JP3042982B2 - Composite sheet materials for thermoforming and interior parts for automobiles - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermoforming composite sheet material suitable for an interior material for automobiles requiring a shock absorbing function, and an automobile interior part formed by using this sheet material.

[0002]

2. Description of the Related Art Normally, various interior parts are mounted in a vehicle cabin, and have a function of improving the interior aesthetics and protecting an occupant against external force applied to the vehicle.

FIGS. 10 and 11 are a front view and a sectional view, respectively, of an automobile door trim mounted on a side wall panel of a vehicle body. The automobile door trim 1 is formed into a desired curved surface shape, and has a shape-retaining property and a shape to a vehicle body panel. Core material 2 with mounting rigidity
And a skin material 3 that is integrally attached to the surface of the core material 2 and imparts decorativeness.

Next, various methods for manufacturing the door trim 1, such as a press molding method, an injection molding method, and a stamping molding method, have been implemented. A conventional example which is inexpensively implemented is shown in FIGS. As shown in FIG. 12, the hopper 4a of the extruder 4 is
Resin and wood flour are supplied, kneaded in the extruder 4, and T
The sheet material is extruded from the die 4b into a sheet shape, and the sheet thickness is adjusted by a roll 5 to form a sheet material S.

After the sheet material S is softened by heating with an infrared heater or the like, as shown in FIG. 13, the sheet material S is placed on a lower die 6 for cold press molding, and the skin material 3 is set thereon. Then, the upper die 7 for cold press molding is lowered, and the sheet material S is drawn and formed by the engagement of the upper and lower dies 6 and 7 for cold press molding to form the core material 2 and the surface of the core material 2. The skin material 3 is adhered integrally.

[0006]

As described above, in the low-cost type of the conventional car door trim 1, a so-called resin board in which an organic filler such as wood powder is mixed into a PP resin is used as the core material 2. However, the core member 2 has a small stress absorbing function at the time of collision, and is not satisfactory from the viewpoint of occupant protection, especially when a relatively large impact is applied to the vehicle from the side such as a side collision.

Further, when the core material 2 is broken by an impact,
Sharp edges tend to occur, which is not preferable from the viewpoint of protection of occupants.

The present invention has been made in view of such circumstances, and particularly, a composite sheet material for thermoforming suitable as an automobile interior material having excellent shock absorbing function and an automobile interior molded using the same. It aims to provide parts.

[0009]

In order to achieve the above-mentioned object, a composite sheet material for thermoforming according to the present invention comprises a resin board layer comprising a thermoplastic resin mixed with an organic filler such as wood flour; talc thermoplastic resin, an inorganic filler such as glass fiber, formed by laminating integrally into a sheet by a shock absorbing layer two-layer extruder having a high impact strength prepared by adding a predetermined amount of rubber component, rubber shock absorbing layer Ingredients are resin and inorganic
It has a binder action and an elastic action with the filler .

Here, the material of the resin board layer is P
It is composed of a thermoplastic resin such as P resin and PE resin, and an organic filler such as wood flour, waste paper and wood chips. The ratio of the thermoplastic resin to the organic filler is 40 to 60 parts by weight of the thermoplastic resin, The range of 60 to 40 parts by weight is good, and in particular, 55 parts by weight of wood powder is good for 45 parts by weight of the thermoplastic resin.

On the other hand, the composition of the shock absorbing layer is a thermoplastic resin such as a PP resin or a PE resin to which a predetermined amount of an inorganic filler and a rubber component are added. Examples of the inorganic filler include talc, glass fiber, charcoal and the like. Examples of the rubber component include synthetic rubber such as butadiene rubber and isoprene rubber, and natural rubber.

The resin, the inorganic filler, and the rubber component in the shock absorbing layer are preferably compounded by, for example, 70 parts by weight of PP resin, 25 parts by weight of talc, and 5 parts by weight of butadiene rubber.

As for the lamination and integration of the resin board layer and the shock absorbing layer, the two layers are simultaneously extruded by a T-die of a two-layer extruder and integrated by a pressure roll to obtain the thermoforming according to the present invention. Composite sheet material is obtained.

Next, the thermoformed composite sheet material according to the present invention is particularly suitable for door trims, rear corner trims, etc., which are installed in side panels of a vehicle body, because of its excellent shock absorbing function.

For example, after the composite sheet material for thermoforming is preheated and softened, the door trim and the rear corner trim may be formed by cold press molding integrally with the skin material. After preheating and softening the composite sheet material for thermoforming, cold press molding to the desired shape, and then transferring the drawing pattern etc. engraved on the cavity mold surface, or mixing a pigment for appropriately coloring in the shock absorbing layer It can also be used as interior parts with a skinless structure.

As is apparent from the above constitution, the composite sheet material for thermoforming according to the present invention comprises a resin board layer obtained by mixing a thermoplastic resin and an organic filler, an inorganic filler and a rubber in the thermoplastic resin. Since the impact absorbing layer to which the components are added in a predetermined amount is laminated and integrated into a sheet by a two-layer extruder, when the sheet material is thermoformed and used as a core material for interior parts, the impact absorbing layer Can effectively absorb the stress at the time of impact, and the shock absorbing layer does not become a sharp edge even if broken due to the rubber component contained in the impact absorbing layer.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of a composite sheet material for thermoforming according to the present invention and interior parts for automobiles formed using the same will be described in detail with reference to the accompanying drawings.

FIG. 1 is an external view of a composite sheet material for thermoforming according to the present invention, FIG. 2 is an explanatory view showing a process for forming the composite sheet material, and FIGS. 3 and 4 use the composite sheet material for thermoforming. 5 and FIG. 7 are sectional views showing a manufacturing process of the door trim, and FIG. 8 shows a second embodiment applied to an automobile door trim. FIG. 9 is a sectional view showing a molding process of the vehicle door trim.

First, referring to FIGS. 1 and 2, the composite sheet material for thermoforming according to the present invention will be described.

In FIG. 1, a composite sheet material 1 for thermoforming is shown.
Numeral 0 is composed of a two-layer structure laminate of a resin board layer 11 and a shock absorbing layer 12.

More specifically, the resin board layer 11 has a structure in which an organic filler is mixed in a thermoplastic resin. As the thermoplastic resin, PP resin, PE resin, or the like is preferable from the viewpoint of cost, moldability, and the like. Wood powder, waste paper, wood chips, organic fibers, and the like can be used as the organic filler, and the mixing ratio of the thermoplastic resin and the organic filler is from 40 to 60 thermoplastic resins.
The range of the weight of the organic filler is preferably 60 to 40 parts by weight, and more preferably 45 parts by weight of the thermoplastic resin and 55 parts by weight of the organic filler.

On the other hand, the shock absorbing layer 12 is
An inorganic filler and a rubber component are added to the interior of the same type of PP resin and PE resin as the thermoplastic resin used in 1.

As the inorganic filler, talc, charcoal,
Materials that increase the rigidity, such as mica and glass fiber, are suitable. As the rubber component, natural rubber and the like can be used in addition to synthetic rubber such as butadiene rubber and isoprene rubber. It has a function of giving a binder effect and an elastic effect to the shock absorbing layer 12.

The mixing ratio of the thermoplastic resin, the inorganic filler and the rubber component in the shock absorbing layer 12 is such that the inorganic filler such as talc is 25 parts by weight and the rubber component such as butadiene rubber is 5 parts by weight with respect to 70 parts by weight of the thermoplastic resin. And the like.

Next, the step of forming the composite sheet material 10 for thermoforming will be described with reference to FIG.
The thermoplastic resin and the organic filler which are the materials of the resin board layer 11 are supplied to the first hopper 21 of No. 0 and kneaded in the two-layer extruder 20.

Further, a thermoplastic resin, an inorganic filler, and a rubber component, which are materials of the shock absorbing layer 12, are supplied into the second hopper 22 and kneaded similarly in the two-layer extruder 20, and the T-die 23 is formed. From resin board layer 11 and shock absorbing layer 12
Are simultaneously extruded into a sheet shape, and the composite sheet material 10 for thermoforming shown in FIG.

FIGS. 3 and 4 are a front view and a sectional view, respectively, of an automobile door trim formed using the composite sheet material 10 for thermoforming.
Is composed of a core material 31 having shape retention and rigidity for attachment to a vehicle body panel, and a skin material 32 attached to the surface of the core material 31 to provide decorativeness and softness.

In the door trim 30 for an automobile, the core material 31 is a composite sheet material 1 for thermoforming.
0 is used, and the core material 31 is the resin board layer 1 on the inner surface.
1 and a two-layer structure of the shock absorbing layer 12 in contact with the skin material 32.

Accordingly, since the door trim 30 for an automobile is composed of the resin board layer 11 which is inexpensive and excellent in mass productivity as the core material structure and the shock absorbing layer 12 which has a high impact strength, the side impact and the like are provided. When a relatively large shock is applied from the side of the vehicle, the shock absorbing layer 12 effectively absorbs the shock load, does not break easily, and even if it breaks, it is contained in the shock absorbing layer 12. Sharp edges are not formed due to the rubber component, which is extremely effective in protecting occupants' safety.

As an embodiment of the door trim 30,
The resin board layer 11 is made of a mixture of PP resin and wood flour, and 55 parts by weight of wood flour is added to 45 parts by weight of PP resin. 25 parts by weight of talc as an inorganic filler and 5 parts by weight of butadiene rubber as a rubber component are respectively added. The thickness of the resin board layer 11 is set to 1.5 mm, and the thickness of the shock absorbing layer 12 is set to 1.0 mm. Uses a PVC sheet.

Next, the molding process of the door trim 30 for an automobile will be described with reference to FIGS.

First, the composite sheet material 10 is preheated and softened to a predetermined temperature by the heater device 40, and then placed on the surface of the lower die 50 for cold press molding as shown in FIG.

Then, the skin material 32 is set between the die and the upper die 51 for cold press molding located above the die while holding the peripheral edge by the clamp device 52.

Thereafter, as shown in FIG. 7, the upper die 51 for cold press molding is moved down by a predetermined stroke, and the upper and lower dies 50, 51 for cold press molding are engaged and pressed to form the composite sheet material 10 into a required shape. The core material 31 is formed into a required shape, and the skin material 32 is integrally attached to the surface of the core material 31 to complete the forming of the door trim 30 shown in FIGS.

FIG. 8 shows another embodiment in which the composite sheet material for thermoforming 10 according to the present invention is applied to an automobile door trim. This automobile door trim 60 has a core material in which the skin material 32 is eliminated. 31 is a single unit configuration.

That is, the door trim 60 for an automobile is a single body of the core material 31 (two-layer structure of the resin board layer 11 and the shock absorbing layer 12), and has a high shock absorbing function by the shock absorbing layer 12 and a sharp edge. It is not formed and is also advantageous in terms of occupant protection. In particular, by eliminating the skin material 32, it is possible to achieve a lightweight and inexpensive configuration, and to maintain decorativeness, as shown in FIG. To
If the drawing pattern 53 is engraved on the mold surface of the upper mold 51 for cold press molding, or a pigment of appropriate color is appropriately mixed at the time of extrusion molding of the shock absorbing layer 12, good design properties can be maintained.

The embodiment in which the thermoforming composite sheet material 10 according to the present invention is applied to the door trims 30, 60 has been described above. The rear corner trim installed on the side of the rear occupant of a two-door hardtop vehicle or the like is described. In addition to being able to be used as an effective side collision type even when applied to etc., it can also be used effectively as a trim panel to be installed in a rear parcel shelf, luggage room or trunk room, the applicable range of the composite sheet material according to the present invention is Extremely wide.

[0038]

As described above, the present invention has the following special functions and effects.

(1) Since the composite sheet material for thermoforming according to the present invention is constituted by laminating and integrating a resin board layer and an impact absorbing layer into a sheet by a two-layer extruder, the same method as the conventional method is used. In addition to being easily molded, the presence of the shock absorbing layer can effectively absorb external shock loads, and the rubber component in the shock absorbing layer suppresses the formation of sharp edges, thereby protecting occupants. Can be reliably achieved.

(2) According to the second aspect of the present invention, since a two-layer structure of the resin board layer and the shock absorbing layer is employed as the core material of the interior part, it is relatively easy to be installed from the side of the vehicle such as a side collision. When a large impact is applied, the impact can be effectively absorbed by the impact absorbing layer, which is effective for safety measures in the event of a side collision.

(3) According to the third aspect of the present invention, the composite sheet material including the resin board layer and the shock absorbing layer is formed into a required shape, and the surface of the shock absorbing layer is decorated. Therefore, it has an effect of having an excellent shock absorbing function while having a lightweight and inexpensive configuration.

[Brief description of the drawings]

FIG. 1 is an external view showing a composite sheet material for thermoforming according to the present invention.

FIG. 2 is an explanatory view showing a step of forming a composite sheet material for thermoforming according to the present invention.

FIG. 3 is a front view showing an automobile door trim formed using the sheet material according to the present invention.

FIG. 4 is a sectional view taken along line IV-IV in FIG. 3;

FIG. 5 is a cross-sectional view showing a preheating step of the composite sheet material in the door trim manufacturing method.

FIG. 6 is a cross-sectional view showing a step of setting a composite sheet material and a skin material in the door trim manufacturing method.

FIG. 7 is a sectional view showing a cold press forming step in the door trim manufacturing method.

FIG. 8 is a sectional view showing another embodiment of an automobile door trim formed using the composite sheet material according to the present invention.

FIG. 9 is a cross-sectional view showing a material setting process in the manufacturing process of the door trim shown in FIG. 8;

FIG. 10 is a front view showing a conventional automobile door trim.

11 is a sectional view taken along line XI-XI in FIG.

FIG. 12 is an explanatory view showing a step of forming a conventional resin board.

FIG. 13 is an explanatory view showing a conventional cold press forming process of a resin board and a skin material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Composite sheet material for thermoforming 11 Resin board layer 12 Shock absorbing layer 20 Two-layer extruder 30, 60 Door trim for automobile 31 Core material 32 Skin material 50 Lower die for cold press molding 51 Upper die for cold press molding

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B29C 43/00-43/58 B60R 13/02

Claims (3)

(57) [Claims] 1. A resin board layer (11) in which an organic filler such as wood powder is mixed in a thermoplastic resin, and a high impact obtained by adding a predetermined amount of an inorganic filler such as talc or glass fiber and a rubber component to the thermoplastic resin. shock absorbing layer having an intensity (12) and a two-layer extruder (20) by formed by laminating integrally into a sheet, the rubber component in the impact absorption layer (12), the resin and no
A composite sheet material for thermoforming characterized by having a binder action and an elastic action with a filler . 2. The composite sheet material for thermoforming (10) according to claim 1, which is formed by press-forming integrally with a skin material (32) after preheating and softening, and is mounted on a side wall of a vehicle body ,
In the event of a side collision, the impact absorbing layer (12) absorbs the impact load.
Both are interior parts for automobiles characterized by suppressing sharp edges . 3. The thermoforming composite sheet material (10) is preheat-softened and then press-molded into a required shape, and a squeezed pattern is transferred to the surface of the shock absorbing layer (12) located on the surface side. colored or, alternatively shock absorbing layer (12) is, is furnished to the vehicle body side wall, the side collision impact absorbing layer
(12) absorbs shock load and sharp
Automotive interior parts characterized by minimizing damage.