle.

In this way, interior materials for automobiles have a significant influence on the aesthetics of automobiles, and therefore, aesthetic demands are increasingly increasing in the current trend of individualization of automobiles.

Accordingly, in recent years, there is an increasing demand for automotive interior materials made of automotive interior materials such as automotive interior materials in order to obtain aesthetics and high-quality texture in appearance.

An object of the present invention is to provide an automotive interior material in which different materials such as metal or fabric are inlaid on a surface of a real material in a real material automobile interior material such as real wood and real carbon.

In addition, it is intended to provide a method of manufacturing a vehicle interior material in which different materials such as metal or fabric are inlaid on a real material.

In addition, an object of the present invention is to provide a method for manufacturing a vehicle interior material capable of preventing deformation such as shrinkage or expansion in the surface material layer during the manufacturing process of the interior material of the vehicle.

In addition, it is intended to provide a method of manufacturing a luxurious automobile interior material in which the pattern of the decorative part can be exposed on the surface material layer as it is.

An automobile interior material according to an aspect of the present invention includes a real material layer and a decorative part inserted into the real material layer so that a part of the surface of the real material layer is exposed, and the real material layer includes a surface material layer, a non-woven fabric layer, and It may include any one selected from a combination.

The real material layer may further include a decorative material sheet underneath.

The surface material layer may be a veneer sheet or a carbon sheet.

The nonwoven layer may include any one selected from a nonwoven sheet, a glue sheet, and a combination thereof.

The decorative portion may include at least one selected from aluminum, copper, stainless steel, steel, and fabric materials.

The thickness of the vehicle interior material may be 0.6 to 2.2 mm.

The manufacturing method of an automobile interior material according to an aspect of the present invention includes the steps of preparing a surface material layer, a decoration part, and a non-woven fabric layer, joining the non-woven fabric layer, the decoration part and the surface material layer in order by a flat press, and the decoration Sanding the surface material layer so that at least a portion of the portion is exposed, and molding the sanded nonwoven fabric layer, the decorative portion, and the surface material layer into a predetermined shape.

In the bonding step, a protective member may be disposed on at least one of an outer surface of the surface material layer and an outer surface of the nonwoven fabric layer.

The protective member may be a silicone pad or a paper board.

The nonwoven layer may be impregnated with an adhesive.

In the sanding step, the thickness of the surface material layer may be reduced to 40% to 90% compared to the thickness of the surface material layer before sanding.

After sanding the surface material layer and before the molding, the bonded surface material layer, the decorative portion, and the nonwoven fabric layer may be cut into a predetermined size.

After the molding step, it may further include injection molding a support portion located under the nonwoven fabric layer.

In the injection molding step, a nonwoven fabric layer impregnated with an adhesive may be additionally attached to the lower portion of the nonwoven fabric layer.

A method of manufacturing an automobile interior according to an aspect of the present invention includes forming an inlay part through etching or raker cutting on a real material layer in which a surface material layer and a non-woven fabric layer are sequentially stacked, inserting a decorative part into the inlay part, and Sanding the protruding portion of the decorative portion may be included.

The thickness of the inlay may be equal to or less than the thickness of the real material layer.

A method of manufacturing a vehicle interior according to an aspect of the present invention includes removing an etched portion excluding the decorative portion from the surface of the decorative material sheet by etching or laser cutting, laminating a surface material layer on the upper surface of the decorative material sheet and compressing it with a press, It may include the step of exposing the decoration by sanding the surface of the surface material layer.

A method of manufacturing an automobile interior material according to an aspect of the present invention may include laminating a decorative part on an upper surface of a real material layer and compressing it with a press, and sanding the real material layer from which the decorative part protrudes.

The real material layer may include any one selected from a surface material layer, a nonwoven fabric layer, and a combination thereof.

The surface material layer may be a veneer sheet or carbon.

The decorative portion may include at least one selected from aluminum, copper, stainless steel, steel, and fabric materials.

As described above, the vehicle interior manufacturing method according to an aspect of the present invention can prevent deformation such as shrinkage or expansion in the surface material layer during the manufacturing process.

In addition, the automobile interior material manufactured in the method for manufacturing a vehicle interior material according to an aspect of the present invention may be used as a luxurious decoration part by exposing a specific pattern of the decoration part on the surface of the surface material layer as it is.

In addition, by using inlays in conventional real wood or real carbon products, it is possible to provide a more refined, luxurious and diverse aesthetic.

In addition, existing molds and fixtures can be applied as they are, so it is economical and efficient because no additional cost is required for facility construction.

1 is a view showing a process of manufacturing a vehicle interior material according to a first embodiment of the present invention.
2 is a view showing another process of manufacturing a vehicle interior material according to the first embodiment of the present invention.
3 is a view showing another process of manufacturing a vehicle interior material according to the first embodiment of the present invention.
4 is a view showing another process of manufacturing a vehicle interior material according to the first embodiment of the present invention.
5 is a view showing a process of manufacturing a vehicle interior material according to a second embodiment of the present invention.
6 is a flow chart showing a process of manufacturing a vehicle interior material according to the first embodiment of the present invention.
7 to 13 are views illustrating a process of manufacturing a vehicle interior material according to the first embodiment of the present invention.
14 to 16 are views for explaining another process of manufacturing a vehicle interior material according to the first embodiment of the present invention.
FIG. 17 is a photograph of an automobile interior material in which the surface of the surface material layer is sanded so that the decoration part is exposed.
18 is a photograph of an automobile interior material that has been laser-cut before being molded into a predetermined shape.
19 is a photograph of an automobile interior material molded by a press.

The present invention is intended to illustrate specific embodiments and to be described in detail in the detailed description, since various transformations may be applied and various embodiments may be provided. However, this is not intended to limit the present invention to a specific embodiment, it should be understood to include all conversions, equivalents, and substitutes included in the spirit and scope of the present invention.

The terms used in the present invention are used only to describe specific embodiments, and are not intended to limit the present invention. Singular expressions include plural expressions unless the context clearly indicates otherwise. In the present invention, terms such as'include' or'have' are intended to designate the presence of features, numbers, steps, actions, components, parts, or a combination thereof described in the specification, but one or more other features. It is to be understood that the presence or addition of elements or numbers, steps, actions, components, parts, or combinations thereof does not preclude in advance.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. In this case, it should be noted that in the accompanying drawings, the same components are indicated by the same reference numerals as much as possible. In addition, detailed descriptions of known functions and configurations that may obscure the subject matter of the present invention will be omitted. For the same reason, some elements in the accompanying drawings are exaggerated, omitted, or schematically illustrated.

Hereinafter, a vehicle interior material according to a first embodiment of the present invention will be described.

1 is a view showing a process of manufacturing a vehicle interior material according to a first embodiment of the present invention, Figure 2 is a view showing another process of manufacturing a vehicle interior material according to the first embodiment of the present invention. 3 is a view showing another process of manufacturing a vehicle interior material according to the first embodiment of the present invention, Figure 4 is a view showing another process of manufacturing a vehicle interior material according to the first embodiment of the present invention.

1 to 4, the vehicle interior material according to the first exemplary embodiment of the present invention may include a real material layer R and a decoration part 500. According to this embodiment, the decoration part 500 may be exposed on the surface of the real material layer R. As a result, various textures, depths, and designs can be implemented in the vehicle interior material, and there is an effect of further enhancing the sense of quality of the real material automotive interior material.

The real material layer R may include any one selected from the surface material layer 100, the nonwoven fabric layer 200, and a combination thereof. More specifically, the real material layer R may include only the surface material layer 100. Alternatively, the real material layer R may include a surface material layer 100 and a nonwoven fabric layer 200.

The surface material layer 100 may be a veneer sheet or a carbon sheet. By including veneer or carbon sheet, natural patterns can be maximized and a sense of depth can be realized, and it can meet eco-friendly trends and display a luxurious appearance.

For example, the surface material layer 100 is a layer made of real wood, and may be manufactured by cutting the wood into a thin thickness. The surface material layer 100 may be a veneer sheet made of thin natural wood. These veneers can be applied to luxurious decorative materials by the unique texture and pattern of veneers.

According to this embodiment, the decoration part 500 may be partially exposed on the surface of the real material layer R. Meanwhile, the decoration part 500 may not be exposed, or part or all may be exposed on the lower surface of the real material layer R.

At this time, as shown in FIG. 1 (c), the decorative portion 500 may be included only in the surface material layer 100. Alternatively, the decoration part 500 may be included in the surface material layer 100 and the nonwoven fabric layer 200. That is, the decoration part 500 may penetrate the surface material layer 100 and extend to the nonwoven fabric layer 200.

The decorative part 500 is located under the surface material layer 100, and the decorative part 500 may be exposed from the surface material layer 100 by sanding or the like.

As the decorative part 500 is exposed between the surface material layers 100, the feeling that the decorative part 500 is embedded in the surface material layer 100 or a metal thin film is attached to the surface of the surface material layer 100 can be transmitted (FIG. 17). To Figure 19). In this way, as the decorative part 500 exhibits a specific shape on the surface of the surface material layer 100, it may be used as a luxurious decorative part by a combination of wood and metal.

The decoration part 500 may include at least one selected from a metal material such as aluminum, copper, stainless steel (SUS), and steel, and a fabric material.

Fabric materials can be selected and used without limitation, such as general fabrics or fabrics, in the case of using processes such as etching or laser cutting, but fabrics with high strength may be selected and used according to the characteristics of the manufacturing method. In this case, the strength is the strength of bamboo, and it is preferable to include hard fibers.

The decorative part 500 includes a material different from the surface material layer 100 of the real material layer, and uses a mixture of different materials such as wood and metal, carbon and metal, wood and fabric, or carbon and fabric. It has the effect of realizing a sense and design, and enhancing the sense of luxury of real-material automobile interior materials.

According to the present embodiment, the decoration part 500 may represent a simple shape such as a straight line, a circle, a square, a triangle, etc., or a complex shape such as a specific pattern or pattern.

The length of at least one of the horizontal and vertical lengths of the decoration part 500 is smaller than the length of at least one of the horizontal and vertical lengths of the real material layer R. That is, the decoration part 500 may be included in the real material layer R in the form of a strip.

Meanwhile, the thickness of the decorative part 500 may be equal to or smaller than the thickness of the surface material layer 100 before sanding. If the thickness of the decorative part 500 is greater than the thickness of the surface material layer 100, when the decorative part 500 is bonded to the lower surface material layer 100, the protruding height of the decorative part 500 increases, and thus the surface material layer 100 The amount of the decoration part 500 to be removed during the sanding process increases. Therefore, it takes a little time to remove the decoration part 500 in the sanding process, and it may take a little more time to complete the vehicle interior material according to the present embodiment.

The nonwoven fabric layer 200 may be formed of a nonwoven fabric layer impregnated with a separate adhesive. At this time, the adhesive is polyvinyl acetate, phenol, melamine, urea, polyurethane, polyamide, ethylene vinyl acetate epoxy, polyester, polyvinyl alcohol, acrylonitrile butadiene rubber, styrene butadiene rubber, alkyd, acetylcellulose and nitrocellulose. It may be formed of one selected from the group consisting of.

The nonwoven fabric layer 200 is formed of at least one composition selected from the group consisting of glass fibers, carbon fibers, polyester fibers, polyamide fibers, polyurethane fibers, acrylic fibers, polyolefin fibers, polyethylene terephthalate fibers, cellulose fibers and pulp. Can be.

Meanwhile, a support part 300 (refer to FIG. 13) may be positioned under the real material layer R. The support part 300 may be formed on the rear surface of the surface material layer 100 and the nonwoven fabric layer 200 while the injection product injected into the rear surface of the real material layer R is cured. The support part 300 fixes the surface material layer 100 to a specific object while supporting the surface material layer 100 and the nonwoven fabric layer 200. For example, the support part 300 may easily fix the surface material layer 100 to the interior of the vehicle. In this case, the support part 300 may have a thickness of 3.3 to 3.7 mm, but is not limited thereto.

The thickness of the vehicle interior material of the present invention may be 0.6 to 2.2 mm excluding the support part 300. This is the thickness after compression by the wood press, and is not limited to the above range, and may be formed in various thicknesses.

Automobile interior parts of the present invention may further include a coating layer on the top. This may be formed through PUR casting, and may have a thickness of 0.7 to 1.0 mm, but is not limited thereto.

Hereinafter, a vehicle interior material according to a second embodiment of the present invention will be described.

5 is a view showing a process of manufacturing a vehicle interior material according to a second embodiment of the present invention.

5, a vehicle interior material according to a second embodiment of the present invention includes a surface material layer 100, a decorative material sheet 50, and a decorative part 500, and the vehicle interior material according to the first embodiment described above. In the same manner as, the decorative part 500 may be exposed on the surface of the surface material layer 100. At this time, the decorative material sheet 50 is located under the surface material layer 100, the decorative part 500 is made in a shape protruding from the surface of the decorative material sheet 50, the decorative part 500 and the decorative material sheet 50 Is formed integrally. According to this embodiment, the decoration part 500 may be formed by etching or laser cutting a part of the decoration material sheet 50. A detailed description of this will be described later.

Hereinafter, a method of manufacturing a vehicle interior material according to a first embodiment of the present invention will be described.

1 is a view showing a process of manufacturing a vehicle interior material according to a first embodiment of the present invention.

According to the present embodiment, the decorative portion 500 and the surface material layer 100 are disposed on the non-woven fabric layer 200, as in FIG. 1(a), the non-woven fabric layer 200 of 0.4 to 0.8 mm and 0.4 to 0.6 The decorative portion 500 is inserted between the surface material layer 100 of mm.

Then, as in the step of FIG. 1(b), the non-woven fabric layer 200 and the surface material layer 100 are laminated by compressing with a wood press (not shown), and between the non-woven fabric layer 200 and the surface material layer 100 The decoration part 500 is inserted. Accordingly, the nonwoven fabric layer 200 and the surface material layer 100 are stacked on each other to form a real material layer R.

When the nonwoven fabric layer 200 and the surface material layer 100 are compressed by a wood press (not shown), a part of the surface material layer 100 is protruded by the decoration part 500. At this time, while the decoration part 500 is pressed by the wood press, a part of the decoration part 500 may be inserted into the nonwoven fabric layer 200.

In this embodiment, as in the step of FIG. 1 (c), the upper surface of the surface material layer 100 is sanded to expose the decorative part to form the decorative part 500. The vehicle interior material 610 may be manufactured by flat molding so that the surface material layer 100 and the decorative portion 500 have the same height. The thickness of the vehicle interior material is preferably 0.6 to 2.2mm, but is not limited thereto.

Meanwhile, a support part 300 (refer to FIG. 13) may be coupled under the real material layer R. The support part 300 may be formed on the rear surface of the surface material layer 100 and the nonwoven fabric layer 200 while the injection product injected into the rear surface of the real material layer R is cured. The support part 300 fixes the surface material layer 100 to a specific object while supporting the surface material layer 100 and the nonwoven fabric layer 200.

In the following, another method of manufacturing a vehicle interior material according to a first embodiment of the present invention will be described with reference to FIG. 2.

2 is a view showing another process of manufacturing a vehicle interior material according to the first embodiment of the present invention.

According to the present embodiment, as in the step of FIG. 2 (a), a real material layer R including the surface material layer 100 and the nonwoven fabric layer 200 in order is prepared.

Thereafter, as shown in FIG. 2(b), an inlay portion H penetrating the real material layer R is formed on the real material layer R through etching or laser cutting. The inlay portion H may correspond to a space in which the decoration portion 500 is inserted in the real material layer R. The width of the inlay portion H may be equal to or smaller than the width of the decorative portion 500. As a result, the decorative portion 500 can be fixed in the inlay portion H in a manner that is forcibly fitted to the real material layer R.

As shown in step 2(c), the decoration part is inserted into the inlay part H, and the part where the decoration part protrudes above the real material layer R as in step 2(d) is sanded to form the decoration part 500 Thus, the vehicle interior material 620 is manufactured. The inlay portion (H) may include a known adhesive means such as an adhesive so that the decorative portion can be attached, and the type is not limited.

In this case, the thickness of the inlay portion H may be formed equal to the thickness of the real material layer R. Accordingly, the decorative part 500 formed on the inlay part H also has the same thickness as the thickness of the real material layer R, and the decorative part 500 is formed on a part of the surface and the back surface of the real material layer R. Exposed. The thickness of the interior of the vehicle is preferably 0.6 to 2.2mm, but is not limited thereto.

In the following, another method of manufacturing an automobile interior material according to a first embodiment of the present invention will be described with reference to FIG. 3.

3 is a view showing another process of manufacturing a vehicle interior material according to the first embodiment of the present invention.

According to this embodiment, as in the step of FIG. 3 (a), after preparing a real material layer (R) including the surface material layer 100 and the non-woven fabric layer 200 in order, as in the step of FIG. 3 (b) The inlay portion H is formed on the real material layer R through etching or laser cutting. Unlike in FIG. 2, the inlay portion H of FIG. 3B may be formed in a groove shape in the real material layer R without penetrating through the real material layer R.

As shown in step 3(c), the decoration part 500 is inserted into the inlay part H, and the decorative part 500 is sanded by sanding the part protruding above the real material layer R as in step 3(d). ) To manufacture a vehicle interior material 630. The inlay may include a known bonding means such as an adhesive so that the decoration may be attached, and the type is not limited.

In this case, the thickness of the inlay portion H may be formed to be smaller than the thickness of the real material layer R. Accordingly, the decorative portion 500 formed on the inlay portion H also has a thickness smaller than that of the real material layer R. The real material layer R includes a surface material layer 100 and a non-woven fabric layer 200, and the decorative part 500 may be included only in the surface material layer 100, and the surface material layer 100 and the non-woven fabric layer 200 It can also be included in. In this case, the decoration part 500 is exposed on a part of the surface of the real material layer R, and the decoration part 500 is not exposed on the rear surface of the real material layer.

The thickness of the vehicle interior material of this embodiment is preferably 0.6 to 2.2mm, and the thickness of the decorative part is preferably 0.4 to 0.6mm, but is not limited thereto.

In the following, another method of manufacturing an automobile interior material according to a first embodiment of the present invention will be described with reference to FIG. 4.

4 is a view showing another process of manufacturing a vehicle interior material according to the first embodiment of the present invention.

According to this embodiment, as shown in step 4(a), after laminating the decorative part on the upper surface of the real material layer R, compressing it with a wood press as in step 5(b) and applying pressure to the real material layer Make sure the decorations are inserted. Unlike the above-described manufacturing method, in the present manufacturing method, a separate inlay portion H into which the decorative portion 500 can be inserted is not formed in the real material layer R. That is, without forming a separate inlay portion (H), the decorative portion (500) is pressed and inserted into the real material layer (R).

Thereafter, a part of the decoration part 500 protruding above the real material layer R is sanded, and the surface height of the real material layer and the decoration part is the same as in FIG. 5(c), thereby manufacturing the automobile interior material 650. .

In the following, a method of manufacturing a vehicle interior material according to a second embodiment of the present invention will be described with reference to FIG. 5.

5 is a view showing a process of manufacturing a vehicle interior material according to a second embodiment of the present invention.

In this embodiment, as shown in Fig. 5 (a) step, the decorative portion sheet 50 is prepared. The decorative part sheet 50 includes a decorative part 500 and an etched part 50a. In this embodiment, the upper part of the decorative part sheet 50, that is, the etched part 50a is removed to form the decorative part 500 on the decorative part sheet 50.

More specifically, as shown in step 5(b), the etched portion 50a except for the decorative portion 500 is removed by etching or laser cutting.

5(c), the surface material layer 100 is laminated on the upper surface of the decorative sheet 50 after the etched part 50a has been removed, and compressed with a wood press.

As a result, a laminate of the surface material layer 100 and the decorative sheet 50 is formed as shown in FIG. 5(d). At this time, a part of the surface material layer 100 positioned on the decorative part 500 is protruded.

5(e), the upper surface of the surface material layer 100 is sanded to expose the decorative part 500, and the interior material 640 is manufactured by flat molding.

It is preferable that the thickness of the vehicle interior material is 0.6 to 2.2 mm, and the thickness of the surface material layer is preferably 0.4 to 0.6 mm, but is not limited thereto.

The manufacturing method of an automobile interior material of the present invention may further include insert injection in an injection mold, milling through a milling jig, and coloring. In addition, if necessary, a polyurethane (PU) spray step or a reactive polyurethane (PUR, poly urethane reactive) casting step may be further included.

The present invention is very economical since it is not necessary to construct a new facility because the existing real material automobile interior manufacturing molds and fixtures can be applied as they are. Specifically, the existing mold equipment can be used as it is for wood press, insert injection, and PUR casting. In addition, existing jig tools such as material preparation jig, milling jig, and inspection tool can be used as it is.

Hereinafter, a method of manufacturing a vehicle interior material according to the first embodiment of the present invention shown in FIG. 1 will be described in detail with reference to FIGS. 6 to 13.

6 is a flowchart illustrating a process of manufacturing a vehicle interior material according to a first embodiment of the present invention, and FIGS. 7 to 13 are views illustrating a process of manufacturing a vehicle interior material according to the first embodiment of the present invention.

6 to 13, the vehicle interior manufacturing method according to the first embodiment of the present invention, the step of providing a surface material layer 100, a decorative portion 500 and a non-woven fabric layer 200 (S100), a surface material The step of bonding the layer 100, the decorative part 500 and the non-woven fabric layer 200 (S200), sanding the surface material layer 100 (S300), the surface material layer 100, the decorative part 500 and the non-woven fabric It may include forming the layer 200 into a predetermined shape (S400).

According to this embodiment, before molding into a predetermined shape, the bonding surface material layer 100, the decoration part 500, and the non-woven fabric layer 200 are spread flatly by a flat press 10, and then the decoration part 500 A process of sanding the surface of the surface material layer 100 to a predetermined thickness so as to be exposed. In this way, by sanding the thickness of the surface material layer 100 to a predetermined predetermined thickness, it is possible to prevent the surface material layer 100 from being deformed during the molding process. On the other hand, the decorative portion 500 is exposed in a specific pattern on the surface of the surface material layer 100, and may be used as a luxurious decorative portion by a combination of wood and metal.

Referring to FIG. 7, the surface material layer 100 is a layer made of real wood, and may be manufactured by cutting the wood into a thin thickness. The surface material layer 100 may be a veneer made of thin natural wood. Such veneer can be applied to a luxurious decoration part by the unique texture and pattern of veneer.

The decorative part 500 is located under the surface material layer 100, and the decorative part 500 may be exposed from the surface material layer 100 by a sanding operation to be described later.

As the decorative part 500 is exposed between the surface material layers 100, the feeling that the decorative part 500 is embedded in the surface material layer 100 or a metal thin film is attached to the surface of the surface material layer 100 can be transmitted (FIG. 17). To Figure 19). In this way, as the decorative part 500 exhibits a specific shape on the surface of the surface material layer 100, it may be used as a luxurious decorative part by a combination of wood and metal.

The decoration part 500 may include stainless steel, copper, aluminum, copper, or the like. However, it is not necessarily limited thereto, and the decoration part 500 may include all metals other than the above-described metal. The decoration part 500 may be made of a fabric material as described above in addition to metal.

According to the present embodiment, the decoration part 500 may represent a simple shape such as a straight line, a circle, a square, a triangle, etc., or a complex shape such as a specific pattern or pattern.

Meanwhile, the thickness of the decorative part 500 may be equal to or smaller than the thickness of the surface material layer 100 before sanding. If the thickness of the decorative part 500 is greater than the thickness of the surface material layer 100, when the decorative part 500 is bonded to the lower surface material layer 100, the protruding height of the decorative part 500 increases, and thus the surface material layer 100 The amount of the decoration part 500 to be removed during the sanding process increases. Therefore, it takes a little time to remove the decoration part 500 in the sanding process, and it may take a little more time to complete the vehicle interior material according to the present embodiment.

The nonwoven fabric layer 200 may be bonded to the surface material layer 100 and the bottom surface of the decorative portion 500 to fix the surface material layer 100 to another member. At this time, the decoration part 500 is positioned between the surface material layer 100 and the nonwoven fabric layer 200.

The nonwoven fabric layer 200 may be formed of a nonwoven fabric layer impregnated with a separate adhesive. At this time, the adhesive is polyvinyl acetate, phenol, melamine, urea, polyurethane, polyamide, ethylene vinyl acetate epoxy, polyester, polyvinyl alcohol, acrylonitrile butadiene rubber, styrene butadiene rubber, alkyd, acetylcellulose and nitrocellulose. It may be formed of one selected from the group consisting of.

The nonwoven fabric layer 200 is formed of at least one composition selected from the group consisting of glass fibers, carbon fibers, polyester fibers, polyamide fibers, polyurethane fibers, acrylic fibers, polyolefin fibers, polyethylene terephthalate fibers, cellulose fibers and pulp. Can be.

According to this embodiment, the nonwoven fabric layer 200 bonded to the surface material layer 100 is described as one sheet. However, the present invention is not necessarily limited thereto, and two or more nonwoven fabric layers 200 may be bonded to the surface material layer 100 if necessary. When two or more nonwoven fabric layers 200 are bonded to the surface material layer 100, two or more nonwoven fabric layers 200 are continuously attached to the lower surface material layer 100. For example, the surface material layer 100, the decoration part 500, the non-woven fabric layer 200, the non-woven fabric layer 200 may be attached in this order.

Before bonding the surface material layer 100 and the non-woven fabric layer 200 to each other, the surface material layer 100 and the non-woven fabric layer 200 are cut into the same size or similar size in advance. The surface material layer 100 and the non-woven fabric layer 200 having the same or similar size to each other are put into the flat press 10 to bond the surface material layer 100 and the non-woven fabric layer 200 to each other.

Referring to FIG. 8, the step of bonding the surface material layer 100, the decoration part 500, and the nonwoven fabric layer 200 to each other (S200) may be performed by a flat press 10 having a flat contact surface. That is, the flat press 10 may have a flat surface in contact with the surface material layer 100 and the nonwoven fabric layer 200. However, the surface of the surface material layer 100 may be formed to be convex on the surface of the surface material layer 100 where the decoration part 500 is located due to the decoration part 500 located below.

The flat plate press 10 is composed of an upper flat press 11 and a lower flat press 13 facing each other, and the pressure surfaces of the upper flat press 11 and the lower flat press 13 are flat. It can be made in the form of a flat plate. Here, the pressure surface represents a surface in which the surface material layer 100 and the nonwoven fabric layer 200 to be bonded to each other contact each other.

The surface material layer 100 and the nonwoven fabric layer 200 are disposed in parallel with each other between the upper and lower flat presses 11 and 13 of the flat press 10. At this time, the decoration part 500 is positioned between the surface material layer 100 and the nonwoven fabric layer 200.

Thereafter, while the upper flat press 11 and the lower flat press 13 move toward each other, the surface material layer 100, the decoration part 500, and the non-woven fabric layer 200 may be compressed and bonded to each other. In the present embodiment, it is described as moving both the upper flat type press 11 and the lower flat type press 13, but is not necessarily limited thereto, and only one of the upper flat type press 11 and the lower flat type press 13 You can move. For example, while the upper plate type press 11 moves toward the lower plate type press 13, the surface material layer 100 and the nonwoven fabric layer 200 may be bonded to each other.

According to this embodiment, before bonding the surface material layer 100, the decorative portion 500, and the non-woven fabric layer 200 to each other by the flat press 10, the protective member 600 is attached to the surface of the surface material layer 100 I can make it. The protective member 600 may prevent the surface of the surface material layer 100 from being damaged by the flat press 10. When the surface material layer 100 and the nonwoven fabric layer 200 are attached to each other by the flat press 10, the protection member 600 may be removed from the surface of the surface material layer 100.

However, in FIG. 8, it is described that the protective member 600 is attached only to the surface of the surface material layer 100, but is not limited thereto, and may be attached to the surface of the nonwoven fabric layer 200.

At this time, the protection member 600 may be a silicone pad or a paper board. The silicon pad may be a plate made of a silicon material and having a predetermined thickness. Paperboard includes all thick paper, and in particular, chipboard may be applied.

According to this embodiment, the protection member 600 has a larger area than the surface material layer 100 in order to prevent damage to the surface of the surface material layer 100 by the flat press 10. I can. That is, the protective member 600 may have an area capable of covering the entire surface of the surface material layer 100. Thereby, when the flat plate press 10 presses the surface material layer 100 and the nonwoven fabric layer 200, the upper flat plate press 11 or the lower flat plate press 13 is directly applied to the surface material layer 100 and the nonwoven fabric layer. In order to prevent contact with the layer 200, the protective member 600 having a larger area than the surface material layer 100 is applied.

When the flat plate press 10 bonds the surface material layer 100 and the nonwoven fabric layer 200 to each other, the upper flat plate press 11 and the lower flat plate press 13 are applied to the surface material layer 100 and the nonwoven fabric layer 200. ) Are pressed against each other for a certain period of time at a predetermined pressure.

In this way, when the bonding of the surface material layer 100, the decorative portion 500, and the non-woven fabric layer 200 is completed by the flat press 10, the decorative portion between the surface material layer 100 and the non-woven fabric layer 200 ( While 500) is positioned, the surface material layer 100 and the nonwoven fabric layer 200 are in close contact and fixed to each other. In addition, the surface material layer 100 and the nonwoven fabric layer 200 may be formed in a flat plate shape.

In this embodiment, when the surface material layer 100 and the non-woven fabric layer 200 are flatly bonded by the flat press 10, the surface of the surface material layer 100 is sanded to a predetermined thickness with a sanding machine 30 to be described later. It's easy. A detailed description of this will be described later.

Referring to FIG. 9, after the surface material layer 100 and the nonwoven fabric layer 200 are bonded with the decoration part 500 therebetween, a process of sanding the surface of the surface material layer 100 may be performed. In this embodiment, the surface of the surface material layer 100 is sanded using the sanding machine 30. Here, the sanding process refers to a process of finely cutting the surface of the surface material layer 100. However, the sanding process of the surface material layer 100 is not limited to the sanding machine 30, and various tools capable of processing the wood surface may be applied.

According to the present embodiment, through the sanding process (S300), the thickness of the surface material layer 100 may be reduced to approximately 40% to 90% of the thickness of the surface material layer 100 before sanding. For example, after the surface material layer 100 and the non-woven fabric layer 200 are bonded to each other by a flat press 10, the thickness of the surface material layer 100 may be usually 0.4 mm to 0.6 mm. When the thickness of 100) is 0.6 mm, the thickness of the surface material layer 100 may be 0.24 mm to 0.54 mm when the sanding process is performed.

In general, as the thickness of the surface material layer 100 is thicker, the surface material layer 100 is molded by molding presses 31 and 33, or when an injection product is bonded to the surface material layer 100 by injection molding, the surface material layer 100 ), deformation occurs frequently, such as contraction or expansion. This is deformed due to moisture or the like in the surface material layer 100.

Therefore, as in the present embodiment, if the surface material layer 100 is sanded to a predetermined thickness after the sanding process (S300) and before the molding step (S400), it is possible to prevent the surface material layer 100 from being deformed during the molding or injection process. have.

In this embodiment, while moving the surface of the surface material layer 100 to which the sanding machine 30 is bonded, the thickness of the surface material layer 100 is evenly reduced. By the sanding operation of the sanding machine 30, the surface material layer 100 may be reduced to a certain thickness.

When the surface of the surface material layer 100 is sanded by the sanding machine 30, the thickness of the surface material layer 100 decreases and the decorative portion 500 located under the surface material layer 100 is exposed. When the sanding process (S300) is completed, the decorative portion 500 is exposed while the surface of the surface material layer 100 is flat. That is, as shown in FIG. 17, the pattern of the decorative portion 500 unique to the surface of the flat surface material layer 100 is exposed as it is.

Referring to FIG. 10, when the sanding operation (S300) of the surface material layer 100 is completed, the surface material layer 100, to which the decoration part 500 is exposed, is formed into a certain shape using molding presses 31 and 33. . Specifically, the surface material layer 100 and the non-woven fabric layer 200 are disposed between the engraved upper molding press 31 and the embossed lower molding press 33, and the surface material layer 100 and the non-woven fabric layer are bonded to each other. (200) can be molded into a certain shape (see Fig. 19).

The upper forming press 31 and the lower forming press 33 press the surface material layer 100 and the non-woven fabric layer 200 positioned therebetween at a constant pressure and temperature, thereby forming the surface material layer 100 and the non-woven fabric layer 200. It can be molded into a certain shape.

In this embodiment, it will be described that the surface material layer 100 to which the decorative portion 500 is exposed is directly injected into the molding presses 31 and 33 to form the surface material layer 100 and the nonwoven fabric layer 200. However, before introducing the surface material layer 100 and the nonwoven fabric layer 200 into the molding presses 31 and 33, the surface material layer 100 and the nonwoven fabric layer 200 may be cut to a certain size (see FIG. 18). ). At this time, in order to cut the surface material layer 100 and the nonwoven fabric layer 200, it may be cut with various cutting machines such as a laser.

Referring to FIG. 11, when molding the surface material layer 100 and the nonwoven fabric layer 200 bonded to each other by the molding presses 31 and 33, an additional nonwoven fabric layer 400 is positioned under the nonwoven fabric layer 200, The surface material layer 100, the decoration part 500, the non-woven fabric layer 200, and the additional non-woven fabric layer 400 may be sequentially stacked and formed.

In this case, the additional nonwoven fabric layer 400 is a nonwoven fabric layer impregnated with a separate adhesive, and may be made of the same material as the nonwoven fabric layer 200 directly bonded to the surface material layer 100. Therefore, a detailed description of the additional nonwoven fabric layer 400 will be omitted.

Referring to FIG. 12, when the molding step S400 is completed, an injection step of injecting an injection product under the molded surface material layer 100 and the nonwoven fabric layer 200 may be performed. In the injection step, after the surface material layer 100 and the non-woven fabric layer 200 molded in a certain shape are injected into the injection molds 51 and 53, the surface material layer 100 and the non-woven fabric layer 200 are passed through the injection material feeder 60. Inject the injection product on the back side.

Accordingly, while the injection product injected into the rear surface of the nonwoven fabric layer 200 is cured, the support part 300 may be formed on the rear surface of the surface material layer 100 and the nonwoven fabric layer 200. The support part 300 fixes the surface material layer 100 to a specific object while supporting the surface material layer 100 and the nonwoven fabric layer 200. For example, the support part 300 may easily fix the surface material layer 100 to the interior of the vehicle.

Thereafter, a trimming process may be further performed to remove unnecessary injection products after the injection process.

Referring to FIG. 13, when the injection step is completed, a painting process may be performed on the surface of the surface material layer 100 so that the surface material layer 100 may exhibit a specific color. The painting process may be performed by applying a stain capable of displaying a specific color on the surface of the surface material layer 100. At this time, the method of applying the stain to the surface of the surface material layer 100 is to spray the stain with a spray and apply it to the surface material layer 100, or apply a liquid stain to the surface material layer 100 by applying it to a sponge or the like, or apply a solid stain to the surface material layer 100. It may be applied by rubbing on the surface of the surface material layer 100.

In the following, another method of manufacturing an automobile interior material according to the first embodiment of the present invention will be described in detail with reference to FIGS. 14 to 16.

14 to 16 are views for explaining another process of manufacturing a vehicle interior material according to the first embodiment of the present invention.

14 to 16, according to the present embodiment, in the injection step of forming the support part 300 under the surface material layer 100 and the non-woven fabric layer 200, the decorative part 500 is included in the surface material layer 100. It is possible to form a groove to be located. In addition, after the injection step is completed, the decorative part 500 may be inserted and fixed in the groove formed on the surface of the surface material layer 100.

In the above-described method of manufacturing the interior of the vehicle illustrated in FIGS. 5 to 12, before performing an injection step of injecting an injection product, the decoration part 500 is inserted and fixed to the surface material layer 100. That is, before the injection step, the decorative part 500 is inserted and fixed to the surface material layer 100 by a separate process.

However, in this embodiment, without inserting the decorative part 500 on the surface of the surface material layer 100 before the injection step, a groove to be inserted and fixed in the surface material layer 100 in the injection step is formed at the same time. can do.

According to the present embodiment, as shown in FIG. 15, the surface of the surface material layer 100 comes into close contact with the upper injection mold 51 by the pressure of the injection product injected through the injection product injector 60. In this case, a groove may be formed on the surface of the surface material layer 100 by the protrusion 51a formed in the upper injection mold 51. That is, the support part 300 may be formed under the surface material layer 100 and the nonwoven fabric layer 200 by the injection product, and at the same time, a groove in which the decoration part 500 will be located may be formed on the surface of the surface material layer 100.

Thereafter, as shown in FIG. 16, the decorative portion 500 is inserted into a groove formed on the surface of the surface material layer 100. Then, by a sanding process, the surface of the automobile interior material is sanded so that the heights of the surface material layer 100 and the decoration part 500 are the same by sanding the decorative part 500 protruding higher than the surface of the surface material layer 100. It can be formed flat.

According to the manufacturing method of an automobile interior material according to the present embodiment, before molding into a predetermined shape by a press or the like, the surface material layer 100 and the non-woven fabric layer 200 are bonded, and the surface material layer 100 is immediately sanded to the surface material layer. It is possible to prevent (100) from being deformed during the molding process. In addition, the decoration part 500 is exposed in a specific pattern on the surface of the surface material layer 100, and thus it may be used as a luxurious decoration part by a combination of wood and metal.

As described above, one embodiment of the present invention has been described, but those of ordinary skill in the relevant technical field add, change, delete or add components within the scope not departing from the spirit of the present invention described in the claims. It will be possible to variously modify and change the present invention by means of the like, and it will be said that this is also included within the scope of the present invention.

10 flat press
30 sanding machine
31, 33 forming press
100 surface material layer
200 non-woven layer
300 support
500 decorations

Claims (21)

Real material layer and
Includes a decorative part inserted into the real material layer so that a part of the surface of the real material layer is exposed,
The real material layer includes any one selected from a surface material layer, a nonwoven fabric layer, and a combination thereof. The method of claim 1,
The real material layer further comprises a decorative material sheet in the lower, automobile interior material. The method of claim 1,
The surface material layer is a veneer sheet or a carbon sheet, automobile interior material. The method of claim 1,
The non-woven fabric layer comprises any one selected from a non-woven fabric sheet, a glue sheet, and a combination thereof, automobile interior material. The method of claim 1,
The decorative portion includes at least one selected from aluminum, copper, stainless steel, steel, and fabric materials. The method of claim 1,
The thickness of the automotive interior material is 0.6 to 2.2 mm, automotive interior material. Providing a surface material layer, a decorative portion, and a nonwoven fabric layer;
Bonding the nonwoven fabric layer, the decoration part, and the surface material layer in order by a flat press;
Sanding the surface material layer so that at least a portion of the decorative portion is exposed; And
Forming the sanded non-woven fabric layer, the decorative portion, and the surface material layer into a predetermined shape; including, automobile interior manufacturing method. The method of claim 7,
In the joining step,
A method for manufacturing an automobile interior material, wherein a protective member is disposed on at least one of an outer surface of the surface material layer and an outer surface of the nonwoven fabric layer. The method of claim 7,
The protective member is a silicon pad or a paper board, a method for manufacturing a vehicle interior material. The method of claim 7,
The nonwoven fabric layer is impregnated with an adhesive, a method for manufacturing automobile interior materials. The method of claim 7,
In the sanding step,
The thickness of the surface material layer is reduced to 40% to 90% compared to the thickness of the surface material layer before sanding. The method of claim 7,
After sanding the surface material layer and before the molding,
Cutting the bonded surface material layer, the decorative portion, and the non-woven fabric layer to a predetermined size, automobile interior manufacturing method. The method of claim 7,
After the shaping step,
The method of manufacturing a vehicle interior material further comprising the step of injection-molding a support portion positioned under the nonwoven fabric layer. The method of claim 13,
In the injection molding step,
A method for manufacturing an automobile interior material by additionally attaching a nonwoven fabric layer impregnated with an adhesive under the nonwoven fabric layer. Forming an inlay on the real material layer in which the surface material layer and the nonwoven fabric layer are sequentially stacked through etching or raker cutting;
Inserting a decorative portion into the inlay; And
Sanding the protruding portion of the decorative portion; Containing, a method of manufacturing a vehicle interior. The method of claim 15,
The thickness of the inlay is the same as or less than the thickness of the real material layer, a method of manufacturing a vehicle interior material. Removing the etched portions excluding the decorative portions from the surface of the decorative material sheet by etching or laser cutting;
Laminating a surface material layer on the upper surface of the decorative material sheet and compressing it with a press;
Sanding the surface of the surface material layer to expose the decoration; Containing, the manufacturing method of the vehicle interior material. Laminating the decoration on the upper surface of the real material layer and compressing it with a press;
Sanding the real material layer from which the decorative portion protrudes; Containing, the manufacturing method of the vehicle interior material. The method of claim 18,
The real material layer comprises any one selected from a surface material layer, a nonwoven fabric layer, and a combination thereof. The method according to any one of claims 7 to 19,
The surface material layer is a veneer sheet or a carbon sheet, a method of manufacturing a vehicle interior material. The method according to any one of claims 7 to 19,
The decorative portion includes at least one selected from aluminum, copper, stainless steel, steel, and fabric materials, a method of manufacturing a vehicle interior material.

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