JP7226127B2 - Method for manufacturing vehicle interior material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing an interior material for a vehicle .

2. Description of the Related Art Conventionally, molded structures (vehicle interior materials) are known in which a resin molding is integrally formed with a base material containing fibers and a thermoplastic resin. Patent Literature 1 listed below describes a manufacturing method for forming a resin molding by pressing a substrate with a mold and then injecting a molten thermoplastic resin onto the substrate. The thermoplastic resin injected onto the substrate mixes with the thermoplastic resin that makes up the substrate. As a result, the resin molding is bonded to the base material.

Japanese Patent No. 5186883

However, in the vehicle interior material disclosed in Patent Document 1, when the resin molded body is joined in the plate surface direction of the base material, there is a risk that the bonding strength and bending strength may decrease at the boundary between the base material and the resin molded body. There is In that case, for example, when force is applied to the vehicle interior material due to the expansion of the airbag, the boundary between the base material and the resin molded body may separate, or the stress may concentrate on the boundary, causing the vehicle interior material to become unusable. may be bent.

The present invention has been completed based on the above circumstances, and one of the objects thereof is to provide a vehicle interior material in which the bonding strength between the base material and the resin is increased. Another object of the present invention is to provide a vehicle interior material having higher bending strength.

The present invention relates to an interior material for a vehicle, comprising a plate-shaped base material composed of at least fibers and a thermoplastic resin, and a plate-like base material composed of at least a thermoplastic resin. and a resin joint portion joined along the plate surface, and the end portion of the base material is characterized in that the end edge thereof is configured in an uneven shape.

According to such a vehicle interior material, since the edge of the base material is configured to be uneven, the edge is not configured to be uneven (for example, the edge of the base material is linear), the bonded area between the base material and the resin bonding portion increases. As a result, the bonding strength increases due to the anchor effect, making it difficult for the substrate and the resin bonding portion to separate. In addition, according to the uneven edge, when a force is applied to the vehicle interior material, it is possible to suppress the concentration of stress on the boundary portion between the base material and the resin joint portion, and the boundary portion can be suppressed. It is possible to prevent the vehicle interior material from bending as a starting point.

In the above configuration, the edge of the base material may have a non-linear protruding end that most protrudes toward the resin joint portion.

When a force is applied to the vehicle interior material, a linear crease is formed at the boundary between the base material and the resin joint, and the vehicle interior material may be bent at the crease. However, according to the vehicle interior material as described above, the edge of the base material has a non-linear protruding end that protrudes most toward the resin joint side of the edge of the base material. Even if a force is applied to the substrate, the stress is more likely to be dispersed on the base material side than on the resin joint side. Further, since the base material contains fibers and has relatively high rigidity, it is possible to increase the bending strength of the vehicle interior material.

In the above configuration, the edge of the base material may be curved.

According to such a vehicle interior material, even when force is applied to the vehicle interior material, stress is less likely to be concentrated on the boundary portion between the base material and the resin joint portion, and the bending strength can be increased. .

In the above configuration, another member may be disposed in contact with or in close proximity to the rear surface side of the end portion of the base material.

According to such a vehicle interior material, for example, it is possible to save space without providing a rib for reinforcing the boundary portion between the end portion of the base material and the resin joint portion on the back side of the boundary portion. It is possible to provide a vehicle interior material that is

The present invention also provides a method for manufacturing an interior material for a vehicle, comprising: creating a structure composed of at least fibers and a thermoplastic resin and having uneven edges; It is characterized by injecting a thermoplastic resin into the cavity of the molding die while pressing, and bonding the resin member along the plate surface to the uneven edge.

According to such a method for manufacturing an interior material for a vehicle, a resin joint portion (resin member) is joined along the plate surface of the structure to the uneven edge of the end of the structure. Interior materials can be manufactured.

Further, in the above manufacturing process, the structure may be prepared by cutting a mat obtained by matting at least the fibers and the thermoplastic resin so that the edges of the mat are uneven. . According to such a method for manufacturing a vehicle interior material, the ends cut from the mat can be reused as a material for producing another mat.

In the manufacturing process, the structure is formed by forming a plate-like plate-like body from a mat obtained by matting at least the fibers and the thermoplastic resin, and forming the plate-like body with an uneven edge. It can be created by cutting so as to be

ADVANTAGE OF THE INVENTION According to this invention, it becomes possible to provide the interior material for vehicles with which the joint strength of a base material and resin becomes higher. In addition, it is possible to provide a vehicle interior material having a higher bending strength.

1 is a perspective view showing a vehicle interior material according to Embodiment 1. FIG. Cross-sectional view of vehicle interior material (section taken along line II-II in FIG. 1) Enlarged view of the bottom edge of the substrate The perspective view which shows the state before cut|disconnecting an edge part from a plate-shaped body. The perspective view which shows the process which cut|disconnects an edge part from a plate-shaped body and creates a preboard. Sectional view showing a state in which the mold is opened and a preboard is placed between the upper mold and the lower mold. Cross-sectional view showing the process of molding the base material with the mold closed Diagram showing the process of injecting resin into the cavity (lower mold viewed from above) Diagram showing the process of filling the cavity with resin (lower mold viewed from above) FIG. 10 is an enlarged view of an end portion of a base material in the vehicle interior material according to the second embodiment; FIG. 11 is an enlarged view of an end portion of a base material in a vehicle interior material according to Embodiment 3; FIG. 11 is an enlarged view of an end portion of a base material in a vehicle interior material according to Embodiment 4; FIG. 11 is a perspective view showing a step of cutting the end portion from the mat in the method of manufacturing the vehicle interior material according to the fifth embodiment; FIG. 11 is a cross-sectional view showing a state in which the mold is opened and the mat is placed between the upper mold and the lower mold in the manufacturing method of the vehicle interior material according to the modification;

<Embodiment 1>
Embodiment 1 of the present invention will be described with reference to FIGS. 1 to 9. FIG. In this embodiment, a pillar garnish (vehicle interior material) 1 mounted on an automobile (vehicle) as a vehicle will be described. Each figure will be described with an arrow direction FR as the front, an arrow direction RR as the rear, an arrow direction T as the upper side, an arrow direction B as the lower side, an arrow direction IN as the interior side, and an arrow direction OUT as the exterior side.

The pillar garnish 1 is an interior material that is attached to a columnar center pillar (B pillar) made of sheet metal from the inside of the passenger compartment using an attachment member such as a clip. As shown in FIG. 1, the pillar garnish 1 includes a main wall portion 1A that forms a surface facing the interior of the vehicle and a surface that faces the front of the vehicle. It is a plate-shaped body having a vertical direction and having a side wall portion 1B and a rear side wall portion 1C that constitutes a surface facing the rear of the vehicle and is curved from the rear end of the main wall portion 1A toward the outside of the vehicle. The pillar garnish 1 includes a plate-like main body (base material) 10 made of fibers and a thermoplastic resin, and resin joints 30 made of a thermoplastic resin. An opening 15 is provided in the central portion of the main body 10 so as to open toward the interior and exterior of the vehicle.

As the fibers constituting the main body 10, fibers selected from wood fibers obtained by disassembling wood or the like, bast plant fibers such as kenaf, inorganic fibers such as glass fibers and carbon fibers, synthetic resin fibers, etc. are adopted. can do. Thermoplastic resins such as polyethylene, polypropylene, polyethylene terephthalate, and polylactic acid can be used as the thermoplastic resin that forms the main body portion 10 and the resin joint portion 30 . The thermoplastic resin forming the body portion 10 and the thermoplastic resin forming the resin joint portion 30 may be the same type of thermoplastic resin or different types of thermoplastic resins. A portion indicated by a plurality of dots is the resin joint portion 30, and a portion indicated by a plurality of wavy lines is the main body portion 10 in FIGS.

The resin joint portion 30 is joined to the end portions 11 , 12 , 13 and 14 of the body portion 10 along the plate surface of the body portion 10 so as to be flush with each other. Specifically, in the body portion 10, the upper end portion is the upper end portion 11, the lower end portion is the lower end portion 12, the front side and exterior side end is the front end portion 13, and the rear side and exterior side end is The upper portion 31 of the resin joint portion 30 is integrally joined to the upper end portion 11 of the main body portion 10 so as to have the same thickness. Similarly, in the resin joint portion 30, the lower side portion 32, the front side portion 33, and the rear side portion 34 have the same thickness as the lower end portion 12, the front end portion 13, and the rear end portion 14 of the body portion 10, respectively. are integrally joined together. The resin joint portion 30 is joined to the entire circumference of the body portion 10 so as to surround the ends 11 , 12 , 13 , and 14 of the body portion 10 .

As shown in FIG. 2, a position adjusting member (another member) 2 for adjusting the position of the seat belt up and down, for example, is arranged in close proximity to the side (rear side) of the main body 10 on the outside of the passenger compartment. It is The position adjusting member 2 is arranged close to the rear surface side of the upper end portion 11 and the lower end portion 12 of the main body portion 10 . The position adjusting member 2 is exposed from the opening 15 of the main body 10 (not shown in FIG. 1). The other member is not limited to the position adjusting member 2, and may be any member that is in contact with or close to the back side of one of the ends 11, 12, 13, and 14 of the main body 10. FIG.

In the body portion 10, the upper end portion 11 and the lower end portion 12 are configured such that their edges 11D and 12D are uneven. Below, the lower end portion 12 will be specifically described with reference to FIG. 3, which is an enlarged view thereof. The lower end portion 12 includes a plurality of convex portions 16 protruding toward the lower side portion 32 side of the resin joint portion 30 (a shape protruding outward from the plate surface of the main body portion 10) and a resin joint portion. and a plurality of concave portions 18 that are recessed from the lower side portion 32 side of the main body portion 10 (a shape recessed toward the inner side of the plate surface of the main body portion 10). The convex portion 16 has a triangular shape with a protruding end 16D1, which will be described later, as a vertex. The protrusions 16 and the recesses 18 are provided alternately and continuously in the front-rear direction.

The convex portion 16 has a convex edge portion 16</b>D that is an edge forming a triangular outer shape of the convex portion 16 and that is joined to the lower side portion 32 of the resin joint portion 30 . The concave portion 18 has a concave edge portion 18</b>D that is an edge forming the concave outer shape of the concave portion 18 and that is joined to the lower side portion 32 of the resin joint portion 30 . The convex edge portion 16D and the concave edge portion 18D are connected in the front-rear direction to form a zigzag (uneven) edge 12D. The tip of the edge 12D that protrudes most toward the lower side portion 32 of the resin joint portion 30 is the protruding end 16D1. The projecting end 16D1 is point-like and non-linear.

An end portion 36 of the lower side portion 32 of the resin joint portion 30 fills the space between the adjacent convex portions 16 in a triangular shape up to the concave edge portion 18D of the concave portion 18 . In addition, the resin joint portion 30 has a shape in which the thermoplastic resin leaks in the thickness direction of the lower end portion 12 of the main body portion 10 (that is, the resin joint portion 30 partially penetrates the convex portion 16 and the concave portion 18 of the main body portion 10 in the thickness direction). It may be joined in the form of covering from Also, the upper end portion 11 of the main body portion 10 has the same configuration as the lower end portion 12 .

Next, referring to FIGS. 4, 6, and 7, a cutting device 60 for cutting the plate-like body 40 to manufacture the preboard 50 and a mold 70 for manufacturing the pillar garnish 1 using the preboard 50 are described. explain. As shown in FIG. 4, the cutting device 60 comprises a pedestal portion 66 that serves as a pedestal, and a lid portion 61 arranged to face the pedestal portion 66 from above. The lid portion 61 includes a recessed portion 62 that is recessed upward. The pedestal portion 66 has a raised portion 67 that rises upward. Zigzag blade portions 63 and 68 are provided on both end sides of the recessed portion 62 and the raised portion 67 . The cutting device 60 cuts the ends 41 and 41 of the plate-like body 40 with the blades 63 and 68 by disposing the plate-like body 40 between the lid portion 61 and the base portion 66 and pressing the plate-like body 40 . be done. Note that the configuration of the cutting device is not limited to this. For example, the cutting device may comprise a base having a zigzag blade and a lid having a receiving portion for receiving the blade. Moreover, the cutting device may be one that cuts the plate-like body by a movable blade or a laser. The fibers and thermoplastic resin forming the plate-like body 40 are the same as the fibers and thermoplastic resin forming the main body 10 of the pillar garnish 1 .

As shown in FIG. 6, the molding die 70 presses the preboard 50 from above and below to mold the base material 10 . The molding die 70 is arranged above, and is arranged below so as to face the upper mold 71 that presses the preboard 50 from the surface side that will be the back surface (the surface on the outside of the vehicle interior) of the base material 10, and the upper mold 71. and a lower mold 76 that presses the preboard 50 from the side of the base material 10 that will be the surface (the surface inside the passenger compartment).

The upper die 71 is a movable die that can be moved vertically with respect to the lower die 76 by a driving device (eg, an electric motor, an air cylinder, a hydraulic cylinder, etc.) not shown. FIG. 6 shows a state in which the upper mold 71 moves away from the lower mold 76 and the mold 70 is opened. FIG. 7 shows a state in which the upper mold 71 moves closer to the lower mold 76 and the mold 70 is closed. A space (cavity) S is formed between the upper mold 71 and the lower mold 76 when the mold 70 is closed.

An injection device 80 capable of injecting molten thermoplastic resin is provided above the upper mold 71 . The thermoplastic resin injected from the injection device 80 is the same as the thermoplastic resin forming the resin joint portion 30 of the pillar garnish 1 . The upper die 71 is provided with a sprue 72 for circulating the thermoplastic resin injected from the injection device 80 into the cavity S. The injection device 80 can inject molten thermoplastic resin into the cavity S through the sprue 72 .

Next, a method for manufacturing the pillar garnish 1 will be described with reference to FIGS. 4 to 9. FIG. The method of manufacturing the pillar garnish 1 can be broadly divided into a plate-like body preparation step of preparing a plate-like plate-like body 40 from a mat obtained by matting fibers and a thermoplastic resin, and a step of cutting the plate-like body 40. Including a structure creation step of creating a preboard (structure) 50 and an injection step of injecting a thermoplastic resin while pressing the preboard 50 with a molding die 70 to join the resin member (resin joint portion) 30. .

In the plate-like body preparation step, fibers and a thermoplastic resin are mixed to form a mat, and the plate-like body 40 is prepared by pressing and heating the obtained mat so as to have a predetermined thickness. As shown in FIG. 4 , in the structure creating process, the plate-like body 40 is arranged between the lid portion 61 and the base portion 66 of the cutting device 60 , and the plate-like body 40 is cut by the lid portion 61 and the base portion 66 . are pressed, the edge portions 41 and 41 of the plate-like body 40 are cut by the blade portions 63 and 68 . Then, as shown in FIG. 5, a preboard 50 is obtained in which the edges 51D and 52D of the ends 51 and 52 on both sides are cut in a zigzag shape (concave and convex shape).

Subsequently, in the injection process, as shown in FIG. 6, the preboard 50 is placed between the upper mold 71 and the lower mold 76 in the open mold 70, and then the upper mold 71 is brought close to the lower mold 76. Let Then, as shown in FIG. 7, the molding die 70 heated to a predetermined temperature is brought into a closed state, and the preboard 50 is pressed from above and below to mold the base material 10 . Edges 51 and 52 of the preboard 50 are formed as edges 11 and 12 having zigzag edges 11D and 12D as shown in FIG. 8, and the thickness of the base material 10 is adjusted to a predetermined thickness. A central portion of the base material 10 is punched out by a punching part 77 provided in a lower mold 76 to form the opening 15 .

Further, as shown in FIGS. 7 and 8, the pre-board 50 (base material 10) is pressed by the molding die 70 heated to a predetermined temperature, and the molten thermoplastic resin R is injected into the cavity S from the injection device 80. . At the lower end portion 12 of the base material 10, the thermoplastic resin R flows from the plate surface direction of the base material 10, and joins the zigzag edge 12D along the plate surface of the base material 10. The thermoplastic resin R joins the convex edge portions 16D of the plurality of convex portions 16 and the concave edge portions 18D of the plurality of concave portions 18 (see FIG. 3) from the plate surface direction.

As shown in FIG. 9, the thermoplastic resin R is continuously injected into the cavity S from the injection device 80 . Then, the cavity S is filled with the thermoplastic resin R so as to surround the ends 11 , 12 , 13 and 14 of the base material 10 . At the upper end portion 11 of the base material 10, the thermoplastic resin R flows from the plate surface direction of the base material 10, and joins the zigzag-shaped edge 11D along the plate surface of the base material 10. By cooling the molding die 70 in this state, the thermoplastic resin R is joined to the edges 11D and 12D of the base material 10 along the plate surface of the base material 10 (resin joint). form 30; Then, the pillar garnish 1 is obtained by removing the obtained structure from the mold 70 .

Next, the effects of this embodiment will be described. In the present embodiment, a plate-like body portion 10 made of fibers and a thermoplastic resin and a plate-like body portion 10 made of a thermoplastic resin are provided along the plate surface of the body portion 10 with respect to the ends 11 and 12 of the body portion 10 . The pillar garnish 1 is provided with a joined resin joint portion 30, and the end portions 11, 12 of the main body portion 10 are configured such that the edges 11D, 12D thereof are uneven.

According to such a pillar garnish 1, since the edges 11D and 12D of the ends 11 and 12 of the main body 10 are configured to be uneven, the edges 11D and 12D are not configured to be uneven. The area where the body portion 10 and the resin joint portion 30 are bonded is increased compared to the case where the end portion of the body portion is linear, for example. As a result, the bonding strength increases due to the anchor effect, and the main body portion 10 and the resin bonding portion 30 are less likely to separate. Further, according to the uneven edges 11D and 12D, when a force is applied to the pillar garnish 1, it is possible to suppress concentration of stress on the boundary portion between the main body portion 10 and the resin joint portion 30. It is possible to prevent the pillar garnish 1 from bending with the boundary portion as a starting point.

Further, the end portions 11 and 12 of the main body portion 10 are configured such that a protruding end 16D1 of the end edges 11D and 12D that protrudes most toward the resin joint portion 30 is non-linear. When a force is applied to the pillar garnish 1, a linear crease is formed at the boundary between the main body 10 and the resin joint 30, and the pillar garnish 1 may be bent at the crease. However, according to the pillar garnish 1 as described above, the end portions 11 and 12 of the main body portion 10 have a non-linear protruding end 16D1 that protrudes most toward the resin joint portion 30 among the edges 11D and 12D. Therefore, even when force is applied to the pillar garnish 1, the stress is more likely to be dispersed toward the main body portion 10 than toward the resin joint portion 30 side. Since the main body 10 contains fibers and has relatively high rigidity, the bending strength of the pillar garnish 1 can be increased.

Further, the position adjusting member 2 is arranged in contact with or in close proximity to the rear surface side of the ends 11 and 12 of the main body 10 . According to such a pillar garnish 1, for example, a rib for reinforcing the boundary portion between the end portions 11 and 12 of the main body portion 10 and the resin joint portion 30 is not provided on the back side of the boundary portion, thereby saving space. can be provided.

Further, in the present embodiment, a preboard (structure) 50 which is composed of at least fibers and a thermoplastic resin and has uneven edges 51D and 52D is prepared, and the preboard 50 is pressed by a molding die 70. , a thermoplastic resin is injected into the cavity S of the mold 70, and the resin joint portion (resin member) 30 is joined along the plate surface to the uneven edges 11D and 12D. A manufacturing method is shown.

According to the manufacturing method of the pillar garnish 1, the resin joints ( The pillar garnish 1 including the resin member) 30 can be manufactured.

In the present embodiment, the preboard (structure) 50 is formed by forming a plate-like plate-like body 40 from a mat obtained by matting fibers and a thermoplastic resin, and forming the plate-like body 40 with an uneven edge. A method for manufacturing the pillar garnish 1 is shown, in which the pillar garnish 1 is cut into a shape.

In addition, as a comparative example, the edge of the end of the main body (base material) is linear (non-concavo-convex). Assuming that the zigzag (concave and convex) configuration is Example 1, the area where the end portion of the main body and the resin joint portion are joined is about 1.5 in Example 1 compared to the comparative example. doubled the value. In addition, when the bending strength was measured by applying a load to the portion where the end of the main body and the resin joint were joined, the bending strength in Example 1 was at least twice as high as that in the comparative example. rice field.

<Embodiment 2>
Next, Embodiment 2 of the present invention will be described with reference to FIG. In the present embodiment, a pillar garnish (vehicle interior material) having a configuration of the end portion of the main body (base material) different from that in the first embodiment is illustrated. In addition, in this embodiment, the same reference numerals are used for the same portions as those in the above-described embodiment, and overlapping descriptions of structures, manufacturing processes, functions and effects are omitted.

The lower end portion 212 of the base material 210 has an uneven edge 212D. Specifically, the lower end portion 212 includes a plurality of protrusions 216 protruding toward the lower side portion 232 of the resin joint portion 230 and a shape recessed from the lower side portion 232 side of the resin joint portion 230 . and a plurality of recesses 218 forming a concave shape at . The convex portion 216 has a square shape. The protrusions 216 and the recesses 218 are provided alternately and continuously in the front-rear direction.

The convex portion 216 includes a convex edge portion 216D that is the edge of the protruding end that most protrudes toward the lower side portion 232 side of the resin joint portion 230, and side edge portions 217D that are lateral edges of the convex portion 216. . The convex edge portion 216</b>D and the side edge portion 217</b>D are edges forming the square shape of the convex portion 216 and are edges joined to the lower side portion 232 of the resin joint portion 230 . The recessed portion 218 includes a recessed edge portion 218</b>D that is an edge forming an outer shape that is recessed toward the main body portion 210 side (toward the inner side of the plate surface of the main body portion 210 ) and that is joined to the lower side portion 232 of the resin joint portion 230 . The convex edge portion 216D and the concave edge portion 218D are connected by the side edge portion 217D. The convex edge portion 216D and the concave edge portion 218D extend parallel to each other, and the side edge portion 217D extends perpendicular to the convex edge portion 216D and the concave edge portion 218D. The convex edge portion 216D, the side edge portion 217D, and the concave edge portion 218D are connected in the front-rear direction to form an uneven edge 212D.

As in the present embodiment, when the edge of the end of the main body portion is configured to be uneven (the convex portion is square) as Example 2, the end of the main body and the resin joint portion are joined. In Example 2, the measured area was approximately 1.9 times larger than that in the comparative example. In addition, when the bending strength was measured by applying a load to the portion where the end of the main body and the resin joint were joined, the bending strength of Example 2 was about twice as high as that of the comparative example. rice field.

<Embodiment 3>
Next, Embodiment 3 of the present invention will be described with reference to FIG. In the present embodiment, a pillar garnish (vehicle interior material) having a configuration of the end portion of the main body portion (base material) different from that of the above-described embodiment is exemplified. In addition, in this embodiment, the same reference numerals are used for the same portions as those in the above-described embodiment, and overlapping descriptions of structures, manufacturing processes, functions and effects are omitted.

A lower end 312 of the substrate 310 includes a plurality of protrusions 316 and a plurality of recesses 318 . The convex portion 316 has a trapezoidal shape with a convex edge portion 316D, which will be described later, as the upper base. The protrusions 316 and the recesses 318 are provided alternately and continuously in the front-rear direction.

The convex portion 316 includes a convex edge portion 316D that is the edge of the projecting end that protrudes most toward the lower side portion 332 side of the resin joint portion 330, and side edge portions 317D that are lateral edges of the convex portion 316. . A convex edge portion 316</b>D and a side edge portion 317</b>D are edges forming the trapezoidal outline of the convex portion 316 and are edges joined to the lower side portion 332 of the resin joint portion 330 . The recessed portion 318 has a recessed edge portion 318D that forms an outer shape that is recessed toward the main body portion 310 side (toward the inner side of the plate surface of the main body portion 310). The convex edge portion 316D and the concave edge portion 318D are connected by the side edge portion 317D. The convex edge portion 316D and the concave edge portion 318D extend in parallel directions. The convex edge portion 316D, the side edge portion 317D, and the concave edge portion 318D are connected in the front-rear direction to form an uneven edge 312D.

As in the present embodiment, when the edge of the end of the main body is configured in an uneven shape (the convex portion is trapezoidal) as Example 3, the end of the main body and the resin joint are joined. In Example 3, the surface area was about 1.7 times larger than that in the comparative example. In addition, when the bending strength was measured by applying a load to the portion where the end of the main body and the resin joint were joined, the bending strength of Example 3 was about twice as high as that of the comparative example. rice field.

<Embodiment 4>
Next, Embodiment 4 of the present invention will be described with reference to FIG. In the present embodiment, a pillar garnish (vehicle interior material) having a configuration of the end portion of the main body portion (base material) different from that of the above-described embodiment is exemplified. In addition, in this embodiment, the same reference numerals are used for the same portions as those in the above-described embodiment, and overlapping descriptions of structures, manufacturing processes, functions and effects are omitted.

A lower end portion 412 of the base material 410 has a curved edge 412D. Specifically, the lower end portion 412 includes a plurality of convex portions 416 that protrude in a round shape toward the lower side portion 432 side of the resin joint portion 430 and and a plurality of recesses 418 that are recessed in a hollow round shape. The convex portions 416 and the concave portions 418 are provided alternately and continuously in the front-rear direction.

The convex portion 416 includes a projecting end 416D1 that most projects toward the lower portion 432 side of the resin joint portion 430, and a side edge portion 417D that is a lateral edge of the projecting end 416D1. The protruding end 416 D 1 and the side edge 417 D are edges forming the round bulging outer shape of the projection 416 and are edges joined to the lower side 432 of the resin joint 430 . The projecting end 416D1 is point-like and non-linear. The recessed portion 418 is an edge forming an outer shape that is recessed in a round shape toward the main body portion 410 (toward the inner side of the plate surface of the main body portion 410), and is a recessed edge joined to the lower side portion 432 of the resin joint portion 430. A portion 418D is provided. The projecting end 416D1 and the concave edge 418D are connected by a side edge 417D. The projecting end 416D1, the side edge portion 417D, and the recessed edge portion 418D are connected in the front-rear direction to form a wavy (curved) edge 412D.

With such a pillar garnish, even when force is applied to the pillar garnish, stress is less likely to concentrate on the boundary portion between the base material 410 and the resin joint 430, and bending strength can be increased.

<Embodiment 5>
Next, Embodiment 5 of the present invention will be described with reference to FIG. In this embodiment, a method for manufacturing a pillar garnish (vehicle interior material) is exemplified in which the manufacturing process is different from that of the above-described embodiment. In addition, in this embodiment, the same reference numerals are used for the same portions as those in the above-described embodiment, and overlapping descriptions of structures, manufacturing processes, functions and effects are omitted.

As shown in FIG. 13, a mat M1 obtained by mixing fibers and a thermoplastic resin to form a mat is arranged between a lid portion 561 and a base portion 566 of a cutting device 560, and an edge of the mat M1 is cut. The portions 541 and 541 are cut by blade portions 563 and 568 . Then, a mat (structure) M2 is obtained by cutting such that the edges 551D and 552D of the ends 551 and 552 on both sides are zigzag (concavo-convex) (structure forming step). A preboard is produced by heating while pressing the obtained mat M2 so as to have a predetermined thickness (see FIGS. 5 and 6 in Embodiment 1).

According to this method of manufacturing a pillar garnish, the ends 541, 541 of the mat M1 cut by the blades 563, 568 can be reused as materials for producing other mats.

<Modification>
Next, a modified example of the present invention will be described with reference to FIG. In this modified example, a method of manufacturing a pillar garnish (interior material for a vehicle), which is different in the manufacturing process from that of the fifth embodiment, is illustrated. In addition, in the present modification, the same reference numerals are used for the same parts as in the fifth embodiment, and duplicate descriptions of the structure, manufacturing process, action and effect are omitted.

As shown in FIG. 14, in the mold 70 in the open state, after placing the mat (structure) M2 obtained in the structure forming step between the upper mold 71 and the lower mold 76, a predetermined The thermoplastic resin is injected into the cavity while being pressed by the molding die 70 so as to have a thickness. Then, a pillar garnish is obtained by joining a resin member (resin joint portion) along the plate surface to the edges 551D and 552D of the ends 551 and 552 of the mat M2.

<Other embodiments>
The present invention is not limited to the embodiments described above and illustrated in the drawings. For example, the following embodiments are also included in the technical scope of the present invention. can be implemented with various changes.

(1) In addition to the above embodiments, the configuration of the end portion of the base material can be changed as appropriate. In the above-described embodiment, the edges of the upper end and lower end of the base material are configured to be uneven, but the present invention is not limited to this. For example, in addition to the upper end and lower end of the base material, the front end and rear end of the base material may have uneven edges. That is, the edge of the base material may be configured to be uneven over the entire circumference of the edge.

(2) The vehicle interior material can be appropriately modified in addition to the above embodiments. In the above embodiment, the vehicle interior material is a pillar garnish, but it is not limited to this. For example, vehicle interior materials may be door trims, instrument panels, roof linings, and the like.

(3) The vehicle interior material and the method for manufacturing the vehicle interior material illustrated in the above embodiments are not limited to those provided for vehicles, and may be provided for various vehicles. For example, the manufacture of the above-mentioned vehicle interior materials and vehicle interior materials for vehicles such as trains and amusement vehicles as ground vehicles, airplanes and helicopters as flying vehicles, and ships and submarines as sea and undersea vehicles. method can be applied.

DESCRIPTION OF SYMBOLS 1... Pillar garnish (vehicle interior material), 2... Position adjustment member (another member), 10, 210, 310, 410... Body part (base material), 11, 12, 13, 14, 212, 312, 412, 551, 552... Ends 11D, 12D, 212D, 312D, 412D, 551D, 552D... Edges 16D1, 416D1... Protruding ends 30, 230, 330, 430... Resin joints (resin members) 50... Preboard (Structure), M2... Mat (Structure), 70... Mold, S... Cavity

Claims (4)

It is composed of at least fibers and a thermoplastic resin , and of the peripheral edges, both the edge of at least one edge and the edge of the other edge located on the opposite side of the one edge are uneven . a structure creation step of creating a structure with
After the structure forming step, while pressing the structure with a molding die, a thermoplastic resin is injected into the cavity of the molding die, and the two edges of the uneven shape are applied to the plate surface. an injection step of joining the resin member to the two edges of the uneven shape by joining the thermoplastic resin along the
In the injection step, a thermoplastic resin is injected into the cavity from the side of the one end so as to bond the thermoplastic resin to the uneven edge of the one end of the structure. A thermoplastic resin is formed in the cavity to flow the thermoplastic resin around the peripheral edge of the structure and to bond the thermoplastic resin to the uneven edge of the other end of the structure. A method for manufacturing an interior material for a vehicle, characterized by continuously injecting a resin . 2. The method of manufacturing an interior material for a vehicle according to claim 1 , wherein the structure is formed by cutting a mat obtained by matting at least the fibers and the thermoplastic resin so that the edges of the mat are uneven. . The structure is formed by forming a plate-like body from a mat obtained by matting at least the fibers and the thermoplastic resin, and cutting the plate-like body so that the edges of the plate-like body are uneven. The manufacturing method of the vehicle interior material according to claim 1 . In the structure forming step, the structure is formed so that both the edge of the one end portion and the edge of the other end portion are uneven due to concave portions and convex portions arranged along the direction of the plate surface. make,
The vehicle according to any one of claims 1 to 3, wherein in the injection step, the thermoplastic resin is injected into the cavity so that the thermoplastic resin flows from the plate surface direction of the structure. A method for manufacturing an interior material.

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