WO2017159172A1 - Method for manufacturing vehicle interior material, and vehicle interior material - Google Patents

Abstract

A method for manufacturing a vehicle interior material comprises: molding a blank including a thermoplastic material into a base material 10 having a required shape including air Ar, using a blank molding die; moving the base material 10 from the blank molding die to an injection molding die 310 that has a general surface 340 matched with the shape of the base material 10, and a mold surface 330 including a pressing portion 350 for compressing a first surrounding portion 11 disposed around a gate 316 of the base material 10 more than a second surrounding portion 12 disposed around the first surrounding portion 11; injecting a resin R1 from the gate 316 into a cavity CA1 of the injection molding die 310 in which the base material 10 below the melting point of the thermoplastic material has been disposed prior to mold clamping; and extracting the base material 10 together with a molded portion 50 of the resin R1 from the injection molding die 310 to obtain an interior material 1 comprising the base material 10 to which the molded portion 50 is bonded, wherein at least a part of the thickness of the first surrounding portion 11 compressed by the pressing portion 350 has been recovered.

Description

Method for manufacturing vehicle interior material, and vehicle interior material

The present invention relates to a vehicle interior material in which a molded part of resin by injection molding is joined to a molded base material, and a manufacturing method thereof.

JP-A-2014-188688 discloses a method for manufacturing a door trim that includes a trim board containing fibers and a thermoplastic resin, and a mounting boss with a rib that is injection-molded on the trim board. The preboard before molding is press-molded with a mold in a heated state, and in that state, that is, in a cavity for a ribbed mounting boss formed on the mold in a high temperature state in which the thermoplastic resin contained in the preboard is melted. When the molten resin is injected, a ribbed mounting boss is formed on the trim board. That is, the same mold is used for the press molding of the preboard and the injection molding for the mounting boss with rib, and the mold has a cavity for forming the base material and a cavity for forming the mounting boss with rib. The cavity for forming the mounting boss includes a rib runner that connects the gate serving as the resin injection port to the mounting boss forming space. The lower mold of the molding apparatus for press-molding the preboard is formed with a projecting portion that projects toward the upper mold along the runner. Since the rear surface of the trim board is strongly pressed by the protruding portion, a situation where the molten resin enters between the protruding portion and the rear surface of the trim board, that is, a situation where the molten resin oozes out on the rear surface of the trim board is suppressed.

In the manufacturing method disclosed in Japanese Patent Application Laid-Open No. 2014-188688, in order to suppress a situation where a part of the preboard enters the cavity for the ribbed mounting boss when the preboard is press-molded, first, the ribbed mounting boss of the preboard is used. A hot pressing process is performed in which the hot pressing is performed so that the molding portion is a thin-walled concave portion than the periphery. After that, the preboard having the concave portion is press-molded into a required shape by a mold, and in this state, molten resin is injected to form a mounting boss with ribs. The preboard having the concave portion has a substantially flat plate shape and does not have a required shape as a door trim.

JP 2014-188688 A

The base material immediately after press molding has a thermoplastic resin contained therein in a molten state. In this state, if the rear surface of the trim board is strongly pressed by the protrusions in the vicinity of the runner, the substrate surface may be locally deteriorated such that in an extreme case, the substrate surface is locally damaged. In particular, when a skin material is bonded to the surface of a base material by press molding, there is a concern that the design properties as an interior material may be reduced if the skin material is locally degraded. In addition, the softened trim board may be deformed and enter the runner, which may hinder the flow of molten resin in the runner. There is a possibility of not.
In addition to the door trim, the above-described problem similarly exists for various vehicle interior materials such as a deck side trim and a roof trim.

The present invention has a purpose of providing a novel method for manufacturing a vehicle interior material and a new vehicle interior material.

The vehicle interior material manufacturing method of the present invention includes a material forming step of forming a material containing a thermoplastic material into a base material having a required shape containing air with a material forming die,
A general surface matched to the shape of the base material, and a pressing portion that compresses the first peripheral portion around the gate of the base material more than the second peripheral portion around the first peripheral portion. A transfer step of transferring the substrate from the material mold to an injection mold having a mold surface;
An injection step of injecting a resin from the gate into a cavity of the injection mold in which the base material, which is less than the melting point of the thermoplastic material before clamping, is disposed;
The interior in which the molding part is joined to the base material in which at least part of the thickness of the first peripheral part compressed by the pressing part is restored together with the base part taken out from the injection mold together with the molding part made of the resin And an extraction step of obtaining a material.

Further, the vehicle interior material of the present invention includes a molded base material having a through-hole penetrating in the thickness direction,
A molded part of resin bonded to one surface side of the base material and connected to a trace of a resin injection gate on the other surface side of the base material through the through hole. Have

According to the inventions according to claims 1 to 5, when manufacturing an interior material for a vehicle in which a resin molding portion by injection molding is bonded to a base material, excellent molding is performed while suppressing resin leakage from around the gate. A novel manufacturing method capable of forming the portion can be provided.
According to the invention which concerns on Claim 6, it can provide the novel vehicle interior material by which it was suppressed that the resin leak generate | occur | produces in the surface by which the molding part was joined.

FIG. 1 is a vertical cross-sectional view showing an example of the interior of an automobile in a state where the illustration of a side surface is omitted. FIG. 2 is a side view showing an example of an interior material having a molded portion on the vehicle outer side as viewed from the vehicle outer side. FIG. 3 is a cross-sectional view schematically showing an example of a cross section of the interior material at the position A1-A1 in FIG. FIG. 4 is a diagram schematically illustrating an example of a method for manufacturing an interior material. FIG. 5 is a diagram schematically illustrating a main part of a mold surface of an injection mold. FIG. 6 is a cross-sectional view schematically showing an example in which at least a part of the thickness of the first peripheral portion compressed by the pressing portion is restored in the base material of the interior material taken out from the injection mold. FIG. 7 is a side view showing an example of an interior material having a molding portion on the indoor side as seen from the indoor side. FIG. 8 is a diagram schematically illustrating an example of a manufacturing method including a hole forming step. FIG. 9 is a cross-sectional view schematically showing an example in which an interior material having a molding portion on the indoor side is taken out from an injection mold. FIG. 10 is a diagram schematically illustrating a main part of a mold surface of an injection mold. FIG. 11 is a diagram schematically illustrating a main part of a mold surface of an injection mold. FIG. 12 is a side view showing an example of the interior material before cutting as viewed from the vehicle outer side. FIG. 13 is a diagram schematically illustrating a method for evaluating the limit flow length of a resin.

Hereinafter, embodiments of the present invention will be described. Of course, the following embodiments are merely examples of the present invention, and all the features shown in the embodiments are not necessarily essential to the means for solving the invention.

(1) Summary of technology included in the present invention:
First, the outline of the technology included in the present invention will be described with reference to the examples shown in FIGS. FIGS. 1 to 13 are diagrams schematically showing examples. The enlargement ratios in the respective directions shown in these drawings may be different, and the drawings may not be consistent. Of course, each element of the present technology is not limited to the specific example indicated by the reference numeral.

[Aspect 1]
As illustrated in FIGS. 4 and 8, the method for manufacturing the vehicle interior material 1 according to the present technology includes a material forming step ST1, a transfer step ST2, an injection step ST3, and a take-out step ST4. In the material forming step ST1, a material containing a thermoplastic material (for example, the material sheet 20) is formed into a base material 10 having a required shape containing air Ar by using a material forming die (for example, a press forming die 210). In the transfer step ST <b> 2, the general surface 340 matched to the shape of the base material 10, and the first peripheral portion 11 around the gate 316 in the base material 10 is around the first peripheral portion 11. The base material 10 is transferred from the raw material mold (210) to the injection mold 310 having the mold surface 330 including the pressing part 350 to be compressed more than the second peripheral part 12. In the injection step ST3, a resin is applied from the gate 316 to the cavity CA1 of the injection mold 310 in which the base material 10 which has been made less than the melting point (preferably less than the softening point) of the thermoplastic material before clamping is placed. R1 is injected. In the extraction step ST4, the base material 10 is taken out from the injection mold 310 together with the molding part 50 made of the resin R1, and at least a part of the thickness of the first peripheral part 11 compressed by the pressing part 350 is restored. The interior material 1 in which the molded part 50 is bonded to the base material 10 is obtained.

In the first aspect, the first peripheral portion 11 around the gate 316 in the base material 10 disposed in the injection mold 310 is compressed more than the second peripheral portion 12 around the first peripheral portion 11. . Therefore, the resin leak that the resin R1 enters between the mold surface 330 and the substrate back surface 10b from the gate 316, that is, the resin leak that the resin R1 oozes out to the substrate back surface 10b is suppressed. As a result, by increasing the injection pressure, it becomes possible to increase the limit flow length that means the maximum length through which the resin R1 injected from the gate 316 flows.
Further, there is a concern that the base material 10 disposed in the injection mold 310 may be deformed and enter the cavity CA1 when the melting point of the thermoplastic material is equal to or higher than the melting point of the thermoplastic material, and the flow of the resin R1 in the cavity CA1 in which the molded part 50 is to be formed. There is. If the flow of the resin R1 in the cavity CA1 is hindered, there is a possibility that a part of the molded part 50 is not formed. In the first aspect of the present technology, since the base material 10 disposed in the injection mold 310 is less than the melting point of the thermoplastic material before clamping, the deformation of the base material 10 is suppressed and the base material 10 is a cavity. It becomes difficult to enter CA1, and the fluidity of the resin R1 is improved. Thereby, the favorable shaping | molding part 50 is formed. Therefore, this aspect can form a good molded portion while suppressing resin leakage from around the gate when manufacturing a vehicle interior material in which a molded portion of resin by injection molding is bonded to a base material. A novel manufacturing method can be provided.
Furthermore, when the base material 10 is taken out from the injection mold 310 together with the molding part 50, at least a part of the thickness of the first peripheral part 11 compressed by the pressing part 350 in the base material 10 is restored. Thereby, deterioration of the interior material due to locally strong pressing is suppressed.

Here, the base material containing air includes a base material in which fibers are aggregated, a base material made of foamed resin, a base material that combines fibers and foamed resin, and the like. For example, the material for forming the base material on which the fibers are aggregated includes a material sheet on which the fibers are aggregated.
The material molding includes press molding, injection molding, and the like. That is, the material mold includes a press mold, an injection mold, and the like. To mold the material, press the material sheet containing air into the base material of the required shape containing air with a press mold, or form the base material of the required shape while injecting the material into the injection mold and foaming. Injection molding, etc. are included.
The first peripheral portion of the substrate may be a portion limited to the periphery of the gate, or may include a portion along the molded portion. The pressing portion of the mold surface may be a portion excluding the cavity around the gate. Accordingly, the first peripheral portion of the base material may be a portion excluding the molding portion around the gate.
The injected resin includes a molten resin, a curable liquid resin, and the like.
The interior material obtained in the extraction step may be an interior material before the unnecessary portion is cut off.

[Aspect 2]
As illustrated in FIG. 6 and the like, the length W1 from the outer periphery 316o of the gate 316 of the first peripheral portion 11 to the second peripheral portion 12 in the direction D5 along the substrate 10 may be 1 to 10 mm. Good. If the length is 1 mm or more, resin leakage around the gate can be effectively suppressed, and if the length is 10 mm or less, deterioration of the interior material 1 due to locally strong pressing can be effectively suppressed. it can. In this aspect, since the first peripheral portion 11 to which a strong press is locally applied in the base material 10 is a narrow range around the gate, the manufacturing method capable of further suppressing deterioration of the interior material due to the strong press locally. Can be provided.
In the present application, “Min to Max” means a minimum value Min or more and a maximum value Max or less.

[Aspect 3]
Further, as illustrated in FIG. 8, in the method for manufacturing the vehicle interior material 1 according to the present technology, a material (for example, the material sheet 20) is formed on the base material 10 having a required shape with a material forming die (for example, a press forming die 210). Material forming step ST1 to be performed;
An injection mold 310 having a mold surface 330 including a general surface 340 matched to the shape of the base material 10 is disposed on one surface side of the base material 10 with a cavity CA1 and the other surface of the base material 10. A transfer step ST2 for transferring the substrate 10 from the raw material mold (210) to an injection mold 310 having a gate 316 on the side;
An injection step ST3 for injecting resin R1 from the gate 316 into the cavity CA1 of the injection mold 310 in which the base material 10 having the through hole 14 penetrating in the thickness direction D3 is disposed;
The molding part 50 made of the resin R1 includes an extraction step ST4 for taking out the interior material 1 joined to one surface side of the base material 10 from the injection mold 310.

The resin leakage around the gate is less likely to occur on the one surface side without the gate 316 than on the other surface side with the gate 316 in the base material 10. In the above aspect 3, since the resin molded portion 50 by injection molding is bonded to one side of the base material 10 without the gate 316, the vehicle interior material in which the resin molded portion by injection molding is bonded to the base material is manufactured. When manufacturing, the manufacturing method which can suppress that resin leak generate | occur | produces in the surface by which the shaping | molding part is joined in a base material can be provided. When joining a molding part to the surface side of a base material, it becomes possible to suppress the fall of the design nature by resin leak generating on the surface side of a base material.

Here, the manufacturing method may further include a hole forming step ST5 for forming the through hole 14 penetrating the base material 10 in the thickness direction D3.

[Aspect 4]
As illustrated in FIG. 8, the material molding die (210) may have a structure (for example, a perforated structure 220) for forming the through hole 14 in the base material 10. The hole forming step ST5 may be a step of forming the through hole 14 in the base material 10 by molding the material with the material molding die (210). This aspect can provide a production method capable of improving the production efficiency of the interior material in which the molded part is joined to the one surface side of the base material.

[Aspect 5]
The resin R1 may be a foamable resin. The molding part 50 may be formed of a foamed resin. In this embodiment, the limit flow length of the resin can be increased by the foaming force of the resin R1, and thus a suitable manufacturing method can be provided.

[Aspect 6]
Further, as illustrated in FIGS. 7 to 9, the vehicle interior material 1 of the present technology is bonded to the molded base material 10 having the through hole 14 penetrating in the thickness direction D3 and one surface side of the base material 10. And a molded part 50 connected to the trace 60 of the resin injection gate 316 on the other surface side of the base material 10 through the through hole 14. .

As described above, the resin leakage around the gate is less likely to occur on the one surface side where the gate 316 is not present than on the other surface side where the gate 316 is present in the base material 10. In the above aspect 6, since the resin molded portion 50 by injection molding is bonded to the one surface side without the gate 316 in the base material 10, occurrence of resin leakage on the surface on the side where the molded portion is bonded is suppressed. A new vehicle interior material can be provided. When the molded part is bonded to the surface side of the base material, a novel vehicle interior material in which a decrease in design property due to resin leakage occurring on the surface side of the base material can be provided.

(2) Specific examples of vehicle interior materials manufactured by the manufacturing method of the present technology:
FIG. 1 shows an example of the interior of an automobile in a state in which the illustration of the side portion is omitted. FIG. 2 shows an example of a vehicle interior material as viewed from the outside of the vehicle. In the lower part of FIG. 2, the reinforcing rib 51 (example of the molding part 50) is illustrated in an enlarged manner. FIG. 3 schematically shows an example of a cross section of the vehicle interior material at the position A1-A1 in FIG. In these figures, FRONT, REAR, UP, and DOWN indicate front, rear, upper, and lower, respectively. The positional relationship between the left and right is based on the direction of looking forward from the automobile 100. Reference sign D1 indicates the longitudinal direction of the automobile 100, reference sign D2 indicates the vertical direction of the automobile 100, reference sign D3 indicates the thickness direction of the vehicle interior material 1, and reference sign D4 indicates the direction in which the reinforcing rib 51 extends. , D5 indicates a direction along the substrate 10. The extending direction D4 of the reinforcing rib 51 shown in FIG. 2 and the like is included in the direction D5 along the base material 10.

An automobile 100 shown in FIG. 1 is a road traveling automobile designed and equipped to be used on a road. For example, a metal body panel such as a steel plate surrounds the passenger compartment SP1 and the luggage compartment SP2 and covers the vehicle body. Forming. Further, the automobile 100 shown in FIG. 1 is a wagon type passenger automobile in which a rear luggage compartment SP2 is connected to the passenger compartment SP1 and includes two rows of seats 101 (front seat and rear seat). Of course, automobiles to which the present technology can be applied include automobiles other than the two-row seat type such as the three-row seat type, and also include so-called station wagons, one-box cars, etc., and sedan-type automobiles.

Various interior materials 1 are arranged on the body panel of the automobile 100 on the indoor (SP1, SP2) side. A deck side trim 111 (an example of the interior material 1) is installed on the deck side panel (an example of the vehicle body panel) on the side from the cargo compartment SP2 on the cargo compartment SP2 side. A door trim 112 (an example of the interior material 1) is installed on the side of the vehicle compartment SP1 on a door panel (an example of a vehicle body panel) located on the side from the vehicle compartment SP1. Similarly, a pillar trim 113 (an example of the interior material 1) is installed on a side of the pillar (an example of the vehicle body panel) from the passenger compartment SP1 on the side of the passenger compartment SP1. A roof trim 114 (an example of the interior material 1) is installed on the interior side (SP1, SP2) side of the roof panel (an example of the vehicle body panel) above the passenger compartment SP1 and the cargo compartment SP2.

2 and 3 show an example of a deck side trim as an example of the interior material 1. In the deck side trim 111 shown in FIG. 3, the front surface 10 a of the base material 10 molded into a required shape having irregularities and the backing 40 of the skin material 30 are bonded together, and a part of the back surface 10 b of the base material 10 is made of resin. The reinforcing rib 51 is integrally formed by injection molding. The deck side trim 111 is disposed on the left and right side portions of the luggage compartment SP2, and gives a good design to the luggage compartment SP2 connected to the passenger compartment SP1. The reinforcing ribs 51 are arranged near the outer periphery or on a large plane where rigidity as an interior material tends to be insufficient with respect to the base material 10 formed in a three-dimensional shape.
The vehicle interior material of the present technology may not have the skin material 30 and the backing 40. In this case, the surface 10a becomes the design surface of the vehicle interior material instead of the skin material 30.

The base material 10 is a base material containing air Ar, such as a base material 10A in which fibers F1 are aggregated, a base material 10B made of foamed resin, a base material in which fibers and foamed resin are combined, and a heat such as a thermoplastic resin. A substrate containing a plastic material can be used.

As the fibrous base material 10A, a fiber aggregate formed by collecting fibers F1 and including air Ar, such as a breathable press-molded fiber mat, can be used. The base material 10A may be a fiber assembly having a multilayer structure such as a fiber mat in which a design layer, a shape retaining layer, and a sound absorbing layer are laminated.
The fibers F1 for forming the base material 10A include synthetic resin fibers (including elastomers) such as thermoplastic resins, fibers obtained by adding additives to synthetic resins, inorganic fibers such as glass fibers and carbon fibers, and plant fibers such as kenaf. In addition, a fiber including a thermoplastic fiber such as a thermoplastic resin fiber can be used. The thermoplastic resin may be a polyolefin resin such as polypropylene (PP) resin or polyethylene resin (PE), a polyester resin such as polyethylene terephthalate (PET) resin, a polyamide (PA) resin, an acrylic (PMMA) resin, or the like. . The fiber F1 may include a main fiber and an adhesive fiber (binder), and may include a fiber having a conjugate structure such as a core-sheath structure or a side-by-side structure. In addition, when inorganic fibers such as glass fibers are mixed with thermoplastic fibers, the rigidity of the substrate can be increased. The thermoplastic material included in the base material 10A may be included in the fiber F1, or may be included in a material other than the fiber F1.

The thickness Tb of the base material 10A is preferably 1 mm or more and 8 mm or less, more preferably 2 mm or more and 7 mm or less from the viewpoint of obtaining light weight and required rigidity. The basis weight of the base material 10A is preferably 450 g / m ² or more and 1200 g / m ² or less from the viewpoint of obtaining light weight and required rigidity.

For the base material 10B made of foamed resin, a foamed molded body formed by foaming a resin material and including bubbles (air Ar) can be used. For example, injection molding can be used for foam molding of the resin material. Further, the base material 10B may have a multilayer structure such as a foamed resin molded product with a skin layer left on the surface, or a molded product in which a substantially non-foamed layer is laminated on at least one surface of the foamed resin layer.
As long as the resin material for forming the substrate 10B includes a thermoplastic material such as a thermoplastic resin, various synthetic resins (including elastomers) can be used, and additives may be added. . The thermoplastic resin for forming the base material 10B can be a polyolefin resin such as PP resin or PE resin, a polystyrene (PS) resin, a combination thereof, or the like, and includes additives such as fillers. Also good. For foaming of the resin, physical foaming that dissolves the gas pressurized in the cylinder into the molten resin, chemical foaming that adds a chemical foaming agent and mixes the gas into the molten resin by thermal decomposition or chemical reaction, etc. are adopted. be able to. Foaming agents include volatile blowing agents that generate hydrocarbons such as butane and pentane, organic blowing agents such as azodicarbonamide (ADCA) and hydrazodicarbonamide, and inorganic blowing agents that generate carbon dioxide gas such as ammonium carbonate. , Etc. can be used.

The thickness Tb of the base material 10B is preferably 1 mm or more and 8 mm or less, more preferably 2 mm or more and 7 mm or less from the viewpoint of obtaining light weight and required rigidity. The basis weight of the substrate 10B is preferably 450 g / m ² or more and 1200 g / m ² or less from the viewpoint of obtaining light weight and required rigidity.

As the skin material 30, non-woven fabric, woven fabric, knitted fabric, carpet, synthetic resin (including elastomer), rubber, and the like can be used. A backing (backing layer) 40 may be formed on the back surface of the skin material 30. For the backing 40, a synthetic resin such as a thermoplastic resin (including an elastomer) or the like can be used. As the thermoplastic resin, a low-melting-point thermoplastic resin such as low density polyethylene and ethylene vinyl acetate can be used.

As shown in FIG. 2, the resin reinforcing rib 51 (an example of the molding unit 50) integrally formed on a part of the back surface 10 b of the base material 10 is directed in the direction D <b> 4 along the back surface 10 b of the base material 10. It extends. The reinforcing rib 51 shown in FIG. 2 is formed in a thin plate shape extending so as to be substantially orthogonal to the substrate back surface 10b. By joining the reinforcing ribs 51 to the base material 10, the rigidity of the base material 10 is enhanced, and the shape-retaining property of the base material 10 formed into an uneven shape along the vehicle body panel can be enhanced. can get. In particular, when the base material 10 is a fiber assembly formed by assembling the fibers F1, a high reinforcing effect can be obtained.
The height Hr of the reinforcing rib is not particularly limited, but can be, for example, about 2 to 10 mm. The thickness Tr of the reinforcing rib is not particularly limited, but can be, for example, about 1 to 5 mm. The reinforcing rib 51 can be formed by injection molding a molten resin R1 as illustrated in FIGS. 4 to 6, and a trace 60 of the gate 316 may be formed.

Various synthetic resins (including elastomers) can be used as the resin material for forming the molded part 50, and additives may be added. From the viewpoint of ease of molding, a thermoplastic resin such as a thermoplastic resin may be used. A resin material is preferred. The thermoplastic resin may be a polyolefin resin such as PP resin or PE resin, acrylonitrile butadiene styrene (ABS) resin, a combination thereof, or the like, and may contain additives such as fibers. When an ABS resin or the like having a low coefficient of linear expansion is used as the resin material, it is possible to obtain an interior material having good reinforcing ribs in which shrinkage of the reinforcing ribs due to cooling is suppressed and the base material is less warped. As the fibers, inorganic fibers such as glass fibers and carbon fibers, plant fibers such as kenaf, combinations thereof, and the like can be used. When inorganic fibers such as glass fibers are used as the fibers, an interior material having good reinforcing ribs in which the warpage of the substrate is effectively suppressed can be obtained.

Alternatively, a foamable resin may be used for the molten resin R1 shown in FIG. 6, and the molded part 50 may be formed of a foamed resin that is injection-molded so as to include bubbles. Then, since the limit flow length of the molten resin can be increased by the foaming force of the molten resin R1, the number of gates can be reduced or the degree of freedom of the shape (design) of the molded part 50 such as the surface shape can be improved. it can. Moreover, since the injection pressure can be lowered, resin leakage around the gate can be further effectively suppressed, and deterioration of the interior material such as the skin material can be further effectively suppressed. Furthermore, since shrinkage due to cooling of the injection resin is further suppressed, warping of the base material is further effectively suppressed.

As the resin material for forming the molded part 50 with the foamed resin, the above-described various synthetic resins can be used, and additives may be added. From the viewpoint of ease of molding, a thermoplastic resin such as a thermoplastic resin may be used. A resin material is preferred. As in the case of the base material 10B made of a foamed resin, the foaming of the resin is performed by adding a physical foaming or chemical foaming agent that dissolves the gas pressurized in the cylinder into the molten resin, and by thermal decomposition or chemical reaction. Chemical foaming or the like mixed into the molten resin can be employed. As the foaming agent, a volatile foaming agent, an organic foaming agent, an inorganic foaming agent, or the like can be used. As the resin material, a thermoplastic resin such as a PP resin is particularly preferably used, and it is preferable to use a material added with a filler such as talc, for example, 15 to 25% by weight. When a filler such as talc is added to the resin material, the filler becomes the core of foaming and the foamed state is improved, so that warping of the base material is further effectively suppressed.

In addition, the shaping | molding part 50 joined to the base material 10 may be a clip mounting seat, a resin frame attached to the opening of the interior material, an injection structure having a collar part, a decoration part, and the like in addition to the reinforcing rib. Here, the said clip attachment seat is a site | part for attaching the clip for fixing an interior material to counterpart members, such as a vehicle body panel. For example, a claw of a separate maintenance cover (service cover) that covers a maintenance hole (example of an opening) provided in a deck side trim (an example of an interior material) so as to be openable and closable is fitted into the resin frame. There are possible resin frames. The injection structure having the flange portion is integrated with the flange portion so that, for example, the end of the opening serving as an air intake port (louver) provided in the deck side trim is closed so that the inside cannot be seen through the opening. There are formed injection structures and the like. A specific example of the decoration unit will be described later.

(3) First manufacturing method of vehicle interior material:
FIG. 4 schematically shows a first method for manufacturing the interior material 1 as an example of a method for manufacturing the vehicle interior material. FIG. 5 schematically shows the main part of the mold surface 330 of the fixed mold 314 as an example of the mold surface of the injection mold. FIG. 6 schematically shows a state where the interior material 1 having the molding part 50 on the vehicle exterior side is taken out from the injection mold 310 as an example of taking out the interior material from the injection mold. FIG. 6 schematically shows an example of a cross section of the injection molding machine 300 at the position A2-A2 in FIG.

In the manufacturing method shown in FIGS. 4 to 6, a fiber assembly in which thermoplastic fibers are aggregated on a material sheet 20 (example of material) for forming a substrate 10 having a required shape (that is, a fiber assembly containing air Ar). ) And a thermoplastic resin is used as a resin material for injection molding the reinforcing ribs 51 and the like. The manufacturing method includes a material forming step ST1, a transfer step ST2, an injection step ST3, and a take-out step ST4. In the material forming step ST1, the material setting step ST1a for setting the material sheet 20 before press forming on a press mold 210 (an example of a material forming die) and the material sheet 20 before forming are pressed by the press molding machine 200. A pressing step ST1b for forming is included.

The press molding machine 200 shown in FIG. 4 is provided with an upper mold 212 and a lower mold 214 constituting the press mold 210 so as to be close to and away from each other. The upper mold 212 is a mold having a mold surface that matches the concavo-convex shape (example of required shape) of the interior material 1 on the cargo compartment SP2 side. The lower mold 214 is a mold having a mold surface that matches the concavo-convex shape (an example of a required shape) of the back surface 10 b of the substrate 10. In FIG. 4, the upper mold 212 is movable and the lower mold 214 is fixed. However, the upper mold 212 may be fixed and the lower mold 214 may be movable, or both molds 212 and 214 may be movable.

In the injection molding machine 300 shown in FIG. 4, a movable mold 312 and a fixed mold 314 that constitute an injection mold 310 are provided so as to be close to and away from each other. The mold 312 may be a fixed mold and the mold 314 may be a movable mold, or both molds 312 and 314 may be movable.

The movable mold 312 is a mold having a mold surface 330 matched with the concave and convex shape on the cargo compartment SP2 side of the interior material 1. Therefore, the mold surface 330 in the movable mold 312 shown in FIG. 4 is included in the general surface matched with the shape of the base material 10. The fixed mold 314 shown in FIGS. 5 and 6 presses the general surface 340 matched to the uneven shape of the back surface 10b of the base material 10 and the specific portion (first peripheral portion 11) of the base material 10 more than the surroundings. The mold has a mold surface 330 including a portion 350. The mold surface 330 of the fixed mold 314 is formed with a cavity CA1 for forming the reinforcing rib 51 and, if necessary, a clip mounting seat. In each cavity CA1, molten thermoplastic resin R1 is injected from injection device 320 through gate 316. Since the gate 316 is disposed in the middle of the long cavity CA1, the efficiency of the injection process ST3 is enhanced. The pressing portion 350 is formed around the resin injection gate 316, and the first peripheral portion 11 around the gate 316 of the base material 10 is moved from the second peripheral portion 12 around the first peripheral portion 11. Is also compressed in the thickness direction D3.

5 and 6, the length W1 from the outer periphery 316o of the gate 316 of the first peripheral portion 11 to the second peripheral portion 12 in the direction D5 along the base material 10 is substantially equal to the width W2 of the pressing portion 350. Adapted. The width W2 of the pressing portion 350 is a length from the inner periphery (the outer periphery 316o of the gate 316) to the outer periphery 350o in the direction D6 along the general surface 340. The length W1 of the first peripheral portion 11 and the width W2 of the pressing portion 350 are preferably 1 mm or more, and more preferably 1.5 mm or more. If these lengths W1 and W2 are equal to or greater than the lower limit, resin leakage from the gate 316 to areas other than the required region can be effectively suppressed, and the limit flow length of the injected molten resin R1 increases, so the number of gates Can be effectively reduced. Further, the lengths W1 and W2 are preferably 10 mm or less, more preferably 5 mm or less, and further preferably 3 mm or less. If these lengths W1 and W2 are set to the upper limit or less, the first peripheral portion 11 to which a strong press is locally applied in the base material 10 becomes a narrow range around the gate. Deterioration of the skin material can be effectively suppressed.

In this specific example, the pressing portion 350 and the first peripheral portion 11 are limited to a predetermined range (lengths W1, W2) from the outer periphery 316o of the gate 316, and along the cavity CA1 and the reinforcing rib 51 outside this predetermined range. There is no pressing part or first peripheral part. If the pressing portion is in a wide range, the trace of the pressing portion may remain in a wide range and the design of the interior material may be deteriorated. However, the pressing portion 350 and the first peripheral portion 11 are limited to a predetermined range around the gate. Therefore, deterioration of the interior material due to locally strong pressing can be effectively suppressed, and the limit flow length of the molten resin R1 can be increased.

The height H1 of the pressing part 350 corresponds to the amount by which the base material 10 arranged in the injection mold 310 is compressed in the thickness direction D3. The height H1 of the pressing part 350 is preferably 0.2 mm or more, and more preferably 0.3 mm or more. If the height H1 is equal to or higher than the lower limit, resin leakage from the gate 316 to a region other than the required region can be effectively suppressed, and the number of gates is effectively reduced because the limit flow length of the injected molten resin R1 increases. Can be reduced. Moreover, 1.0 mm or less is preferable and, as for the height H1 of the press part 350, 0.7 mm or less is more preferable. When the height H1 is set to the upper limit or less, the first peripheral portion 11 to which a strong press is locally applied in the base material 10 is in a narrow range around the gate. Therefore, the interior material (for example, a skin material) by the strong press locally is used. Deterioration can be effectively suppressed.

Next, details of each process shown in FIG. 4 will be described in order.
In the first material setting step ST1a, the material sheet 20 to which the required shape is not given is heated to the softening point of the thermoplastic material or higher, preferably the melting point of the thermoplastic material or higher, and set between the molds 212 and 214. . Although not shown in FIG. 4, the skin material 30 and a backing 40 or the like may be stacked on the surface 20 a of the material sheet 20 as necessary. In this case, the skin material 30 and, if necessary, the backing 40 and the like may be heated to overlap the surface 20a side of the material sheet 20 before press molding and set between the molds 212 and 214. Of course, when the raw material sheet 20, the skin material 30, and the backing 40 are integrated in a raw fabric state as necessary, they may be heated at the same time. When the heated material sheet 20 has an adhesive function, heating of the skin material 30 and the backing 40 may be omitted, or the backing 40 itself may be omitted. In the subsequent press step ST1b, at least the material sheet 20 is press-molded into a three-dimensional shape by bringing both molds 212 and 214 close to each other. When the skin material 30 is stacked, a laminate of the base material 10 having the required shape (specifically, the base material 10A in which the fibers F1 shown in FIG. 3 are assembled) and the skin material 30 is obtained, and the skin material 30 and the backing 40 are obtained. When the substrate is stacked, a laminate of the base material 10, the backing 40 and the skin material 30 having a required shape is obtained. In this manner, the material sheet 20 is press-molded onto the base material 10 having a required shape (material molding step ST1).

In the subsequent transfer step ST2, the molds 212 and 214 of the press molding machine 200 are separated from each other to take out the base material 10 having a required shape or a laminate thereof (hereinafter simply referred to as the base material 10). Move between 312 and 314 and set. During the transfer from the press mold 210 to the injection mold 310, the base material 10 cools down to below the melting point of the thermoplastic material, and the thermoplastic material is solidified. The temperature of the base material 10 set in the injection mold 310 is preferably less than the softening point of the thermoplastic material. The temperature decrease of the substrate 10 may be a temperature decrease due to natural cooling in the atmosphere, or may be a temperature decrease due to forced cooling such as applying cold air.

As shown in FIGS. 4 to 6, the mold surface 330 of the movable mold 312 is matched with the concavo-convex shape on the front surface 10a side of the base material 10, and the mold surface 330 of the fixed mold 314 is matched with the concavo-convex shape of the base material back surface 10b. The general surface 340 and the pressing portion 350 that compresses the base material 10 more than the surroundings are provided. Accordingly, when both the molds 312 and 314 of the injection molding machine 300 are closed, that is, when the mold is clamped, the first peripheral portion 11 around the gate 316 of the base material 10 is located around the first peripheral portion 11. Compressed in the thickness direction D3 rather than the two surrounding portions 12. FIG. 6 shows that the first peripheral portion 11 has a thickness (Tb−H1) obtained by subtracting the height H1 of the pressing portion 350 from the original thickness Tb. Here, before the mold clamping, the base material 10 is made less than the melting point of the thermoplastic material, and the solidification of the thermoplastic material is proceeding. Accordingly, the first peripheral portion 11 pressed by the pressing portion 350 is elastically deformed and has a restoring force. Moreover, it is suppressed that the base material 10 deform | transforms by being pressed by the compressed 1st surrounding part 11, and enters into cavity CA1 for reinforcement ribs.

In the subsequent injection step ST3, the gate 316 is inserted into the cavity CA1 for the reinforcing rib in a closed state in which both the molds 312 and 314 on which the base material 10 set to a temperature lower than the melting point of the thermoplastic material, preferably lower than the softening point is set, are closed. A molten resin R1 is injected. As described above, the first peripheral portion 11 around the gate 316 in the base material 10 arranged in the injection mold 310 is compressed more than the second peripheral portion 12 around the first peripheral portion 11. Therefore, the resin leak that molten resin R1 enters from the gate 316 between the mold surface 330 and the substrate back surface 10b is suppressed. In particular, the presence of the pressing portion 350 that protrudes toward the movable mold 312 on the mold surface 330 of the fixed mold 314 with the gate 316 effectively suppresses resin leakage around the gate.
As described above, the reinforcing rib 51 and the clip mounting seat and the like are injection-molded as necessary, and when the resin R1 is solidified, the reinforcing rib 51 and the like are joined and fixed to a part of the back surface 10b of the base material 10 including the air Ar. It becomes a state.

In the subsequent extraction step ST4, both molds 312 and 314 of the injection molding machine 300 are separated from each other, and the base material 10 is extracted from the injection mold 310 together with the reinforcing ribs 51 and the like made of the molten resin R1. At this time, the first peripheral portion 11 compressed by the pressing portion 350 is substantially restored to the original thickness Tb as in the state ST81 of FIG. 6 by its own restoring force, or as in the state ST82 of FIG. Restoring to the thickness (Tb−H2) approaching the original thickness Tb, leaving a slight trace 13 of the pressing portion 350. In the state ST82, since the depth H2 of the trace 13 is smaller than the height H1 of the pressing portion 350, a part of the thickness of the first peripheral portion 11 has been restored.
As mentioned above, in extraction process ST4, the interior material 1 with which the shaping | molding part 50 was joined to the base material 10 in which at least one part of the thickness of the 1st surrounding part 11 compressed by the press part 350 was decompress | restored is obtained.

In addition, when using the base material 10B (refer FIG. 3) made of a foamed resin for the base material 10 of a required shape, for example, a resin material (an example of a raw material) is injected into a material mold for injection molding into a required shape and foamed. Then, injection molding is performed so as to include bubbles (air Ar) (the material molding step ST1), and the obtained foam molded body (base material 10B) having a required shape is transferred from the material molding die to the injection molding die 310 ( The transfer step ST2). During the transfer from the raw material mold to the injection mold 310, the substrate 10B cools down to below the melting point (preferably below the softening point) of the thermoplastic material. When the injection mold 310 is clamped, the first peripheral portion 11 pressed by the pressing portion 350 in the base material 10B is elastically deformed and compressed in the thickness direction D3 more than the second peripheral portion 12, and has a restoring force. is doing. When the molten resin R1 is injected into the cavity CA1 in the injection step ST3 and the base material 10B is taken out from the injection mold 310 together with the reinforcing ribs 51 and the like by the molten resin R1 in the extraction step ST4, at least the thickness of the first peripheral portion 11 is reached. The interior material 1 in which the molding part 50 is joined to the base material 10B partially restored is obtained.

The manufactured interior material 1 is lightweight because the base material 10 having a required shape is at least one of the base material 10A in which the fibers F1 are aggregated and the base material 10B made of foamed resin. Moreover, since the resin-made reinforcing ribs 51 formed integrally with a part of the base material back surface 10b extend along the base material back surface 10b, the interior material 1 having a light weight and a required rigidity can be obtained.

In this specific example, the first peripheral portion 11 around the gate 316 of the base material 10 disposed in the injection mold 310 is compressed more than the second peripheral portion 12 around the first peripheral portion 11. Therefore, resin leakage from around the gate is suppressed. As a result, it is possible to increase the limit flow length of the molten resin R1 injected from the gate 316 by increasing the injection pressure.
In addition, since the thermoplastic material contained in the base material 10 disposed in the injection mold 310 is solidified, the deformation of the base material 10 is suppressed and the base material 10 becomes difficult to enter the cavity CA1, and the molten resin The fluidity of R1 is improved. Thereby, the reinforcing rib 51 etc. are formed favorably.

Furthermore, when the base material 10 is taken out from the injection mold 310 together with the reinforcing ribs 51 and the like, at least a part of the thickness of the first peripheral portion 11 compressed by the pressing portion 350 in the base material 10 is restored. Thereby, degradation of the interior material 1 due to locally strong pressing is suppressed, the quality of the interior material 1 is improved, and when the skin material 30 is joined to the base material 10, degradation of the skin material 30 is suppressed.
Therefore, this specific example suppresses resin leakage from around the gate when manufacturing a vehicle interior material in which a molded part of resin by injection molding is bonded to a base material, and deterioration of the interior material due to locally strong pressing. It is possible to form a good molded part while suppressing the above.

(4) Second manufacturing method of vehicle interior material:
FIG. 7 shows an example of a vehicle interior material (for example, door trim 112) having a molding portion on the indoor (for example, vehicle compartment SP1) side as viewed from the indoor side. The decoration part 52 (example of the shaping | molding part 50) is expanded and illustrated in the lower part of FIG. FIG. 8 schematically shows a second manufacturing method of the interior material 1 as an example of a method for manufacturing the interior material for a vehicle. FIG. 9 schematically shows how the interior material 1 having the molding part 50 on the indoor side is removed from the injection mold 310 as an example of extracting the interior material from the injection mold. FIG. 10 schematically shows the main part of the mold surface 330 of the fixed mold 314 as an example of the mold surface of the injection mold. Since the cavity CA1 of this specific example is on the mold surface 330 of the movable mold 312 without the gate 316, the position of the cavity CA1 corresponding to the mold surface 330 of the fixed mold 314 is indicated by a two-dot chain line. That is, there is a cavity CA1 for the decorative portion on the surface 10a (one surface example) side of the base material 10 arranged in the injection mold 310, and on the back surface 10b (example on the other surface) side of the base material 10. There is a gate 316.

In the door trim 112 shown in FIG. 7, the skin material 30 is provided on the design surface on the side of the vehicle compartment SP <b> 1, and the decorative portion 52 is joined to the surface of the skin material 30. In addition, in the interior material without a skin material, the decoration part 52 may be joined to the base-material surface 10a used as a design surface. The decorating unit 52 can be applied to a part representing a vehicle name, a character or emblem of an automobile manufacturer, a design such as a pattern for decorating an interior material, a character that can be substituted for a caution label, or the like.
The first peripheral portion 11 around the gate 316 (see FIGS. 8 to 10) in the base material 10 behind the skin material 30 shown in FIG. 7 is along the decorating portion 52 and the cavity CA1. The second peripheral part 12 around the peripheral part 11 is compressed in the injection step ST3.

In the manufacturing method shown in FIGS. 8 and 9, a thermoplastic resin is used as a resin material for injection molding the decorative portion 52 and the like using a fiber assembly in which thermoplastic fibers are gathered in the material sheet 20 (example of material). Used. In addition to the above-described steps ST1 to ST4, the manufacturing method includes a hole forming step ST5 for forming the through hole 14 penetrating the base material 10 in the thickness direction D3. Thereby, in injection process ST3, molten resin R1 is inject | emitted from the back surface 10b side of the base material 10 to the surface 10a side of the base material 10 through the through-hole 14, and the decorating part 52 is made into the design surface side of the interior material 1. Can be formed. The hole forming step ST5 shown in FIG. 8 is performed when the material forming step ST1 is performed. By forming the material sheet 20 with the press mold 210 (an example of the material forming die), the through holes 14 are formed in the base material 10. Form. Therefore, the press mold 210 has a perforated structure 220 for forming the through hole 14 in the base material 10. The punching structure 220 shown in FIG. 8 has a convex portion 222 for punching that protrudes from the mold surface of the upper die 212 toward the lower die 214, and the lower portion so as to be separated from the upper die 212 at a position corresponding to the convex portion 222. It has a recess 224 that is recessed from the mold surface of the mold 214.

The pressing part 350 of the injection mold shown in FIG. 10 is not limited to the predetermined width W2 from the outer periphery 316o of the gate 316, but from the edge CA1o of the cavity CA1 corresponding to the decorating part 52 in the mold surface 330 of the fixed mold 314. It is also formed within the range of the predetermined width W4. In the case of this specific example, even if the portion (first peripheral portion 11 or the like) along the cavity CA1 in the interior material 1 deteriorates, at least of the deteriorated portion (first peripheral portion 11 or the like) in a state along the decorative portion 52. Since a part is hidden by the decoration part 52, the good design of the interior material surface is maintained.
Here, in the direction D5 along the substrate 10, the length W3 from the edge of the cavity CA1 of the first peripheral portion 11 to the second peripheral portion 12 and along the cavity CA1 in the direction D6 along the general surface 340. The width W4 of the pressing portion 350 is preferably 1 mm or more, and more preferably 1.5 mm or more. Thereby, resin leakage from the cavity CA1 to a region other than the required region can be effectively suppressed. Further, these lengths W3 and W4 are preferably 10 mm or less, more preferably 5 mm or less, and even more preferably 3 mm or less. Thereby, degradation of the interior material (for example, skin material) due to locally strong pressing can be effectively suppressed. Further, the height (H3) of the pressing portion 350 along the cavity CA1 is preferably 0.2 mm or more, and more preferably 0.3 mm or more. Thereby, resin leakage from the cavity CA1 to a region other than the required region can be effectively suppressed. Further, the height H3 of the pressing portion 350 is preferably 1.0 mm or less, and more preferably 0.7 mm or less. Thereby, degradation of the interior material (for example, skin material) due to locally strong pressing can be effectively suppressed.

Next, each step shown in FIG. 8 will be described in order.
In the first material setting step ST1a, the material sheet 20 to which the required shape is not given is heated to the softening point of the thermoplastic material or higher, preferably the melting point of the thermoplastic material or higher, and set between the molds 212 and 214. . Of course, the skin material 30 and a backing 40 or the like may be stacked on the material sheet 20 as necessary. In the subsequent press step ST1b, at least the material sheet 20 is press-molded into a three-dimensional shape by bringing both molds 212 and 214 close to each other. At this time, the projection 222 of the perforated structure 220 penetrates at least the material sheet 20 and forms the through hole 14 at least in the material sheet 20 with the recess 224 (hole forming step ST5).

In the subsequent transfer step ST2, the molds 212 and 214 of the press molding machine 200 are separated from each other to take out the base material 10 having a required shape or a laminate thereof (hereinafter simply referred to as the base material 10). Move between 312 and 314 and set. During this time, the substrate 10 cools to below the melting point of the thermoplastic material. When the injection mold 310 is closed, the first peripheral portion 11 around the gate 316 and the cavity CA1 in the base material 10 is compressed in the thickness direction D3 more than the second peripheral portion 12 around the first peripheral portion 11. Is done. FIG. 9 shows that the first peripheral portion 11 has a thickness (Tb−H3) obtained by subtracting the height H3 of the pressing portion 350 from the original thickness Tb. The first peripheral portion 11 pushed by the pressing portion 350 is elastically deformed and has a restoring force.

In the subsequent injection step ST3, both molds 312 and 314 on which the base material 10 set to a temperature lower than the melting point of the thermoplastic material, preferably lower than the softening point is set, are closed through the through holes 14 of the base material 10 in a closed state. The molten resin R1 is injected from the gate 316 into the cavity CA1. That is, the molten resin R1 flows from the gate 316 of the fixed mold 314 through the through hole 14 and flows into the cavity CA1 of the movable mold 312. As described above, the first peripheral portion 11 around the gate 316 and the cavity CA1 in the base material 10 arranged in the injection mold 310 is more than the second peripheral portion 12 around the first peripheral portion 11. Since it is compressed, the resin leakage that the molten resin R1 oozes out to the front surface 10a and the back surface 10b of the base material 10 is suppressed. In particular, the presence of the pressing portion 350 that protrudes toward the movable mold 312 on the mold surface 330 of the fixed mold 314 with the gate 316 effectively suppresses resin leakage around the gate.
By the above, the decoration part 52 and a reinforcement rib, a clip mounting seat, etc. are injection-molded as needed, and if resin R1 solidifies, the decoration part 52 will be joined to a part of surface 10a of the base material 10 containing air Ar. And become fixed.

In the subsequent extraction step ST4, both molds 312 and 314 of the injection molding machine 300 are separated from each other, and the base material 10 is extracted from the injection mold 310 together with the decorating portion 52 and the like made of the molten resin R1. At this time, the first peripheral portion 11 that has been compressed by the pressing portion 350 is almost restored to its original thickness Tb as shown in the lower part of FIG. The thickness is restored to approach the original thickness Tb. Here, even if the first peripheral portion 11 or the corresponding skin material 30 deteriorates, at least a part of the deteriorated portion is hidden by the decorative portion 52 in a state along the decorative portion 52, so that the surface of the interior material is good. The design is preserved.
As described above, in the extraction step ST4, the interior material in which the molded part 50 is joined to the surface 10a (one example) of the base material 10 in which at least a part of the thickness of the first peripheral part 11 compressed by the pressing part 350 is restored. You will get 1. The interior material 1 includes a molded base material 10 having a through hole 14 penetrating in the thickness direction D3, and a resin molding portion 50 bonded to one surface side of the base material 10 through the through hole 14. And a molded part 50 connected to the trace 60 of the resin injection gate 316 on the other surface side of the substrate 10.

Resin leakage around the gate is less likely to occur on the front surface 10a side without the gate 316 than on the back surface 10b side with the gate 316 in the substrate 10. In this specific example, the decorative portion 52 is bonded to the surface 10a side without the gate 316 in the base material 10. Therefore, when manufacturing the vehicle interior material in which the molded portion of the resin by injection molding is bonded to the base material. It is possible to suppress the occurrence of resin leakage on the surface side to which the molded part is bonded in the base material. Thereby, the fall of the designability by the resin leak generate | occur | producing on the surface side of a base material is suppressed.
As described above, this specific example also suppresses resin leakage from the periphery of the gate when manufacturing a vehicle interior material in which a molded part of resin by injection molding is bonded to a base material, and by locally strong pressing It is possible to form a good molded part while suppressing deterioration of the interior material.

Note that the hole forming step ST5 may be performed after the material forming step ST1. For example, the through-holes 14 may be formed in the base material 10 by a cutting die or manual processing on the base material 10 having a required shape.

(5) Third method for producing vehicle interior materials:
When the gate cannot be set at the product position in the injection mold due to the placement of the hot runner, etc., after the molding part is injection-molded after setting the gate at the position outside the product and from the base material to which the molded part is joined You may implement the cutting process which separates a product and an unnecessary part.
FIG. 11 schematically shows the main part of the mold surface 330 of the fixed mold 314 as an example of the mold surface of the injection mold. FIG. 12 shows an example of the interior material before cutting from the outside of the vehicle. In the lower part of FIG. 12, an elongated reinforcing rib 51 (an example of the molding part 50) intersecting with the cutting line LN1 and its periphery are shown in an enlarged manner.

In the interior material 2 before cutting shown in FIG. 12, the interior material 1 as a product and the unnecessary portion 3 to be cut are connected with a virtual cutting line LN1 as a boundary. The trace 60 of the gate 316 is formed in the unnecessary portion 3 of the reinforcing rib 51. The injection mold 310 for forming the reinforcing rib 51 shown in FIG. 12 has a long cavity CA1 extending from the gate 316 at the position of the unnecessary portion 3 toward the product portion and intersecting the cutting line LN1. is doing. Thereby, the molten resin R1 injected from the gate 316 at the position of the unnecessary portion 3 flows toward the product portion, and the reinforcing rib 51 is formed.

The mold surface 330 shown in FIG. 11 includes a general surface 340 that matches the required shape of the base material 10 in the interior material 2 before cutting, and at least a specific portion of the base material 10 in the unnecessary portion 3 (first surrounding portion 11). It includes a pressing part 350 that presses more than the surroundings. The pressing portion 350 set as the unnecessary portion 3 in the mold surface 330 shown in FIG. 11 is not limited to the predetermined width W2 from the outer periphery 316o of the gate 316, but for the reinforcing rib in the mold surface 330 from the gate 316 to the cutting line LN1. It is also formed within a predetermined width W6 from the edge CA1o of the cavity CA1. In the case of this specific example, since there is no need to consider the deterioration of the substrate surface in the unnecessary portion 3 outside the product, the width W6 of the pressing portion 350 may be wider than the width W4 shown in FIG. The length W5 from the edge of the cavity CA1 of the first peripheral portion 11 to the second peripheral portion 12 in the direction D5 along the substrate 10, and the pressing portion along the cavity CA1 in the direction D6 along the general surface 340 The width W6 of 350 is preferably 7 mm or more, and more preferably 10 mm or more. Note that the height of the pressing portion 350 along the cavity CA1 is preferably 0.2 mm or more, and more preferably 0.3 mm or more.

On the other hand, the pressing part 350 is not formed in the part corresponding to the product in the mold surface 330. Thereby, the trace of the press part 350 does not remain in the interior material 1, and deterioration of the interior material due to locally strong pressing is effectively suppressed.
In the case where the pressing portion is formed along the cavity CA1 corresponding to the product in the mold surface 330, the width of the pressing portion (corresponding to the width W4 shown in FIG. 10) corresponds to the unnecessary portion 3. It is preferable that the pressing portion 350 is narrower than the width W6.

As a manufacturing method of the interior material 1, for example, after performing the material forming process ST1, the transfer process ST2, the injection process ST3, and the take-out process ST4 in order, the interior material 2 obtained before cutting is cut along the cutting line LN1. What is necessary is just to implement the removal process which cuts and removes the unnecessary part 3. FIG.
This example also suppresses resin leakage from the periphery of the gate when manufacturing vehicle interior materials in which the molded part of the resin by injection molding is bonded to the base material, and suppresses deterioration of the interior material due to strong local pressing. However, a good molded part can be formed.

(6) Modification:
Various modifications can be considered for the present technology.
For example, the present technology is applicable to a door trim 112, a pillar trim 113, a roof trim 114, a trunk interior material, and the like.
The present technology can also be applied to the base material 10 in which the base material 10A in which the fibers F1 are aggregated and the base material 10B made of foamed resin are mixed.

(7) Example:
EXAMPLES Hereinafter, although an Example is shown and this invention is demonstrated concretely, this invention is not limited by the following examples.

[Base material sample]
The base material sample 1 has a PET fiber (average fiber length 51 mm, fiber diameter 3.3 dtex (decitex)), PP fiber (average fiber length 64 mm, fiber diameter 6.6 dtex), and a core having a melting point of 255 to 265 ° C. A fiber aggregate having a basis weight of 800 g / m ² mixed with a PET-copolymer resin core-sheath fiber (average fiber length 51 mm, fiber diameter 4.4 dtex) having a melting point of 110 ° C. was used.
The substrate sample 2, a fiber aggregate having a basis weight of 800 g / m ² of a mixture of PP and glass fibers, which were laminated to backing the PE resin to a plain knee pan nonwoven having a basis weight of 200 g / m ² as a surface material Was used.

[testing machine]
FIG. 13 schematically shows a testing machine for measuring the limit flow length of the molten resin. In the lower part of FIG. 13, the external appearance of the fixed mold 314 is schematically shown. The testing machine shown in FIG. 13 has a movable mold 312, a fixed mold 314, and a molten resin injection device 320. In the fixed mold 314, a gate 316 and a long cavity CA1 are formed. The fixed die 314 can change the height Hr of the reinforcing rib to be injection-molded and the presence or absence of a pressing portion around the gate. A base material sample having a temperature lower than the softening point of the thermoplastic resin contained in the base material sample was placed in a testing machine. The thickness Tr of the reinforcing rib was 2.0 mm, the width W2 of the pressing portion was 2.0 mm, and the height H1 of the pressing portion was 0.5 mm. The molds 312 and 314 had a temperature of 50 ° C., and a 230 ° C. PP resin (specific gravity 0.9, MFR (melt mass flow rate) 30 g / 10 min) was used as the molten resin, and the injection speed was 50 mm / sec.

[Evaluation methods]
In each of the following test sections 1 to 6, a molten resin is injected to form an interior material sample with and without a pressing portion, and a limit flow length is measured. It was visually evaluated whether or not there was any deterioration.

[Evaluation results]
The limit flow length when there is a pressing portion, the limit flow length when there is no pressing portion, and whether deterioration due to compression of the base material sample by the pressing portion is shown below.

In addition, when there was a press part, the resin leak around a gate was not seen.

In all the test sections 1 to 6, the limit flow length of the molten resin was increased by 30 to 40 mm when the pressing portion was present compared to the case without the pressing portion. This is probably because resin leakage around the gate was suppressed. In all the test sections 1 to 6, the thickness of the first peripheral portion compressed by the pressing portion in the base material sample was almost restored, and the interior material sample was not deteriorated due to the compression by the pressing portion.
As mentioned above, when manufacturing the interior material for vehicles in which the molding part of the resin by injection molding is joined to the base material, while suppressing the resin leakage from the periphery of the gate, while suppressing the deterioration of the interior material due to the local strong press It was confirmed that a good molded part can be formed.

(8) Conclusion:
As described above, according to the present invention, in various aspects, it is good while suppressing resin leakage from around the gate when manufacturing a vehicle interior material in which a molded part of resin by injection molding is bonded to a base material. The technique etc. which can form a simple forming part can be provided. Needless to say, the above-described basic actions and effects can be obtained even with a technique that does not have the constituent elements according to the dependent claims but includes only the constituent elements according to the independent claims.
In addition, the configurations disclosed in the above-described examples are mutually replaced or the combination is changed, the known technology and the configurations disclosed in the above-described examples are mutually replaced or the combinations are changed. The configuration described above can also be implemented. The present invention includes these configurations and the like.

1 ... interior material, 2 ... interior material before cutting, 3 ... unnecessary part,
10 ... base material, 10A ... base material in which fibers are gathered, 10B ... base material made of foamed resin,
10a ... front surface, 10b ... back surface, 11 ... first peripheral portion, 12 ... second peripheral portion, 13 ... trace,
14 ... through hole,
20 ... Material sheet (example of material), 20a ... Surface,
30 ... skin material, 40 ... backing,
50 ... molded part, 51 ... reinforcing rib, 52 ... decorative part, 60 ... trace,
100 ... car, 101 ... seat,
111 ... Deck side trim, 112 ... Door trim,
113 ... pillar trim, 114 ... roof trim,
200 ... press molding machine,
210 ... press mold (example of material mold), 212 ... upper mold, 214 ... lower mold,
220 ... perforated structure, 222 ... convex part, 224 ... concave part,
300 ... injection molding machine, 310 ... injection mold, 312 ... movable mold, 314 ... fixed mold,
316 ... Gate, 316o ... Outer periphery, 320 ... Injection device,
330 ... mold surface, 340 ... general surface, 350 ... pressing portion, 350o ... outer periphery,
Ar ... Air, CA1 ... Cavity, CA1o ... Edge,
D1 ... front-rear direction, D2 ... vertical direction, D3 ... thickness direction, D4 ... extended direction,
D5: direction along the substrate, D6: direction along the general surface,
F1 ... fiber, H1 ... height of the pressing part, H2 ... depth of the mark of the pressing part, LN1 ... cutting line,
R1 ... resin,
SP1: Car compartment, SP2: Cargo,
ST1 ... Material forming step, ST1a ... Material setting step, ST1b ... Pressing step,
ST2 ... Transfer process, ST3 ... Injection process, ST4 ... Removal process, ST5 ... Hole formation process,
W1, W3, W5: Length of the first peripheral portion, W2, W4, W6: Width of the pressing portion.

Claims (6)

1. A material molding process for molding a material containing a thermoplastic material into a base material having a required shape including air with a material molding die,
   A general surface matched to the shape of the base material, and a pressing portion that compresses the first peripheral portion around the gate of the base material more than the second peripheral portion around the first peripheral portion. A transfer step of transferring the substrate from the material mold to an injection mold having a mold surface;
   An injection step of injecting a resin from the gate into a cavity of the injection mold in which the base material, which is less than the melting point of the thermoplastic material before clamping, is disposed;
   The interior in which the molding part is joined to the base material in which at least part of the thickness of the first peripheral part compressed by the pressing part is restored together with the base part taken out from the injection mold together with the molding part made of the resin A method for producing an interior material for a vehicle, comprising a step of taking out the material.
2. The method for manufacturing an interior material for a vehicle according to claim 1, wherein a length from the outer periphery of the gate of the first peripheral portion to the second peripheral portion in the direction along the base material is 1 to 10 mm.
3. Further comprising a hole forming step of forming a through hole penetrating in the thickness direction with respect to the base material;
   The cavity is on one side of the base material disposed in the injection mold, and the gate is on the other side of the base material,
   In the injection step, a resin is injected from the gate into the cavity through the through hole,
   The method for manufacturing an interior material for a vehicle according to claim 1, wherein, in the extracting step, an interior material in which the molded portion is joined to one surface side of the base material is obtained.
4. The material molding die has a structure for forming the through hole in the base material;
   The said hole formation process is a manufacturing method of the interior material for vehicles of Claim 3 which is a process of forming the said through-hole in the said base material by shape | molding the said raw material with the said raw material shaping | molding die.
5. The method for manufacturing an interior material for a vehicle according to any one of claims 1 to 4, wherein the resin is a foamable resin, and the molded part is formed of a foamed resin.
6. A molded substrate having a through-hole penetrating in the thickness direction;
   A molded part of resin joined to one surface side of the base material and connected to a trace of a gate for resin injection on the other surface side of the base material through the through hole. Interior material.

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