WO2020261352A1

WO2020261352A1 - Interior component for automobile

Info

Publication number: WO2020261352A1
Application number: PCT/JP2019/025028
Authority: WO
Inventors: 俊介長木
Original assignee: 河西工業株式会社
Priority date: 2019-06-25
Filing date: 2019-06-25
Publication date: 2020-12-30

Abstract

[Problem] To provide a method for manufacturing an interior component for an automobile which is suitable for broadening the selection range of materials that can be used as the constituent material of the interior component for an automobile, and which is suitable for preventing anomalous events, namely the detachment of welded parts. [Solution] A method for manufacturing an interior component M for an automobile includes a heating step, a welding step, and a preheating-imparting step. In the heating step, a backing layer 210 is melted in a first region S1. In the welding step, the outer-edge area of a laminating material 1 is folded over and is thereby set so that a surface material 2 bends while wrapping around a core material and the backing layer, and as a result of this folding, the backing layer in the first region S1 comes into contact with the backing layer outside the first region as an adhesive layer, whereby the parts of the backing layer are welded together. In the preheating-imparting step, before the welding, the region of the entire backing layer that is adjacent to the first region is set as a second region S2, and preheating is imparted to the set second region S2.

Description

Interior parts for automobiles

The present invention relates to a method for manufacturing an automobile interior part that constitutes an automobile interior such as an automobile interior ceiling, and is particularly suitable for broadening the selection range of materials that can be used as a constituent material for the automobile interior part, and is welded. It is suitable for preventing defects such as peeling of parts and molding defects.

As automobile interior parts of this type, for example, door trims, side trims of luggage rooms, and interior ceilings are known (see, for example, Patent Document 1).

FIG. 3A is a cross-sectional view of a laminated material used when manufacturing a conventional interior part for an automobile (ceiling inside an automobile), and FIG. 3B uses the laminated material of FIG. 3A. It is sectional drawing of the conventional car interior parts (the ceiling in a car) manufactured by the above. Further, FIG. 4A is an explanatory diagram of a heating process when manufacturing the conventional automobile interior parts (ceiling inside the car) of FIG. 3B, and FIG. 4B is welding during the manufacturing. It is explanatory drawing of a process.

With reference to FIGS. 3A and 3B, the conventional interior parts for automobiles (ceiling inside the vehicle) M are made of a laminated material 50, and the vicinity of the outer edge 5A of the laminated material 50 is folded inward and welded. The laminated material 50 has a structure in which the skin material 3 is bonded to the resin base material 51.

With reference to FIG. 3A, the skin material 3 described above includes a skin surface layer 301 (a layer constituting the design surface of the ceiling inside the vehicle) formed of a breathable material, and a skin intermediate layer 302 made of a urethane material. And, it has a three-layer structure of the epidermis back surface layer 303 formed of non-woven fabric.

Further, the resin base material 51 described above has a five-layer structure, and of the five-layer structure, the first layer 51-1 is configured as a layer containing a glass fiber mat and an adhesive, and the second layer 51. -2 is a core material made of a semi-rigid urethane material or the like, and the third layer 51-3 is made of the same material as the first layer 51-1. The fourth layer 51-4 is formed of a PP resin (polypropylene) film as a non-ventilating layer (ventilation blocking layer), and the fifth layer 51-5 is a backing material layer, that is, the back surface of the ceiling material (with the above-mentioned design surface). Consists of the opposite side) and is made of a fabric roughly woven with PET filament yarn.

Then, the folded shape near the outer edge of the laminated material 50 described above is formed by the manufacturing method shown in FIG. The manufacturing method of FIG. 4 is roughly classified into a heating step of FIG. 4A and a welding step of FIG. 4B.

In the heating step of FIG. 4A, the terminal of the laminated material 50 is placed at a position slightly inside the outer edge of the backing material layer (fifth layer 51-5) (specifically, as shown in FIG. 4B). The heat shield plate D is arranged at the folded position), and the region from the arranged heat shield plate D to the outer edge of the backing material layer (fifth layer 51-5) is set as the first region S1 and set. By heating the first region S1 with hot air H1, the PP resin of the fourth layer 51-4 is melted in the first region S1 and soaks into the backing material layer (fifth layer 51-5). It becomes crowded.

Further, in the welding step of FIG. 4B, as described above, the molten PP resin of the fourth layer 51-4 is infiltrated into the backing material layer (fifth layer 51-5). By wrapping around the outer edge of the laminated material 50 and folding it inward with sesame GM, the skin material 3 is made into each layer (core material (second layer 51-2)) and back material layer (fifth layer 51) of the resin base material 51. -5) etc.) are set so as to be in a bent state, and the backing material layer (fifth layer 51-5) as described above in the first region S1 is used as an adhesive layer by folding back. The backing material layers (fifth layer 51-5) are welded to each other by abutting against the backing material layer (fifth layer 51-5) outside the first region S1.

By the way, in the conventional ceiling material (interior parts M for automobiles), there is a demand that the fourth layer 51-4 (non-ventilation layer (ventilation prevention layer)) be formed of a nylon-based material. The reason is that nylon-based materials have a higher melting point than PP resin (polypropylene), so that it is difficult for holes to open during heating.

However, in response to such a requirement, when the fourth layer 51-4 (non-ventilating layer (ventilation blocking layer)) is formed of a nylon-based material, in the conventional vehicle interior ceiling material, the backing material layer (first) described above is used. Layers 51-5) There is a problem of peeling at the welded parts of each other. This is because nylon-based materials have poor heat retention and are easily cooled as compared with PP resin (polypropylene) films. For this reason, in the conventional ceiling material, the material selection range of the backing material (specifically, the backing material layer (fifth layer 51-5)) that can be used is narrow, and the material adjacent to the backing material layer is the first. For the layer 51-4 of 4, that is, the non-breathable layer (ventilation blocking layer), only a limited material such as PP resin (polypropylene) film could be used.

By the way, in consideration of the characteristics peculiar to the nylon-based material as described above, a method of setting a high temperature for heating by the hot air H is also conceivable. However, in this method, damage to the core material (second layer 51-2) (for example, when the core material is composed of the above-mentioned semi-hard urethane material, it becomes brittle due to carbonization due to heat or has cushioning properties. There is a problem that molding defects occur frequently due to excessive amount of

Japanese Unexamined Patent Publication No. 2013-52563

The present invention has been made to solve the above problems, and an object of the present invention is suitable for broadening the selection range of materials that can be used as constituent materials for interior parts for automobiles, and peeling of welded parts. It is an object of the present invention to provide a method for manufacturing an interior part for an automobile, which is suitable for preventing such defects and molding defects.

In order to achieve the above object, the present invention is a method for manufacturing an interior component for an automobile, which is made of a laminated material having a skin material on the front side of the core material and a backing material layer on the back side of the concentric material. A region from a position slightly inside the outer edge of the backing material layer to the outer edge of the backing material layer is set as a first region, and the set first region is heated after the heating step and the heating step. By folding back the vicinity of the outer edge of the laminated material inward, the skin material is set to be in a bent state by involving the core material and the backing material layer, and the folding back causes the inside of the first region. The backing material includes a welding step of welding the backing material layers to each other by abutting the backing material layer outside the first region as an adhesive layer, and before the welding step, the backing material. A region adjacent to the first region of the entire layer is set as a second region, and a preheating applying step of applying preheating to the set second region is provided.

The present invention may be characterized in that the layer adjacent to the backing material layer is made of a nylon-based material.

The present invention may be characterized in that the first region and the second region are separated by the position of the heat shield plate.

The present invention may be characterized in that the heating temperature in the first region is higher than the preheating temperature in the second region.

In the present invention, as described above, before the welding step, a region adjacent to the first region (heating region) of the entire backing material layer is set as the second region, and the set second region is used. It was configured to give preheating. Therefore, in the welding step, the backing material layer in the first region is welded to, that is, the backing material layer in the second region is activated by preheating, and the backing material layers are joined by welding. Since the strength is increased, it is possible to use materials that could not be used in the past due to insufficient joint strength, such as nylon-based materials, and preheating below the heating temperature causes less damage to the core material. Provided is a method for manufacturing an automobile interior part, which is suitable for broadening the selection range of materials that can be used as a constituent material for an automobile interior part, and is suitable for preventing defects such as peeling of welded parts and molding defects. obtain.

FIG. 1 (a) is a cross-sectional view of a laminated material used when manufacturing an automobile interior part (in-vehicle ceiling) by applying the present invention, and FIG. 1 (b) uses the laminated material of FIG. 1 (a). Cross-sectional view of the interior parts for automobiles (ceiling inside the car) manufactured in the above. FIG. 2A is an explanatory diagram of a heating step and a preheating step in manufacturing the conventional automobile interior parts of FIG. 1B, and FIG. 2B is an explanatory diagram of a welding step in the manufacturing thereof. FIG. 3A is a cross-sectional view of a laminated material used when manufacturing a conventional interior part for an automobile (ceiling inside a car), and FIG. 3B is manufactured using the laminated material of FIG. 3A. Cross-sectional view of a conventional automobile interior part (in-vehicle ceiling). FIG. 4A is an explanatory diagram of a heating process when manufacturing the conventional automobile interior parts (ceiling inside the vehicle) of FIG. 3B, and FIG. 4B is an explanatory diagram of a welding process during the manufacturing.

Hereinafter, the best mode for carrying out the present invention will be described in detail with reference to the attached drawings.

FIG. 1 (a) is a cross-sectional view of a laminated material used when manufacturing an interior part for an automobile by applying the present invention, and FIG. 1 (b) is a cross-sectional view using the laminated material of the same figure (a). It is sectional drawing of the manufactured car interior parts (car interior ceiling).

Referring to FIG. 1, the automobile interior component M of FIG. 1B is used as an interior ceiling of an automobile, and is composed of the laminated material 1 of FIG. 1A and the laminated material 1. The structure is such that the vicinity of the outer edge 1A is folded inward and welded. Further, the laminated material 1 in FIG. 6A has a structure in which a sheet-shaped skin material 3 is bonded to a plate-shaped resin base material 2.

<< Details of skin material 3 >>
The epidermis material 3 has a three-layer structure of an epidermis surface layer 301, an epidermis intermediate layer 302, and an epidermis back surface layer 303, and the epidermis surface layer 301 is formed of a breathable material such as a woven fabric, a knitted fabric, or a non-woven fabric, and is used for automobiles. It constitutes the design surface (surface exposed inside the automobile) of the interior component M. Further, the epidermis intermediate layer 302 is made of an elastic material, for example, a urethane material. The skin back surface layer 303 is provided with, for example, a fabric roughly woven with PET filament yarn or a non-woven fabric made of PET fiber as a means for obtaining an improvement in the bonding strength of the skin material 3 with respect to the resin base material 2 (specifically, due to the anchor effect). It is configured.

<< Details of resin base material 2 >>
The resin base material 2 has a 10-layer structure. In the following description, the 10 layers will be referred to as a first layer, a second layer, ..., And a tenth layer in this order from the top, and each layer will be described with reference numerals 201 to 210.

The first layer 201 is made of a PP resin (polypropylene) film. In the automobile interior component M of FIG. 1B, the PP resin film of the first layer 201 is in contact with the skin back surface layer 303 in a state of being softened and melted by heating, and the contacted PP resin (polypropylene) film. By entering the gap of the skin back surface layer 303 in a molten state, the above-mentioned anchor effect is generated, and the skin material 3 is bonded to the resin base material 2 and the bonding strength thereof is improved.

The second layer 202 is made of PP resin (polypropylene) powder, and the third layer 203 is made of glass fiber material, so that the PP resin powder enters the gaps of the glass fiber material and its The PP resin powder that has entered softens and melts by heating and functions as a binder that connects the glass fibers to each other, so that the second layer 202 and the third layer 203 are made of glass fiber reinforced plastic (GFRP: Glass Fiber) as a whole. Reinforced Plastics) layer is formed, and it functions as a means for holding the entire shape of the interior component M for automobiles in a required shape by the shape holding performance of GFRP. In addition, what kind of fiber is adopted, for example, carbon fiber is used instead of the above-mentioned glass fiber, and this point may be appropriately changed as necessary.

The fourth layer 204 is made of a high density polyethylene (HDPE) material and functions as an adhesive to form the above-mentioned GFRP layer composed of the second and

third layers

202 and 203 and the fifth layer. It functions as a means for joining the layer 205. It is also possible to use another adhesive instead of high-density polyethylene.

The fifth layer 205 is a core material, which is made of a semi-rigid urethane material or the like, and is hard enough to be dented when pressed with force with a finger. In the interior component M for automobiles of FIG. 2, a semi-rigid urethane material is applied as an example of such a core material, but the present invention is not limited to this, and the fifth material has the same function as the semi-rigid urethane material. Layer 205 may be configured.

The sixth layer 206 is made of the same material (high-density polyethylene material) as the fourth layer 204, and its function is also adhesive as in the fourth layer 204. Further, the seventh layer 207 is made of the same material (glass fiber material) as the third layer 203. The eighth layer 208 is made of the same material (PP resin powder) as the second layer 202, and the seventh layer 207 and the eighth layer 208 are also the second and third layers described above. Like the

layers

202 and 203, the GFRP layer is formed as a whole, and the sixth layer 206 exists as a means for adhering the GFRP layer and the fifth layer 205.

The ninth layer 209 is made of a non-breathable material, and by blocking the ventilation that penetrates the front and back surfaces of the automobile interior component M, the design surface (specifically) of the automobile interior component M due to such ventilation. Specifically, it functions as a means for preventing the surface of the skin material 3) from becoming dirty. As a specific example of the non-breathable material, a nylon-based material is used for the interior component 1 for automobiles in FIG.

The tenth layer 210 constitutes a backing material layer, that is, a back surface of the automobile interior component 1 (a surface opposite to the above-mentioned design surface), and is made of the same material as the skin back surface layer 303 described above. As an example of the material thereof, the interior component M for an automobile in FIG. 2 uses a fabric (PET · Scrim) roughly woven with PET filament yarn.

As can be seen from the above description, the laminated material 1 of FIGS. 1A and 1B is provided with a skin material 3 on the front side of the core material (fifth layer 205) and is a concentric material (fifth layer). The structure is provided with a backing material layer (10th layer 210) on the back side of 205).

<< Explanation of manufacturing method of interior parts M for automobiles >>
As described above, the automobile interior component M of FIG. 1B has a structure in which the vicinity of the outer edge 1A of the laminated material 1 is folded inward and welded, and the automobile interior component having such a folded welding structure is formed. M prepares the laminated material 1 of FIG. 1A described above, and a series of manufacturing steps including the later-described << heating step >>, << preheating applying step >>, and << welding step >> for the laminated material 1. It can be manufactured by processing with.

FIG. 2A is an explanatory diagram of a heating process and a preheating step when manufacturing an interior part for an automobile of FIG. 1B, and FIG. 2B is an explanatory diagram of a welding process during the manufacturing thereof. is there.

《Heating process》
In the heating step, as shown in FIG. 2A, the position slightly inside the outer edge of the backing material layer (10th layer 210) (specifically, the laminated material 1 as shown in FIG. 2B). The heat shield plate D is arranged at the position where the terminal is folded back, and the region from the position of the heat shield plate D to the outer edge of the backing material layer (10th layer 210) is defined as the first region S1. By heating the set first region S1, the nylon-based material of the ninth layer 209 melts in the first region S1 and permeates into the backing material layer (tenth layer 210). It is in the state. The backing material layer (tenth layer 210) in this state functions as an adhesive layer having an adhesive ability due to the molten nylon material that has soaked into the backing material layer (tenth layer 210). Although hot air H1 is used for the above-mentioned heating, it is also possible to use a heating method other than heating by hot air H1.

<< Welding process >>
In the welding step, as shown in FIG. 2B, after the heating step, that is, the nylon-based material of the ninth layer 209 melted as described above soaks into the backing material layer (tenth layer 210). In the packed state, the vicinity of the outer edge 1A of the laminated material 1 is rolled up and folded back inward by the sesame GM, so that the skin material 3 becomes each layer of the resin base material 2 (core material (fifth layer 205) and backing material layer (third). The backing material layer (10th layer 210) in the first region S1 is set to be in a bent state by being involved in the 10 layers 210), etc., and the adhesive layer having the above-mentioned adhesive ability is obtained by folding back the layers. As a result, the backing material layers (10th layer 210) are welded to each other by abutting against the backing material layer (10th layer 210) outside the first region S1.

<< Preheating process >>
As shown in FIG. 2A, in the preheating step, a region adjacent to the first region S1 of the entire backing material layer (10th layer 210) is previously formed before the welding step described above. It is set as the second region S2, and preheating is applied to the set second region S2.

By applying the preheating as described above, in the welding step described above, the backing material layer (10th layer 210) in the first region S1 is welded, that is, the backing material layer S2 in the second region S2 is formed. In the activated state, the bonding strength by welding between the backing material layers (10th layer 210) was increased, and sufficient bonding strength was obtained in the welded portion.

<< About heating and preheating >>
The temperature of the hot air M in the heating step is set to be 100 ° C. or higher and 180 ° C. or lower, and the surface temperature of the first region S1 heated by the hot air M is set to a temperature of 180 ° C. or higher and 230 ° C. or lower. I'm adjusting. The reason is that, in the automobile interior component M of FIG. 2, a nylon-based material is used as the ninth layer 209 adjacent to the backing material layer (tenth layer 210) as described above, and the nylon-based material is used. Generally, since it softens at around 190 ° C., it does not melt below 100 ° C., so that the backing material layers (10th layer 210) cannot be welded to each other. On the other hand, if the temperature exceeds 180 ° C., damage to the core material (fifth layer 205) (for example, when the core material (fifth layer 205) is composed of the above-mentioned semi-hard urethane material, it is worn out by carbonization due to heat. This is because it becomes too brittle, the cushioning property is lowered, etc.).

In the preheating applying step, as a specific example of applying the preheating to the second region S2, a method of bringing the heated iron plate into contact with the second region S2 or a method of blowing hot air toward the second region S2. Etc. can be applied.

Further, the surface temperature of the second region S2 heated by preheating is adjusted so as to be a temperature of 80 ° C. or higher and 100 ° C. or lower. The reason is that the effect of preheating is low below 80 ° C and sufficient bonding strength cannot be obtained by welding, while preheating above 100 ° C is excessive and affects the following (1) and (2). This is because it suffices if it is heated to a certain extent.

(1) When the first region S1 is bent and then pressed against the second region S2, the second region S2 (receiving side) should be hard, but when the temperature exceeds 100 ° C., the base material itself becomes soft. start.
(2) If the temperature exceeds 100 ° C., the film begins to crack and becomes breathable. (The first region S1 is breathable after heating, but the second region S2 is non-breathable, so that the folded-back overlapping portion can also be non-breathable. If there is breathability, dust in the room will be trapped inside the room. It sticks to the surface.)

According to the manufacturing method of the embodiment described above, as described above, the region adjacent to the first region S1 (heating region) of the entire backing material layer 210 is set as the second region S2 before the welding step. Then, preheating was applied to the set second region S2. Therefore, in the welding step, the backing material layer 210 in the first region S1 is welded, that is, the backing material layer 210 in the second region S2 is activated by preheating, and the backing material layers 210 are in a state of being activated by preheating. Since the bonding strength due to welding is increased, it is possible to effectively prevent peeling of the welded portion, and it has become possible to use a material that could not be conventionally used due to insufficient bonding strength, such as a nylon-based material. In other words, it was possible to broaden the selection range of materials that can be used as constituent materials for interior parts for automobiles. Further, preheating below the heating temperature causes less damage to the core material 205, which is suitable for preventing defects such as molding defects.

The present invention is not limited to the embodiments described above, and more modifications can be made by a person having ordinary knowledge in the field within the technical idea of the present invention.

For example, the present invention can be applied to interior parts for automobiles other than the ceiling inside the car.

1 Laminated material 2 Resin base material 201 First layer 202 Second layer 203 Third layer 204 Fourth layer 205 Fifth layer (core material)
206 6th layer 207 7th layer 208 8th layer 209 9th layer 210 10th layer (lining material layer)
3 Skin material 301 Skin surface layer 302 Skin intermediate layer 303 Skin back layer D Heat shield GM Entrained sesame H1, H2 Hot air M Automotive interior parts S1 First area S2 Second area

Claims

A method for manufacturing an interior part for an automobile, which is made of a laminated material having a skin material on the front side of the core material and a backing material layer on the back side of the concentric material.
A heating step in which a region from a position slightly inside the outer edge of the backing material layer to the outer edge of the backing material layer is set as a first region and the set first region is heated.
After the heating step, the outer edge of the laminated material is folded back inward so that the skin material is in a bent state by involving the core material and the backing material layer, and the folding back causes the first. The backing material layer in the region 1 includes a welding step of welding the backing material layers to each other by abutting the backing material layer outside the first region as an adhesive layer.
Prior to the welding step, a preheating applying step of setting a region adjacent to the first region of the entire backing material layer as a second region and applying preheating to the set second region is performed. A method of manufacturing interior parts for automobiles, which is characterized by being provided.
The method for manufacturing an interior part for an automobile according to claim 1, wherein the layer adjacent to the backing material layer is made of a nylon-based material.
The method for manufacturing an interior component for an automobile according to claim 1, wherein the first region and the second region are separated by the position of a heat shield plate.
The method for manufacturing an interior component for an automobile according to claim 1, wherein the heating temperature in the first region is higher than the preheating temperature in the second region.