JPH1044334A - Interior material for automobile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable the effective prevention of heat shrinkage, the stable installation of an interior material, and the preservation of good properties of appearance and design over a long period by mixing a specified quantity of an inorganic filler which regulates heat shrinkage into a resin skin layer. SOLUTION: Into a resin skin layer is mixed 5-15 pts.wt. of an inorganic filler which regulates heat shrinkage. A roof trim 10 is almost constituted from an expandable core material 20 molded in a desired shape and a skin material 30 which is stuck integrally to the surface side of the core material 20 and has good surface touch and appearance. It is molded in a somewhat warped shape to accord with the indoor surface shape of a roof panel. Foamed PPO resin is used as the core material 20, and a PPO resin skin layer 22 is formed integrally on both sides of a PPO resin foam layer 21.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile interior material suitable for an automobile molded ceiling and the like, and more particularly to an automobile interior material which eliminates deformation due to heat shrinkage and installation failure.

[0002]

2. Description of the Related Art In recent years, as a roof trim for an automobile to be installed in a roof panel of a passenger car, it is lightweight, and has excellent rigidity and heat resistance.
Synthetic resin foams having heat resistance, such as a core material (abbreviation of polyphenylene oxide) and a maleic acid-modified foamed PS (abbreviation of polystyrene) core material, are increasingly used as the core material.

FIGS. 5 and 6 show a mounting structure for attaching a roof trim using a foamed PPO core material to a ceiling of a vehicle. FIG. 5 shows an overall structure, and FIG. 6 shows a main structure.

In the drawings, a roof trim 1 is made of foam P
A skin material 3 such as cloth is adhered to the surface of a foamable core material 2 such as PO, and the foamable core material 2 is formed of a foam layer 2a.
The resin skin layer 2b is integrated on the front and back surfaces of the resin layer, and the skin layer 2b has a function of securing shape retention and controlling a variation in thickness when the foamed layer 2a expands.

[0005] Then, a method of manufacturing the roof trim 1,
A description will be given of a conventional example of an attachment structure to the roof panel 4. As a method of manufacturing the roof trim 1, a foamable core material 2 in which a resin skin layer 2b is integrated on the front and back surfaces of a foam layer 2a and a skin material 3 are provided. The foamed core material 2 and the skin material 3 are pressed and integrated by a cold press molding die after heating and softening after heating and softening to a shape of the roof panel 4 with the peripheral edge held by a clamp device. It is obtained by molding it into a slightly curved shape along it.

On the other hand, in order to attach the roof trim 1 to the roof panel 4, fixed points are set on the front side and the rear side of the roof trim 1, and a resin bracket 5 is mounted on the back side of the roof trim 1. The roof trim 1 is attached to the roof panel 4 by attaching and fixing the clip 6 to the bracket 5 and fitting the clip 6 into the mounting holes (front side 4a, rear side 4b) of the roof panel 4. However, the fact is that usually, the front side is attached as a reference point, and then the rear side is fixed accordingly.

[0007]

However, the foam P
The foamable core material 2 such as PO has a large degree of thermal shrinkage with respect to the metal roof panel 4, and in particular, shrinkage distortion is likely to occur along the longitudinal direction of the vehicle.

For this reason, the rear mounting hole 4b formed in the roof panel 4 is usually formed in an elongated shape along the longitudinal direction of the vehicle as shown in FIG. Has a play of ± 6 mm along the longitudinal direction of the vehicle.

When the bracket 5 is mounted on the roof trim 1, the mounting tolerance of the bracket 5 is ± 2 mm along the longitudinal direction of the vehicle. Therefore, the mounting tolerance of the clip 6 with respect to the mounting hole 4b of the roof panel 4 is Is regulated to ± 4 mm along the front-rear direction, but actually, since the expandable core material 2 shrinks by 5 mm or more, cracking of the bracket 5
When the bracket 5 does not come off, the terminal part of the roof trim 1 is apt to be deformed, such as waving, and the appearance is remarkably deteriorated. It was pointed out.

The present invention has been made in view of such circumstances, and is a light-weight, heat-resistant foamed PPO or foamed PPO.
In automotive interior materials using foamable core materials such as S,
Heat shrinkage can be effectively prevented, stable installation of interior materials,
It is another object of the present invention to provide an automotive interior material capable of ensuring excellent appearance design over a long period of time.

[0011]

Means for Solving the Problems In order to achieve the above-mentioned object, the present invention provides a foamed raw material having a resin skin layer laminated on the front and back surfaces of a resin foam layer, which is heated and softened, and then formed into a required shape. In automotive interior materials that have been trimmed,
In the resin skin layer, 5 to 15 parts by weight of an inorganic filler for controlling heat shrinkage is mixed.

The interior material is applied to a roof trim mounted on a roof panel of a vehicle, a door trim mounted on a side wall panel of a vehicle body, a rear corner trim, and a trim component installed in a trunk room or a luggage room. it can.

As the foamable core material, a foamed PPO core material, a foamed PS core material or the like is used. In the case of a foamed PPO core material, a PPO film is integrally formed as a resin skin layer on the front and back surfaces of the PPO foamed layer. Has been

In the case of the expanded PS core material, a resin skin layer of a polystyrene film also modified with maleic acid is formed on the front and back surfaces of a polystyrene foam layer modified with maleic acid. The material and the foamed PS core material are characterized by being lightweight and having excellent heat resistance and rigidity.

Next, as the inorganic filler to be mixed into the resin skin layer, talc, charcoal, silica, mica and the like can be used, and talc is preferable in terms of cost and function.

Next, the mixing ratio of the inorganic filler is 5 to 1
The reason for using 5 parts by weight is that if it is less than 5 parts by weight, a satisfactory effect of suppressing heat shrinkage cannot be obtained, and if it exceeds 15 parts by weight, the moldability of the resin skin layer is impaired.

In another embodiment, when 15 to 30 parts by weight of an inorganic filler and 5 to 10 parts by weight of a rubber composition are mixed in a resin skin layer, the mixing ratio of the inorganic filler increases and the moldability tends to decrease. However, it is characterized by adding 5 to 10 parts by weight of a rubber composition to supplement moldability.

As the rubber composition, synthetic rubber such as butadiene rubber and isoprene rubber or natural rubber can be used. When the ratio of the rubber composition is less than 5 parts by weight, the effect of maintaining good moldability is small. Conversely, if the rubber composition is 10
If the amount exceeds the weight part, the risk of the input cost is increased with respect to the expected effect.

As is clear from the above configuration, the interior material for automobiles according to the present invention has a foamable core material in which a predetermined amount of inorganic filler is contained in the resin skin layer laminated on the front and back surfaces of the foam layer. Even when the base is mixed, the inorganic filler does not shrink even if the base of the resin skin layer shrinks due to a change in environmental temperature, so that shrinkage of the entire foamable core material can be suppressed to a very small level.

Further, when a high proportion of inorganic filler and a rubber composition for supplementing moldability are mixed in the resin skin layer, the heat shrinkage of the expandable core material can be reduced by the high proportion of inorganic filler without impairing moldability. It is possible to more effectively suppress it.

[0021]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, an embodiment of an automobile interior material according to the present invention will be described in detail with reference to the accompanying drawings, with reference to an embodiment applied to a core material of an automobile roof trim.

FIG. 1 is a partially cutaway perspective view showing a roof trim, FIG. 2 is a schematic partial sectional view showing the structure of the roof trim,
FIG. 3 is an explanatory view showing a step of forming a raw foam core material, and FIG. 4 is a schematic partial sectional view showing another embodiment of the roof trim.

Referring to FIG. 1, a roof trim 10 for an automobile to which the present invention is applied has a recess formed on a front side for accommodating an occupant and a sun visor for a passenger seat, respectively. Are formed at three places on both sides of the housing for accommodating an assist grip or the like.

As shown in FIG. 2, the roof trim 10 is integrally adhered to a foamable core material 20 formed into a required shape and a surface side of the foamable core material 20 to obtain a good surface feel and And a skin material 30 having a surface appearance, and is formed into a slightly curved shape so as to conform to the indoor surface shape of a roof panel (not shown).

More specifically, in the present embodiment, the foamable core material 20 uses a foamed PPO resin, and a PPO resin skin layer 22 is integrally formed on the front and back surfaces of a PPO resin foam layer 21. And P in the present embodiment
The PO resin is not pure PPO but is modified by adding polystyrene in consideration of cost and the like.

As to specific numerical values of the foamable core material 20, the basis weight of the PPO resin foam layer 21 is 500 to 600.
g / m ² , the thickness of the PPO resin skin layer 22 is 0.18 m
m, and a material having a total thickness of 3.5 mm at the time of the raw material of the foamable core material 20 is softened by heating to 6 to 8 m
After being expanded to m, the foamed core material 20 is compressed by cold press molding and drawn to a final thickness of about 3 to 5 mm.

On the other hand, a cloth is used as the skin material 30, and a hot melt film (not shown) is laminated on the back surface of the cloth 30, and the foamable core material 20 and the skin material 30 are overlapped and preheated. Then, the foamable core material 20 and the skin material 30 are integrated with each other via the hot melt film by cold press molding the both.

The skin material 30 may be lined with a cushion material such as a polyurethane foam which imparts cushioning properties to the back surface of the cloth.

The feature of the present invention is that a stable installation can be expected by effectively suppressing heat shrinkage in an automotive roof trim 10 manufactured using a foamable core material 20 such as a foamed PPO resin. An object of the present invention is to prevent appearance defects such as warpage deformation and wavy deformation due to heat shrinkage.

For this purpose, PP in the foamable core material 20 is used.
Inorganic filler 4 for suppressing thermal shrinkage in O resin skin layer 22
The feature is that 0 is mixed.

FIG. 3 schematically shows a process of forming the raw material M in the expandable core material 20.
Through which the PPO resin foam layer 21 is extruded into a sheet shape, and the PPO resin skin layer 22 is supplied from the respective supply rolls 51 to the front and back sides of the PPO resin foam layer 21,
An original fabric M of the expandable core material 20 is formed by the press roll 52.

The PPO resin skin layer 22 is made of PP
An inorganic filler 40 is mixed in addition to the O resin. As the inorganic filler 40, talc, charcoal, silica, mica, or the like can be used.

The mixing ratio of the inorganic filler 40 is 5 to 15% based on the total weight of the PPO resin skin layer 22.
A range of parts by weight is preferred.

The reason for this is that if the mixing ratio of the inorganic filler 40 is less than 5 parts by weight, there is almost no effect of suppressing the heat shrinkage, and if the mixing ratio exceeds 15 parts by weight, the resin skin layer 22 This is because the moldability is reduced and it is difficult to form a complicated uneven shape as the roof trim 10.

For example, if 5 parts by weight of talc is mixed as the inorganic filler 40 in the PPO resin skin layer 22,
Compared with the conventional structure, the conventional structure has 5/10
Heat shrinkage of 00 mm or more is 2/1000 mm
It has become possible to suppress the degree of shrinkage due to thermal shrinkage.

FIG. 4 shows a second embodiment of the present invention, in which the roof trim 10 for an automobile is also applied.

The same parts as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.

In the second embodiment, the PPO resin skin layer 2 laminated on the front and back surfaces of the PPO resin foam layer 21
A high ratio of the inorganic filler 40 and fillers of the rubber composition 41 for compensating the moldability are added to the inside.

Examples of the inorganic filler 40 include talc, charcoal, silica, mica and the like, which can be appropriately selected. The addition ratio of the inorganic filler 40 is higher than that of the first embodiment. , PPO resin skin layer 22
15 to 30 parts by weight based on the total weight of

The reason for setting the upper limit to 30 parts by weight is as follows.
If the amount exceeds the weight part, the moldability is significantly reduced.

As the rubber composition 41, various rubber compositions such as natural rubber can be used in addition to synthetic rubber such as butadiene rubber and isoprene rubber. In the present embodiment, butadiene rubber is used. The addition ratio of rubber is set to 5 to 10 parts by weight.

The reason is that if the addition ratio of the rubber composition 41 is less than 5 parts by weight, good moldability cannot be ensured, and it is difficult to form a complicated shape such as the uneven shape of the roof trim 10. On the contrary, when the addition ratio of the rubber composition 41 exceeds 10 parts by weight, the economical risk is large for the expected effect.

For example, when 30 parts by weight of talc as a high proportion of inorganic filler 40 and 5 parts by weight of butadiene rubber as a rubber composition 41 for supplementing moldability are added to the inside of the PPO resin skin layer 22, the heat shrinkage of the roof trim 10 is reduced. The degree can be suppressed within 0.5 to 1.0 / 1000 mm, and the heat shrinkage can be further suppressed.

Accordingly, it is of course possible to prevent the outer trimming of the terminal of the roof trim 10 such as a waving fault or a warping fault, and also to manage the mounting error to the roof panel and the mounting error of the bracket relatively roughly. There is.

In the embodiment described above, the foamed PPO resin is used. However, the foamed PS core material can be used in place of the foamed PPO resin. The application can be set widely, such as applicable.

[0046]

As described above, the automotive interior material according to the present invention has the following special effects.

(1) The interior material for automobiles according to the present invention has a structure in which an inorganic filler for suppressing heat shrinkage is mixed in an appropriate ratio into the resin skin layer of the foamable core material, and therefore, the interior material for the automobile is subject to fluctuations in environmental temperature. Since the heat shrinkage of the interior material can be suppressed to a small extent, problems such as breakage of brackets and detachment of clips for attaching the interior material to the panel can be eliminated, and stable attachment of the interior material to the panel can be guaranteed for a long time. It has the effect of.

(2) The interior material for automobiles according to the present invention has a structure in which an inorganic filler for suppressing heat shrinkage is mixed at an appropriate ratio in a resin skin layer laminated on the front and back surfaces of the foam layer. It is possible to suppress the heat shrinkage of the interior material due to the fluctuation of the interior material, so that the terminal portion of the interior material does not deform such as waving or warpage, and the initial shape can be favorably maintained for a long time. Has an effect.

(3) The second aspect of the present invention has a structure in which a high proportion of an inorganic filler and a rubber composition are added in an appropriate amount to the resin skin layer. Because it can be regulated to a small size, in addition to the effect of stably attaching the interior material to the panel and effectively preventing wavy deformation, etc., the mounting tolerance of brackets and panels due to extremely small heat shrinkage This has the effect that it can be set small.

[Brief description of the drawings]

FIG. 1 is a partially cutaway perspective view showing an automobile roof trim showing one embodiment of an automobile interior material according to the present invention.

FIG. 2 is a schematic sectional view showing a configuration of the automotive roof trim shown in FIG.

FIG. 3 is an explanatory diagram showing a step of forming a raw foam core material used in the present invention.

FIG. 4 is a schematic cross-sectional view showing the configuration of another embodiment of the interior material for a vehicle according to the present invention.

FIG. 5 is an overall view showing a mounting structure for mounting a conventional automobile roof trim to a roof panel.

FIG. 6 is a partial perspective view showing a mounting structure for mounting a conventional automobile roof trim to a roof panel.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Automotive roof trim 20 Foamable core material 21 PPO resin foam layer 22 PPO resin skin layer 30 Skin material 40 Inorganic filler 41 Rubber composition 50 T-die extruder 51 Supply roll 52 Crimping roll M Foamable core material

Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location B32B 31/18 9349-4F B32B 31/18 // C01B 33/22 C01B 33/22

Claims (3)

[Claims] 1. A foamable core material (M) in which a resin skin layer (22) is laminated on the front and back surfaces of a resin foam layer (21) is heat-softened, formed into a required shape, and trimmed. An interior material for an automobile, comprising 5 to 15 parts by weight of an inorganic filler (40) for controlling heat shrinkage in the resin skin layer (22). 2. A foamable core material (M) in which a resin skin layer (22) is laminated on the front and back surfaces of a resin foam layer (21) is heat-softened, formed into a required shape, and trimmed. In the automotive interior material, the resin skin layer (22) contains 15 to 30 parts by weight of an inorganic filler (40) for controlling heat shrinkage and a rubber composition (41) for improving moldability. Is 5 to 1
An interior material for automobiles, wherein 0 parts by weight are added. 3. The interior material for an automobile according to claim 1, wherein said inorganic filler (40) is talc.