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
  • 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
  • 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
  • B32B5/18—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

Definitions

• 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 larninate having a sandwich structure that can be used as an interior base material for a vehicle.
• the present invention provides a method of producing a vehicle interior material having a sandwich structure, comprising the steps of:
• thermoformable polyurethane foam having open cells and a density of 20 to 100 kg/m 3 ,
• 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
• the present invention also provides a laminate comprising:
• thermoformable polyurethane foam having open cells and a density of 20 to l00 kg/m 3 ;
• (B) layers composed of vegetable fibers of 100 g/m 2 to 300 g/m 3 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;
• the vegetable fibers are those obtained by cutting or grinding of hemp, kenaf, sisal fibers, bamboo fibers, wood fibers.
• thermoformable polyurethane foam having open cells may have a density of 20 to 100 kg/m 3 , for example, 25 to 40 kg/m 3 , particularly 25 to 35 kg/m 3 .
• the polyurethane form is preferably a rigid polyurethane foam.
• the rigid polyurethane foam is one obtained by reacting a polyisocyanate component and a polyol 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/m 2 for example, at 100 to 200 g/m 2 as a reinforcing material.
• 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.
• 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, biba arborvitae, cherry, poplar, or fir.
• thermosetting adhesive forms bonds between the polyurethane foam and the vegetable fibers and bonds between the vegetable fibers each other.
• the adhesive is immersed among the vegetable fibers to form a layer made of the vegetable fibers and the adhesive.
• the tl ermosetting 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(dimemylaminoethyl) ether, N,N ⁇ ' ⁇ ' ⁇ '-pentametJ yldiethylenetriamine, triemylenediamine, or dimemylethanolamine).
• an amine such as monoamine, diamine, or triamine (for example, bis(dimemylaminoethyl) ether, N,N ⁇ ' ⁇ ' ⁇ '-pentametJ yldiethylenetriamine, triemylenediamine, or dimemylethanolamine).
• 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.
• a polyhydric alcohol for example, ethylene glycol, glycerin, trimethylolpropane, pentaerythritol, sorbitol, sugar
• a polyether polyol for example, ethylene glycol, glycerin, trimethylolpropane, pentaerythritol, sorbitol, sugar
• polyester polyol for example, ethylene glycol, glycerin, trimethylolpropane, pentaerythritol, sorbitol, sugar
• polyether polyol examples 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-dime ylemylamine, or ⁇ ethylenetriamine).
• alkylene oxide for example, propylene oxide or ethylene oxide
• an aliphatic amine for example, monoethylamine, ethylenediamine, N,N-dime ylemylamine, or ⁇ ethylenetriamine
• 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.
• a skin for surface decoration and/or a film 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, from 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 film 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.
• thermosetting adhesive or one component (for example, aromatic polyisocyanate) of the thermosetting adhesive is mixed with the vegetable fibers in advance, the mixture may be applied on both surface of the polyurethane foam.
• 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 from 0.2 to 2 mm.
• 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.
• 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 interfulcrum distance of 100 mm and a test speed of 50 mm/min.
• the moldability was judged by the rigidity at the demolding, the damage degree of the skin for surface decoration, and the like.
• Polymeric MDI (SBU Isocyanate 0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 70 g/m 2 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/m 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 g/m 2 by a spray.
• wood fibers type: groundwood pulp
• a nonwoven fabric polyester: thickness 0.1 mm
• 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 though having a density (apparent density) of 0.15 g/cm 3 and a weight per unit area of 750 g/m 2 to be extremely light, exhibited a flexural modulus of 3,000 kg/cm 2 and had a full capability as a ceiling material.
• 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/m 2 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/m 2 .
• the mixture of polymeric MDI and bamboo fibers was spread uniformly at a basis weight of about 200 g/m 2 on both surfaces of the polyurethane foam sheet having the urethanization catalyst- containing water applied thereon.
• a skin 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.
• 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/m 2 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 gm 2 .
• wood fibers groundwood pulp
• polymeric MDI SBU Isocyanate 0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.
• the mixture of polymeric MDI and wood fibers was spread uniformly at a basis weight of about 200 g/m 2 on both surfaces of the sheet having the urethanization catalyst-containing water applied thereon.
• a skin 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/cm 3 and a weight per unit base material area of 700 g/m 2 .
• the rigidity at the demolding time was low, and it was difficult to demold the molded product Moreover, the flexural modulus was only as much as 1,000 kg/cm 2 , 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.

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)

Applications Claiming Priority (3)

Publications (1)

Family

ID=16760983

Family Applications (1)

Country Status (12)

Families Citing this family (25)

Family Cites Families (4)

• 1999
  • 1999-08-04 JP JP11221067A patent/JP2001047544A/ja active Pending
• 2000
  • 2000-07-24 BR BR0012948-8A patent/BR0012948A/pt not_active Application Discontinuation
  • 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/zh not_active Expired - Lifetime
  • 2000-07-24 PL PL00353240A patent/PL353240A1/xx not_active Application Discontinuation
  • 2000-07-24 MX MXPA02001171A patent/MXPA02001171A/es not_active Application Discontinuation
  • 2000-07-24 HU HU0202086A patent/HUP0202086A2/hu unknown
  • 2000-07-24 EP EP00951434A patent/EP1206348A1/en not_active Withdrawn
  • 2000-07-24 CA CA002391726A patent/CA2391726A1/en not_active Abandoned
  • 2000-07-24 KR KR1020027001488A patent/KR20020016937A/ko not_active Application Discontinuation
• 2002
  • 2002-12-16 HK HK02109112.2A patent/HK1047562B/zh not_active IP Right Cessation

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events