JP3503829B2 - Automotive interior materials - Google Patents
Automotive interior materialsInfo
- Publication number
- JP3503829B2 JP3503829B2 JP26824693A JP26824693A JP3503829B2 JP 3503829 B2 JP3503829 B2 JP 3503829B2 JP 26824693 A JP26824693 A JP 26824693A JP 26824693 A JP26824693 A JP 26824693A JP 3503829 B2 JP3503829 B2 JP 3503829B2
- Authority
- JP
- Japan
- Prior art keywords
- honeycomb core
- laying
- fiber material
- thermoplastic resin
- skin fiber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 239000000463 material Substances 0.000 title claims description 28
- 239000004745 nonwoven fabric Substances 0.000 claims description 17
- 239000002657 fibrous material Substances 0.000 claims description 15
- 229920005992 thermoplastic resin Polymers 0.000 claims description 10
- 239000000758 substrate Substances 0.000 claims description 3
- 239000011162 core material Substances 0.000 claims 3
- 238000003860 storage Methods 0.000 description 5
- 239000000835 fiber Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- -1 polypropylene Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
Landscapes
- Passenger Equipment (AREA)
- Laminated Bodies (AREA)
Description
【発明の詳細な説明】
【０００１】
【産業上の利用分野】この発明は自動車のフロアパネル
上に敷設する敷設内装材に関する。
【０００２】
【従来の技術】従来、自動車の室内装飾用の内装材とし
てフロアパネル上にはカーペット類を敷設している。た
とえば図４はラッゲージルーム５０への敷設例である。
この種のカーペットはニードルパンチカーペット、タフ
テッドカーペット、不織布などであり、裏面に熱可塑性
樹脂のバッキングをほどこして、おおむねフロアパネル
にそった形状に付形してなるものである。カーペットは
ある程度のかたさを有しているとはいえ、繊維を主体に
した柔軟な素材であって、本質的にフロアパネルにもた
れる敷設態様である。この敷設態様はカーペットのフロ
アパネルへの敷設方法としておおむね好便なものである
がフロアパネルの一部にはこのような敷設態様がゆるさ
れない部位もある。たとえば、非常用タイヤ収納用の凹
部の上への敷設などである。この場合、フロアパネルに
凹凸があるから、これにそってカーペットが波うってし
まうし、カーペットを介して床面の凹凸が触感されるか
ら好ましくない。そこで従来図４のＡ−Ａ’線断面図５
に示すように、この部分だけは凹部２１より大きい面積
の硬質板４０をもって凹部に蓋をして、その上からカー
ペット１１を敷設する方法（たとえば実開昭６２−１１
７１７８号）が提案されている。これはいちおう前記の
課題を克服する。しかしながら、別体の硬質板を配置す
ることによるタイヤ取り出しにくさ、見栄えの悪さに加
えて、重量の増加という問題を派生して好ましくない。
さらに、工具収納用凹部２２の上への敷設においても、
同様に硬質板４０’をもって蓋をしてカーペットを敷設
するが、この部位を開閉可能な蓋構造とするためにヒン
ジ片を形成する必要がある。従来の方法はカーペットの
裏面に硬質板を接着して、カーペットの硬質板を接着し
てある部分と硬質板のない部分の境界をヒンジ片１５’
にする方法により、開閉動作を繰り返すことによるカー
ペットと硬質板の剥離を避けるために、補強用の不織布
４５を接着して補強する必要があり、煩雑な工程を要す
るものであった。
【０００３】ところで、この種の非常用タイヤおよび非
常用タイヤ収納用の凹部の寸法関係として通常、（凹部
の深さ＞タイヤの厚さ）の関係が満たされていることは
従来の内装材の敷設態様から必然のことである。しかし
ごく一部の車両において、（凹部の深さ＜タイヤの厚
さ）なる関係のものもある。これはたとえば、寒冷地仕
様車などの特殊な仕様の車両において、タイヤの厚さが
通常の車両より大きいものを採用する必要があり、しか
して、その仕様の車両の量産数が少ないために、ボディ
パネル形状は普通仕様車と共有している場合などにおこ
る。このような場合、もはや前記のような従来の敷設態
様は不可能であるため、不都合を甘受してカーペットを
敷設するしかなかった。
【０００４】
【発明が解決しようとする課題】本発明は上記課題にか
んがみ、特に自動車のフロアパネルの非常用タイヤ収納
用の凹部に、この凹部の深さより厚さの厚いタイヤを収
納した状態で、フロアパネルの上面をおおって敷設する
に好適な、軽量で剛性のある自動車用敷設内装材の製造
方法および敷設内装材を提供する。
【作用】本発明の内装材は、ハニカムコアの表面に目付
量が２００ｇ／ｍ2 未満の低目付の不織布が接着してあ
り、表皮繊維材の裏面に熱可塑性樹脂の裏打がほどこさ
れているので、表皮繊維材を加熱して裏打を軟化させ、
（あるいは同時にハニカムコアも加熱して）軟化した裏
打に不織布を入りこませるように積層押圧して両者を
（接着剤を用いずに）一体化するとともに、成形するこ
とができるこの内装材は、軽量で高剛性であり、特に耐
押圧荷重にすぐれることで下方に空間をもって敷設して
も、波うちをおこしたりすることがない。また、ハニカ
ムコアを切欠くことで、容易にヒンジ態様の一辺を形成
することができる。
【０００５】
【課題を解決するための手段】課題を解決するための本
発明の手段は、少なくとも片面に目付け量２００ｇ／ｍ
2 未満の不織布をあらかじめ積層してなる熱可塑性樹脂
のハニカムコア基材と、裏面に熱可塑性樹脂の裏打をほ
どこした表皮繊維材を、それぞれの熱可塑性樹脂が軟化
するまで加熱し、次いでハニカムコア基材の不織布と表
皮繊維材の裏打が向き合うように重ねて、表皮繊維材と
ハニカムコア基材を押圧一体化すると同時に所要の形状
に成形する自動車のフロアパネル上に敷設する自動車用
敷設内装材の製造方法およびこの製造方法によって得ら
れる自動車用敷設内装材であり、また、この自動車用敷
設内装材において、この内装材の少なくとも、この内装
材を敷設するフロアパネルの非常用タイヤ収納用凹部の
上面は、一般面より突出した凸形状に成形されている自
動車用敷設内装材、および、この内装材中に含まれる少
なくとも一辺が、ハニカムコア基材を切欠いてなるヒン
ジ片に形成されている自動車用敷設内装材である。
【０００６】
【実施例】以下、図面にもとづいて、本発明の好適な一
実施例を説明する。図１は本発明の敷設内装材１０であ
り、おおむね敷設位置のラッゲージルームにそった外形
である。ハニカムコア１３は、ポリプロピレン樹脂シー
トに多数の円柱突起を形成し、さらに両面を同樹脂のラ
イナーで被覆したものである。厚さが５ｍｍ、目付け量
は１５００ｇ／ｍ2 であり、片面に不織布１４を接着し
ている。不織布は目付け量が１００ｇ／ｍ2 、ポリプロ
ピレン繊維８５％、ポリエステル繊維１５％の混繊不織
布である。表皮繊維材１１はポリエステル繊維のプレー
ン調ニードルパンチカーペット、目付け量が２５０ｇ／
ｍ2 であり、裏面に低密度ポリエチレン樹脂の裏打１２
を目付け量２５０ｇ／ｍ2 ほどこしてなる。表皮繊維材
とハニカムコアの一体化および同時成形は以下のように
おこなう。まず、表皮繊維材を裏面側（裏打側）から加
熱して、熱可塑性樹脂である裏打を軟化状態におく。ま
た同じく熱可塑性樹脂からなるハニカムコアも加熱して
可塑性を発現する状態にしておく。次に、ハニカムコア
の不織布を接着してある面を上にして、上側から表皮繊
維材を重ね、これを上下対のプレス成形型内に配して押
圧付形する。不織布の毛羽が裏打の中に入り込んで固着
されることで、表皮繊維材とハニカムコアが一体化さ
れ、付形形状が固定された段階で、脱型することによ
り、目的の敷設材を得ることができる。この敷設内装材
の成形において、敷設位置フロアパネルの非常用タイヤ
収納用凹部の上面は、一般面より突出した凸形状に成形
されている。これは、図１のＡ−Ａ’線断面図である図
２にしめされるように、ハニカムコアの可塑性を利用し
て、しぼり成形してなるものである。凸形状の大きさ
は、タイヤ収納凹部より大きい直径の円形であり、高さ
は２０〜５０ｍｍ程度である。さらに好ましい実施態様
は、工具収納用凹部の上面を開閉可能な蓋構造にするた
め、ハニカムコアを直線状に切欠いてヒンジ片を形成す
る。これは図１のＢ−Ｂ’線断面図である図３に詳細が
示されるが、ハニカムコアを厚さ方向に切断する直線状
の切欠１３ａであって、しかしてこの切欠はハニカムコ
アの上側に位置する不織布、表皮繊維材には達しないも
のであって、表皮繊維材（裏打）、不織布によって柔軟
で耐久性に優れたヒンジ片１５となっている。
【０００７】
【発明の効果】本発明の敷設内装材は、軽量、高剛性、
成形性の各特性がすぐれる。表皮材と基材を接着剤を用
いずに一体化し、同時に成形することができる。特に、
自動車のフロアパネルの非常用タイヤ収納用の凹部上を
凸形状に成形し、この凹部に凹部の深さより厚さの厚い
タイヤを収納した場合に敷設するのに好適である。また
強固なヒンジ片を簡単に形成することができる。Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laying interior material laid on a floor panel of an automobile. Conventionally, carpets are laid on floor panels as interior materials for interior decoration of automobiles. For example, FIG. 4 shows an example of laying in a luggage room 50.
This type of carpet is a needle punch carpet, a tufted carpet, a non-woven fabric, or the like, and is formed by applying a backing made of a thermoplastic resin on the back surface and forming a shape substantially along the floor panel. Although the carpet has a certain degree of hardness, it is a flexible material mainly composed of fibers, and is essentially a laying mode leaning against a floor panel. This laying mode is generally convenient as a method of laying carpets on floor panels, but there are some parts of the floor panel where such laying modes are not relaxed. For example, laying on a recess for storing emergency tires. In this case, since the floor panel has irregularities, the carpet undulates along with the irregularities, and the irregularities on the floor surface are tactilely sensed through the carpet, which is not preferable. Therefore, a cross-sectional view taken along line AA ′ of FIG.
As shown in FIG. 7, only this portion is covered with a hard plate 40 having an area larger than that of the recess 21, and the carpet 11 is laid thereon (for example, see Japanese Utility Model Application Laid-Open No. 62-11).
No. 7178) has been proposed. This overcomes the aforementioned problems. However, in addition to the difficulty of taking out the tire and the poor appearance due to the arrangement of the separate hard plate, the problem of an increase in weight is undesirably caused.
Furthermore, in laying on the tool storage recess 22,
Similarly, the carpet is laid with the lid covered with the hard plate 40 ', but it is necessary to form a hinge piece in order to form a lid structure capable of opening and closing this part. In the conventional method, a hard plate is bonded to the back surface of the carpet, and the boundary between the portion where the hard plate is bonded to the carpet and the portion where the hard plate is not provided is hinged 15 '.
In order to avoid the peeling of the carpet and the hard plate due to the repeated opening and closing operations, it is necessary to bond and reinforce the nonwoven fabric 45 for reinforcement, which requires a complicated process. By the way, the dimensional relationship between this kind of emergency tire and the recess for accommodating the emergency tire usually satisfies the relationship (depth of recess> thickness of tire), which means that a conventional interior material has This is inevitable from the laying mode. However, in a very small number of vehicles, there is also a relation of (depth of concave portion <thickness of tire). This is because, for example, in a special specification vehicle such as a cold region specification vehicle, it is necessary to adopt a tire having a thickness greater than that of a normal vehicle, and since the number of vehicles of that specification is small, The body panel shape occurs when it is shared with a normal specification car. In such a case, since the conventional laying mode as described above is no longer possible, the carpet has to be laid without any inconvenience. SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and particularly, in a state in which a tire having a thickness greater than the depth of the concave portion is stored in a concave portion for storing an emergency tire of an automobile floor panel. A method for manufacturing a lightweight and rigid automobile laying interior material suitable for laying over an upper surface of a floor panel, and a laying interior material are provided. In the interior material of the present invention, a nonwoven fabric having a low basis weight of less than 200 g / m 2 is adhered to the surface of the honeycomb core, and a backing of a thermoplastic resin is provided on a back surface of the skin fiber material. So, heat the skin fiber material to soften the backing,
This interior material, which can be laminated and pressed (without using an adhesive) to form a non-woven fabric into the softened backing (or by heating the honeycomb core at the same time) to integrate them together (without using an adhesive), It is lightweight and highly rigid, and has excellent pressure resistance, so that it does not wobble even if it is laid with a space below. In addition, by cutting out the honeycomb core, one side of the hinge mode can be easily formed. [0005] Means for solving the problems of the present invention is that at least one side has a basis weight of 200 g / m2.
A honeycomb core substrate of a thermoplastic resin obtained by previously laminating less than 2 nonwoven fabrics, and a skin fiber material having a backing of a thermoplastic resin on the back surface are heated until each thermoplastic resin is softened, and then a honeycomb core is formed. An automotive laying interior material laid on an automobile floor panel, which is formed by stacking the nonwoven fabric of the base material and the backing of the skin fiber material facing each other and pressing and integrating the skin fiber material and the honeycomb core base material into the required shape. And an automobile laying interior material obtained by the production method, and in this automobile laying interior material, at least one of the interior lining materials includes an emergency tire storage recess of a floor panel on which the interior lining material is laid. The upper surface has an interior laying material for automobiles formed into a convex shape protruding from a general surface, and at least one side included in the interior material has c. This is an automobile interior lining material formed on a hinge piece formed by cutting out a honeycomb core base material. Hereinafter, a preferred embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a laying interior material 10 according to the present invention, which has an outer shape generally along a luggage room at a laying position. The honeycomb core 13 is formed by forming a large number of cylindrical protrusions on a polypropylene resin sheet, and further covering both surfaces with a liner of the same resin. The thickness is 5 mm, the basis weight is 1500 g / m 2 , and the nonwoven fabric 14 is adhered to one side. The non-woven fabric is a mixed non-woven fabric having a basis weight of 100 g / m 2 , 85% of polypropylene fibers, and 15% of polyester fibers. The skin fiber material 11 is a plain needle punch carpet made of polyester fiber, and the basis weight is 250 g /.
m 2 , and a low-density polyethylene resin
Is weighed about 250 g / m 2 . The integration and simultaneous molding of the skin fiber material and the honeycomb core are performed as follows. First, the skin fiber material is heated from the back side (backing side), and the backing, which is a thermoplastic resin, is kept in a softened state. Similarly, a honeycomb core made of a thermoplastic resin is also heated to a state where plasticity is developed. Next, with the surface of the honeycomb core to which the nonwoven fabric is adhered facing up, the skin fiber material is overlaid from above, and this is placed in a pair of upper and lower press molds and pressed to form. When the fluff of the nonwoven fabric enters into the backing and is fixed, the skin fiber material and the honeycomb core are integrated. Can be. In forming the laid interior material, the upper surface of the emergency tire storage recess of the floor panel at the laid position is formed in a convex shape protruding from the general surface. As shown in FIG. 2, which is a cross-sectional view taken along the line AA ′ of FIG. 1, this is formed by squeezing using the plasticity of the honeycomb core. The size of the convex shape is a circle having a diameter larger than that of the tire housing concave portion, and the height is about 20 to 50 mm. In a further preferred embodiment, in order to form a lid structure capable of opening and closing the upper surface of the tool storage recess, the honeycomb core is cut linearly to form a hinge piece. This is shown in detail in FIG. 3, which is a cross-sectional view taken along the line BB 'in FIG. 1, and is a straight notch 13a for cutting the honeycomb core in the thickness direction. , And does not reach the nonwoven fabric and the skin fiber material. The skin fiber material (lining) and the nonwoven fabric form the hinge piece 15 which is flexible and has excellent durability. [0007] The laying interior material of the present invention is lightweight, high rigidity,
Excellent moldability characteristics. The skin material and the base material can be integrated without using an adhesive and molded at the same time. In particular,
The present invention is suitable for laying when a tire having a thickness greater than the depth of the concave portion is formed into a convex shape on the concave portion for storing the emergency tire of the floor panel of the automobile, and the concave portion is formed in the concave portion. In addition, a strong hinge piece can be easily formed.
【図面の簡単な説明】
【図１】本発明の敷設内装材斜視図
【図２】図１のＡ−Ａ線断面図
【図３】図１のＢ−Ｂ線断面図
【図４】従来の敷設内装材を自動車に敷設した状態を示
す
【図５】図４のＣ−Ｃ線断面図
【符号の説明】
１０・・・・敷設内装材
１１・・・・表皮繊維材
１２・・・・裏打
１３・・・・ハニカムコア
１３ａ・・・切欠
１４・・・・不織布
１５，１５’・・ヒンジ片
１６・・・・凸形状
２０・・・・フロアパネル
２１・・・・タイヤ収納用凹部
２２・・・・工具収納用凹部
４０，４０’・・硬質板
４５・・・・補強用不織布
５０・・・・自動車ラッゲージルームBRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a laying interior material according to the present invention; FIG. 2 is a cross-sectional view taken along line AA of FIG. 1; FIG. 3 is a cross-sectional view taken along line BB of FIG. FIG. 5 shows a state in which the laying interior material is laid on the automobile. FIG. 5 is a cross-sectional view taken along the line CC of FIG. · Backing 13 ··· Honeycomb core 13a · · · Notch · · · · Nonwoven fabric 15 and 15 '· · Hinge piece 16 · · · Convex shape 20 · · · Floor panel 21 · · · · For tire storage Recess 22: Tool recess 40, 40 ', Hard plate 45: Reinforced nonwoven fabric 50: Car luggage room
───────────────────────────────────────────────────── フロントページの続き (58)調査した分野(Int.Cl.7，ＤＢ名) B60N 3/04 B32B 3/12 B32B 27/12 ──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. 7 , DB name) B60N 3/04 B32B 3/12 B32B 27/12
Claims (1)
/ｍ２未満の不織布をあらかじめ積層してなる熱可塑性
樹脂のハニカムコア基材と、裏面に熱可塑性樹脂の裏打
をほどこした表皮繊維材を、それぞれの熱可塑性樹脂が
軟化するまで加熱し、次いでハニカムコア基材の不織布
と表皮繊維材の裏打が向き合うように重ねて、表皮繊維
材とハニカムコア基材を押圧一体化すると同時に所要の
形状に成形してなることを特徴とする自動車のフロアパ
ネル上に敷設する自動車用敷設内装材。(57) [Claims 1] At least one side has a basis weight of 200 g
/ m 2 a non-woven fabric less than the honeycomb core substrate of thermoplastic resin pre-laminated, and the skin fiber material lined with thermoplastic resin on the back, heated until each thermoplastic resin is softened, then An automobile floor panel characterized in that the nonwoven fabric of the honeycomb core substrate and the backing of the skin fiber material are stacked so as to face each other, and the skin fiber material and the honeycomb core material are pressed and integrated and formed into a required shape at the same time. Automotive interior materials to be laid on top.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26824693A JP3503829B2 (en) | 1993-09-29 | 1993-09-29 | Automotive interior materials |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26824693A JP3503829B2 (en) | 1993-09-29 | 1993-09-29 | Automotive interior materials |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0796791A JPH0796791A (en) | 1995-04-11 |
| JP3503829B2 true JP3503829B2 (en) | 2004-03-08 |
Family
ID=17455927
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP26824693A Expired - Fee Related JP3503829B2 (en) | 1993-09-29 | 1993-09-29 | Automotive interior materials |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3503829B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11794670B2 (en) | 2018-03-29 | 2023-10-24 | Kotobukiya Fronte Co., Ltd. | Automobile component |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ES2365196T3 (en) * | 2009-10-16 | 2011-09-26 | Rieter Technologies Ag | SANDWICH TYPE CONSTRUCTION AS A PANEL FOR THE AUTOMOTIVE INDUSTRY. |
| WO2019108127A1 (en) * | 2017-11-29 | 2019-06-06 | ST Engineering Aerospace Ltd. | Method of manufacturing a composite sandwich structure |
-
1993
- 1993-09-29 JP JP26824693A patent/JP3503829B2/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11794670B2 (en) | 2018-03-29 | 2023-10-24 | Kotobukiya Fronte Co., Ltd. | Automobile component |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0796791A (en) | 1995-04-11 |
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