JPS60257242A - Pad material for automobile - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of the Invention) The present invention relates to a padding material for an automobile, and particularly to a padding material for an automobile applied to thickened portions of automobile interior parts such as door trims and rear corners.

(Prior art and its problems) In order to provide a cushioning effect to the door waist portion of automobile interior parts, such as door trims, against which the shoulders of passengers collide, the door waist portion is usually formed thick.

Among the methods of manufacturing interior parts having thickened parts such as door trims, the most common conventional technology is
There are foam molding methods such as urethane resin.

This molding method involves first coating a silicone resin mold with urethane resin for forming a skin, drying it to form a skin, and then setting the silicone resin mold -F in a foam mold.
Thereafter, the urethane foaming mixture is injected into the urethane skin surface, the core material is set, and the foaming mold is closed. After the urethane foaming reaction is completed, the product in which the core material, foam material, and skin material are integrally molded is taken out from the mold.

However, this foam molding method is not economical because it requires high material costs and man-hours. Moreover, holes commonly called voids are formed in this urethane foam, which often results in poor appearance, so we want to prevent the occurrence of these voids! However, it is necessary to carefully control the molding conditions and the fine blending composition of the urethane, which has the drawback of being extremely difficult to manage.

Therefore, recently, attention has been paid to a method of attaching a skin material to a core material by vacuum forming to create interior parts.

In this method, a molded urethane pad material is adhered to a part of a core material such as a board that has been previously formed into a drum shape, and a non-breathable skin material such as a PvC sheet is attached to one side of the core material. It is attached by vacuum forming.

However, since the molded urethane pad material has poor rigidity, it has the disadvantage of poor workability when bonded onto the core material, and the urethane pad material undergoes large heat shrinkage after molding, resulting in shrinkage distortion. There is also the problem that the pad material swells due to the adhesive, resulting in wrinkles and walnuts in the skin material, resulting in poor appearance.

Moreover, since the pad material lacks rigidity during vacuum forming, the unevenness formed on the surface of the core material passes through the pad material and directly appears on the skin material, resulting in an unsightly appearance.

(Object of the invention) This invention was made in view of the circumstances mentioned above, and its object is to provide a pad material for automobiles that is inexpensive and has improved workability. ,
The pad material of the present application is applied to the thickened parts of interior parts such as doors [-rims, etc., and interior parts that are preferable in terms of appearance are 1.
il! (l 7)

(Structure and Effects of the Invention) In order to achieve this object, an automobile characterized in that Semi-Koafel impregnated with an unreacted thermosetting resin and urethane for low-temperature molding are integrally molded by hot pressing. This is a method that uses molded urethane pad material, especially in thickened areas such as the door waist part of door trims.The manufacturing cost is much lower than the conventional urethane foam molding method, and the molded urethane pad material is used. Even compared to the conventional example, the use of inexpensive semi-cured felt reduces loss, and the stiffness of the cured felt significantly improves workability. In contrast, this rigid felt acts as a wall and does not affect the skin material, and the presence of hardened felt prevents wrinkles and walnuts on the skin material against heat shrinkage of urethane and corrosion of adhesives. This has various effects such as being able to manufacture interior parts with good aesthetics and without causing any problems.

(Description of Embodiments) Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

1 and 2 show a pad material for an automobile according to the present invention. FIG. 1 is a cross-sectional view during hot press molding, and
The figure is a cross-sectional view before hot-press molding.

In the drawings, a pad material 1 is manufactured by integrally molding semi-cured felt 2 impregnated with unreacted phenolic resin and urethane 3 for low temperature molding using hot press molds 4 and 5. J3, 4a and 5a in the figure are heaters installed in the molds 4 and 5.

Furthermore, the molding conditions were molding temperature; 150'C to 170°C;
Molding time: 1 minute, whereby the urethane 3 for low-temperature molding is molded into the desired shape, and the unreacted thermosetting resin impregnated in the semi-cured felt 2 is cured. Then, the urethane 3 formed into the desired shape is thermally welded to the hardened felt 2, and the felt 2
The fibers between 1 and 3 enter between 1 and 3, and the two are firmly joined due to their anchoring effect.

Next, FIGS. 3 to 5 show examples in which the automotive pad material according to the present invention is applied to the door waist portion of a door rim.

FIG. 3 is a perspective view showing the entire door trim 6. FIG.

This door trim 61. &, the core material 7 and the pad material 1. and an outer skin 8.More specifically, the core material 7 is formed by extruding a composite material made of a mixture of polypropylene and wood flour into a sheet shape, heating and softening the sheet, and then shaping it into the desired shape. It is press-molded, and the skin material 8 is made of a non-porous PVC sheet 9 in order to provide appropriate cushioning properties to the lower surface of the non-breathable PVC sheet 9.
A PVC foam sheet 10 lined is used,
This skin material 8 is bonded to the upper surfaces of the core material 7 and pad material 1 via the adhesive layer 11 by vacuum forming.

Reference numeral 6 in the figure indicates the door waist portion, and the pad material 1 of the present invention is applied to this thickened portion. Incidentally, reference numeral 12 is an armrest that is attached after forming the door 1 and the rim 6.

FIG. 4 and FIG. 5 are explanatory diagrams showing the culm of the door trim 6.

Note that FIG. 4 shows the state before vacuum forming, and FIG. 5 shows the state during vacuum forming.

First, the core material 7 to which the pad material 1 is adhered is placed on the vacuum mold 13. This mold 13 has an opening 1 for vacuum forming.
3a are provided at appropriate locations and are connected to a vacuum pump 15 through a suction pipe 14.

Further, the core material 7 is also provided with a plurality of lower grooves a for vacuum forming in advance.

Now, an adhesive layer 11 is formed on the upper surface of the core material 7 and the pad material 1 by coating, and then the skin material 8 softened by preheating is applied to the core material 7. Pad material 1
Place it across the top surface of the

Then, the outer periphery of the product is sealed by the clamping device 16, and the vacuum pump 15 is activated to suck the air present between the core material 7 and the skin material 8, and one skin material Paste material E3 (see Figure 5).

The first embodiment is applied to a door trim 6, but
The present invention can also be applied to other areas such as rear 1-ner, body side, etc., and has a wide range of applications.

[Brief explanation of drawings]

1 and 2 show a pad material for an automobile according to the present invention. FIG. 1 is a cross-sectional view during hot-press molding, and FIG. 2 is a cross-sectional view before hot-press molding. 3 to 5 show an embodiment in which the present invention is applied to the door 1 - rim, FIG. 3 is a partially cutaway perspective view of the door 1 - rim, and FIGS. 4 and 5 are 4 is a sectional view showing the state before molding, and FIG. 5 is a sectional view showing the state during molding. 1... Automobile pad material 2... Semi-cure felt 3... Urethane for low temperature molding 4.5... Press mold 6... Door 1-rim 7... Core material 8... Skin material 9... Non-breathable sheet 10... Foaming sheet 11... Adhesive layer 12... Armrest 13... Vacuum forming 14... Suction tube 15... Vacuum pump 16... ... Clamping device patent applicant Kasai] - Gyo Co., Ltd. Figure 1 Figure 2 Figure 3 Figure 4

Claims (1)

[Claims] (1) An automobile pad material characterized by integrally molding semi-cured felt impregnated with unreacted thermosetting resin and urethane for low-temperature molding by hot pressing.