JPH09170179A - Interior material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent bending of an interior material such as a ceiling material of an automobile, etc., and to bend the interior material in a fixed direction. SOLUTION: A bending adjusting sheet 15 is bonded to one side or both sides of a base 13 of an interior material 12. The base 13 is prevented from bending or is bent in a fixed direction by rigidity or heat shrinkage of the bending adjusting sheet 15.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior material such as an automobile ceiling material.

[0002]

2. Description of the Related Art For example, as shown in FIG. 9, a ceiling material (2) of an automobile (1) is attached to a base material (3) and a hot melt sheet (5) on the surface of the base material (3). The ceiling material (2) is formed by molding the base material (3).
A method in which a hot melt sheet (5) lined with (4) is heat-softened and pressure-bonded to the base material (3), or a skin material
A method in which the hot-melt sheet (5) lined with (4) is placed in a heat-softened state on an unformed base material (3), and the skin material (4) is pressure-bonded to the base material (3) at the same time as molding. Is manufactured by.

[0003]

During the manufacturing process of the ceiling material (2), the base material (3) as well as the skin material (4) is heated. The ceiling material (2) is allowed to cool after manufacturing, but the base material
Due to the difference in heat shrinkage stress between (3) and the skin material (4), for example, when the heat shrinkage stress of the skin material (4) is larger than that of the base material (3), the ceiling material (2) is allowed to cool during cooling. Is pulled in the direction of the arrow by the skin material (4), and as shown by the dotted line, it warps with respect to the curved shape. When the ceiling material (2) warps as described above, there is a problem in that a gap S is created between the vehicle body (1) and the ceiling material (2) and the appearance of the vehicle ceiling is impaired. Even interior materials other than ceiling materials, such as door trim,
If warpage occurs due to the difference in heat shrinkage stress between the base material and the skin material after molding, the door trim will not fit in the door panel, and a gap will be created between the door panel and the door trim, or the door trim will fit in the door panel. Cannot be done.

[0004]

[Means for Solving the Problems] As a means for solving the above-mentioned conventional problems, the present invention is to attach a warpage adjusting sheet to one side or both sides of the substrate in order to adjust the warpage of the substrate. is there. The substrate is prevented from being warped or given a warp in a desired direction by the warpage adjusting sheet.

In the present invention, the base material for the interior material is, for example, a resin felt in which fibers are bound with a synthetic resin,
Cardboard, polystyrene foam, polypropylene foam, semi-rigid polyurethane foam, synthetic resin impregnated soft polyurethane foam and the like are used.

A skin material is attached to the surface of the base material,
As the surface material, for example, knitted fabric, non-woven fabric, synthetic leather, laminated material of synthetic leather and non-woven fabric, laminated material of non-woven fabric and plastic foam, laminated material of synthetic leather and plastic foam, etc. are used. The non-woven fabric and the non-woven fabric are made of synthetic fibers such as polyester fibers, polyethylene fibers, polypropylene fibers, polyamide fibers, acrylic fibers, urethane fibers, polyvinyl chloride fibers, polyvinylidene chloride fibers, and acetate fibers. Leather, polyurethane leather, polyamide leather, etc., and the plastic foam is, for example, polyethylene foam, polypropylene foam, polystyrene foam, polyurethane foam, or the like.

The warpage adjusting sheet is for preventing the substrate from warping or giving a warp in a predetermined direction, and the warpage adjusting sheet is, for example, a polyethylene sheet, a polypropylene sheet, an ethylene-propylene copolymer sheet, Ethylene-vinyl acetate copolymer sheet, polyvinyl chloride sheet, polystyrene sheet, polyester sheet, polyamide sheet, urethane resin sheet, acrylonitrile-butadiene copolymer sheet, styrene-butadiene copolymer sheet, acrylonitrile-butadiene-styrene copolymer sheet Plastic sheets such as united sheets, knitted fabrics or nonwoven fabrics similar to those used for skin materials,
When using a glass fiber sheet or the like as a material, in the case of preventing the warpage of the substrate, a warpage adjusting sheet having a heat shrinkage stress that balances the warpage stress is attached to the surface of the substrate opposite to the warpage direction, or the glass is used. A high-rigidity sheet that resists warp stress, such as a fibrous sheet, a thermosetting resin-impregnated knitted fabric, or a non-woven fabric, is used as the warp adjusting sheet. Further, in order to warp the interior material in a predetermined direction, a warpage adjusting sheet having a heat shrinkage stress larger than that of the base material is attached to the surface of the base material on the side where the warp is applied.

As described above, according to the present invention, the warp of the interior material is prevented or the warp of a predetermined direction is given depending on the balance between the heat shrinkage stress of the base material or the skin material of the interior material and the warp adjusting sheet. In order to balance the heat shrinkage stress of the above with the heat shrinkage stress of the base material or the skin material, the heat shrinkage rate, thickness, density and the like of the warpage adjusting sheet are taken into consideration.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION

[Example 1] Fig. 1 shows a ceiling material (12) which is an interior material of an automobile.
Is shown. As shown in FIG. 2, the ceiling material (12) has a base material (13) formed in a ceiling shape, and a skin material (14) stacked on the base material (13) to form an upper mold (18) and a lower mold.
The skin material (14) is used as a base material by a crimping mold (17) consisting of (19)
The base material (13) is produced by pressure bonding to (13).
A warpage adjusting sheet (15) having a heat shrinkage stress larger than that of the skin material (14) is attached to the backside of the skin material (14), and the skin material (14) includes a hot melt sheet (16) such as a polyethylene sheet or a polyamide sheet. ), The hot melt sheet (16) of the skin material (14) is heated by the softening state to form the base material (1).
3) is attached. In the above interior material (12), due to the heat shrinkage stress of the skin material (14), it tends to inward as shown by the dotted line in FIG. 9 during cooling, but the heat shrinkage stress of the skin material (14) If the heat shrinkage stress of the warp adjusting sheet (15) is set to be larger than that of the warp adjusting sheet (15), the interior material (12) is stretched by the contraction of the warp adjusting sheet (15) during cooling as shown by the dotted line in FIG. Bend out. The warpage adjusting sheet (15) is, for example, a polyester sheet, and the thickness of the sheet is adjusted in order to set the heat shrinkage stress of the sheet to be larger than that of the skin material (14). When the warpage adjusting sheet (15) is a high-rigidity sheet such as a glass fiber sheet, the high-rigidity sheet does not heat-shrink and resists the heat-shrinking stress of the skin material (14). The warp of 12) is prevented.

Example 2 In this example, a thermoplastic foam such as polyethylene foam, polypropylene foam, polystyrene foam and polyvinyl chloride foam is used as the substrate (23). The thermoplastic foam is heat-softened and overlapped with a skin material (24) as shown in FIG. 4, and is molded by a molding die (27) consisting of an upper die (28) and a lower die (29) to form an interior material. (22) but polyethylene sheet, polypropylene sheet, ethylene-propylene copolymer sheet in order to prevent drawdown during heat softening,
Ethylene-vinyl acetate copolymer sheet, polyvinyl chloride sheet, polystyrene sheet, polyester sheet, polyamide sheet, urethane resin sheet, acrylonitrile-butadiene copolymer sheet, styrene-butadiene copolymer sheet, acrylonitrile-butadiene-styrene copolymer sheet Use a plastic sheet (25) such as a united sheet as a backup material. When the plastic sheet (25) is used as a warpage adjusting sheet and its heat shrinkage stress is set to be larger than that of the skin material (24), the interior material (2
2) During cooling, the interior material (22) warps as shown by the dotted line in FIG. As shown in FIG. 6, the plastic sheet (2
If you attach 5) to the front side of the substrate (23), the interior material (22
A) During cooling, the interior material (22A) is prevented from inwardly warping as shown by the dotted line so that the molded shape is not sagged. Conventionally, a non-woven fabric having no heat shrinkability has been used as a backup material, but in that case, the interior material may warp or bulge due to the difference in heat shrinkage stress between the skin material and the base material.

[Embodiment 3] As shown in FIG. 7, the interior material (32) using the semi-rigid polyurethane foam as the base material (33) has the raw material (33A) from the nozzle (37) on the plastic sheet (35A). It is poured out, and the plastic sheet (35B) is further pressed by the roll (38) to form a sheet, and the raw material (33
A) is heated by a heating device (39) to foam and harden it to form a base material (33). In this way the plastic sheet (35
The base material (33) sandwiched between (A, 35B) is molded in a heat-softened state in the same manner as in Example 2 and the skin material (34) is pressure-bonded to the interior material.
(32). In the interior material (32), the plastic sheet (35B) is used as a warpage adjusting sheet, and the heat shrinkage stress of the plastic sheet (35B) is set to be larger than that of the plastic sheet (35A) and the skin material (34). For example, during cooling, the interior material (32) warps as shown by the dotted line in FIG.

[0012]

Therefore, according to the present invention, the warp of the interior material can be prevented or warped in a desired direction.

[Brief description of the drawings]

1 to 3 show an embodiment of a first embodiment of the present invention.

FIG. 1 Perspective view of ceiling material (interior material)

[Fig. 2] Illustration of skin material crimping process

FIG. 3 is a sectional view taken along line AA in FIG. 1 and FIGS. 4 to 6 show an embodiment of a second embodiment of the present invention.

FIG. 4 is an explanatory view of a molding process.

[Fig. 5] Illustration of warpage of interior material

FIG. 6 is an explanatory diagram of a warp state of interior material. FIGS. 7 and 8 show an embodiment of a third embodiment of the present invention.

FIG. 7 is an explanatory diagram of a base material manufacturing process

FIG. 8 is an explanatory view of the warpage state of the interior material.

FIG. 9 is an explanatory view of a conventional warp state of interior materials.

[Explanation of symbols]

 12,22,32 Ceiling material (interior material) 13,23,33 Base material 14,24,34 Skin material 15,25,35B Warpage adjusting sheet

Claims (4)

[Claims] 1. An interior material comprising a base material and a warpage adjusting sheet attached to one or both surfaces of the base material. 2. The substrate according to claim 1, comprising a base material, a sheet adhered to one surface of the base material, and a warpage adjusting sheet adhered to the other surface of the base material. Interior materials 3. The interior material according to claim 2, wherein the sheet is a skin material. 4. The interior material according to claim 1, 2 or 3, wherein the warpage adjusting sheet imparts outward warpage to the interior material.