JP2002028997A - Plate-shaped foamed molded item with skin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior finishing material which is stiff and light in weight. SOLUTION: A plate-shaped foamed molded item contains a plate-shaped foamed item 11 molded to constitute at least a core portion, a sheet-like fiber reinforcement 13 comprising a fiber assembly and a resin penetrating into the clearance of the fibers to solidify and having the same composition as the foamed item, the sheet-like fiber reinforcement 13 being molded on at least a part of the surface of the foamed item into one body, and a skin material 12 molded to cover the surface of the fiber reinforcement 13 into one body. Light weight is achieved and at the same time stiffness is maintained by using the plate-shaped foamed item 11 as the core portion and placing thereon the sheet-like fiber reinforcement 13 made of the fiber assembly formed by impregnating and the solidifying resin having the same composition as the foamed item 11.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plate-like foam molded article with a skin material. This plate-like foamed body with a skin material has rigidity and strength, and is used for various interior materials, for example, interior materials for automobiles.

[0002]

2. Description of the Related Art As an interior material of an automobile, in particular, an interior material used for a floor portion of a rear luggage compartment of a vehicle, as shown in FIG. 2, a veneer plate 61 as a base material and a skin bonded to the veneer plate 61. There is an interior material 60 made of a material 62. Also, as shown in FIG. 3, an interior material 70 and the like made of a blow base material 71 made of synthetic resin hollowed by blow molding as a base material and a skin material 72 adhered to the blow base material 71 at the time of blow molding or thereafter. Were present.

[0003]

However, when a plywood or a blown base material is used as the base material of the interior material, there is a problem that the weight of these materials is large. That is, assuming that a load is placed on the interior material, it is necessary to have a certain load-carrying capacity in order to support a certain mass. Therefore, it is necessary to increase the thickness of the plywood. Also, in the case of a blown base made of synthetic resin, it is necessary to increase the thickness of the blown base and insert a metal pipe or the like into the blown base to reinforce the blown base. As a result, there has been a problem that the mass increases.

Accordingly, an object of the present invention is to provide a rigid and lightweight interior material.

[0005]

Means for Solving the Problems As a result of earnest studies, the present inventor has found that at least a core-shaped plate-shaped foam is formed, and at least a part of the foam is integrally formed on the surface of the foam. A sheet-shaped fiber reinforcing material made of a resin having the same composition as that of the foamed material, which is impregnated and solidified in the fiber assembly and the fiber gap thereof, and a skin material integrally covered with the surface of the fiber reinforcing material and molded. The present invention has invented a plate-shaped foam molded article with a skin material, characterized by containing:

[0006] By using a plate-like foam as the core as described above, the thickness of the plate-like foam molded product with a skin material can be provided, and the weight of the plate-like foam molded product with a skin material can be reduced. Made it possible.

A sheet-like fiber reinforcing material made of a resin which is impregnated and solidified in a fiber aggregate and a fiber gap thereof and has the same composition as a plate-like foam is integrally formed on at least a part of the surface of the plate-like foam. By being molded, it is possible to impart rigidity to the plate-like foam molded article with a skin material. That is, a resin having the same composition as that of the plate-like foam is impregnated into the fiber gaps of the fiber assembly and solidified, whereby a rigid sheet-like fiber reinforcing material can be formed. Since the sheet-like fiber reinforcing material is molded in a state of being joined to the foam when forming and molding the foam, it is integrally molded with at least a part of the surface of the foam to be molded. Since the fiber reinforcing material is integrally molded on a part of the surface of the foam, rigidity can be given to the plate-like foam molded article with the skin material having the foam as a core.

Further, by arranging the sheet-like fiber reinforcing material on both sides of the plate-like foam and sandwiching the foam serving as a core portion, the plate-like molded body with the skin material can be given more rigidity. . The surface of the fiber reinforcing material, that is, the surface opposite to the side in contact with the foam is integrally covered with the molded skin material, so that the design can be improved by the skin material.

Further, since the plate-like foam with a skin material of the present invention is formed by molding, the shape can be selected relatively freely, and it can be easily formed into a predetermined shape. it can.

[0010] By inserting a reinforcing member such as a metal or synthetic resin pipe or an angle material into the foam, it is possible to improve the loadability.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of a plate-like foam molded article with a skin material of the present invention (hereinafter referred to as "plate-like foam molded article" as appropriate) will be described below. The plate-like foamed molded article of the present invention comprises a plate-shaped foam composed of a resin molded at least constituting a core portion, and a fiber assembly integrally molded on at least a part of the surface of the plate-shaped foam. A sheet-like fiber reinforcing material made of a resin having the same composition as the plate-like foam, which is impregnated and solidified in the body and its fiber gap, and a skin material integrally covered with the surface of the fiber reinforcing material and molded. including.

The core of the plate-like foam molded article of the present invention is a plate-like foam. Since the foam is formed by molding, the shape of the foam can be freely selected and the foam can be easily formed into a predetermined shape.

As the foam, a foam made of a synthetic resin can be used. For example, a synthetic resin foam such as a polyurethane foam, an epoxy resin foam, or a polyamide foam can be used.

From the viewpoint of ensuring the rigidity of the plate-like foamed molded article, it is preferable to use a rigid foam. For example, it is preferable to use a rigid polyurethane foam, a semi-rigid polyurethane foam, or the like. Rigid polyurethane foams are particularly preferred. Rigid polyurethane foam is a general-purpose resin,
Inexpensive and easy to handle.

The bulk density of this foam is 0.01 to 0.2 k
g / m ³ , 0.05 to 0.1 kg / m ³
Is preferred. If the bulk density is small, the load resistance and strength are reduced, but if the bulk density is too large, it is disadvantageous for weight reduction.

The thickness of the plate-like foam is 10 to 25 m.
m, preferably 12 to 20 mm.
If the thickness is too small, the load resistance and strength decrease, and if the thickness is too large, the production cost increases and the mass also increases.

It is preferable that a metal or synthetic resin pipe or angle material is inserted into the plate-like foam as a reinforcing material. By inserting the pipe or the angle member into the foam as described above, the load resistance of the core portion is improved, and therefore, the load resistance of the plate-like foam molded article of the present invention is also improved.

An appropriate material can be used for the pipe or the angle material. For example, iron as a metal, stainless steel, aluminum, etc., polyethylene as a synthetic resin,
Polypropylene, polyethylene terephthalate, polyamide, or the like can be used. The shape or size of the pipe or the angle material can be set to an appropriate shape and size so as to conform to the shape and size of the plate-like foam molded article of the present invention.

A sheet-like fiber reinforcing material is integrally formed on at least a part of the surface of the plate-like foam. This fiber reinforcing material is composed of a fiber aggregate and a resin which is impregnated and solidified in the fiber gap and has the same composition as a plate-like foam. As described above, the sheet-like fiber reinforcing material has the fibers and the solidified resin entangled with each other, so to speak, is embedded in the solidified resin with the fibers serving as a core, and therefore can have excellent rigidity.

This sheet-like fiber reinforcing material is integrally formed on at least a part of the surface of a plate-like foam. In other words, as the resin to be impregnated and solidified in the fiber gap of the fiber aggregate, a resin having the same composition as the plate-like foam is used. When the plate-like foam is generated and molded, the plate-like foam is simultaneously formed. Since the sheet-like fiber reinforcing material is also molded in a state of being joined to the body, the sheet-like fiber reinforcing material and the plate-like foam can be molded in a state of being integrally joined.

Since the sheet-like fiber reinforcing material is integrally formed on at least one surface of the plate-like foam, the plate-like foam molded article of the present invention comprises only the plate-like foam as the core. It can have better rigidity than the molded article used as the part.

This sheet-like fiber reinforcing material can be joined and laminated on one surface of the plate-like foam, or can be joined and laminated on both surfaces. In this case, by laminating the plate-like foam on both sides so as to sandwich the plate-like foam, the rigidity of the plate-like foam molded body is further enhanced. Therefore, from the viewpoint of strengthening the rigidity, it is preferable to laminate the sheet-like fiber reinforcing material on both sides of the plate-like foam.

As the fiber aggregate, a fiber aggregate having a fiber gap that can be impregnated with the resin constituting the foam can be used. For example, a nonwoven fabric, felt, or the like can be used. The fibers constituting these nonwoven fabrics and felts include thermoplastic fibers such as polyethylene terephthalate and polypropylene, cotton fibers, loose hair, hemp, kenaf,
Natural fibers such as bamboo can be used.

The basis weight of the fiber assembly is determined by the load resistance, strength,
It can be adjusted to an appropriate amount in consideration of mass, moldability, and the like. In this case, 200 to 1500 g / m ² is preferable,
300-800 g / m < ² > is more preferable. If the basis weight is small, the load resistance and strength decrease, and if the basis weight is large, the mass increases, and the thickness of the fiber aggregate itself increases, and the formability decreases.

The resin impregnated and solidified in the fiber gap of the fiber assembly is a resin having the same composition as the plate-like foam used for the core. That is, a liquid material for forming a plate-like foam is impregnated into the fiber gaps of the fiber assembly and solidified. Therefore, the resin and the plate-like foam are made of the same material. Note that the resin solidified in the fiber gap of the fiber assembly does not necessarily foam. However, it is a resin solidified in a state where foaming is restricted because it is solidified in a fiber gap.

A skin material integrally covering the surface of the sheet-like fiber reinforcing material and formed by molding is laminated. Since the skin material is molded, the skin material can be easily formed into a shape that integrally covers the surface of the sheet-like fiber reinforcing material.

When the sheet-like fiber reinforcing material is laminated on both sides of the plate-like foam, the skin material is laminated on the sheet-like fiber reinforcing material. It will have skin material on both sides. When the sheet-like fiber reinforcing material is laminated only on one side of the plate-like foam, the plate-like foam molded article of the present invention has a skin material only on one surface.

This skin material is not particularly limited, and an appropriate material can be used. For example, leather, artificial leather, decorative film, tufted carpet, woven, knitted, non-woven,
Felt or the like can also be used. In this case, it is preferable to use a tufted carpet, a woven fabric, a nonwoven fabric, or the like as the skin material from the viewpoint of moldability.

When a non-breathable skin material such as leather, artificial leather, decorative film, etc. is used, there is no fear that the resin impregnated and solidified in the fiber gap of the fiber reinforcing material will seep out onto the surface of the skin material. The skin material can be directly laminated on the fiber assembly impregnated with the resin, and the skin material can be bonded to the fiber assembly.

When a fibrous structure such as a woven fabric, a knitted fabric, a nonwoven fabric, and a felt is used as the skin material, polypropylene, polyamide, rayon, polyethylene terephthalate, cotton, hemp, bamboo, or the like can be used as the fiber. In this case, polypropylene, polyamide, polyethylene terephthalate and the like are preferable. This is because the skin material using these materials is excellent in physical properties such as surface texture and light resistance.

When a fibrous structure is used as the skin material, the basis weight of the skin material is not particularly limited and can be an appropriate amount, but can be generally 100 to 600 g / m ^2, and generally 200 to 600 g / m ^2. 400 g / m ² is preferred.

When a skin material made of a fiber structure such as a woven fabric, a knitted fabric, a nonwoven fabric, a felt, and a tufted carpet is used, a film-like material made of a thermoplastic resin is interposed between the skin material and the above-mentioned fiber structure. It is preferable to provide a bonding layer. In general, the fiber structure has a fiber gap and has air permeability, so that when the fiber structure is used as the skin material, the polyurethane resin may ooze out on the surface of the skin material. Therefore, a film-like bonding layer made of a thermoplastic resin such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymer (EVA) to which calcium carbonate is added as a filler is provided between the skin material and the fiber assembly. In the case where a material made of fibers such as a non-woven fabric is used as the skin material, it is possible to prevent the resin impregnated in the fiber gap of the fiber aggregate from seeping into the skin material and to maintain the design of the skin material. it can.

As the thermoplastic resin used here, polyethylene or polypropylene is preferable. These are general-purpose resins, are inexpensive, have excellent workability, and can further reduce the basis weight.

The plate-shaped foam molded article with a skin material of the present invention having such a structure can be manufactured as follows. However, it is not necessarily limited to the following description, and can be manufactured by an appropriate method.

The skin material and the fiber assembly are laminated. The skin material and the fiber assembly can be adhered to the fiber assembly by applying an adhesive to the skin material. The skin material and the fiber aggregate can also be bonded by utilizing the adhesiveness of the resin impregnated and solidified in the fiber gap. It is effective for a skin material such as a decorative film, artificial leather or the like which does not cause the resin to seep onto the surface of the skin material.

Further, when a fibrous structure such as a non-woven fabric or the like in which the resin is likely to seep onto the surface of the skin material is used as the skin material, a film-like thermoplastic resin is formed between the skin material and the fiber assembly. It is preferable to provide a bonding layer to bond the skin material and the fiber aggregate.

In this case, a thermoplastic resin film such as polypropylene or polyethylene is interposed between the skin material and the fiber assembly, and a bonding layer made of a film-like thermoplastic resin can be formed and bonded. . This bonding process is performed by laminating a thermoplastic resin in a molten state extruded from an extruder with a T-die between a skin material and a fiber assembly, and pressing and bonding using a cooling roll to integrate them. Thus, the skin material and the fiber aggregate can be joined by forming a film-like joining layer.

Further, a thermoplastic resin film is laminated between the skin material and the fiber assembly, and the laminate comprising the skin material, the thermoplastic resin film and the fiber assembly is subjected to calendering using a heating roll. Then, the thermoplastic resin film is melted to form a film-like joining layer, so that the skin material and the fiber aggregate can be joined. As described above, the bonding layer is provided between the skin material and the fiber aggregate, so that the resin can be prevented from seeping out to the surface of the skin material.

Then, the fiber assembly and the skin material are heated by a heater, and a predetermined shape can be formed using a cold press so that the skin material integrally covers the fiber assembly. In this case, when the bonding layer is formed between the fiber assembly and the skin material, the thermoplastic resin film can be formed with the thermoplastic resin film interposed between the fiber assembly and the skin material.

The integrally molded fiber assembly and the skin material are placed in a mold for molding a plate-like foam molded product as a final product. In this case, when a bonding layer is formed between the fiber assembly and the skin material, the integrally formed fiber assembly, the bonding layer, and the skin material are arranged in this mold. . Further, a pipe or angle material made of metal or synthetic resin may be arranged in this mold so that the pipe or angle material is inserted into the foam when the foam is molded.

The method of producing and molding a foam can be carried out by an appropriate method depending on the type of the foam.

For example, for a rigid polyurethane foam, a polyol and an isocyanate, which are raw materials of the rigid polyurethane foam, are mixed, and a mixed liquid stirred is poured into this mold. In this manner, the fiber mixture is impregnated with the mixture, and the mixture is foamed to produce a rigid polyurethane foam. At this time, the mixed liquid impregnated in the fiber gap of the fiber assembly is solidified into the polyurethane resin to form a sheet-like fiber reinforcing material together with the fiber assembly. Since it is molded in a mold in this way, it can be relatively easily molded into a predetermined shape.

When the rigid polyurethane foam expands,
Pressure can be applied to the mold to bring the rigid polyurethane foam to the desired bulk density. In this case, the pressure is approximately 49-9.
It can be carried out at 80 kPa, preferably 98 to 490 kPa. In this case, the temperature of the mold can be set at 20 to 60 ° C, preferably 25 to 40 ° C.

In this way, the plate-shaped rigid polyurethane foam, the sheet-like fiber reinforcing material integrally molded on the surface of the rigid polyurethane foam, and the sheet-like fiber reinforcing material were integrally covered and molded. A plate-shaped foam molded article with a skin material including a skin material can be produced.

[0045]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a plate-like foam molded article with a skin material of the present invention will be described below with reference to FIG. The plate-like foam molded body 10 with a skin material of the present embodiment is formed by integrally molding a plate-like foam 11 constituting a core portion and being molded, and a surface on both sides of the plate-like foam 11. Sheet-like fiber reinforcement 1
3 and a skin material 12 which is formed by integrally covering the surface of the sheet-like fiber reinforcing material 13 with a film-like joining layer 14 interposed therebetween.
A steel pipe is inserted.

The rigid plate-like foam molded article 10 with a skin material of the present example was 750 mm long, 1000 mm wide and 20 m thick.

The plate-like foam molded article 10 with a skin material of the present embodiment
The plate-like foam 11 constituting the core portion was a plate-like rigid polyurethane foam. This plate-shaped rigid polyurethane foam 11 had a bulk density of 0.1 kg / m ³ . The rigid polyurethane foam had a density of 0.034 kg / m ³ when formed without applying pressure, that is, a free density.

A sheet-like fiber reinforcing material 13 is integrally formed on both sides of the plate-like rigid polyurethane foam. This sheet-like fiber reinforcing material 13 was composed of a fiber assembly and a polyurethane resin impregnated and solidified in the fiber gap on both sides. The thickness of the sheet-like fiber reinforcement 13 was 2 m on both sides.

As the fiber aggregate, a nonwoven fabric obtained by performing needle punching on a fiber web composed of coarse hair, polypropylene fiber, polyethylene terephthalate fiber and the like was used. The basis weight of this nonwoven fabric was 500 g / m ² .
The polyurethane resin has the same composition as the plate-shaped rigid polyurethane foam, and is obtained by impregnating a mixed solution for producing the rigid polyurethane foam into the interstices of the fibers and solidifying the mixture.

The surface of the sheet-like fiber reinforcing material 13 is
The skin material 12 is integrally molded via a film-like bonding layer 14 and molded. As the skin material 12, a nonwoven fabric made of polyethylene terephthalate fiber was used on both sides. The thickness of the skin material was 0.5 mm. The basis weight of this nonwoven fabric was 200 g / m ² .

The film-like joining layer 14 was made of polyethylene on both sides. The thickness of the bonding layer was 0.3 mm on both sides. The basis weight of the film-like joining layer 14 made of polyethylene was 250 g / m ² .

Two iron pipes were inserted into the rigid polyurethane foam as reinforcing members 15. Iron pipes
Both of them have a diameter of 15.9 mm and are inserted parallel to the horizontal direction. The distance between the two iron pipes was 250 mm. By inserting the iron pipe into the plate-like foam in this way, the bending in the longitudinal direction was reinforced, and the load resistance of the rigid plate-like foam molded product 10 with the skin material was improved.

The plate-like foam molded article 10 with a skin material of the present embodiment
Was produced as follows.

Fused polyethylene extruded from an extruder with a T-die is laminated on a non-woven fabric made of polyethylene terephthalate fiber used as the skin material 12, and the above-mentioned hair, polypropylene fiber, polyethylene terephthalate fiber, etc. The formed fiber web was laminated with a nonwoven fabric subjected to needle punching, and the sheet-like laminate was integrated by pressing using a cooling roll. Then, the integrated sheet-like laminate was cut into predetermined dimensions after cooling.

Next, the cut sheet-like laminate is heated by a heater (a set temperature of 350 ° C.) to soften and melt the film-like joining layer 14 made of the fiber aggregate and polyethylene to a predetermined shape. Was molded using a cold press and cooled.

Further, the molded sheet-shaped laminate was set in a mold, and an iron pipe as a reinforcing member 15 was set in a predetermined position. The polyol and the isocyanate were mixed and stirred at a predetermined ratio to prepare a mixed liquid as a raw material of the rigid polyurethane foam, and the mixed liquid was poured into a mold. In this way, the fiber assembly was impregnated with the solution as the raw material of the rigid polyurethane foam.

After the introduction, the sheet was covered with a mold, and the rigid polyurethane foam was foamed and cured to form a rigid polyurethane foam to be a plate-like foam 11 constituting a core, and was solidified. At the same time, the solution impregnated in the fiber assembly was solidified into the polyurethane resin, and the sheet-like fiber reinforcement 13 composed of the polyurethane resin and the fiber assembly was integrally formed on the surface of the rigid polyurethane foam.

By trimming the outer periphery of the plate-like foam molded product, the manufacture of the plate-like foam molded product 10 with a skin material was completed.

The plate-like foam molded body 10 was subjected to a load resistance test. First, when a weight was put on the plate-shaped foam molded article 10 at room temperature, the deformation amount at 65 kg was almost 0 mm.
Further, when a weight was put on the plate-like foamed molded body 10 at room temperature, it was not broken even at 130 kg.

Next, the plate-like foam molded article 10 was subjected to a wet-cooling heat cycle test. The test conditions were as follows:
At a temperature of 50 ° C. and a humidity of 95% for 23.5 hours,
This cycle was repeated four times, with one cycle consisting of successively placing at a temperature of -30 ° C. for 7.5 hours and further continuing at a temperature of 80 ° C. and a humidity of 0% for 15.5 hours. As a result, no problem occurred in the plate-like foam molded article 10.

[0061]

The plate-like foam with a skin material of the present invention uses a plate-like foam as a core, so that the plate-like foam with a skin material has a thickness, and the plate-like foam with a skin material is formed. It has made it possible to reduce the weight of the body.

A fibrous aggregate and a sheet-like fiber reinforcing material made of a resin having the same composition as the plate-like foam impregnated into the fiber gap and integrally formed with the plate-like foam are integrally formed on at least a part of the surface of the foam. This makes it possible to impart rigidity to the plate-like foam molded article with a skin material. The sheet-like fiber reinforcement made of the fiber aggregate and the resin impregnated and solidified in the fiber gap can have excellent rigidity. By forming the sheet-shaped fiber reinforcing material integrally with at least a part of the surface of the foam, rigidity can be given to the skin-molded plate-shaped foam molded body. In addition, by arranging the sheet-like fiber reinforcing material on both sides of the foam and sandwiching the foam, rigidity can be given to the plate-like foam molded product with the skin material.

Since the surface of the fiber reinforcing material is integrally covered with the molded skin material, the design can be improved by the skin material.

Since the plate-like foam with a skin material of the present invention is formed by molding, its shape can be selected relatively freely, and it can be easily formed into a selected predetermined shape.

By inserting a reinforcing material such as a metal or synthetic resin pipe or angle material into the foam,
The load resistance of the foam molded article with the skin material can be improved.

[Brief description of the drawings]

FIG. 1 is a view conceptually showing a partial cross section of a plate-shaped foam molded article with a skin material of an example.

FIG. 2 is a diagram conceptually showing a cross section of a conventional interior material.

FIG. 3 is a view conceptually showing a cross section of a conventional interior material.

[Explanation of symbols]

 10: Plate-shaped foam molded article with skin material 11: Foamed body 12: Skin material 13: Fiber reinforcement 14: Joint layer 15: Reinforcement

Continued on the front page F term (reference) 3D023 BA01 BB01 BE07 BE10 4F100 AK04 AK07 AK42 AK51A AK51B AK51D AT00C AT00E BA05 BA06 BA10C BA10E DG15B DG15D DJ01A DJ06B DJ06D EH23 GB33 JK01 JL00 YY00Y

Claims (8)

[Claims] 1. A foamed plate-like foam which forms at least a core portion and is molded integrally with at least a part of the surface of the foamed body, and is impregnated and solidified into a fiber assembly and a fiber gap thereof. A sheet-like foam molding with a skin material, comprising: a sheet-like fiber reinforcement made of a resin having the same composition as a foam; and a skin material integrally covering the surface of the fiber reinforcement. body. 2. The plate-like foamed article with a skin material according to claim 1, wherein the foamed article is a rigid polyurethane. 3. The foamed plate-like molded product with a skin material according to claim 1, wherein the fiber reinforcing material and the skin material are arranged on both sides of the foam. 4. A method according to claim 1, further comprising a film-like bonding layer made of a thermoplastic resin for integrally bonding the two, between the skin material and the fiber reinforcing material. Plate-like foam molded article. 5. The plate-like foam molded article with a skin material according to claim 4, wherein the thermoplastic resin is one of polypropylene and polyethylene. 6. The foamed plate-like molded product with a skin material according to claim 1, wherein the fiber aggregate is a felt. 7. The fiber aggregate has a basis weight of 200 to 1.
The weight is 500 g / m ^2.
A plate-like foam molded article with a skin material as described in 1 above. 8. The skin material according to claim 1, 2, 3, 4, 5, 6, or 7, wherein a metal or synthetic resin pipe or angle material is inserted into the foam as a reinforcing material. Plate-shaped foam molded article.