JPS5928461B2 - Manufacturing method for vehicle interior materials - Google Patents

Description

【発明の詳細な説明】 従来、自動車その他の車輛用内装材を内装面に応当して
予め成形された基材の内面側に熱溶着型接着剤を介し織
布、不織布、塩化ビニル樹脂その他の熱可塑性樹脂シー
ト等の表装材を貼合せて製造する場合、（支）貼合せ面
に熱溶着型接着剤層を設けた表装材を加熱して該接着剤
を溶融すると共に表装材を軟化させておき、あるいは貼
合せ面に前記接着剤層を設けた成形基材を加熱して該接
着剤を溶融させると共にこれに貼合される表装材は別に
加熱して軟化させておき、前記成形基材と表装材とを成
形型を用い加圧若しくは真空により圧着して貼合せ、又
０３）何れか一方若しくは両方に熱溶着型接着剤層を有
する表装材と成形基材とを該接着剤の熱溶着温度に加熱
した成形型にかけ前記同様に圧着して貼合せているが、
前記（支）では表装材がその軟化点以上に加熱され、又
前記（２）では表装材の表面（内装材の表面になる面）
力功口熱された型面に接して、表面の織目が潰れたり、
シボが消失したり、表面に艶を生じ不自然な光沢になつ
たりした不合格品が生じ易く、仕上りがよく見栄のすぐ
れた貼合せ品が高能率で得難いものである。[Detailed Description of the Invention] Conventionally, interior materials for automobiles and other vehicles have been coated with woven fabrics, non-woven fabrics, vinyl chloride resins, and other materials using a heat-welding adhesive on the inner surface of a preformed base material corresponding to the interior surface. When manufacturing by laminating facing materials such as thermoplastic resin sheets, (support) the facing material with a heat-welding adhesive layer provided on the pasting surface is heated to melt the adhesive and soften the facing material. Alternatively, the molded base material with the adhesive layer provided on the bonding surface is heated to melt the adhesive, and the facing material to be bonded to this is heated separately to soften it, and then the molded base material is heated to melt the adhesive. 03) The facing material and the molding base material, which have a heat-welding adhesive layer on either or both, are bonded together using pressure or vacuum using a mold. They are pasted together by applying pressure to the mold heated to the heat welding temperature and bonding in the same manner as above.
In the above (support), the facing material is heated above its softening point, and in the above (2), the surface of the facing material (the surface that will become the surface of the interior material)
When it comes into contact with the heated mold surface, the surface weave may collapse,
Rejected products with grains disappearing or gloss on the surface with an unnatural luster are likely to occur, making it difficult to produce laminated products with a good finish and good appearance with high efficiency.

本発明は成形基材をこれに貼合される表装材の成形貼合
せが可能な温度に加熱すると共にこれに使用する成形型
はその型温を加圧貼合せ中少くとも表装材の軟化点以下
に保持するもので、表装材表面の織目や、しぼの消失が
なく、又表面に不自然な光沢も生ぜず、仕上り及び見栄
のよいものが高能率で容易にできるものである。以下実
施例について説明すると、表装材を貼合せる成形基材は
各種動植物繊維、合成繊維、ぼろ、織物その他の布帛の
裁断屑を解繊した繊維に熱可塑性若しくは熱硬化性樹脂
接着剤の単独あるいは混合してその所定量を混合し、所
要の厚み、形状の層状体に形成し、これを自動車その他
の車輛天井、側壁等の内装面に応当して作成された加圧
成形型に入れて適当な条件下に加圧加熱して所定形状に
成形されたファイバーボード製がある。The present invention heats the molded base material to a temperature at which the facing material to be laminated thereon can be molded and laminated, and the mold used for this heats the mold temperature to at least the softening point of the facing material during pressure lamination. The surface of the covering material does not lose its texture or grain, nor does it produce any unnatural luster on the surface, and can easily produce a good finish and appearance with high efficiency. To explain the following examples, the molding base material to which the facing material is attached is made of fibers made from various animal and plant fibers, synthetic fibers, rags, fabrics, and other fabrics, and a thermoplastic or thermosetting resin adhesive is used alone or A predetermined amount of the mixture is mixed, formed into a layered product of the desired thickness and shape, and placed in a pressure mold made to suit interior surfaces such as ceilings and side walls of automobiles and other vehicles. There are fiberboard products that are molded into a predetermined shape by being heated under pressure under certain conditions.

上記繊維層状体を形成する繊維中に熱可塑性合成繊維を
含むものには接着剤を混合しない場合もある。又発泡し
た若しくは発泡しない且適度に腰の強い各種合成樹脂を
主材として成形したもの、段ボールを主材として成形し
たもの等がある。上記成形基材の内面側に貼合される表
装材には、塩化ビニル樹脂、ポリアミド樹脂、その他の
合成樹脂シート、不織布、織布、編布等があり、必要に
応じてこれらの裏面にポリウレタンフオームその他のフ
オーム、フエルト等の緩衝材を接着、縫着等して重着し
たものもある。In some cases, the fibers forming the fiber layered body containing thermoplastic synthetic fibers may not be mixed with an adhesive. There are also molded materials mainly made of foamed or non-foamed and moderately strong synthetic resins, and molded materials made mainly of corrugated cardboard. The facing material to be bonded to the inner surface of the molded base material includes vinyl chloride resin, polyamide resin, other synthetic resin sheets, nonwoven fabrics, woven fabrics, knitted fabrics, etc. If necessary, polyurethane may be applied to the back side of these materials. There are also cushioning materials such as foam, other foam, and felt that are glued or sewn together.

上記成形基材の加熱温度は加圧型において前記表装材を
加圧貼合する際少くとも貼合用接着剤が溶融して接着可
能になるような適当な温度に選択されるものであり、例
えば、シート状の一般のホツトメルト型接着剤を使用す
る場合、該基材は少くとも表面温度を約１１０〜１５０
℃に加熱して好結果が得られることが多い。The heating temperature of the molding substrate is selected to be an appropriate temperature such that at least the laminating adhesive melts and becomes bondable when the facing material is laminated under pressure in a pressure mold. When using a general hot melt adhesive in the form of a sheet, the substrate has a surface temperature of at least about 110 to 150
Good results are often obtained by heating to ℃.

前記成形基材の加熱は該基材の成形時に加えた熱を利用
して成形直後の加熱状態にあるものをそのまま若しくは
これを更に加熱したものでもよく、熱効率の向上が可能
になる。上記貼合せに使用される熱溶融型接着剤はエチ
レン一酢酸ビニル共重合体系、ポリアミド系、工チレン
ーアクリル共重合体系、ポリエステル系、ポリウレタン
系その他があり、これら接着剤は予め前記表装材の貼合
せ面に適当な方法で塗着固化して置き、あるいはシート
状のものを前記表装材の貼合せ面に仮着等して使用でき
る。The heating of the molded base material may be performed by utilizing the heat added during molding of the base material, which is in a heated state immediately after molding, or by further heating it, thereby making it possible to improve thermal efficiency. The hot-melt adhesives used for the above lamination include ethylene monovinyl acetate copolymer systems, polyamide systems, ethylene-acrylic copolymer systems, polyester systems, polyurethane systems, and others. It can be used by applying and hardening it on the surface to be bonded by an appropriate method, or by temporarily attaching a sheet-like material to the surface to be bonded to the surface material.

上記の如く加熱された成形基材に表装材を貼合せるには
、例えば成形基材の貼合せ面を上にして応当する加圧成
形型（下型）に挿入し、その上に貼合せ面に予め適当な
熱溶融型接着剤のフイルムを仮着若しくは該熱溶融型接
着剤の塗布して形成された固化層を設けた表装材を適当
な方法で張設し、表装材の上から前記下型に対向する押
圧型（上型）で、圧力約０．１〜５．０ｋ９／ｄにして
、約１０〜６０秒間加圧する。In order to laminate the facing material to the heated molded base material as described above, for example, insert the molded base material with the laminate side facing up into the corresponding pressure mold (lower mold), and then place the laminate surface on top of the molded base material. A covering material with a solidified layer formed by temporarily adhering a film of a suitable hot-melting adhesive or coating the hot-melting adhesive is applied in advance to the surface by an appropriate method, and the above-mentioned Pressure is applied for about 10 to 60 seconds at a pressure of about 0.1 to 5.0 k9/d using a pressing die (upper die) facing the lower die.

この場合加圧貼合せ中の前記型温は表装材の軟化点以下
、好ましくは約４０℃以下に保持されるもので、必要に
応じて型は水冷その他の方法で冷却される。上下型は共
に軟化点以下に保持してもよいが、表装材の表面と接す
る型例えば上型を軟化点以下に保持しても同様の効果が
楊られることもある。本発明は上述の如く表装材の貼合
せ面に設けられた接着剤の融着温度以上に加熱された成
形基材に前記の熱溶融型接着剤を有する表装材を圧接す
るから、表装材の貼合せ面の熱溶融型接着剤は加熱され
た成形基材の熱によつて溶融すると共に、表装材自体も
該接着剤の付着側が成形に支障ない程度適当に軟化し、
表装材は成形基材の表面形状に応当して形付されると共
に前記の溶融した接着剤は固化し全面にわたり均一強固
な接着ができ、そのさい圧接は、表装材の軟化点以下に
保持された型を用いるから、表装材表面のしぼが消失し
たり、織目がつぶれたり、表面に不自然な艶が出たりし
て外見を損することが全然なく、前記接着剤の固化も迅
速で早急に型から取出しても変形することがなく、型の
回転も極めて早くなるし、表装材の裏面上にポリウレタ
ンフオーム等の緩衝材を裏装した場合でも、該溶融接着
剤が緩衝材内に深く浸入固化してその緩衝性を阻害する
こともなく、且そのさい接着剤が緩衝材内に浸入しない
から、少量の接着剤の使用で充分強固な貼合せができ、
前記不良品のないことと型の回転率のよい点と相俟つて
経済的にも有利なもので、自動車その他の車輛の天井、
側壁、特に成形天井、嵌込み天井、嵌込み壁等量産に好
適である。In this case, the temperature of the mold during pressure lamination is kept below the softening point of the facing material, preferably at about 40° C. or below, and the mold is cooled by water cooling or other methods as necessary. Although both the upper and lower molds may be maintained at a temperature below the softening point, the same effect may be obtained even if the mold in contact with the surface of the facing material, such as the upper mold, is held at a temperature below the softening point. In the present invention, as described above, the facing material having the hot-melt adhesive is pressure-bonded to the molded base material heated above the melting temperature of the adhesive provided on the bonding surface of the facing material. The hot-melt adhesive on the bonding surface is melted by the heat of the heated molding base material, and the surface material itself is appropriately softened on the side to which the adhesive is attached to an extent that does not interfere with molding.
The facing material is shaped according to the surface shape of the molded base material, and the molten adhesive solidifies to form a uniform and strong bond over the entire surface, and the pressure welding is maintained below the softening point of the facing material. Since a mold is used, there is no loss of wrinkles on the surface of the covering material, collapse of the weave, or unnatural gloss on the surface, which will not damage the appearance, and the adhesive will harden quickly. It does not deform even when removed from the mold, the mold rotates extremely quickly, and even when a cushioning material such as polyurethane foam is lined on the back side of the facing material, the molten adhesive does not penetrate deeply into the cushioning material. Since the adhesive does not penetrate and harden and impair its cushioning properties, and the adhesive does not penetrate into the cushioning material, a sufficiently strong bond can be achieved with the use of a small amount of adhesive.
Combined with the absence of defective products and the high rate of mold turnover, it is economically advantageous, and can be used for the ceilings of automobiles and other vehicles.
Suitable for mass production of side walls, especially molded ceilings, inset ceilings, inset walls, etc.

例１ ほろ、織物屑等を解繊した繊維材料１５５０９／ＴＩに
対し樹脂分５５０９／ｍ”の割合で熱硬化性樹脂を混合
付着させ自動車の天井内張りの大きさに応じた所定巾、
厚さの長尺の繊維層状体ｌこ形成する。Example 1 A thermosetting resin is mixed and adhered to the fiber material 15509/TI, which is made by defibrating fabric waste, etc., at a resin content of 5509/m'' to a predetermined width according to the size of the ceiling lining of an automobile.
A thick long fiber layered body is formed.

Claims (1)

【特許請求の範囲】[Claims] １ 内装面に応当して所要形状に形付けられた成形基材
の所要面に熱溶融型接着剤を介して表装材を貼合せる場
合、前記成形基材を少くとも表装材の貼合せ面に設けら
れた熱溶融型接着剤の融着可能温度に加熱し、成形基材
と表装材との貼合面を対向させて表装材の軟化点以下に
保持された型にかけて加圧し表装材を成形基材に貼合す
ることを特徴とする車輛用内装材の製造方法。1. When bonding a facing material to the required surface of a molded base material shaped into a desired shape corresponding to the interior surface via a hot-melt adhesive, the molded base material is attached at least to the surface to be bonded of the facing material. The adhesive is heated to a temperature at which it can be fused, and the surfaces to be bonded between the molding base material and the facing material are placed facing each other, and pressure is applied to the mold, which is maintained below the softening point of the facing material, to form the facing material. A method for manufacturing a vehicle interior material, which comprises laminating it onto a base material.