JP2021049683A - Method for manufacturing interior material for vehicle and interior material for vehicle - Google Patents

Method for manufacturing interior material for vehicle and interior material for vehicle Download PDF

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JP2021049683A
JP2021049683A JP2019173078A JP2019173078A JP2021049683A JP 2021049683 A JP2021049683 A JP 2021049683A JP 2019173078 A JP2019173078 A JP 2019173078A JP 2019173078 A JP2019173078 A JP 2019173078A JP 2021049683 A JP2021049683 A JP 2021049683A
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mat
foamable resin
resin
back surface
foamable
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JP7322631B2 (en
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光希 柚原
Koki Yuhara
光希 柚原
亮 中嶌
Ryo Nakajima
亮 中嶌
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Toyota Boshoku Corp
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Abstract

To provide an interior material for a vehicle which can improve a joint strength with a resin member, an interior material for a vehicle having a smooth surface, and an interior material for a vehicle which is light-weight and has high rigidity.SOLUTION: A method for manufacturing an interior material for a vehicle includes: a mat preparation step of creating a mat M composed of fibers in which foamable resins R2 and R1 are coated onto a surface A and a rear face B; and a pressing step of arranging the mat M and a bracket 40 having an uneven part 41 between a pair of molding dies 50 so that the uneven part 41 faces the rear face B side of the mat M, and then pressing the mat M while pressing it with the pair of molding dies 50 on the condition that the surface side foamable resin R2 coated onto the surface A of the mat A is more foamed than the rear face side foamable resin R1 coated onto the rear face B of the mat M.SELECTED DRAWING: Figure 2

Description

本発明は、乗物用内装材の製造方法及び乗物用内装材に関する。 The present invention relates to a method for manufacturing an interior material for a vehicle and an interior material for a vehicle.

従来、乗物用内装材及びその製造方法として、特許文献１に記載のものが知られている。特許文献１に記載の乗物用内装材（内装基材）の製造方法では、上型と下型とからなる成形型に、樹脂からなり、突起が多数個差出されたブラケットをセットし、上型と下型との間に、繊維と樹脂とからなる内装基材原反をセットし、加熱すると共に押圧成形しブラケットの突起を内装基材原反に食い込ませて内装基材を製造することが開示されている。 Conventionally, as an interior material for a vehicle and a method for manufacturing the same, those described in Patent Document 1 are known. In the method for manufacturing an interior material (interior base material) for a vehicle described in Patent Document 1, a bracket made of resin and having a large number of protrusions is set in a molding die composed of an upper die and a lower die, and the upper die is formed. It is possible to manufacture an interior base material by setting an interior base material raw fabric made of fiber and resin between the mold and the lower mold, heating it, and pressing and molding it so that the protrusions of the bracket bite into the interior base material raw fabric. It is disclosed.

特開平８−２２９９６６号公報Japanese Unexamined Patent Publication No. 8-229966

しかしながら、特許文献１に開示の乗物用内装材の製造方法では、内装材原反を成形型で押圧する際に、突起が内装材原反の繊維を押し込んでしまい、当該繊維が押し込まれた部分に樹脂がにじみ出てしまう。すると、樹脂部材（ブラケット）と基材（内装基材原反）との接合強度が低下し、樹脂部材が基材から剥がれてしまう可能性が考えられる。一方、乗物用内装材は、例えば表皮を張るためや意匠性を向上させるために、その表面が平滑であることが望ましい。また、乗物用内装材は、軽量かつ高剛性であることが望ましい。 However, in the method for manufacturing an interior material for a vehicle disclosed in Patent Document 1, when the interior material raw material is pressed by a molding die, the protrusions push in the fibers of the interior material raw material, and the portion where the fibers are pushed in. The resin oozes out. Then, it is considered that the bonding strength between the resin member (bracket) and the base material (interior base material raw material) is lowered, and the resin member may be peeled off from the base material. On the other hand, it is desirable that the surface of the interior material for vehicles is smooth, for example, in order to stretch the skin or improve the design. Further, it is desirable that the interior material for a vehicle is lightweight and highly rigid.

本発明は上記のような事情に基づいて完成されたものであって、樹脂部材との接合強度を向上することができる乗物用内装材を提供することを目的の一つとする。また、表面が平滑な乗物用内装材を提供することをさらなる目的の一つとする。さらに、軽量かつ高剛性な乗物用内装材を提供することをさらなる目的の一つとする。 The present invention has been completed based on the above circumstances, and one of the objects of the present invention is to provide an interior material for a vehicle capable of improving the joint strength with a resin member. Another object of the present invention is to provide an interior material for a vehicle having a smooth surface. Furthermore, one of the further purposes is to provide a lightweight and highly rigid interior material for vehicles.

本発明は、乗物用内装材の製造方法であって、少なくとも繊維により構成され、その表裏面に発泡性樹脂を塗布したマットを作成するマット作成工程と、一対の成形型の間に、前記マットと凹凸部を備えた樹脂部材とを、前記凹凸部が前記マットの裏面側を向く形で配した後に、前記マットの表面に塗布した発泡性樹脂を前記マットの裏面に塗布した発泡性樹脂よりも発泡させる条件のもと、前記一対の成形型で前記マットを押圧しつつ加熱する押圧工程と、を含むことに特徴を有する。 The present invention is a method for manufacturing an interior material for a vehicle, which is between a mat making step of making a mat composed of at least fibers and coated with a foamable resin on the front and back surfaces thereof and a pair of molding dies. And the resin member provided with the uneven portion, after the uneven portion is arranged so as to face the back surface side of the mat, the foamable resin applied to the front surface of the mat is applied to the back surface of the mat. It is also characterized by including a pressing step of heating the mat while pressing the mat with the pair of molding dies under the condition of foaming.

このような乗物用内装材の製造方法によると、押圧工程において、マットの表面に塗布した発泡性樹脂（以下、表面側発泡性樹脂と呼ぶ）をマットの裏面に塗布した発泡性樹脂（以下、裏面側発泡性樹脂と呼ぶ）よりも発泡させることで、表面側発泡性樹脂が、マットの裏面側に含浸しやすくなる。そして、表面側発泡性樹脂が繊維を裏面側へ移動させつつ、樹脂部材の凹凸部に繊維を押し付けて、マットと樹脂部材とを接合させることができる。これにより、樹脂部材の凹凸部にマットの繊維が密着しやすくなり、マットと樹脂部材との接合強度が向上する。また、表面側発泡性樹脂がマットの表面側において含浸することで、マットの表面に平滑性を付与することができる。尚、仮に表面側発泡性樹脂がマットの裏面に至るまで含浸しなかったとしても、裏面側発泡性樹脂がマットの裏面側において含浸することで、マットの裏面側の強度を保ち、マットの裏面側において繊維が剥き出した状態になってしまうことを防ぐことができる。さらに、樹脂部材が接合したマットを冷却することで、表面側に設けられた発泡性樹脂高含有部と、裏面側に設けられ、発泡性樹脂高含有部に比して、繊維に対する発泡性樹脂の含有率が低い発泡性樹脂低含有部と、を備える基材を作成することができる。これにより、発泡性樹脂低含有部において繊維と樹脂部材の凹凸部とが密着し、樹脂部材の接合強度が向上した乗物用内装材を製造することができる。また、マットが繊維と発泡性樹脂とにより構成されるため、軽量かつ剛性の高い乗物用内装材を製造することができる。 According to such a method for manufacturing an interior material for a vehicle, in a pressing step, a foamable resin (hereinafter referred to as a front-side foamable resin) applied to the surface of the mat is applied to the back surface of the mat (hereinafter, referred to as a foamable resin). By foaming rather than foaming on the back surface side (referred to as foaming resin on the back surface side), the foaming resin on the front surface side can be easily impregnated on the back surface side of the mat. Then, while the foamable resin on the front surface side moves the fibers to the back surface side, the fibers can be pressed against the uneven portions of the resin member to join the mat and the resin member. As a result, the fibers of the mat easily adhere to the uneven portion of the resin member, and the bonding strength between the mat and the resin member is improved. Further, by impregnating the surface-side foamable resin on the surface side of the mat, smoothness can be imparted to the surface of the mat. Even if the front surface side foaming resin is not impregnated up to the back surface of the mat, the back surface side foaming resin is impregnated on the back surface side of the mat to maintain the strength of the back surface side of the mat and the back surface of the mat. It is possible to prevent the fibers from being exposed on the side. Further, by cooling the mat to which the resin member is bonded, the foamable resin for the fiber is compared with the foamable resin high content portion provided on the front surface side and the foamable resin high content portion provided on the back surface side. It is possible to prepare a base material comprising a foaming resin low content portion having a low content of. As a result, it is possible to manufacture an interior material for a vehicle in which the fiber and the uneven portion of the resin member are in close contact with each other in the low foaming resin content portion and the bonding strength of the resin member is improved. Further, since the mat is composed of fibers and foamable resin, it is possible to manufacture a lightweight and highly rigid interior material for vehicles.

また、前記一対の成形型は、前記マットを裏面側から押圧する下型と、前記マットを表面側から押圧する上型とを備えるものとされ、前記押圧工程において、前記上型が前記下型よりも高い温度となる条件で、前記マットを押圧しつつ加熱することとすることができる。 Further, the pair of molding dies are provided with a lower mold that presses the mat from the back surface side and an upper mold that presses the mat from the front surface side. In the pressing step, the upper mold is the lower mold. It is possible to heat the mat while pressing it under the condition that the temperature becomes higher than that.

このような乗物用内装材の製造方法によると、表面側発泡性樹脂を裏面側発泡性樹脂よりも速く発泡させることができる。これにより、裏面側発泡性樹脂の発泡が完了する前に表面側発泡性樹脂をマットの裏面側に含浸させることができるので、表面側発泡性樹脂が繊維をマットの裏面側へ移動させやすくなり、樹脂部材の凹凸部に繊維を押し付けやすくなる。 According to such a method for manufacturing an interior material for a vehicle, the front-side foamable resin can be foamed faster than the back-side foamable resin. As a result, the front surface side foaming resin can be impregnated on the back surface side of the mat before the foaming of the back surface side foaming resin is completed, so that the front surface side foaming resin can easily move the fibers to the back surface side of the mat. , It becomes easy to press the fiber against the uneven part of the resin member.

また、前記マット作成工程において、前記マットの表面に塗布した発泡性樹脂の量が、前記マットの裏面に塗布した発泡性樹脂の量よりも多くなるようにして前記マットを作成することとすることができる。 Further, in the mat making step, the mat is made so that the amount of the foamable resin applied to the front surface of the mat is larger than the amount of the foamable resin applied to the back surface of the mat. Can be done.

このような乗物用内装材の製造方法によると、マットの表面から裏面側に含浸する表面側発泡性樹脂の量が、マットの裏面から表面側に含浸する裏面側発泡性樹脂の量よりも多くなるので、繊維がマットの裏面側に移動しやすくなる。 According to such a method for manufacturing interior materials for vehicles, the amount of front-side foamable resin impregnated from the front surface to the back surface side of the mat is larger than the amount of back-side foamable resin impregnated from the back surface side to the front surface side of the mat. Therefore, the fibers can easily move to the back side of the mat.

また、前記マット作成工程において、前記マットの表面に塗布した発泡性樹脂は、前記マットの裏面に塗布した発泡性樹脂よりも発泡倍率が高いこととすることができる。このような乗物用内装材の製造方法によると、表面側発泡性樹脂が裏面側発泡性樹脂よりもマットに含浸しやすくなり、繊維がマットの裏面側に移動しやすくなる。 Further, in the mat making step, the foamable resin applied to the surface of the mat can have a higher foaming ratio than the foamable resin applied to the back surface of the mat. According to such a method for manufacturing an interior material for a vehicle, the front-side foamable resin is more likely to be impregnated into the mat than the back-side foamable resin, and the fibers are more likely to move to the back side of the mat.

また、前記マット作成工程において、前記マットは、少なくとも繊維により構成され、その表裏面に発泡性樹脂を塗布した繊維体を２つ重ねて作成することとすることができる。 このような乗物用内装材の製造方法によると、押圧工程において、表面側発泡性樹脂と、２つの繊維体の間に配される発泡性樹脂とが発泡し、マットの裏面側に含浸することで、繊維が裏面側に移動しやすくなり、樹脂部材の凹凸部に繊維が押し付けられやすくなる。表面側発泡性樹脂は、２つの繊維体の間に配される発泡性樹脂が繊維を裏面側へ移動させることをサポートすることができる。 Further, in the mat making step, the mat may be made by stacking two fibrous bodies composed of at least fibers and coated with a foamable resin on the front and back surfaces thereof. According to such a method for manufacturing an interior material for a vehicle, in the pressing step, the foamable resin on the front surface side and the foamable resin arranged between the two fiber bodies are foamed and impregnated on the back surface side of the mat. As a result, the fibers are easily moved to the back surface side, and the fibers are easily pressed against the uneven portion of the resin member. The front surface side foaming resin can support the foaming resin arranged between the two fiber bodies to move the fibers to the back surface side.

また、本発明は、乗物用内装材であって、少なくとも繊維と発泡性樹脂とにより構成された基材と、少なくとも樹脂により構成され、前記基材に接合した樹脂部材と、を備え、前記樹脂部材は、凹凸状の凹凸部を備え、前記基材は、発泡性樹脂高含有部と、前記発泡性樹脂高含有部に比して、前記繊維に対する前記発泡性樹脂の含有率が低い発泡性樹脂低含有部と、を備え、前記凹凸部は、前記発泡性樹脂低含有部に接合していることに特徴を有する。 Further, the present invention comprises an interior material for a vehicle, which comprises a base material composed of at least a fiber and a foamable resin, and a resin member composed of at least a resin and bonded to the base material. The member is provided with a concavo-convex concavo-convex portion, and the base material is foamable in which the content of the foamable resin in the fiber is lower than that of the foamable resin high content portion and the foamable resin high content portion. It is characterized in that it includes a resin low content portion, and the uneven portion is joined to the foamable resin low content portion.

このような乗物用内装材によると、基材が繊維と発泡性樹脂とにより構成されるため、軽量かつ剛性の高い乗物用内装材とすることができる。また、樹脂部材の凹凸部が、繊維に対する発泡性樹脂の含有率が低い発泡性樹脂低含有部に接合しているので、発泡性樹脂低含有部において繊維と樹脂部材の凹凸部とが密着し、樹脂部材の接合強度を向上することができる。さらに、発泡性樹脂高含有部は、発泡性樹脂低含有部に比して繊維に対する発泡性樹脂の含有率が高いので、基材のうち樹脂部材が接合した面（裏面）とは反対側の面（表面）において平滑性を付与することができる。 According to such an interior material for a vehicle, since the base material is composed of fibers and a foamable resin, the interior material for a vehicle can be made lightweight and highly rigid. Further, since the uneven portion of the resin member is bonded to the foamable resin low content portion having a low content of the foamable resin with respect to the fiber, the fiber and the uneven portion of the resin member are in close contact with each other in the foamable resin low content portion. , The joint strength of the resin member can be improved. Further, since the foamable resin high content portion has a higher content of the foamable resin with respect to the fiber than the foamable resin low content portion, it is on the side opposite to the surface (back surface) of the base material to which the resin member is bonded. Smoothness can be imparted on the surface (surface).

本発明によれば、樹脂部材との接合強度を向上することができる乗物用内装材を提供することが可能となる。また、表面が平滑な乗物用内装材を提供することが可能となる。さらに、軽量かつ高剛性な乗物用内装材を提供することが可能となる。 According to the present invention, it is possible to provide an interior material for a vehicle capable of improving the joint strength with a resin member. Further, it becomes possible to provide an interior material for a vehicle having a smooth surface. Further, it becomes possible to provide a lightweight and highly rigid vehicle interior material.

実施形態１に係るマットを示す断面図Sectional drawing which shows the mat which concerns on Embodiment 1. 開いた状態の成形型の間にマットと樹脂部材とを配した態様を示す断面図Cross-sectional view showing a mode in which a mat and a resin member are arranged between molding dies in an open state. 閉じた状態の成形型を示す断面図Cross-sectional view showing a molded mold in a closed state 成形型を再度開いた状態にした態様を示す断面図Cross-sectional view showing the mode in which the molding die is opened again. ドアトリムを示す断面図Sectional view showing door trim 実施形態２に係るマットを示す断面図Sectional drawing which shows the mat which concerns on Embodiment 2.

＜実施形態１＞
本発明の実施形態１を図１から図５によって説明する。本実施形態では、図５に示す乗物としての自動車（車両）に搭載されるドアトリム（乗物用内装材）１００と、ドアトリム１００の製造方法について説明する。ドアトリム１００は、繊維と発泡性樹脂とにより構成された板状の基材３０と、樹脂により構成され、基材３０に接合したブラケット（樹脂部材）４０と、を備える。基材３０に接合するものとしては、ブラケットに限られず、ボスやその他の樹脂からなる部材であってもよい。尚、基材３０の上側の面を表面（意匠面）Ａとし、下側の面を裏面Ｂとする。ブラケット４０は、基材３０の裏面Ｂ側に接合している。 <Embodiment 1>
Embodiment 1 of the present invention will be described with reference to FIGS. 1 to 5. In the present embodiment, a door trim (vehicle interior material) 100 mounted on an automobile (vehicle) as a vehicle shown in FIG. 5 and a method for manufacturing the door trim 100 will be described. The door trim 100 includes a plate-shaped base material 30 made of fibers and a foamable resin, and a bracket (resin member) 40 made of resin and bonded to the base material 30. The material to be bonded to the base material 30 is not limited to the bracket, and may be a member made of a boss or other resin. The upper surface of the base material 30 is the front surface (design surface) A, and the lower surface is the back surface B. The bracket 40 is joined to the back surface B side of the base material 30.

基材３０の繊維としては、木材等を解織して得た木質繊維、ケナフ等の靭皮植物繊維、ガラス繊維、炭素繊維等の無機繊維、合成樹脂繊維等を採用することができる。基材３０の発泡性樹脂は、所定温度以上に加熱されることで発泡して硬化する（常温でも発泡反応及び硬化反応は進行するが、所定温度以上に加熱されることで、その反応速度が著しく加速する）樹脂である。この発泡性樹脂としては、例えば、発泡性ポリウレタン樹脂、エポキシ系発泡性樹脂、オレフィン系発泡性樹脂等のうちの１種又は２種以上を組み合わせたものを採用することができる。本実施形態において、発泡性樹脂は、ポリオール化合物、ポリイソシアネート化合物、発泡剤（水）及び触媒等を混合してなる発泡性ポリウレタン樹脂とし、発泡剤（水）の量を適宜変更することで、その発泡倍率を調整することができるものとする。ブラケット４０の素材としては、ポリプロピレンやＡＢＳ等の樹脂を採用することができる。 As the fiber of the base material 30, wood fiber obtained by weaving wood or the like, bast plant fiber such as kenaf, inorganic fiber such as glass fiber or carbon fiber, synthetic resin fiber or the like can be adopted. The foamable resin of the base material 30 foams and cures when heated to a predetermined temperature or higher (the foaming reaction and the curing reaction proceed even at room temperature, but when heated to a predetermined temperature or higher, the reaction rate increases. It is a resin (which accelerates significantly). As the foamable resin, for example, one or a combination of one or more of a foamable polyurethane resin, an epoxy-based foamable resin, an olefin-based foamable resin, and the like can be adopted. In the present embodiment, the effervescent resin is a effervescent polyurethane resin obtained by mixing a polyol compound, a polyisocyanate compound, a foaming agent (water), a catalyst, etc., and the amount of the effervescent agent (water) is appropriately changed. The foaming ratio can be adjusted. As the material of the bracket 40, a resin such as polypropylene or ABS can be adopted.

基材３０は、表面Ａ側に位置する発泡性樹脂高含有部３１と、裏面Ｂ側に位置し、発泡性樹脂高含有部３１に比して、繊維に対する発泡性樹脂の含有率が低い発泡性樹脂低含有部３２と、を備える。発泡性樹脂低含有部３２では、発泡性樹脂高含有部３１に比して繊維が密になっているともいえる。ブラケット４０は、凹凸状の凹凸部４１を備える。凹凸部４１は、ブラケット４０と基材３０との接合面積を大きくして接合力を高めるために設けられている。凹凸部４１は、発泡性樹脂低含有部３２に接合している。 The base material 30 is foamed having a low foamable resin content in the fibers as compared with the foamable resin high content portion 31 located on the front surface A side and the foamable resin high content portion 31 located on the back surface B side. A low content portion 32 of a sex resin is provided. It can be said that the fibers of the foamable resin low content portion 32 are denser than those of the foamable resin high content portion 31. The bracket 40 includes a concavo-convex concavo-convex portion 41. The uneven portion 41 is provided to increase the bonding area between the bracket 40 and the base material 30 to increase the bonding force. The uneven portion 41 is joined to the foamable resin low content portion 32.

続いて、ドアトリム１００を製造する製造装置としての一対の成形型５０について説明する。図２に示すように、一対の成形型５０は、後述するマット状のマットＭを上下方向から押圧しつつ加熱することができる構成とされている。具体的には、一対の成形型５０は、上方に配され、マットＭの表面Ａ（基材３０における表面Ａとなる面）側から押圧して成形する成形面５１Ａを有する上型５１と、上型５１に対向するように下方に配され、マットＭの裏面Ｂ（基材３０における裏面Ｂとなる面）側から押圧して成形する成形面５２Ｂを有する下型５２と、を備える。下型５２は、成形面５２Ｂ側においてブラケット４０を挿入することができる程度に窪んだ窪み部５３を備える。 Subsequently, a pair of molding dies 50 as a manufacturing apparatus for manufacturing the door trim 100 will be described. As shown in FIG. 2, the pair of molding dies 50 have a configuration in which a mat-shaped mat M, which will be described later, can be heated while being pressed from above and below. Specifically, the pair of molding dies 50 are arranged above and have a molding surface 51A which is pressed from the surface A (the surface to be the surface A of the base material 30) side of the mat M to be molded. It is provided with a lower mold 52 which is arranged downward so as to face the upper mold 51 and has a molding surface 52B which is formed by pressing from the back surface B (the surface which becomes the back surface B of the base material 30) side of the mat M. The lower mold 52 includes a recessed portion 53 that is recessed to the extent that the bracket 40 can be inserted on the molding surface 52B side.

上型５１は、図示しない駆動装置（例えば、電動モータ、エアシリンダ、油圧シリンダ等）によって、下型５２に対し上下方向へ移動が可能な可動型とされる。図２では、上型５１が下型５２から離間する方向へ移動した状態（成形型５０が開いた状態）を示している。図３では、上型５１が下型５２に近づく方向へ移動し、マットＭが成形型５０によって押圧されている状態（成形型５０が閉じた状態）を示している。 The upper mold 51 is a movable type that can be moved in the vertical direction with respect to the lower mold 52 by a driving device (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.) (not shown). FIG. 2 shows a state in which the upper mold 51 has moved in a direction away from the lower mold 52 (a state in which the molding mold 50 is open). FIG. 3 shows a state in which the upper mold 51 moves in a direction approaching the lower mold 52 and the mat M is pressed by the molding mold 50 (a state in which the molding mold 50 is closed).

次に、ドアトリム１００の製造方法について説明する。ドアトリム１００の製造方法は、大別すると、図１に示すように、発泡性樹脂Ｒ１，Ｒ２を塗布したマットＭを作成するマット作成工程と、図２から図５に示すように、マットＭとブラケット４０とを一対の成形型５０で押圧しつつ加熱することで、基材３０にブラケット４０が接合してなるドアトリム１００を製造する押圧工程と、を含む。 Next, a method of manufacturing the door trim 100 will be described. The method for manufacturing the door trim 100 is roughly divided into a mat making step of making a mat M coated with foamable resins R1 and R2 as shown in FIG. 1 and a mat M as shown in FIGS. 2 to 5. A pressing step of manufacturing a door trim 100 in which the bracket 40 is joined to the base material 30 by heating the bracket 40 while pressing the bracket 40 with a pair of molding dies 50 is included.

図１に示すように、マット作成工程では、繊維（複数のウェーブ状の線で示す）により構成されたマット（繊維が交絡してなる繊維体）Ｍを用意する。そして、マットＭの表裏面Ａ，Ｂに、発泡性樹脂Ｒ２，Ｒ１を塗布する（これら発泡性樹脂Ｒ１，Ｒ２は、複数のドットで示す）。マットＭを構成する繊維としては、上述した基材３０に採用される繊維と同一のものとする。発泡性樹脂Ｒ１，Ｒ２としては、上述した基材３０に採用される発泡性樹脂と同一のものとする。尚、マットＭの表面Ａに塗布する発泡性樹脂を、表面側発泡性樹脂Ｒ２とし、マットＭの裏面Ｂに塗布する発泡性樹脂を、裏面側発泡性樹脂Ｒ１とする。裏面側発泡性樹脂Ｒ１は、表面側発泡性樹脂Ｒ２よりも小さいドットで示す。 As shown in FIG. 1, in the mat making step, a mat (fiber body formed by entwining fibers) M composed of fibers (indicated by a plurality of wavy lines) is prepared. Then, the foamable resins R2 and R1 are applied to the front and back surfaces A and B of the mat M (these foamable resins R1 and R2 are indicated by a plurality of dots). The fibers constituting the mat M are the same as the fibers used for the base material 30 described above. The foamable resins R1 and R2 are the same as the foamable resins used for the above-mentioned base material 30. The foamable resin applied to the front surface A of the mat M is referred to as the front surface side foamable resin R2, and the foamable resin applied to the back surface B of the mat M is referred to as the back surface side foamable resin R1. The back surface side foamable resin R1 is indicated by dots smaller than the front surface side foamable resin R2.

マットＭの表面Ａには、マットＭの裏面Ｂに塗布した裏面側発泡性樹脂Ｒ１の量よりも多量の表面側発泡性樹脂Ｒ２を塗布する。表面側発泡性樹脂Ｒ２は、裏面側発泡性樹脂Ｒ１よりも発泡倍率が高いものとする。具体的には、表面側発泡性樹脂Ｒ２に混合する水（発泡剤）の割合を、裏面側発泡性樹脂Ｒ１に混合する水の割合よりも高くなるように調整することで、表面側発泡性樹脂Ｒ２の発泡倍率を高くする。 On the front surface A of the mat M, a larger amount of the front surface side foamable resin R2 than the amount of the back surface side foamable resin R1 applied to the back surface B of the mat M is applied. It is assumed that the front surface side foamable resin R2 has a higher foaming ratio than the back surface side foamable resin R1. Specifically, by adjusting the proportion of water (foaming agent) mixed with the front surface side foamable resin R2 to be higher than the proportion of water mixed with the back surface side foamable resin R1, the surface side foamability The foaming ratio of the resin R2 is increased.

次に、押圧工程では、図２に示すように、開いた状態の一対の成形型５０の間に、マットＭとブラケット４０とを配する。マットＭは、その表面Ａが上型５１の成形面５１Ａに対向し、その裏面Ｂが下型５２の成形面５２Ｂに対向する形となるように配される。ブラケット４０は、その凹凸部４１がマットＭの裏面Ｂと向かい合う形となるように、下型５２の窪み部５３に挿入される。 Next, in the pressing step, as shown in FIG. 2, the mat M and the bracket 40 are arranged between the pair of molding dies 50 in the open state. The mat M is arranged so that its front surface A faces the molding surface 51A of the upper mold 51 and its back surface B faces the molding surface 52B of the lower mold 52. The bracket 40 is inserted into the recessed portion 53 of the lower mold 52 so that the uneven portion 41 faces the back surface B of the mat M.

この状態から、上型５１を下型５２に対し徐々に近接させて、一対の成形型５０でブラケット４０とともにマットＭを押圧し、図３に示すように、一対の成形型５０を型閉じ状態にする。すると、マットＭの表面Ａ側が、上型５１の成形面５１Ａに押圧されることで、成形面５１Ａの形に倣うように成形され、マットＭの裏面Ｂ側が、下型５２の成形面５２Ｂに押圧されることで、成形面５２Ｂの形に倣うように成形される。 From this state, the upper mold 51 is gradually brought closer to the lower mold 52, the mat M is pressed together with the bracket 40 by the pair of molding dies 50, and the pair of molding dies 50 are closed. To. Then, the surface A side of the mat M is pressed against the molding surface 51A of the upper mold 51 to be molded so as to follow the shape of the molding surface 51A, and the back surface B side of the mat M becomes the molding surface 52B of the lower mold 52. By being pressed, it is molded so as to follow the shape of the molding surface 52B.

このとき、上型５１を、下型５２よりも高い温度となる条件で昇温し、上型５１と下型５２とを所定温度以上に加熱する。マットＭは、温度差のある上型５１及び下型５２によって押圧されることで、マットＭの表面Ａ側が、マットＭの裏面Ｂ側よりも高い温度で加熱される。 At this time, the temperature of the upper mold 51 is raised under the condition that the temperature is higher than that of the lower mold 52, and the upper mold 51 and the lower mold 52 are heated to a predetermined temperature or higher. When the mat M is pressed by the upper mold 51 and the lower mold 52 having different temperatures, the front surface A side of the mat M is heated at a higher temperature than the back surface B side of the mat M.

このように、マットＭの表面Ａに塗布した表面側発泡性樹脂Ｒ２をマットＭの裏面Ｂに塗布した裏面側発泡性樹脂Ｒ１よりも発泡させる条件のもと、一対の成形型５０でマットＭを押圧しつつ加熱する。裏面側発泡性樹脂Ｒ１は、マットＭの裏面Ｂから表面Ａ側へ拡がって含浸する。表面側発泡性樹脂Ｒ２は、マットＭの表面Ａから裏面Ｂ側へ拡がって含浸する。 As described above, under the condition that the front surface side foamable resin R2 applied to the front surface A of the mat M is foamed more than the back surface side foamable resin R1 applied to the back surface B of the mat M, the mat M is formed by a pair of molding dies 50. Heat while pressing. The back surface side foamable resin R1 spreads from the back surface B of the mat M to the front surface A side and is impregnated. The front surface side foamable resin R2 spreads from the front surface A to the back surface B side of the mat M and is impregnated.

そして、閉じた状態の一対の成形型５０を所定圧力で所定時間保持することで、発泡性樹脂Ｒ１，Ｒ２の発泡が完了して硬化する。すると、図４に示すように、マットＭが、表面Ａ側に位置する発泡性樹脂高含有部３１と、裏面Ｂ側に位置する発泡性樹脂低含有部３２と、を備える基材３０として成形され、ブラケット４０が、基材３０の発泡性樹脂低含有部３２に接合する。一対の成形型５０を冷却した後に、再度開いた状態にした一対の成形型５０から成形体を取り出すことで、図５に示すように、基材３０と、基材３０に接合したブラケット４０とを備えるドアトリム１００を得る。 Then, by holding the pair of molded molds 50 in the closed state at a predetermined pressure for a predetermined time, the foaming of the foamable resins R1 and R2 is completed and cured. Then, as shown in FIG. 4, the mat M is molded as a base material 30 including a foamable resin high content portion 31 located on the front surface A side and a foamable resin low content portion 32 located on the back surface B side. Then, the bracket 40 is joined to the foamable resin low content portion 32 of the base material 30. After cooling the pair of molding dies 50, by taking out the molded body from the pair of molding dies 50 that were opened again, as shown in FIG. 5, the base material 30 and the bracket 40 joined to the base material 30 To obtain a door trim 100 comprising.

続いて、本実施形態の効果について説明する。本実施形態におけるドアトリム１００の製造方法は、繊維により構成され、その表裏面Ａ，Ｂに発泡性樹脂Ｒ２，Ｒ１を塗布したマットＭを作成するマット作成工程と、一対の成形型５０の間に、マットＭと凹凸部４１を備えたブラケット４０とを、凹凸部４１がマットＭの裏面Ｂ側を向く形で配した後に、マットＭの表面Ａに塗布した表面側発泡性樹脂Ｒ２をマットＭの裏面Ｂに塗布した裏面側発泡性樹脂Ｒ１よりも発泡させる条件のもと、一対の成形型５０でマットＭを押圧する押圧工程と、を含む。 Subsequently, the effect of this embodiment will be described. The method for manufacturing the door trim 100 in the present embodiment is between a mat making step of making a mat M which is composed of fibers and coated with foamable resins R2 and R1 on the front and back surfaces A and B and a pair of molding dies 50. After arranging the mat M and the bracket 40 provided with the uneven portion 41 so that the uneven portion 41 faces the back surface B side of the mat M, the surface side foamable resin R2 applied to the surface A of the mat M is applied to the mat M. Includes a pressing step of pressing the mat M with a pair of molding dies 50 under the condition of foaming more than the back surface side foamable resin R1 applied to the back surface B of the above.

このようなドアトリム１００の製造方法によると、押圧工程において、マットＭの表面Ａに塗布した表面側発泡性樹脂Ｒ２をマットＭの裏面Ｂに塗布した裏面側発泡性樹脂Ｒ１よりも発泡させることで、表面側発泡性樹脂Ｒ２が、マットＭの裏面Ｂ側に含浸しやすくなる。そして、表面側発泡性樹脂Ｒ２が繊維を裏面Ｂ側へ移動させつつ、ブラケット４０の凹凸部４１に繊維を押し付けて、マットＭとブラケット４０とを接合させることができる。これにより、ブラケット４０の凹凸部４１にマットＭの繊維が密着しやすくなり、マットＭとブラケット４０との接合強度が向上する。また、表面側発泡性樹脂Ｒ２がマットＭの表面Ａ側において含浸することで、マットＭの表面Ａに平滑性を付与することができる。尚、仮に表面側発泡性樹脂Ｒ２がマットＭの裏面Ｂに至るまで含浸しなかったとしても、裏面側発泡性樹脂Ｒ１がマットＭの裏面Ｂ側において含浸することで、マットＭの裏面Ｂ側の強度を保ち、マットＭの裏面Ｂ側において繊維が剥き出した状態になってしまうことを防ぐことができる。さらに、ブラケット４０が接合したマットＭを冷却することで、表面Ａ側に設けられた発泡性樹脂高含有部３１と、裏面Ｂ側に設けられ、発泡性樹脂高含有部３１に比して、繊維に対する発泡性樹脂の含有率が低い発泡性樹脂低含有部３２と、を備える基材３０を作成することができる。これにより、発泡性樹脂低含有部３２において繊維とブラケット４０の凹凸部４１とが密着し、ブラケット４０の接合強度が向上したドアトリム１００を製造することができる。また、マットＭが繊維と発泡性樹脂とにより構成されるため、軽量かつ剛性の高いドアトリム１００を製造することができる。 According to such a method for manufacturing the door trim 100, in the pressing step, the front surface side foamable resin R2 applied to the surface A of the mat M is foamed more than the back surface side foamable resin R1 applied to the back surface B of the mat M. , The front surface side foamable resin R2 easily impregnates the back surface B side of the mat M. Then, while the front surface side foamable resin R2 moves the fibers to the back surface B side, the fibers can be pressed against the uneven portion 41 of the bracket 40 to join the mat M and the bracket 40. As a result, the fibers of the mat M are easily brought into close contact with the uneven portion 41 of the bracket 40, and the joint strength between the mat M and the bracket 40 is improved. Further, by impregnating the surface-side foamable resin R2 on the surface A side of the mat M, smoothness can be imparted to the surface A of the mat M. Even if the front surface side foamable resin R2 is not impregnated up to the back surface B of the mat M, the back surface side foamable resin R1 is impregnated on the back surface B side of the mat M, so that the back surface B side of the mat M is impregnated. It is possible to maintain the strength of the mat M and prevent the fibers from being exposed on the back surface B side of the mat M. Further, by cooling the mat M to which the bracket 40 is joined, the foamable resin high content portion 31 provided on the front surface A side and the foamable resin high content portion 31 provided on the back surface B side are compared with each other. It is possible to prepare the base material 30 including the foamable resin low content portion 32 having a low foamable resin content ratio with respect to the fiber. As a result, it is possible to manufacture the door trim 100 in which the fibers and the uneven portion 41 of the bracket 40 are in close contact with each other in the foamable resin low content portion 32 and the bonding strength of the bracket 40 is improved. Further, since the mat M is composed of fibers and foamable resin, a lightweight and highly rigid door trim 100 can be manufactured.

また、一対の成形型５０は、マットＭを裏面Ｂ側から押圧する下型５２と、マットＭを表面Ａ側から押圧する上型５１とを備えるものとされ、押圧工程においては、上型５１が下型５２よりも高い温度となる条件で、マットＭを押圧しつつ加熱する。 Further, the pair of molding dies 50 are provided with a lower die 52 that presses the mat M from the back surface B side and an upper die 51 that presses the mat M from the front surface A side. In the pressing step, the upper die 51 is provided. The mat M is heated while being pressed under the condition that the temperature is higher than that of the lower mold 52.

このようなドアトリム１００の製造方法によると、表面側発泡性樹脂Ｒ２を裏面側発泡性樹脂Ｒ１よりも速く発泡させることができる。これにより、裏面側発泡性樹脂Ｒ１の発泡が完了する前に表面側発泡性樹脂Ｒ２をマットＭの裏面Ｂ側に含浸させることができるので、表面側発泡性樹脂Ｒ２が繊維をマットＭの裏面Ｂ側へ移動させやすくなり、ブラケット４０の凹凸部４１に繊維を押し付けやすくなる。 According to such a method for manufacturing the door trim 100, the front surface side foamable resin R2 can be foamed faster than the back surface side foamable resin R1. As a result, the front surface side foamable resin R2 can be impregnated on the back surface B side of the mat M before the foaming of the back surface side foamable resin R1 is completed, so that the front surface side foamable resin R2 impregnates the fibers on the back surface of the mat M. It becomes easy to move to the B side, and it becomes easy to press the fiber against the uneven portion 41 of the bracket 40.

また、マット作成工程においては、マットＭの表面Ａに塗布した表面側発泡性樹脂Ｒ２の量が、マットＭの裏面Ｂに塗布した裏面側発泡性樹脂Ｒ１の量よりも多くなるようにしてマットＭを作成する。このようなドアトリム１００の製造方法によると、マットＭの表面Ａから裏面Ｂ側に含浸する表面側発泡性樹脂Ｒ２の量が、マットＭの裏面Ｂから表面Ａ側に含浸する裏面側発泡性樹脂Ｒ１の量よりも多くなるので、繊維がマットＭの裏面Ｂ側に移動しやすくなる。 Further, in the mat making step, the amount of the front surface side foamable resin R2 applied to the front surface A of the mat M is larger than the amount of the back surface side foamable resin R1 applied to the back surface B of the mat M. Create M. According to such a method for manufacturing the door trim 100, the amount of the front surface side foamable resin R2 impregnated from the front surface A to the back surface B side of the mat M is the back surface side foamable resin impregnated from the back surface B to the front surface A side of the mat M. Since the amount is larger than the amount of R1, the fibers are easily moved to the back surface B side of the mat M.

また、マット作成工程において、マットＭの表面Ａに塗布した表面側発泡性樹脂Ｒ２は、マットＭの裏面Ｂに塗布した裏面側発泡性樹脂Ｒ１よりも発泡倍率が高い。このようなドアトリム１００の製造方法によると、表面側発泡性樹脂Ｒ２が裏面側発泡性樹脂Ｒ１よりもマットＭに含浸しやすくなり、繊維がマットＭの裏面Ｂ側に移動しやすくなる。 Further, in the mat making step, the front surface side foamable resin R2 applied to the surface A of the mat M has a higher foaming ratio than the back surface side foamable resin R1 applied to the back surface B of the mat M. According to such a method for manufacturing the door trim 100, the front surface side foamable resin R2 is more likely to be impregnated into the mat M than the back surface side foamable resin R1, and the fibers are more likely to move to the back surface B side of the mat M.

また、本実施形態において、ドアトリム１００は、繊維と発泡性樹脂とにより構成された基材３０と、樹脂により構成され、基材３０に接合したブラケット４０と、を備え、ブラケット４０は、凹凸状の凹凸部４１を備え、基材３０は、発泡性樹脂高含有部３１と、発泡性樹脂高含有部３１に比して、繊維に対する発泡性樹脂の含有率が低い発泡性樹脂低含有部３２と、を備え、凹凸部４１は、発泡性樹脂低含有部３２に接合している。 Further, in the present embodiment, the door trim 100 includes a base material 30 made of fibers and a foamable resin, and a bracket 40 made of resin and bonded to the base material 30, and the bracket 40 has an uneven shape. 31 And, the uneven portion 41 is joined to the foamable resin low content portion 32.

このようなドアトリム１００によると、基材３０が繊維と発泡性樹脂とにより構成されるため、軽量かつ剛性の高いドアトリム１００とすることができる。また、ブラケット４０の凹凸部４１が、繊維に対する発泡性樹脂の含有率が低い発泡性樹脂低含有部３２に接合しているので、発泡性樹脂低含有部３２において繊維とブラケット４０の凹凸部４１とが密着し、ブラケット４０の接合強度を向上することができる。さらに、発泡性樹脂高含有部３１は、発泡性樹脂低含有部３２に比して繊維に対する発泡性樹脂の含有率が高いので、基材３０の表面Ａにおいて平滑性を付与することができる。 According to such a door trim 100, since the base material 30 is composed of fibers and a foamable resin, the door trim 100 is lightweight and has high rigidity. Further, since the uneven portion 41 of the bracket 40 is bonded to the foamable resin low content portion 32 having a low content of the foamable resin with respect to the fiber, the uneven portion 41 of the fiber and the bracket 40 in the foamable resin low content portion 32. And can be brought into close contact with each other, and the joint strength of the bracket 40 can be improved. Further, since the foamable resin high content portion 31 has a higher content of the foamable resin with respect to the fibers than the foamable resin low content portion 32, smoothness can be imparted to the surface A of the base material 30.

＜実施形態２＞
次に、本発明の実施形態２を図６によって説明する。本実施形態では、上記実施形態とはマットの作成工程が異なる乗物用内装材の製造方法を例示する。なお、本実施形態では、上記実施形態と同じ部位には、同一の符号を用い、構造、工程、作用及び効果について重複する説明は省略する。 <Embodiment 2>
Next, Embodiment 2 of the present invention will be described with reference to FIG. In this embodiment, a method for manufacturing an interior material for a vehicle, in which the mat making process is different from that of the above embodiment, is illustrated. In this embodiment, the same reference numerals are used for the same parts as those in the above embodiment, and duplicate description of the structure, process, action and effect will be omitted.

マット作成工程では、繊維（複数のウェーブ状の線で示す）により構成され、その表裏面２１０Ａ，２１０Ｂ，２２０Ａ，２２０Ｂに発泡性樹脂Ｒ２，Ｒ１（複数のドットで示す）を塗布した繊維体を２つ重ねてマットＭ２を作成する。具体的には、まず、繊維により構成された第１繊維体２１０と、同じく繊維により構成された第２繊維体２２０とを用意する。第１繊維体２１０及び第２繊維体２２０は、マット状をなしており、繊維が交絡してなる不織布とされる。第１繊維体２１０及び第２繊維体２２０を構成する繊維としては、上記実施形態１における基材３０に採用される繊維と同一のものとする。 In the mat making step, a fiber body composed of fibers (indicated by a plurality of wavy lines) and coated with foamable resins R2 and R1 (indicated by a plurality of dots) on the front and back surfaces 210A, 210B, 220A and 220B is formed. Create a mat M2 by stacking two. Specifically, first, a first fiber body 210 made of fibers and a second fiber body 220 made of fibers are prepared. The first fiber body 210 and the second fiber body 220 have a mat-like shape, and are formed as a non-woven fabric in which fibers are entangled. The fibers constituting the first fiber body 210 and the second fiber body 220 are the same as the fibers used for the base material 30 in the first embodiment.

次に、第１繊維体２１０の表面２１０Ａと、第２繊維体２２０の表面２２０Ａとに発泡性樹脂Ｒ２（以下、表面側発泡性樹脂Ｒ２とする）を塗布し、第１繊維体２１０の裏面２１０Ｂと、第２繊維体２２０の裏面２２０Ｂとに発泡性樹脂Ｒ１（以下、裏面側発泡性樹脂Ｒ１とする）を塗布する。裏面側発泡性樹脂Ｒ１は、表面側発泡性樹脂Ｒ２よりも小さいドットで示す。発泡性樹脂Ｒ１，Ｒ２としては、上記実施形態１における基材３０に採用される発泡性樹脂と同一のものとする。 Next, the foamable resin R2 (hereinafter referred to as the front surface side foamable resin R2) is applied to the surface 210A of the first fiber body 210 and the surface 220A of the second fiber body 220, and the back surface of the first fiber body 210 is used. Foamable resin R1 (hereinafter referred to as backside foamable resin R1) is applied to 210B and the back surface 220B of the second fiber body 220. The back surface side foamable resin R1 is indicated by dots smaller than the front surface side foamable resin R2. The foamable resins R1 and R2 are the same as the foamable resins used for the base material 30 in the first embodiment.

そして、第１繊維体２１０に第２繊維体２２０を重ねることで、マットＭ２を作成する。具体的には、第２繊維体２２０を、その裏面２２０Ｂが第１繊維体２１０の表面２１０Ａと向かい合う形で、第１繊維体２１０に積層する。マットＭ２の表面（即ち、第２繊維体２２０の表面）２２０Ａには、表面側発泡性樹脂Ｒ２が塗布されている。マットＭ２の裏面（即ち、第１繊維体２１０の裏面）２１０Ｂにおいては、裏面側発泡性樹脂Ｒ１が塗布されている。マットＭ２の内部（即ち、第１繊維体２１０と第２繊維体２２０との間）には、発泡性樹脂Ｒ２，Ｒ１が２つの繊維体２１０，２２０に挟まれる形で配されている。マットＭ２の内部には、表面２２０Ａ及び裏面２１０Ｂよりも多量の発泡性樹脂Ｒ２，Ｒ１が塗布されていることとなる。 Then, the mat M2 is created by superimposing the second fiber body 220 on the first fiber body 210. Specifically, the second fibrous body 220 is laminated on the first fibrous body 210 so that the back surface 220B thereof faces the front surface 210A of the first fibrous body 210. The surface-side foamable resin R2 is coated on the surface of the mat M2 (that is, the surface of the second fiber body 220) 220A. On the back surface of the mat M2 (that is, the back surface of the first fiber body 210) 210B, the back surface side foamable resin R1 is applied. Inside the mat M2 (that is, between the first fiber body 210 and the second fiber body 220), the foamable resins R2 and R1 are arranged so as to be sandwiched between the two fiber bodies 210 and 220. The inside of the mat M2 is coated with a larger amount of foamable resins R2 and R1 than the front surface 220A and the back surface 210B.

このようなドアトリム（乗物用内装材）の製造方法によると、押圧工程において、マットＭ２の表面２２０Ａに塗布された表面側発泡性樹脂Ｒ２と、２つの繊維体２１０，２２０の間に配される発泡性樹脂Ｒ２，Ｒ１とが発泡し、マットＭ２の裏面２１０Ｂ側に含浸することで、繊維が裏面２１０Ｂ側に移動しやすくなり、ブラケット（樹脂部材）の凹凸部に繊維が押し付けられやすくなる。マットＭ２の表面２２０Ａに塗布された表面側発泡性樹脂Ｒ２は、２つの繊維体の間に配される発泡性樹脂Ｒ２，Ｒ１が繊維を裏面Ｂ側へ移動させることをサポートすることができる。 According to such a method for manufacturing a door trim (interior material for a vehicle), it is arranged between the surface-side foamable resin R2 applied to the surface 220A of the mat M2 and the two fibers 210 and 220 in the pressing step. By foaming the foamable resins R2 and R1 and impregnating the back surface 210B side of the mat M2, the fibers are easily moved to the back surface 210B side, and the fibers are easily pressed against the uneven portion of the bracket (resin member). The front surface side foamable resin R2 applied to the surface 220A of the mat M2 can support the foamable resins R2 and R1 arranged between the two fibrous bodies to move the fibers to the back surface B side.

＜他の実施形態＞
本発明は上記記述及び図面によって説明した実施形態に限定されるものではなく、例えば次のような実施形態も本発明の技術的範囲に含まれ、さらに、下記以外にも要旨を逸脱しない範囲内で種々変更して実施することができる。 <Other Embodiments>
The present invention is not limited to the embodiments described by the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention, and further, within the scope not deviating from the gist other than the following. It can be implemented with various changes.

（１）上記実施形態以外にも、乗物用内装材の製造工程は適宜変更可能である。例えば、マット作成工程は、発泡性樹脂を塗布したマットを、押圧しつつ加熱して、厚みを調整する先行押圧工程を含んでいてもよい。これにより、マットの運搬や保管に適したドアトリムの製造方法を提供することができる。 (1) In addition to the above embodiment, the manufacturing process of the vehicle interior material can be changed as appropriate. For example, the mat making step may include a pre-pressing step of heating the mat coated with the foamable resin while pressing it to adjust the thickness. This makes it possible to provide a method for manufacturing a door trim suitable for transporting and storing a mat.

（２）上記実施形態２以外にも、マット作成工程の手順は適宜変更可能である。上記実施形態２では、第１繊維体及び第２繊維体を積層してマットを作成したが、これに限られない。例えば、繊維により構成され、それぞれの表裏面に発泡性樹脂が塗布された第１繊維体、第２繊維体、第３繊維体を重ねてマットを作成してもよく、繊維により構成され、それぞれの表裏面に発泡性樹脂が塗布された第１繊維体、第２繊維体、第３繊維体、第４繊維体を重ねてマットを作成してもよい。 (2) In addition to the second embodiment, the procedure of the mat making process can be changed as appropriate. In the second embodiment, the first fiber body and the second fiber body are laminated to prepare a mat, but the mat is not limited to this. For example, a mat may be formed by stacking a first fiber body, a second fiber body, and a third fiber body which are composed of fibers and whose front and back surfaces are coated with a foamable resin. The mat may be prepared by stacking the first fiber body, the second fiber body, the third fiber body, and the fourth fiber body coated with the foamable resin on the front and back surfaces of the above.

（３）上記実施形態２以外にも、繊維体の構成は適宜変更可能である。例えば、第１繊維体は、第２繊維体に比して目付が小さく、厚みが小さいものとしてもよい。これにより、マットの裏面側に含浸する発泡性樹脂が、繊維を裏面側へ移動させやすくなり、樹脂部材の凹凸部に繊維を押し付けやすくなる。 (3) In addition to the second embodiment, the structure of the fibrous body can be changed as appropriate. For example, the first fiber body may have a smaller basis weight and a smaller thickness than the second fiber body. As a result, the foamable resin impregnated on the back surface side of the mat makes it easier to move the fibers to the back surface side, and makes it easier to press the fibers against the uneven portion of the resin member.

（４）上記実施形態では、乗物用内装材としてドアトリムを例示したが、これに限られない。例えば、乗物用内装材としては、荷室のサイドトリム、ルーフライニング、ピラーガーニッシュ等、その他の乗物用内装材であってもよい。 (4) In the above embodiment, the door trim is exemplified as the interior material for the vehicle, but the present invention is not limited to this. For example, the interior material for vehicles may be other interior materials for vehicles such as side trims of luggage compartments, roof linings, pillar garnishes, and the like.

（５）上記実施形態で例示した乗物用内装材の製造方法は、車両用に提供されるもの限られず、種々の乗物において提供されるものであってもよい。例えば、地上の乗物としての列車や遊戯用車両、飛行用乗物としての飛行機やヘリコプター、海上や海中用乗物としての船舶や潜水艇などの乗物についても上記乗物用内装材の製造方法を適用することができる。 (5) The method for manufacturing the interior material for a vehicle exemplified in the above embodiment is not limited to that provided for a vehicle, and may be provided for various vehicles. For example, the above method for manufacturing interior materials for vehicles shall be applied to vehicles such as trains and amusement vehicles as ground vehicles, airplanes and helicopters as flight vehicles, and ships and submersibles as marine and underwater vehicles. Can be done.

３０…基材、３１…発泡性樹脂高含有部、３２…発泡性樹脂低含有部、４０…ブラケット（樹脂部材）、４１…凹凸部、５０…成形型、５１…上型、５２…下型、１００…ドアトリム（乗物用内装材）、Ｍ，Ｍ２…マット 30 ... Base material, 31 ... High content of foamable resin, 32 ... Low content of foamable resin, 40 ... Bracket (resin member), 41 ... Concavo-convex part, 50 ... Molding mold, 51 ... Upper mold, 52 ... Lower mold , 100 ... Door trim (interior material for vehicles), M, M2 ... Mat

Claims (6)

少なくとも繊維により構成され、その表裏面に発泡性樹脂を塗布したマットを作成するマット作成工程と、
一対の成形型の間に、前記マットと凹凸部を備えた樹脂部材とを、前記凹凸部が前記マットの裏面側を向く形で配した後に、前記マットの表面に塗布した発泡性樹脂を前記マットの裏面に塗布した発泡性樹脂よりも発泡させる条件のもと、前記一対の成形型で前記マットを押圧しつつ加熱する押圧工程と、を含むことを特徴とする乗物用内装材の製造方法。 A mat making process that creates a mat that is composed of at least fibers and has foamable resin applied to the front and back surfaces.
The mat and the resin member provided with the uneven portion are arranged between the pair of molding dies so that the uneven portion faces the back surface side of the mat, and then the foamable resin applied to the surface of the mat is applied. A method for producing an interior material for a vehicle, which comprises a pressing step of heating the mat while pressing the mat with the pair of molding dies under a condition of foaming more than the foamable resin applied to the back surface of the mat. .. 前記一対の成形型は、前記マットを裏面側から押圧する下型と、前記マットを表面側から押圧する上型とを備えるものとされ、
前記押圧工程において、前記上型が前記下型よりも高い温度となる条件で、前記マットを押圧しつつ加熱することを特徴とする請求項１に記載の乗物用内装材の製造方法。 The pair of molding dies are provided with a lower mold that presses the mat from the back surface side and an upper mold that presses the mat from the front surface side.
The method for manufacturing an interior material for a vehicle according to claim 1, wherein in the pressing step, the mat is heated while being pressed under a condition that the temperature of the upper mold is higher than that of the lower mold. 前記マット作成工程において、前記マットの表面に塗布した発泡性樹脂の量が、前記マットの裏面に塗布した発泡性樹脂の量よりも多くなるようにして前記マットを作成することを特徴とする請求項１または請求項２に記載の乗物用内装材の製造方法。 A claim characterized in that, in the mat making step, the mat is made so that the amount of the foamable resin applied to the surface of the mat is larger than the amount of the foamable resin applied to the back surface of the mat. The method for manufacturing an interior material for a vehicle according to claim 1 or 2. 前記マット作成工程において、前記マットの表面に塗布した発泡性樹脂は、前記マットの裏面に塗布した発泡性樹脂よりも発泡倍率が高いことを特徴とする請求項１から請求項３のいずれか１項に記載の乗物用内装材の製造方法。 Any one of claims 1 to 3, wherein the foamable resin applied to the surface of the mat in the mat making step has a higher foaming ratio than the foamable resin applied to the back surface of the mat. The method for manufacturing interior materials for vehicles described in the section. 前記マット作成工程において、前記マットは、少なくとも繊維により構成され、その表裏面に発泡性樹脂を塗布した繊維体を２つ重ねて作成することを特徴とする請求項１から請求項４のいずれか１項に記載の乗物用内装材の製造方法。 Any one of claims 1 to 4, wherein in the mat making step, the mat is made of at least two fibers, and two fibrous bodies coated with a foamable resin are laminated on the front and back surfaces thereof. The method for manufacturing an interior material for a vehicle according to item 1. 乗物用内装材であって、
少なくとも繊維と発泡性樹脂とにより構成された基材と、
少なくとも樹脂により構成され、前記基材に接合した樹脂部材と、を備え、
前記樹脂部材は、凹凸状の凹凸部を備え、
前記基材は、
発泡性樹脂高含有部と、
前記発泡性樹脂高含有部に比して、前記繊維に対する前記発泡性樹脂の含有率が低い発泡性樹脂低含有部と、を備え、
前記凹凸部は、前記発泡性樹脂低含有部に接合していることを特徴とする乗物用内装材。 Interior material for vehicles
A base material composed of at least fibers and a foamable resin,
A resin member composed of at least a resin and bonded to the base material is provided.
The resin member is provided with an uneven portion having an uneven shape.
The base material is
Highly foamable resin content and
A foamable resin low content portion having a low content of the foamable resin with respect to the fiber as compared with the foamable resin high content portion is provided.
An interior material for a vehicle, wherein the uneven portion is joined to the foamable resin low content portion.
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