JPH0811407B2 - Manufacturing method of interior materials - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing interior materials such as automobile door trims, ceiling materials and rear parcels.

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 6, an interior material (1) has been provided in which a surface material (3) is attached to a surface of a base material (2),
The covering material (3) comprises a skin layer (4) and a foam layer (5).

To produce such an interior material (1), a thermoplastic synthetic resin powder is adhered to a heated mold surface of a predetermined shape, and the powder is melted or gelled to form a skin layer (4). Foam layer (5) by forming a foamable thermoplastic synthetic resin powder on the skin layer (4) and heat-foaming and fusing.
The covering material (3) is manufactured by forming. This is called a slush molding method, and a method of laminating the thus-prepared covering material (3) with the base material (2) is provided.

In order to stack the covering material (3) on the base material (2), the base material (2) formed into a predetermined shape and the covering material (3) are polymerized and then pressure-bonded with a pressure-bonding die, or If the material (2) is a rigid polyurethane foam, there is provided a method of inserting the facing material (3) into the foam molding die when foaming the base material (2).

[0005]

In the above-mentioned conventional method, when the foam layer (5) of the covering material (3) is formed, the surface of the foam layer (5) is not regulated, so that it is not possible to make the thickness uniform. Difficult, if the substrate (2) is composed of a brittle material such as rigid polyurethane foam
(2) The thickness must be increased to secure strength,
For that reason, the manufacturing equipment for molds etc. becomes large-scale,
Further, the weight of the base material (2) also becomes large.

[0006]

[Means for Solving the Problems] As a means for solving the above-mentioned problems, the present invention adheres a thermoplastic synthetic resin powder or a thermoplastic synthetic resin plastisol to a heated mold surface to melt or gel. Step 1 of forming a skin layer (14) by squeezing a foamable thermoplastic synthetic resin powder onto the surface of the skin layer (14) and heat-foaming and fusion to form a foam layer (15). Step 2 of producing a covering material (13) composed of 14) and a foam layer (15) Step 3 of laminating the covering material (13) with a base material (12) via a synthetic resin-impregnated porous sheet (16) The present invention provides a method for manufacturing an interior material (11) including steps 1, 2, and 3 described above.

[0007]

In the present invention, the covering material (1 comprising the skin layer (14) and the foam layer (15) manufactured by the slush molding method is used.
3) is laminated with the base material (12) via the synthetic resin-impregnated porous sheet (16). Since the porous sheet (16) has a cushioning property, it absorbs the nonuniformity of the thickness of the foam layer (15) of the facing material (13). Further, the porous sheet (16) reinforces the base material (12).

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to an embodiment shown in FIGS. 1 to 3. In step 1, as shown in FIG.
1) is heated to 230 ℃ and placed on the powder supply box (22),
The plasticized polyvinyl chloride (PVC) powder (14A) filled in the powder supply box (22) is scattered by a fan into the powder supply box (22) as shown by an arrow to obtain the PVC powder (14A). ) Is attached to the surface of the mold (21). The PVC powder (14A) is melted and gelled to form a skin layer (14).

In step 2, as shown in FIG. 2, the skin layer (1
The mold (21) having 4) formed on the surface is installed on another powder supply box (23) in a heated state and the foamable PVC filled in the powder supply box (23). Powder of thermoplastic synthetic resin such as polyethylene and polypropylene (15A) is scattered by a fan into the powder supply box (23) as shown by the arrow, and the powder (1
5A) is adhered to the surface of the skin layer (14) and heat-foamed to form a foam layer (15).

In this way, the covering material (13) comprising the skin layer (14) and the foam layer (15) is molded by the slush molding method. In step 3, the covering material (13) is shown in FIG. As shown, after lining the synthetic resin-impregnated porous sheet (16), it is inserted into the foam molding die (24), and the urethane molding material (12A) is injected into the foam molding die (24) to make hard polyurethane. A base material (12) made of foam is formed.

The synthetic resin-impregnated porous sheet (16) is
A porous sheet impregnated with a synthetic resin such as polyester, polyurethane, melamine resin, urea resin, phenol resin, and acrylic resin, or a precursor of the above synthetic resin, such as a prepolymer, a monomer, or an oligomer. A plastic foam sheet such as a polyurethane foam sheet or a PVC foam sheet, a non-woven fabric of a fiber such as a glass fiber, a carbon fiber, a polyester fiber, a cotton fiber or a knitted fabric is used. The synthetic resin-impregnated fiber sheet is the most preferable in terms of the reinforcing effect of the base material (12).

In this way, an interior material (11) (door trim) in which the base material (12) is laminated on the surface mounting material (13) is manufactured. However, except for this embodiment, the surface mounting material (13) and the base material are To stack with (12), use the crimping mold (25) as shown in FIG.
Alternatively, the base material (12) formed into a predetermined shape may be pressure bonded.
In this case, as the base material (12), resin felt, cardboard, polystyrene foam, fiber board and the like are used other than the rigid polyurethane foam.

[0013]

Therefore, in the present invention, even when the surface covering material is manufactured by the slush molding method, the interior material having a smooth surface can be formed and the strength can be improved without thickening the base material.

[0014]

[Brief description of drawings]

 1 to 3 relate to an embodiment of the present invention.

FIG. 1 is an explanatory diagram of step 1

FIG. 2 is an explanatory diagram of step 2

FIG. 3 is an explanatory diagram of step 3

FIG. 4 is an explanatory view of another embodiment of step 3.

[Fig. 5] Back perspective view of the door trim

FIG. 6 is a sectional view taken along the line AA in FIG. 5 of the related art.

[Explanation of symbols]

 11 Interior material 12 Base material 13 Surface material 14 Skin layer 15 Foam layer 16 Synthetic resin impregnated porous sheet

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Claims (1)

[Claims] 1. A step of forming a skin layer by adhering a thermoplastic synthetic resin powder or a thermoplastic synthetic resin plastisol onto a heated mold surface to cause melting or gelation thereof. 1. A foamable thermoplastic synthetic material on the skin layer surface. Step 2 of manufacturing a covering material comprising a skin layer and a foaming layer by forming a foaming layer by adhering resin powder and heat-foaming and fusion to form a foaming layer 2 Laminating the covering material with a base material through a synthetic resin-impregnated porous sheet Step 3 of manufacturing interior material manufacturing method characterized by comprising the above steps 1, 2, 3