CA2391726A1 - Method of producing vehicle interior material having sandwich structure - Google Patents
Method of producing vehicle interior material having sandwich structure Download PDFInfo
- Publication number
- CA2391726A1 CA2391726A1 CA002391726A CA2391726A CA2391726A1 CA 2391726 A1 CA2391726 A1 CA 2391726A1 CA 002391726 A CA002391726 A CA 002391726A CA 2391726 A CA2391726 A CA 2391726A CA 2391726 A1 CA2391726 A1 CA 2391726A1
- Authority
- CA
- Canada
- Prior art keywords
- adhesive
- fibers
- polyurethane foam
- vegetable fibers
- mold
- 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.)
- Abandoned
Links
- 239000000463 material Substances 0.000 title claims abstract description 23
- 238000000034 method Methods 0.000 title claims abstract description 13
- 239000000835 fiber Substances 0.000 claims abstract description 46
- 239000000853 adhesive Substances 0.000 claims abstract description 36
- 230000001070 adhesive effect Effects 0.000 claims abstract description 36
- 235000013311 vegetables Nutrition 0.000 claims abstract description 31
- 229920005830 Polyurethane Foam Polymers 0.000 claims abstract description 30
- 239000011496 polyurethane foam Substances 0.000 claims abstract description 30
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 14
- 238000005034 decoration Methods 0.000 claims abstract description 11
- 239000003054 catalyst Substances 0.000 claims description 15
- 229920005862 polyol Polymers 0.000 claims description 13
- 150000003077 polyols Chemical class 0.000 claims description 13
- 229920001228 polyisocyanate Polymers 0.000 claims description 10
- 239000005056 polyisocyanate Substances 0.000 claims description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- 229920002522 Wood fibre Polymers 0.000 claims description 8
- 239000002025 wood fiber Substances 0.000 claims description 8
- 125000003118 aryl group Chemical group 0.000 claims description 7
- 235000017166 Bambusa arundinacea Nutrition 0.000 claims description 6
- 235000017491 Bambusa tulda Nutrition 0.000 claims description 6
- 235000015334 Phyllostachys viridis Nutrition 0.000 claims description 6
- 239000011425 bamboo Substances 0.000 claims description 6
- 244000025254 Cannabis sativa Species 0.000 claims description 5
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 claims description 5
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 claims description 5
- 235000009120 camo Nutrition 0.000 claims description 5
- 235000005607 chanvre indien Nutrition 0.000 claims description 5
- 239000011487 hemp Substances 0.000 claims description 5
- 240000000797 Hibiscus cannabinus Species 0.000 claims description 4
- 244000198134 Agave sisalana Species 0.000 claims description 3
- 244000082204 Phyllostachys viridis Species 0.000 claims 1
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 description 8
- 239000002585 base Substances 0.000 description 8
- 239000012779 reinforcing material Substances 0.000 description 6
- 241001330002 Bambuseae Species 0.000 description 5
- 239000004721 Polyphenylene oxide Substances 0.000 description 5
- 229920000570 polyether Polymers 0.000 description 5
- 239000007921 spray Substances 0.000 description 5
- 239000003365 glass fiber Substances 0.000 description 4
- 239000012948 isocyanate Substances 0.000 description 4
- 150000002513 isocyanates Chemical class 0.000 description 4
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 230000003014 reinforcing effect Effects 0.000 description 3
- 239000002759 woven fabric Substances 0.000 description 3
- QUSNBJAOOMFDIB-UHFFFAOYSA-N Ethylamine Chemical compound CCN QUSNBJAOOMFDIB-UHFFFAOYSA-N 0.000 description 2
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 2
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 description 2
- 125000002947 alkylene group Chemical group 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- -1 polymethylene Polymers 0.000 description 2
- 150000005846 sugar alcohols Polymers 0.000 description 2
- IMNIMPAHZVJRPE-UHFFFAOYSA-N triethylenediamine Chemical compound C1CN2CCN1CC2 IMNIMPAHZVJRPE-UHFFFAOYSA-N 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- GTEXIOINCJRBIO-UHFFFAOYSA-N 2-[2-(dimethylamino)ethoxy]-n,n-dimethylethanamine Chemical compound CN(C)CCOCCN(C)C GTEXIOINCJRBIO-UHFFFAOYSA-N 0.000 description 1
- 241000167854 Bourreria succulenta Species 0.000 description 1
- 241000218645 Cedrus Species 0.000 description 1
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 description 1
- FBPFZTCFMRRESA-JGWLITMVSA-N D-glucitol Chemical compound OC[C@H](O)[C@@H](O)[C@H](O)[C@H](O)CO FBPFZTCFMRRESA-JGWLITMVSA-N 0.000 description 1
- RPNUMPOLZDHAAY-UHFFFAOYSA-N Diethylenetriamine Chemical compound NCCNCCN RPNUMPOLZDHAAY-UHFFFAOYSA-N 0.000 description 1
- PIICEJLVQHRZGT-UHFFFAOYSA-N Ethylenediamine Chemical compound NCCN PIICEJLVQHRZGT-UHFFFAOYSA-N 0.000 description 1
- UEEJHVSXFDXPFK-UHFFFAOYSA-N N-dimethylaminoethanol Chemical compound CN(C)CCO UEEJHVSXFDXPFK-UHFFFAOYSA-N 0.000 description 1
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 1
- 241000018646 Pinus brutia Species 0.000 description 1
- 235000011613 Pinus brutia Nutrition 0.000 description 1
- 241000219000 Populus Species 0.000 description 1
- 241000736892 Thujopsis dolabrata Species 0.000 description 1
- ZJCCRDAZUWHFQH-UHFFFAOYSA-N Trimethylolpropane Chemical compound CCC(CO)(CO)CO ZJCCRDAZUWHFQH-UHFFFAOYSA-N 0.000 description 1
- 241000190021 Zelkova Species 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 235000019693 cherries Nutrition 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 229960002887 deanol Drugs 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 150000004985 diamines Chemical class 0.000 description 1
- ZBCBWPMODOFKDW-UHFFFAOYSA-N diethanolamine Chemical compound OCCNCCO ZBCBWPMODOFKDW-UHFFFAOYSA-N 0.000 description 1
- 239000012972 dimethylethanolamine Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 235000011187 glycerol Nutrition 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 239000002085 irritant Substances 0.000 description 1
- 231100000021 irritant Toxicity 0.000 description 1
- 239000010985 leather Substances 0.000 description 1
- DAZXVJBJRMWXJP-UHFFFAOYSA-N n,n-dimethylethylamine Chemical compound CCN(C)C DAZXVJBJRMWXJP-UHFFFAOYSA-N 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 description 1
- 229920005906 polyester polyol Polymers 0.000 description 1
- 229920006149 polyester-amide block copolymer Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920006389 polyphenyl polymer Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000000600 sorbitol Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 238000003856 thermoforming Methods 0.000 description 1
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical compound CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2311/00—Use of natural products or their composites, not provided for in groups B29K2201/00 - B29K2309/00, as reinforcement
- B29K2311/10—Natural fibres, e.g. wool or cotton
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B2038/0052—Other operations not otherwise provided for
- B32B2038/0076—Curing, vulcanising, cross-linking
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0278—Polyurethane
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/06—Open cell foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/02—Cellular or porous
- B32B2305/022—Foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
- B32B2307/734—Dimensional stability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/10—Natural fibres, e.g. wool, cotton
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2375/00—Polyureas; Polyurethanes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
Landscapes
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Laminated Bodies (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Dry Formation Of Fiberboard And The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
To produce a vehicle interior base material being light and excellent in dimension stability, such as a ceiling material or a door trim material for a vehicle. Used is a method of producing a vehicle interior material having a sandwich structure, comprising the steps of (I) stacking a polyurethane foam, vegetable fibers, a thermosetting adhesive, and optionally a skin for surface decoration and/or a film preventing the exudation of the adhesive, (II) charging the laminate into a mold having a temperature of 80 to 150 ~C, and closing the mold to cure the adhesive, and (III) demolding a molded product after the curing of the adhesive, characterized in that the size of the vegetable fibers is adjusted to be a diameter of at most 1.0 mm and a length of 10 mm to 100 mm.
Description
WO 01/10637 _ 1 _ PCT/EP00/07065 METHOD OF PRODUCING VEHICLE INTERIOR MATERIAL HAVING SANDWICH
STRUCTURE
The present invention relates to a method of producing a vehicle interior base material being light and excellent in dimensional stability, such as a ceiling material or a door trim material for a vehicle, and to a laminate having a sandwich structure that can be used as an interior base material for a vehicle.
As a technique for producing a vehicle interior base material having a sandwich structure, there is proposed a method of producing a molded product in which isocyanate is immersed in a flexible polyurethane foam or a rigid polyurethane foam; water and a urethanization catalyst are added thereto; and both surfaces are reinforced with glass mats (Japanese Patent Kokoku Publication No.
63-7577 (7577/1988) titled "Method of producing a light and rigid or semi-rigid composite panel").
Further, there is also proposed a method of sandwiching a polyurethane foam, which has open cells and is moldable at an ordinary temperature, between two glass mats provided with an adhesive and thermoforming it (Japanese Patent Kokai Publication No. 04-211416 (211416/1992) titled "Method of producing a rigid polyurethane foam having open cells and being moldable at an ordinary temperature, and use of the same for producing a molded article"). In all of these methods, glass fibers are used as a reinforcing material. These glass fibers, though being extremely excellent in reinforcing effects, are considerably expensive and irritant to operator's skin, and are non-flammable when discarded, so that the disposal thereof is a great problem.
There is already an example in which a woven fabric made by weaving fibers made of intertwined hemp with a considerably rough mesh of 2 to 3 mm is used as a reinforcing material (Opel: Vectra etc.). However, if a woven fabric is used as a reinforcing material, wrinkles are generated at a draw-formed portion because it is not fi~eely expandable or contractible. Further, since an adhesive is not easily immersed into the inside of intertwined fibers, the curing is insufficient and the surface is likely to have unevenness.
STRUCTURE
The present invention relates to a method of producing a vehicle interior base material being light and excellent in dimensional stability, such as a ceiling material or a door trim material for a vehicle, and to a laminate having a sandwich structure that can be used as an interior base material for a vehicle.
As a technique for producing a vehicle interior base material having a sandwich structure, there is proposed a method of producing a molded product in which isocyanate is immersed in a flexible polyurethane foam or a rigid polyurethane foam; water and a urethanization catalyst are added thereto; and both surfaces are reinforced with glass mats (Japanese Patent Kokoku Publication No.
63-7577 (7577/1988) titled "Method of producing a light and rigid or semi-rigid composite panel").
Further, there is also proposed a method of sandwiching a polyurethane foam, which has open cells and is moldable at an ordinary temperature, between two glass mats provided with an adhesive and thermoforming it (Japanese Patent Kokai Publication No. 04-211416 (211416/1992) titled "Method of producing a rigid polyurethane foam having open cells and being moldable at an ordinary temperature, and use of the same for producing a molded article"). In all of these methods, glass fibers are used as a reinforcing material. These glass fibers, though being extremely excellent in reinforcing effects, are considerably expensive and irritant to operator's skin, and are non-flammable when discarded, so that the disposal thereof is a great problem.
There is already an example in which a woven fabric made by weaving fibers made of intertwined hemp with a considerably rough mesh of 2 to 3 mm is used as a reinforcing material (Opel: Vectra etc.). However, if a woven fabric is used as a reinforcing material, wrinkles are generated at a draw-formed portion because it is not fi~eely expandable or contractible. Further, since an adhesive is not easily immersed into the inside of intertwined fibers, the curing is insufficient and the surface is likely to have unevenness.
As a result of intensive studies made to obtain a molded product that can be recycled easily and are light and inexpensive without using glass fibers as a reinforcing material, we have discovered that vegetable fibers such as wood fibers, bamboo fibers, cut hemp, and cut kenaf can be fizlly used in place of glass fibers.
In addition, we have discovered that it is advantageous in ternis of costs and effects if vegetable fibers cut to a suitable length and an adhesive are mixed and spread uniformly on a polyurethane foam.
The present invention provides a method of producing a vehicle interior material having a sandwich structure, comprising the steps of (I) stacking (a) a thermoformable polyurethane foam having open cells and a density of 20 to 100 kg/m3, (b) vegetable fibers of 100 g/m2 to 300 gJmz positioned on both main surfaces of the polyurethane foam (a), (c) a thermosetting adhesive foaming bonds between the polyurethane foam (a) and the vegetable fibers (b) and bonds between the vegetable fibers (b) each other, and optionally (d) a skin for surface decoration and/or a filin preventing the exudation of the adhesive, (II) charging the laminate into a mold having a temperature of 80 to 150 °C, and closing the mold to cure the adhesive, and (III) demoldulg a molded product after the curing of the adhesive, characterized in that the size of the vegetable fibers is adjusted to be a diameter of at most 1.0 mm and a length of 10 mm to 100 mm.
The present invention also provides a laminate comprising:
(A) a layer composed of a thermofomlable polyurethane foam having open cells and a density of 20 to 100 kg/m3; and (B) layers composed of vegetable fibers of 100 g/m2 to 300 g/m3 and a thermosetting adhesive, the (A) layer being sandwiched between the two (B) layers, wherein the vegetable fibers have a diameter of at most 1.0 mm and a length of 10 mm to 100 mm.
The laminate is preferably such that the polyurethane foam is a rigid polyurethane foam; the thermosetting adhesive is an adhesive comprising an aromatic polyisocyanate, water, a catalyst, and optionally a polyol; and the vegetable fibers are those obtained by cutting or grinding of hemp, kenaf, sisal fibers, bamboo fibers, wood fibers.
The thermoformable polyurethane foam having open cells may have a density of 20 to 100 kglm3, for example, 25 to 40 kg/m3, particularly 25 to 35 kg/m3.
The polyurethane form is preferably a rigid polyurethane foam.
The rigid polyurethane foam is one obtained by reacting a polyisocyanate component and a polyol 2 5 component.
The polyol component may comprise a polyol, a catalyst, a foaming agent, and optionally a flame-retarder, a viscosity reducer, and a surfactant.
The polyurethane foam may be sheet-like, and may have a thickness of 3 to 8 mm.
In addition, we have discovered that it is advantageous in ternis of costs and effects if vegetable fibers cut to a suitable length and an adhesive are mixed and spread uniformly on a polyurethane foam.
The present invention provides a method of producing a vehicle interior material having a sandwich structure, comprising the steps of (I) stacking (a) a thermoformable polyurethane foam having open cells and a density of 20 to 100 kg/m3, (b) vegetable fibers of 100 g/m2 to 300 gJmz positioned on both main surfaces of the polyurethane foam (a), (c) a thermosetting adhesive foaming bonds between the polyurethane foam (a) and the vegetable fibers (b) and bonds between the vegetable fibers (b) each other, and optionally (d) a skin for surface decoration and/or a filin preventing the exudation of the adhesive, (II) charging the laminate into a mold having a temperature of 80 to 150 °C, and closing the mold to cure the adhesive, and (III) demoldulg a molded product after the curing of the adhesive, characterized in that the size of the vegetable fibers is adjusted to be a diameter of at most 1.0 mm and a length of 10 mm to 100 mm.
The present invention also provides a laminate comprising:
(A) a layer composed of a thermofomlable polyurethane foam having open cells and a density of 20 to 100 kg/m3; and (B) layers composed of vegetable fibers of 100 g/m2 to 300 g/m3 and a thermosetting adhesive, the (A) layer being sandwiched between the two (B) layers, wherein the vegetable fibers have a diameter of at most 1.0 mm and a length of 10 mm to 100 mm.
The laminate is preferably such that the polyurethane foam is a rigid polyurethane foam; the thermosetting adhesive is an adhesive comprising an aromatic polyisocyanate, water, a catalyst, and optionally a polyol; and the vegetable fibers are those obtained by cutting or grinding of hemp, kenaf, sisal fibers, bamboo fibers, wood fibers.
The thermoformable polyurethane foam having open cells may have a density of 20 to 100 kglm3, for example, 25 to 40 kg/m3, particularly 25 to 35 kg/m3.
The polyurethane form is preferably a rigid polyurethane foam.
The rigid polyurethane foam is one obtained by reacting a polyisocyanate component and a polyol 2 5 component.
The polyol component may comprise a polyol, a catalyst, a foaming agent, and optionally a flame-retarder, a viscosity reducer, and a surfactant.
The polyurethane foam may be sheet-like, and may have a thickness of 3 to 8 mm.
The vegetable fibers are distributed uniformly on both sides of a polyurethane foam layer at 100 to 300 g/m2, for example, at 100 to 200 g/m2 as a reinforcing material.
It is necessary that the size of the vegetable fibers is adjusted to a diameter of at most 1.0 mm (for example, 0.2 to 0.8 mm) and a length of 10 to 100 mm (for example, 15 to 50 mm). If fibers having a diameter exceeding 1.0 mm are used as a reinforcing material, unevenness will appear on the surface of the molded product, thereby considerably deteriorating the appearance. The diameter as used herein refers to the smaller of the longitudinal and lateral dimensions of the fiber cross section.
These fibers can be cut to a length of 10 to 100 mm by means of a simple equipment. If the length is smaller than 10 mm, the required reinforcing effects are not obtained, whereas if the fibers are too long, they will be entangled with each other, so that they cannot be dispersed uniformly on the foam.
It is necessary that the size is adjusted to be between 10 and 100 mm in order that the fibers can be spread comparatively easily and uniformly on a molded product such as a vehicle ceiling material having a large area, and in order to obtain sufficient reinforcing effects.
The vegetable fibers may be those obtained by cutting or grinding of vegetables mainly containing cellulose. The vegetable fibers may be, for example, hemp, kenaf, sisal fibers, bamboo fibers, wood fibers. The wood fibers are obtained from wood. The wood may be, for example, cedar, pine, zelkova, sun tree, hiba arborvitae, cherry, poplar, or fir.
The thermosetting adhesive forms bonds between the polyurethane foam and the vegetable fibers and bonds between the vegetable fibers each other. In the case where the vegetable fibers are bonded to each other, the adhesive is immersed among the vegetable fibers to form a layer made of the vegetable fibers and the adhesive.
The thermosetting adhesive may be an adhesive comprising an aromatic polyisocyanate, water, a catalyst, and optionally a polyol.
The aromatic polyisocyanate may be, for example, tolylene diisocyanate, diphenylmethane diisocyanate, or polymethylene polyphenyl polyisocyanate (polymeric MDI), and is preferably polymeric MDI.
It is necessary that the size of the vegetable fibers is adjusted to a diameter of at most 1.0 mm (for example, 0.2 to 0.8 mm) and a length of 10 to 100 mm (for example, 15 to 50 mm). If fibers having a diameter exceeding 1.0 mm are used as a reinforcing material, unevenness will appear on the surface of the molded product, thereby considerably deteriorating the appearance. The diameter as used herein refers to the smaller of the longitudinal and lateral dimensions of the fiber cross section.
These fibers can be cut to a length of 10 to 100 mm by means of a simple equipment. If the length is smaller than 10 mm, the required reinforcing effects are not obtained, whereas if the fibers are too long, they will be entangled with each other, so that they cannot be dispersed uniformly on the foam.
It is necessary that the size is adjusted to be between 10 and 100 mm in order that the fibers can be spread comparatively easily and uniformly on a molded product such as a vehicle ceiling material having a large area, and in order to obtain sufficient reinforcing effects.
The vegetable fibers may be those obtained by cutting or grinding of vegetables mainly containing cellulose. The vegetable fibers may be, for example, hemp, kenaf, sisal fibers, bamboo fibers, wood fibers. The wood fibers are obtained from wood. The wood may be, for example, cedar, pine, zelkova, sun tree, hiba arborvitae, cherry, poplar, or fir.
The thermosetting adhesive forms bonds between the polyurethane foam and the vegetable fibers and bonds between the vegetable fibers each other. In the case where the vegetable fibers are bonded to each other, the adhesive is immersed among the vegetable fibers to form a layer made of the vegetable fibers and the adhesive.
The thermosetting adhesive may be an adhesive comprising an aromatic polyisocyanate, water, a catalyst, and optionally a polyol.
The aromatic polyisocyanate may be, for example, tolylene diisocyanate, diphenylmethane diisocyanate, or polymethylene polyphenyl polyisocyanate (polymeric MDI), and is preferably polymeric MDI.
The water may be 10 to 50 parts by weight, for example,15 to 30 parts by weight, based on 100 parts by weight of the aromatic polyisocyanate.
The catalyst may be, for example, an amine such as monoamine, diamine, or triamine (for example, bis(dimethylaminoethyl) ether, N,NCI'~1'~T"-pentamethyldiethylenetriamine, triethylenediamine, or dimethylethanolamine).
The catalyst may be from 0.1 to 1.0 part by weight, for example, from 0.2 to 0.5 part by weight, based on 100 parts by weight of the aromatic polyisocyanate.
The polyol to be used may be, for example, a polyhydric alcohol (for example, ethylene glycol, glycerin, trimethylolpropane, pentaerythritol, sorbitol, sugar), a polyether polyol, or a polyester polyol.
Examples of the polyether polyol include a polyether polyol obtained by adding an alkylene oxide (for example, propylene oxide or ethylene oxide) to a polyhydric alcohol, and a polyether polyol obtained by adding an alkylene oxide (for example, propylene oxide or ethylene oxide) to an aliphatic amine (for example, monoethylamine, ethylenediamine, N,N-dimethylethylamine, or diethylenetriamine).
The polyether polyol may have a hydroxyl value of 100 to 1000 mgKOH/g, for example, 300 to 600 mgKOH/g.
The amount of polyol may be at most 10 parts by weight, for example, from 2 to 5 parts by weight, based on 100 parts by weight of the polyisocyanate.
The amount of the thermosetting adhesive may be from 50 to 300 parts by weight, for example, 70 to 150 parts by weight, based on 100 parts of the vegetable fibers.
The catalyst may be, for example, an amine such as monoamine, diamine, or triamine (for example, bis(dimethylaminoethyl) ether, N,NCI'~1'~T"-pentamethyldiethylenetriamine, triethylenediamine, or dimethylethanolamine).
The catalyst may be from 0.1 to 1.0 part by weight, for example, from 0.2 to 0.5 part by weight, based on 100 parts by weight of the aromatic polyisocyanate.
The polyol to be used may be, for example, a polyhydric alcohol (for example, ethylene glycol, glycerin, trimethylolpropane, pentaerythritol, sorbitol, sugar), a polyether polyol, or a polyester polyol.
Examples of the polyether polyol include a polyether polyol obtained by adding an alkylene oxide (for example, propylene oxide or ethylene oxide) to a polyhydric alcohol, and a polyether polyol obtained by adding an alkylene oxide (for example, propylene oxide or ethylene oxide) to an aliphatic amine (for example, monoethylamine, ethylenediamine, N,N-dimethylethylamine, or diethylenetriamine).
The polyether polyol may have a hydroxyl value of 100 to 1000 mgKOH/g, for example, 300 to 600 mgKOH/g.
The amount of polyol may be at most 10 parts by weight, for example, from 2 to 5 parts by weight, based on 100 parts by weight of the polyisocyanate.
The amount of the thermosetting adhesive may be from 50 to 300 parts by weight, for example, 70 to 150 parts by weight, based on 100 parts of the vegetable fibers.
Optionally, a skin for surface decoration and/or a filin preventing the exudation of the adhesive may be provided on the layer made of the vegetable fibers and the thermosetting adhesive. The skin for surface decoration may be woven or non-woven fabric of polyolefin, polyester or polyamide, a vinyl leather, or the like. The thickness of the skin for surface decoration may be, for example, from 0.1 to 3 mm.
The film preventing the exudation of the adhesive may be an olefin film or a polyamide film. The thickness of the film preventing the exudation of the adhesive may be, for example, finm 10 to 40 .m.
The laminate can be produced, for example, by applying (for example, applying with a spray) a thermosetting adhesive on both surfaces of a polyurethane foam, spreading vegetable fibers on both surfaces, optionally disposing a skin for surface decoration and/or a filin preventing the exudation of the adhesive to give a laminate, charging the laminate into a mold heated to a temperature of 80 to 150 °C, for example,120 to 140 °C. for pressurizing, curing the adhesive, and demolding the molded product from the mold.
Alternatively, after the thermosetting adhesive or one component (for example, aromatic polyisocyanate) of the thermosetting adhesive is mixed with the vegetable fibers in advance, the mixtlue may be applied on both surface of the polyurethane foam.
In the laminate, the thickness of the layer made of the polyurethane foam may be from 4 to 8 mm, and the thickness of the layer made of the vegetable fibers and the thermosetting adhesive may be fi-om0.2to2mm.
The laminate of the present invention can be used as an interior base material for an automobile, for example, a ceiling material or a door trim material for an automobile.
Hereafter, Examples will be shown, and the present invention will be specifically explained.
The film preventing the exudation of the adhesive may be an olefin film or a polyamide film. The thickness of the film preventing the exudation of the adhesive may be, for example, finm 10 to 40 .m.
The laminate can be produced, for example, by applying (for example, applying with a spray) a thermosetting adhesive on both surfaces of a polyurethane foam, spreading vegetable fibers on both surfaces, optionally disposing a skin for surface decoration and/or a filin preventing the exudation of the adhesive to give a laminate, charging the laminate into a mold heated to a temperature of 80 to 150 °C, for example,120 to 140 °C. for pressurizing, curing the adhesive, and demolding the molded product from the mold.
Alternatively, after the thermosetting adhesive or one component (for example, aromatic polyisocyanate) of the thermosetting adhesive is mixed with the vegetable fibers in advance, the mixtlue may be applied on both surface of the polyurethane foam.
In the laminate, the thickness of the layer made of the polyurethane foam may be from 4 to 8 mm, and the thickness of the layer made of the vegetable fibers and the thermosetting adhesive may be fi-om0.2to2mm.
The laminate of the present invention can be used as an interior base material for an automobile, for example, a ceiling material or a door trim material for an automobile.
Hereafter, Examples will be shown, and the present invention will be specifically explained.
_7_ Examples In the following examples, the evaluation of a molded product was performed as follows.
(1) Flexural modulus The flexural modulus was measured according to JIS K6301. A sample having a length of 150 mm and a width of 50 mm was cut out from a molded product, and the flexural modulus was measured with an interfizlcrum distance of 100 mm and a test speed of SO
mm/min.
(2) Moldability The moldability was judged by the rigidity at the demolding, the damage degree of the skin for surface decoration, and the like.
Example 1 Polymeric MDI (SBU Isocyanate 0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 70 g/m2 by a spray on both surfaces of a thermoformable rigid polyurethane foam sheet (size: 30 cm x 30 cm x 5.5 mm) having open cells and a weight per unit area of 200 g~mz.
Neat, water containing 1 wt% of a urethanization catalyst (SBU Catalyst H544, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 20 g/m2 by a spray.
Then, wood fibers (type: groundwood pulp) having a diameter of 0.7 mm and a length of 10 to 50 mm were spread at a basis weight of about 150 g/m2 on both surfaces, and a nonwoven fabric (polyester: thickness 0.1 mm) of about 40 glm'- was disposed on both surfaces to give a laminate, and the laminate was pressurized for 60 seconds in a mold at 130 °C. to fabricate a molded product having a thickness of 5 mm.
_g_ This molded product, though having a density (apparent density) of 0.15 g/cm3 and a weight per unit area of 750 g/m2 to be extremely light, exhibited a flexural modulus of 3,000 kg/cm2 and had a full capability as a ceiling material.
Example 2 Water containing 1 wt% of a urethanization catalyst (SBU Catalyst H544, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 20 gJm2 by a spray on both surfaces of a thermoformable rigid polyurethane foam sheet (size: 30 cm x 30 cm x S.5 mm) having open cells and a weight per unit area of 200 g/m2.
To 100 parts by weight of bamboo fibers having a diameter of 0.7 mm and a length of 10 to 50 mm were added 50 parts by weight of polymeric MDI (SBU Isocyanate 0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.), and the mixture was well stirred.
The mixture of polymeric MDI and bamboo fibers was spread uniformly at a basis weight of about 200 g/mz on both surfaces of the polyurethane foam sheet having the urethanization catalyst-containing water applied thereon.
Onto the outside thereof, about 200 g/m2 of a skin (polyester: thickness 1 mm) for surface decoration was disposed to give a laminate, and the laminate was pressurized for 60 seconds in a mold at 130 °C. to fabricate a molded product having a thickness of S mm.
This molded product, though having a base material density (apparent density) of 0.14 g/cm3 and a weight per unit base material area of 700 g/m2 to be extremely light, exhibited a flexural modulus of 3,000 kg/cmZ, and the skin for surface decoration had not been damaged at all.
Comparative Example 1 Water containing 1 wt% of a urethanization catalyst (SBU Catalyst H544, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 20 g/mz by a spray on both surfaces of a thermoformable rigid polyurethane foam sheet (size: 30 cm x 30 cm x 5.5 mm) having open cells and a weight per unit area of 200 ~m2.
To 100 parts by weight of wood fibers (groundwood pulp) having a diameter of about 2 mm and a length of 2 to 15 mm were added 50 parts by weight of polymeric MDI (SBU
Isocyanate 0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.), and the mixture was well stirred.
The mixhwe of polymeric MDI and wood fibers was spread uniformly at a basis weight of about 200 g/m2 on both surfaces of the sheet having the urethanization catalyst-containing water applied thereon.
Onto the outside thereof, about 200 g/m2 of a skin (polyester: thickness 1 mm) for surface decoration was disposed to give a laminate, and the laminate was pressurized for 60 seconds in a mold at 130 °C. to fabricate a molded product having a thickness of 5 mm.
This molded product had a base material density (apparent density) of 0.14 g~cm3 and a weight per unit base material area of 700 g/m2. The rigidity at the demolding time was low, and it was di~cult to demold the molded product Moreover, the flexural modules was only as much as 1,000 kg/cmz, so that a molded product usable as a ceiling material could not be obtained.
The molded product obtained according to the present invention, in spite of being extremely light, exhibits a high rigidity.
(1) Flexural modulus The flexural modulus was measured according to JIS K6301. A sample having a length of 150 mm and a width of 50 mm was cut out from a molded product, and the flexural modulus was measured with an interfizlcrum distance of 100 mm and a test speed of SO
mm/min.
(2) Moldability The moldability was judged by the rigidity at the demolding, the damage degree of the skin for surface decoration, and the like.
Example 1 Polymeric MDI (SBU Isocyanate 0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 70 g/m2 by a spray on both surfaces of a thermoformable rigid polyurethane foam sheet (size: 30 cm x 30 cm x 5.5 mm) having open cells and a weight per unit area of 200 g~mz.
Neat, water containing 1 wt% of a urethanization catalyst (SBU Catalyst H544, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 20 g/m2 by a spray.
Then, wood fibers (type: groundwood pulp) having a diameter of 0.7 mm and a length of 10 to 50 mm were spread at a basis weight of about 150 g/m2 on both surfaces, and a nonwoven fabric (polyester: thickness 0.1 mm) of about 40 glm'- was disposed on both surfaces to give a laminate, and the laminate was pressurized for 60 seconds in a mold at 130 °C. to fabricate a molded product having a thickness of 5 mm.
_g_ This molded product, though having a density (apparent density) of 0.15 g/cm3 and a weight per unit area of 750 g/m2 to be extremely light, exhibited a flexural modulus of 3,000 kg/cm2 and had a full capability as a ceiling material.
Example 2 Water containing 1 wt% of a urethanization catalyst (SBU Catalyst H544, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 20 gJm2 by a spray on both surfaces of a thermoformable rigid polyurethane foam sheet (size: 30 cm x 30 cm x S.5 mm) having open cells and a weight per unit area of 200 g/m2.
To 100 parts by weight of bamboo fibers having a diameter of 0.7 mm and a length of 10 to 50 mm were added 50 parts by weight of polymeric MDI (SBU Isocyanate 0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.), and the mixture was well stirred.
The mixture of polymeric MDI and bamboo fibers was spread uniformly at a basis weight of about 200 g/mz on both surfaces of the polyurethane foam sheet having the urethanization catalyst-containing water applied thereon.
Onto the outside thereof, about 200 g/m2 of a skin (polyester: thickness 1 mm) for surface decoration was disposed to give a laminate, and the laminate was pressurized for 60 seconds in a mold at 130 °C. to fabricate a molded product having a thickness of S mm.
This molded product, though having a base material density (apparent density) of 0.14 g/cm3 and a weight per unit base material area of 700 g/m2 to be extremely light, exhibited a flexural modulus of 3,000 kg/cmZ, and the skin for surface decoration had not been damaged at all.
Comparative Example 1 Water containing 1 wt% of a urethanization catalyst (SBU Catalyst H544, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 20 g/mz by a spray on both surfaces of a thermoformable rigid polyurethane foam sheet (size: 30 cm x 30 cm x 5.5 mm) having open cells and a weight per unit area of 200 ~m2.
To 100 parts by weight of wood fibers (groundwood pulp) having a diameter of about 2 mm and a length of 2 to 15 mm were added 50 parts by weight of polymeric MDI (SBU
Isocyanate 0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.), and the mixture was well stirred.
The mixhwe of polymeric MDI and wood fibers was spread uniformly at a basis weight of about 200 g/m2 on both surfaces of the sheet having the urethanization catalyst-containing water applied thereon.
Onto the outside thereof, about 200 g/m2 of a skin (polyester: thickness 1 mm) for surface decoration was disposed to give a laminate, and the laminate was pressurized for 60 seconds in a mold at 130 °C. to fabricate a molded product having a thickness of 5 mm.
This molded product had a base material density (apparent density) of 0.14 g~cm3 and a weight per unit base material area of 700 g/m2. The rigidity at the demolding time was low, and it was di~cult to demold the molded product Moreover, the flexural modules was only as much as 1,000 kg/cmz, so that a molded product usable as a ceiling material could not be obtained.
The molded product obtained according to the present invention, in spite of being extremely light, exhibits a high rigidity.
Claims (2)
1. A method of producing a vehicle interior material having a sandwich structure, comprising the steps of:
(I) stacking (a) a thermoformable polyurethane foam having open cells and a density of 20 to 100 kg/m3, (b) vegetable fibers of 100 g/m2 to 300 g/m2 positioned on both main surfaces of the polyurethane foam (a), (c) a thermosetting adhesive forming bonds between the polyurethane foam (a) and the vegetable fibers (b) and bonds between the vegetable fibers (b) each other, and optionally (d) a skin for surface decoration and/or a film preventing the exudation of the adhesive, (II) charging the laminate into a mold having a temperature of 80 to 150 °C, and closing the mold to cure the adhesive, and (III) demolding a molded product after the curing of the adhesive, characterized in that the size of the vegetable fibers is adjusted to be a diameter of at most 1.0 mm and a length of 10 mm to 100 mm.
(I) stacking (a) a thermoformable polyurethane foam having open cells and a density of 20 to 100 kg/m3, (b) vegetable fibers of 100 g/m2 to 300 g/m2 positioned on both main surfaces of the polyurethane foam (a), (c) a thermosetting adhesive forming bonds between the polyurethane foam (a) and the vegetable fibers (b) and bonds between the vegetable fibers (b) each other, and optionally (d) a skin for surface decoration and/or a film preventing the exudation of the adhesive, (II) charging the laminate into a mold having a temperature of 80 to 150 °C, and closing the mold to cure the adhesive, and (III) demolding a molded product after the curing of the adhesive, characterized in that the size of the vegetable fibers is adjusted to be a diameter of at most 1.0 mm and a length of 10 mm to 100 mm.
2. The method according to claim 1, wherein the polyurethane foam is a rigid polyurethane foam; the thermosetting adhesive is an adhesive comprising an aromatic polyisocyanate, water, a catalyst, and optionally a polyol; and the vegetable fibers are those obtained by cutting or grinding of hemp, kenaf, sisal fibers, bamboo fibers, wood fibers.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP11/221067 | 1999-08-04 | ||
JP11221067A JP2001047544A (en) | 1999-08-04 | 1999-08-04 | Manufacture of car interior material of sandwich structure |
PCT/EP2000/007065 WO2001010637A1 (en) | 1999-08-04 | 2000-07-24 | Method of producing vehicle interior material having sandwich structure |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2391726A1 true CA2391726A1 (en) | 2001-02-15 |
Family
ID=16760983
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CA002391726A Abandoned CA2391726A1 (en) | 1999-08-04 | 2000-07-24 | Method of producing vehicle interior material having sandwich structure |
Country Status (12)
Country | Link |
---|---|
EP (1) | EP1206348A1 (en) |
JP (1) | JP2001047544A (en) |
KR (1) | KR20020016937A (en) |
CN (1) | CN1168600C (en) |
AU (1) | AU767084B2 (en) |
BR (1) | BR0012948A (en) |
CA (1) | CA2391726A1 (en) |
HK (1) | HK1047562B (en) |
HU (1) | HUP0202086A2 (en) |
MX (1) | MXPA02001171A (en) |
PL (1) | PL353240A1 (en) |
WO (1) | WO2001010637A1 (en) |
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KR20040012213A (en) * | 2002-08-01 | 2004-02-11 | 김정태 | Hemp floor and preparation thereof |
US20040151936A1 (en) * | 2003-01-22 | 2004-08-05 | Panolam Industries International, Inc. | Leather laminated decorative panel |
JP4252354B2 (en) * | 2003-04-24 | 2009-04-08 | 三和工業株式会社 | Molded interior material |
US7901765B2 (en) * | 2003-07-25 | 2011-03-08 | Proprietect L.P. | Foam laminate product and process for production thereof |
JP3959092B2 (en) | 2004-12-27 | 2007-08-15 | 住化バイエルウレタン株式会社 | Polyurethane molded product and method for producing the same |
EP1851092B1 (en) * | 2005-02-23 | 2012-06-06 | Li & S CO., LTD . | The member for headliner on motor vehicles of multilayer structure |
DE102005014317A1 (en) * | 2005-03-30 | 2006-10-05 | Carl Freudenberg Kg | Synthetic leather, process for its preparation and its use |
CN101117399B (en) * | 2007-07-06 | 2010-09-29 | 烟台正海兴源汽车内饰件有限公司 | Cystosepiment for passenger car inner decoration ceiling |
EP2250206B1 (en) * | 2008-01-04 | 2012-10-31 | Johnson Controls Technology Company | Trim component with increased renewable materials |
MX2010012439A (en) * | 2008-05-16 | 2011-06-20 | Proprietect Lp | Foam laminate product and process for production thereof. |
CN201427420Y (en) * | 2008-08-29 | 2010-03-24 | 纸艺制品有限公司 | Paper-based composite material |
EP2438102B1 (en) * | 2009-06-05 | 2013-05-01 | Basf Se | Composites which contain a thermoformable polyurethane rigid foam, adhesive and coating material. |
CN102459385B (en) * | 2009-06-05 | 2014-04-30 | 巴斯夫欧洲公司 | Composite parts containing plastically deformable rigid polyurethane foam, adhesive, and covering material |
DE102009048000A1 (en) * | 2009-10-01 | 2011-09-15 | Bayer Materialscience Ag | Composite made of open-cell rigid foam |
CN102001318B (en) * | 2010-08-26 | 2012-10-10 | 无锡吉兴汽车声学部件科技有限公司 | Method for manufacturing automobile headliner by using natural fiber material as main material |
EP2463083B1 (en) * | 2010-12-13 | 2016-06-29 | The Boeing Company | Green aircraft interior panels and method of fabrication |
FR2971198B1 (en) * | 2011-02-04 | 2013-03-01 | Faurecia Automotive Ind | STRUCTURAL PIECE OF A MOTOR VEHICLE AND METHOD OF MANUFACTURING THE SAME |
CN102616066B (en) * | 2012-04-09 | 2015-01-21 | 董建 | Method for assembling modelling assembly with decorative layer on surface |
CN102896843B (en) * | 2012-10-12 | 2016-02-03 | 喻云水 | For making bamboo fiber composite base material and the inside gadget manufacture method of automotive upholstery |
JP2014104603A (en) * | 2012-11-26 | 2014-06-09 | Inoac Corp | Laminate and method for producing the same |
JP6107160B2 (en) * | 2013-01-18 | 2017-04-05 | 三菱自動車工業株式会社 | Vehicle interior materials |
JP6318461B2 (en) * | 2013-01-18 | 2018-05-09 | 三菱自動車工業株式会社 | Bamboo fiber sheet |
CN103395397A (en) * | 2013-08-05 | 2013-11-20 | 扬州顺祥汽车内饰材料有限公司 | Fiber felt composite plate and manufacturing method thereof |
CN103450580A (en) * | 2013-09-16 | 2013-12-18 | 内蒙古大学 | Method for preparing board from waste polyurethane foam, waste plant fiber and waste polystyrene foam |
EP3246159B1 (en) * | 2016-05-17 | 2019-09-11 | Grupo Antonlín-Ingeniería, S.A. | Manufacturing procedure for ceiling trims for vehicles |
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ES1027967Y (en) * | 1994-05-11 | 1995-05-16 | Irausa Ing Sa | SELF-SUPPORTING TRIM FOR INTERIOR COATING OF VEHICLE CEILINGS. |
ATE227212T1 (en) * | 1994-12-22 | 2002-11-15 | Lear Corp | METHOD FOR PRODUCING A FLAT LINING PART FOR MOTOR VEHICLES AND LINING PART PRODUCED THEREFROM |
US6562268B1 (en) * | 1995-12-21 | 2003-05-13 | Davidson Textron, Inc | Interior trim panels and method for manufacturing such panels using silaceous materials |
US5804262A (en) * | 1996-08-16 | 1998-09-08 | United Technologies Automotive Inc. | Vehicle trim panel with natural fiber layers |
-
1999
- 1999-08-04 JP JP11221067A patent/JP2001047544A/en active Pending
-
2000
- 2000-07-24 KR KR1020027001488A patent/KR20020016937A/en not_active Application Discontinuation
- 2000-07-24 PL PL00353240A patent/PL353240A1/en not_active Application Discontinuation
- 2000-07-24 CA CA002391726A patent/CA2391726A1/en not_active Abandoned
- 2000-07-24 BR BR0012948-8A patent/BR0012948A/en not_active Application Discontinuation
- 2000-07-24 MX MXPA02001171A patent/MXPA02001171A/en not_active Application Discontinuation
- 2000-07-24 EP EP00951434A patent/EP1206348A1/en not_active Withdrawn
- 2000-07-24 WO PCT/EP2000/007065 patent/WO2001010637A1/en not_active Application Discontinuation
- 2000-07-24 AU AU64370/00A patent/AU767084B2/en not_active Ceased
- 2000-07-24 CN CNB008111367A patent/CN1168600C/en not_active Expired - Lifetime
- 2000-07-24 HU HU0202086A patent/HUP0202086A2/en unknown
-
2002
- 2002-12-16 HK HK02109112.2A patent/HK1047562B/en not_active IP Right Cessation
Also Published As
Publication number | Publication date |
---|---|
EP1206348A1 (en) | 2002-05-22 |
WO2001010637A1 (en) | 2001-02-15 |
CN1367733A (en) | 2002-09-04 |
PL353240A1 (en) | 2003-11-03 |
HUP0202086A2 (en) | 2002-10-28 |
CN1168600C (en) | 2004-09-29 |
JP2001047544A (en) | 2001-02-20 |
AU6437000A (en) | 2001-03-05 |
HK1047562B (en) | 2005-05-13 |
AU767084B2 (en) | 2003-10-30 |
BR0012948A (en) | 2002-04-30 |
HK1047562A1 (en) | 2003-02-28 |
KR20020016937A (en) | 2002-03-06 |
MXPA02001171A (en) | 2002-07-30 |
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