JPH1071645A - Manufacture of roof lining for car - Google Patents

Abstract

PROBLEM TO BE SOLVED: To apply a device to the skin material bonded to corrugated cardboard being a base material to simultaneously subject all of respective layers to press molding to shape and form them into a predetermined three-dimensional shape by a reduced number of process, to improve the reproducibility of a mold shape and to certainly bond respective parts mutually and prevent the generation of wrinkles in the skin material. SOLUTION: Corrugated cardboard is used as a base material and a fiber mat 2 consisting of polyester fibers and hot-melt fibers is obtained and, further, a skin material 3 is integrated with the fiber mat 2 after the production of the fiber mat 2 and the laminate of the skin material 3 and the fiber mat 2 is superposed on the corrugated cardboard on the side of the fiber mat 2 and the whole is simultaneously shaped and formed into a predetermined three- dimensional shape by a hot press mold 10 and the corrugated cardboard 1 and the fiber mat 2 are bonded and fixed by the hot-melt adhesive 4 preliminarily applied to the fiber mat 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a roof lining for an automobile, which is formed from corrugated cardboard as a base material and formed as a molded ceiling.

[0002]

2. Description of the Related Art Conventionally, a roof lining for an automobile using a corrugated cardboard as a base material is constituted by bonding a cushion layer of urethane foam or the like to a skin material integrally with an intermediate layer. In order to manufacture the roof lining, the corrugated cardboard is formed into a predetermined three-dimensional shape by a hot press in advance, and then the skin material and the cushion layer are hot-pressed into the corrugated cardboard shaped into a predetermined three-dimensional shape in a separate process. In this way, bonding with an adhesive is performed.

In the above-mentioned roof lining manufacturing method, when a corrugated cardboard is formed by press forming the corrugated cardboard as it is, the wrinkles are likely to be formed near the outer periphery where the corrugated cardboard is pressed into a round shape, and the wrinkles are formed on the skin material. Appears after bonding. For this reason, a corrugated cardboard is slit in advance, and a reinforcing paper is attached to the corrugated cardboard to form a predetermined three-dimensional shape.

In addition, since the skin material is bonded in a separate step after the cardboard is press-formed into a predetermined three-dimensional shape, an adhesive cannot be applied to the cardboard in advance, and the adhesive is used to bond the skin material to the cardboard. At the time of application, it is applied to a skin material. Including the application of the adhesive, the slit processing, and the like, the above-described roof lining manufacturing method is not preferable because it requires a large number of steps and is extremely troublesome.

[0005] In addition, the corrugated cardboard has a high elasticity even if it is provided with a slit. Therefore, even if the corrugated board is press-formed into a predetermined round shape near the outer periphery, the cardboard is likely to return, so that the reversibility of the mold is poor. This is the same even when hot pressing is performed to bond the skin material. Therefore, roof lining using corrugated cardboard as a base material generally lacks reproducibility of the mold shape as compared with those using resin felt or the like as a base material.

[0006]

SUMMARY OF THE INVENTION The present invention uses a corrugated cardboard as a base material as a base material, and devises a skin material side to be adhered to the corrugated cardboard, and simultaneously press-molds each layer to reduce the number of steps. A method of manufacturing a roof lining for an automobile that can form a predetermined three-dimensional shape, improve the reproducibility of the shape of the mold, and reliably adhere each member to each other, and prevent wrinkles and the like from occurring on the skin material. The purpose is to provide.

[0007]

According to a first aspect of the present invention, there is provided a method of manufacturing a roof lining for an automobile, comprising a raw material corrugated cardboard as a base material, and a fiber mat comprising polyester fibers and heat fusion fibers. Further, after manufacturing the fiber mat, the skin material is integrated with the fiber mat, the laminate of the skin material and the fiber mat is superimposed on the corrugated cardboard on the fiber mat side, and the three members are heat-pressed into a predetermined solid body. At the same time, the corrugated cardboard and the fiber mat are bonded and fixed with a hot-melt adhesive previously applied to the fiber mat.

According to a second aspect of the present invention, there is provided a method for manufacturing a roof lining for an automobile, comprising a hollow polyester fiber and a heat fusion fiber, or a normal polyester fiber, a mixed fiber of a hollow polyester fiber and a heat fusion fiber. A fiber mat made of fibers is assembled.

According to a third aspect of the present invention, there is provided a method for manufacturing a roof lining for an automobile, comprising a composite heat-fusible fiber having a high melting point component as a core and a low melting point component as a sheath, and a polyester fiber. The fiber mat is to be assembled.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the accompanying drawings, a method for manufacturing a roof lining for an automobile will be described with reference to FIG.
As shown in the figure, the corrugated cardboard 1 is used as a base material, the fiber mat 2 and the skin material 3 are integrated beforehand, overlapped with the corrugated cardboard 1, and a hot press mold is applied to simultaneously form each layer into a predetermined three-dimensional shape. At the same time, the cardboard 1 and the fiber mat 2 are integrally bonded to each other.

Of these materials, a double-faced cardboard 1 comprising front and back runners 1a and 1b and a core paper 1c can be used as the cardboard 1. This corrugated cardboard 1 usually has a thickness of about 5 mm. Even if the corrugated cardboard is used as it is, a slit or reinforcement is provided in the corrugated cardboard 1 in order to prevent wrinkles or the like from occurring in the skin material 3 as described later. There is no need to perform processing such as attaching materials.

The fiber mat 2 is made of a mixture of polyester fibers and heat fusion fibers. This polyester fiber has a length of about 30 to 50 mm and 3 to
Normal polyester fibers having a fiber diameter of about 30 denier can be used.

[0013] In addition to the polyester fiber, a length of 30 to
A fiber mat made of hollow polyester fibers having a fiber diameter of about 6 denier at about 50 mm or a normal polyester fiber and hollow polyester fibers can be used. In addition, a plurality of types of ordinary polyester fibers having different fiber diameters can be mixed by selecting a plurality of types from those having different fiber diameters.

As the heat-fused fiber, any one of polyester fiber, polyethylene fiber and polypropylene fiber having a fiber diameter of about 3 denier and a melting point of about 80 to 130 ° C., or a mixed fiber thereof can be used. Preferably, the melting point is 97
It is good to use polyethylene fiber of about -110 ° C. Each of these fibers can be used in the form of a monofilament or a composite fiber.

When a conjugate fiber is used as the heat-fusible fiber, a concentric core-sheath conjugate fiber having a high melting point component in the core 2a and a low melting point component in the sheath 2b as shown in FIG. 2 is used. Good. Further, as shown in FIG. 3, concentric core-sheath type composite fibers in which cores 2a and 2a 'are formed from different high melting point components can be used.

To produce the fiber mat 2, 60 to 50% of polyester fiber and 40 to 50% of heat fusible fiber
The fibers may be mixed at a ratio of about 5%, and preferably 5% for each fiber.
It is preferable to form a mixture of 0%. The fiber mat 2 can be manufactured by needle punching a mixed fiber of a polyester fiber and a heat fusion fiber. The fiber mat 2 may have a mat thickness of about 6 m and a basis weight of about 150 to 300 g / m ² .

In the manufacturing process of the fiber mat 2,
After the matting of the fiber mat 2, the hot-melt adhesive 4 can be applied to the bonding surface with the cardboard 1 in the same step.
As the adhesive 4, a hot melt adhesive having a melting point of about 90 to 100 ° C. may be applied at about 5 to 10 g / m ² .

The skin material 3 can be integrated with the fiber mat 2 by needle-punching a nonwoven fabric such as a polyester fiber having a fiber diameter of about 3 denier into the fiber mat 2 after manufacturing the fiber mat 2. . The skin material 3 may be formed to a thickness of about 2 mm.

In addition to the nonwoven fabric, a woven fabric such as a tricot made of polyester fiber or the like can be integrated with the fiber mat 2 by subsequently bonding the fiber mat 2 with a hot-melt type adhesive after manufacturing the fiber mat. Like the nonwoven fabric, the skin material 3 is preferable because it has a small shrinkage stress during molding and has air permeability.

The laminated body of the skin material 3 and the fiber mat 2 is placed on the corrugated cardboard 1 on the fiber mat 2 side and placed on the lower mold 10a of the hot press mold 10, as shown in FIG. Thereafter, the upper die 10b of the hot press die 10 is moved downward to heat-press the three members simultaneously. The hot pressing is performed at a set temperature of about 120 ° C. to 140 ° C., and the temperature is preferably set to 130 ° C. The pressing pressure may be about 60 to 100 tons, and the pressing time may be about 30 to 60 seconds.

Depending on the hot pressing, the upper and lower dies 10a, 1
The three members can be simultaneously press-formed into a predetermined three-dimensional shape according to the uneven shape of Ob. At the same time, the fiber mat 2 can be bonded and fixed to the corrugated cardboard 1 with a hot-melt adhesive 4.

In the press molding, the fiber mat 2 adheres between the polyester fibers due to the heat fusion of the heat-fused fibers, and the fiber mat 2 having an initial thickness of about 6 mm as shown in FIG. It is compression molded to a thickness of about 5 mm and cured. For this reason, since the fiber mat 2 can maintain a predetermined three-dimensional shape, the upper and lower molds 10 do not return to the shape.
It is possible to maintain the shape of the shape corresponding to the uneven shape of a and 10b.

Further, since the skin material 3 has a small shrinkage stress during molding, fiber breakage due to shrinkage stress caused by compression molding of the fiber mat 2 can be prevented. Air can be removed. For this reason, the skin material 3 can maintain the shaped shape by the fact that the polyester fiber of the fiber mat 2 keeps the mold surface shape as it is. Therefore, as a whole, it is possible to obtain a product having good reproducibility of the mold shape that can be adhered to the three members integrally and follows the uneven shape of the press mold 10.

In addition, the polyester fiber of the fiber mat 2 serves as a cushioning material for the cardboard 1 and the skin material 3. From this, even if wrinkles or the like due to deep drawing near the outer periphery of the cardboard 1 occur, the cushioning property of the polyester fiber
Wrinkles and the like can be prevented from appearing on the skin material 3.

In addition to the prevention of wrinkles, the reproducibility of the mold shape can be further enhanced by using a core-sheath type fiber as the heat-sealing fiber of the fiber mat 2. In this core-sheath type heat-fused fiber, the sheath portion 2b of the low melting point component is thermally melted to bond the fibers together, and the core portion 2a (2a ') of the high melting point component is left as a fiber, so that the same as the polyester fiber. Function can be exhibited.

The fiber mat 2 functions as a cushion layer because the elasticity of the polyester fiber, particularly the elasticity and resilience of the hollow polyester fiber, and the space between the fibers is maintained. For this reason, the molded product has the same cushioning properties as those made of urethane foam or the like as a cushion layer.
The feel can also be kept good. In addition, since the skin material 3 can be formed into a soft layer together with the fiber mat 2 and has air permeability, the cushioning property and the sound absorbing effect can be enhanced.

[0027]

As described above, according to the method for manufacturing a roof lining for an automobile according to claim 1 of the present invention, the corrugated cardboard is used as it is, and the skin material is previously integrated with the fiber mat. The laminated body of the skin material and the fiber mat is assembled to a corrugated cardboard, and the three members are simultaneously hot-pressed with a hot press mold to form a three-dimensional shape and bond and fix each layer together. The process can be simplified and the production efficiency can be increased.

At the same time, since the fiber mat is interposed between the skin material and the corrugated cardboard, the reproducibility of the die shape following the die surface shape of the press die can be achieved with good reproducibility to form a predetermined three-dimensional shape. be able to. In addition, the fibers can be well bonded to each other by the heat-fused fibers, and furthermore, wrinkling of the skin material can be prevented by the cushioning property of the fiber mat.

According to the method for manufacturing a roof lining for an automobile according to the second aspect of the present invention, the elasticity of the polyester fiber, particularly, the elasticity and resilience of the hollow polyester fiber and voids between the fibers are provided. Therefore, the cushioning property and the feel can be kept good.

According to the method for manufacturing a roof lining for an automobile according to claim 3 of the present invention, the high melting point component is used as the core,
By interposing a mixed fiber mat of a composite type heat-sealing fiber and polyester fiber with a low melting point component as the sheath, the sheath of the low melting point component is melted by heat and the fibers are bonded to each other. Since the core portion remains as a fiber and exhibits the same action as the polyester fiber, the above-described effect can be further enhanced.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing each material to which a method for manufacturing a roof lining for an automobile according to the present invention is applied.

FIG. 2 is an explanatory view showing an example of a heat-fused fiber forming a fiber mat in each of the materials to which the method for manufacturing a roof lining for an automobile according to the present invention is applied.

FIG. 3 is an explanatory view showing another example of the heat fusion fiber of FIG. 2;

FIG. 4 is an explanatory view showing a hot press die to which the method for manufacturing a roof lining for an automobile according to the present invention is applied.

FIG. 5 is a partial cross-sectional view showing a roof lining press-formed by the manufacturing method according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Corrugated cardboard 2 Fiber mat 2a (2a ') High melting point component core 2b Low melting component sheath 3 Skin material 4 Hot melt adhesive 10 Hot press type

Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B29L 9:00 31:58

Claims (3)

[Claims] 1. A fiber mat comprising a polyester fiber and a heat-sealing fiber is obtained by using a raw corrugated cardboard as a base material,
Furthermore, after manufacturing the fiber mat, the skin material is integrated with the fiber mat, and the laminate of the skin material and the fiber mat is superimposed on the cardboard on the fiber mat side, and the three members are formed into a predetermined three-dimensional shape by a hot press mold. A method for manufacturing a roof lining for an automobile, wherein the corrugated cardboard and the fiber mat are fixedly formed at the same time and the cardboard and the fiber mat are bonded and fixed with a hot-melt adhesive previously applied to the fiber mat. 2. A fiber mat comprising hollow polyester fibers and heat fusion fibers or a fiber mat comprising ordinary polyester fibers, a mixture of hollow polyester fibers and heat fusion fibers. A method for manufacturing a roof lining for an automobile according to claim 1. 3. A fiber mat comprising a composite type heat-sealing fiber and a polyester fiber having a high melting point component as a core portion and a low melting point component as a sheath portion. 3. The method for producing a roof lining for an automobile according to 2.