JPH0348911Y2 - - Google Patents

Description

[Detailed Description of the Invention] <Industrial Field of Application> The present invention relates to a molded trim for an automobile, which is formed by laminating a skin material, a cushioning material, and a molded base material.

<Prior Art> Many trims used in automobiles, such as garnishes, door trims, and molded ceilings, have a three-layer structure consisting of a skin material, a cushioning material, and a molded base material. In such a three-layer structure, the cushioning material is provided in a sandwich-like manner between the skin material and the molded base material, and the thickness and molded shape of this cushioning material affect the appearance of the skin material and the luxury appearance of the finished trim. It has become a major influence on the situation. In addition, as the cushioning material, for example, urethane foam or foamed olefin sheet is used, and along with a skin material made of nonwoven fabric or cloth provided on the surface, thermoplastic resin such as fiber board, paper board, or polyethylene sheet is used. It is laminated on a non-breathable molded base material consisting of.

<Problems to be solved by the invention> By the way, in the case of urethane foam used as this type of cushioning material, although a sufficient cushioning effect can be obtained, it does not have the ability to retain the molded shape, so the overall shape is sharp. This is difficult to obtain and inevitably causes a problem of lacking shape appeal.

In addition, in the case of polyolefin foam, it does not have air permeability like urethane foam, so if air gets in when bonding to a non-breathable molding base material, the air will be encapsulated inside the trim. Therefore, after molding, the trim surface has so-called "bulges" or "cracks" caused by the expansion of the air, etc.
This causes problems such as frequent quality defects.

The present invention was devised in view of these circumstances, and is intended to eliminate the above-mentioned problems by improving the material of the cushioning material in the trim consisting of three layers.

<Means for Solving the Problems> That is, the present invention provides a molded trim for an automobile consisting of a laminate of a skin material, a cushioning material, and a molded base material, in which the cushioning material is made of miscellaneous fibers obtained through resource recovery.
90% by weight is mixed with 10 to 30% by weight of thermoplastic fibers or thermoplastic powder whose melting point is lower than that of miscellaneous fibers, and needle processing is performed, and the shape is maintained by melting and solidifying the thermoplastic fibers or thermoplastic powder. It is characterized by being made of a fibrous layer that imparts properties.

<Function> The cushioning material made of the fiber layer not only provides a good cushioning effect, but also has better shape retention than conventional urethane foam, so it is also possible to create a sharp shape.

In addition, this cushioning material has the same breathability as urethane foam, so even if a skin material such as nonwoven fabric is laminated to the surface and then heated and laminated onto a non-breathable molded base material, the surface of the molded trim will remain intact. “Bulging” caused by the expansion of air, etc.
There will be no quality defects caused by "me" or "me".

<Example> Hereinafter, an example in which the molded trim for an automobile according to the present invention is applied to a molded ceiling will be described with reference to the drawings.

FIG. 1 is a front-back sectional view showing the entire molded ceiling, and FIG. 2 is an enlarged view of section A in FIG. 1. In the figure,
A molded ceiling 1 attached to a roof includes a breathable skin material 2 made of nonwoven fabric, cloth, etc., a cushioning material 3 made of a fiber layer, and a molded base material 4 made of a thermoplastic resin sheet such as polyethylene. It consists of layers.

The cushioning material 3 is made of miscellaneous fibers 5 obtained through resource recovery.
Thermoplastic fibers 6 having a melting point lower than that of miscellaneous fibers 5 are mixed into the fibers, and the fibers are intertwined with each other by needle processing to form a fiber layer.
In addition, the mixing ratio of miscellaneous fibers 5 and thermoplastic fibers 6 is 70~
90% by weight miscellaneous fiber 5 and thermoplastic fiber 6 10~
The ratio is adjusted to 30% by weight.

Here, the concept of the miscellaneous fibers 5 includes not only chemical fibers but also natural fibers as long as they can be obtained through resource recovery. For example, specific examples of chemical fibers include synthetic fibers such as polyester-based, polyamide-based, and polyacronitrile-based fibers, semi-synthetic fibers such as acetate-based fibers, and regenerated fibers such as cellulose-based fibers. Moreover, it goes without saying that these may not be used alone, but may be a mixture of a plurality of them.

Further, the thermoplastic fibers 6 function as a binder to strengthen the bonds between the fibers in the miscellaneous fibers 5, and for example, fibers such as polyvinyl chloride, polyethylene, and polypropylene are used. Further, the thermoplastic fiber 6 may be replaced with a thermoplastic powder. The thermoplastic fibers 6 are selected to have a melting point lower than the average melting point of the miscellaneous fibers 5 used, and have a size that allows them to be mixed between the miscellaneous fibers 5.

In addition, the reason why the mixing ratio of miscellaneous fibers 5 and thermoplastic fibers 6 is limited is that if the thermoplastic fibers 6 are less than 10% by weight relative to the miscellaneous fibers 5, the binder function becomes weak and shape retention is not obtained as a whole. It disappears. On the other hand, if the thermoplastic fiber 6 exceeds 30% by weight, not only will the fibers become more bonded to each other and the cushioning effect will be lost, but also the shrinkage will be large, impairing the air permeability, and the heat resistance will also be poor. Therefore, in terms of cushioning effect, air permeability, shape retention, etc., it is optimal to adjust the mixing ratio to 70 to 90% by weight of miscellaneous fibers 5 and 30 to 10% by weight of thermoplastic fibers 6. It becomes the property of

The miscellaneous fibers 5 mixed with the thermoplastic fibers 6 are intertwined with each other by needle processing, and compression molded to a desired thickness to form a fiber layer. In addition, this fiber layer is made of thermoplastic fiber 6
By heating and forming at a temperature higher than the melting point of the fiber, the thermoplastic fibers 6 mixed between the fibers are melted and solidified, and the fibers are properly bonded together, thereby imparting shape retention to the fiber layer. It is. The cushioning material 3 formed in this way has shape retention as well as air permeability, so when laminating the non-air permeable molded base material 4 after laminating the breathable skin material 2, in the molding process. Gas such as air that enters the interior is diffused into the interior of the cushioning material 3, or is prevented from exiting through the breathable skin material 2 laminated on the cushioning material 3. Furthermore, since the thermoplastic fibers 6 are mixed throughout the miscellaneous fibers 5, the skin material 2, the cushioning material 3, and the molding base material 5 are laminated and molded using the binder function of the thermoplastic fibers 6. It also becomes possible.

In this embodiment, a case has been described in which the present invention is applied to a molded ceiling, but it goes without saying that the present invention can be similarly applied to other molded trims.

<Effects of the invention> As explained above, the invention has the following effects.

(a) Compared to conventional urethane foam, the cushioning material made of the fibrous layer allows a sharp shape to be created freely, so the degree of freedom in design of the molded trim can be expanded.

(b) Since the cushioning material made of a fiber layer has breathability, it is possible to prevent the possibility that gas such as air will be trapped inside during the molding process, and this will prevent air etc. generated on the surface of the molded trim. It is possible to eliminate quality defects due to so-called "bulges" and "cracks" caused by expansion.

(c) Since miscellaneous fibers obtained through resource recovery are used,
Resources can be reused and costs can be reduced.

[Brief explanation of the drawing]

FIG. 1 is a front and back sectional view of a molded ceiling shown as an example of a molded trim for an automobile according to the present invention, and FIG. 2 is an enlarged view of section A in FIG. 1. 1... Molded ceiling, 2... Skin material, 3... Cushioning material, 4... Molded base material, 5... Miscellaneous fibers, 6... Thermoplastic fibers.

Claims (1)

[Scope of utility model registration request] In a molded trim for an automobile that has a three-layer structure of a skin material, a cushioning material, and a molded base material, the cushioning material is
Compared to 70-90% by weight of miscellaneous fibers obtained through resource recovery,
Fibers that have shape retention properties by mixing thermoplastic fibers or thermoplastic powders with a melting point lower than that of miscellaneous fibers (30 to 10% by weight), needle processing, and melting and solidifying the thermoplastic fibers or thermoplastic powders. A molded trim for automobiles characterized by being made of a layered body.