JP2003063319A - Interior material for automobile made from recycled material and manufacturing method therefor - Google Patents
Interior material for automobile made from recycled material and manufacturing method thereforInfo
- Publication number
- JP2003063319A JP2003063319A JP2001255954A JP2001255954A JP2003063319A JP 2003063319 A JP2003063319 A JP 2003063319A JP 2001255954 A JP2001255954 A JP 2001255954A JP 2001255954 A JP2001255954 A JP 2001255954A JP 2003063319 A JP2003063319 A JP 2003063319A
- Authority
- JP
- Japan
- Prior art keywords
- automobile
- recycled
- interior
- manufacturing
- interior material
- 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.)
- Granted
Links
Landscapes
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Laminated Bodies (AREA)
- Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)
Abstract
Description
【0001】[0001]
【発明の属する技術分野】本発明は、各種の廃棄物から
製造されるリサイクル材を使用した自動車内装材、及び
その製法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile interior material using a recycled material produced from various kinds of waste, and a method for producing the same.
【0002】[0002]
【従来の技術】環境問題の高まりから、各種の廃棄物を
有効利用する動きが広がっている。特に自動車に関して
は、大量の産業廃棄物が発生する可能性があるため、い
かに廃棄物の利用度を高めることができるかが求められ
ている。2. Description of the Related Art Due to increasing environmental problems, there is a growing trend to effectively use various types of waste. Particularly for automobiles, a large amount of industrial waste may be generated, and therefore, there is a demand for how to improve the utilization rate of waste.
【0003】特に、廃車となった自動車のカーペット、
フロアマット、シート、ドアトリム、天井材、パーセル
シェルフなどの自動車の内装材をいかにしてリサイクル
するかという問題は大きい。In particular, carpets of abandoned automobiles,
There is a big problem of how to recycle automobile interior materials such as floor mats, seats, door trims, ceiling materials, and parcel shelves.
【0004】[0004]
【発明が解決しようとする課題】そこで本発明者は、上
記の様な自動車内装材を原料とするリサイクル材を使用
した全く新しい自動車内装材、及びその製法を開発せん
としたものである。Therefore, the present inventor has made no attempt to develop a completely new automobile interior material using the above-mentioned recycled material made from the automobile interior material, and a manufacturing method thereof.
【0005】[0005]
【課題を解決するための手段】かかる課題を解決せんと
して、本発明者らは鋭意研究の結果、芯材と表皮材とに
分けられる自動車内装材の場合、芯材部分へのリサイク
ル材の利用は容易であったが、従来利用されていなかっ
た表皮材部分にも、リサイクル材を使うことができるこ
とを見出したものであり、しかして本発明の要旨は、以
下に存する。[Means for Solving the Problems] In order to solve the above problems, the inventors of the present invention have made earnest studies and, as a result, in the case of an automobile interior material which is divided into a core material and a skin material, use of a recycled material for the core material portion. Although it was easy, the inventors have found that the recycled material can be used for the skin material portion that has not been conventionally used, and the gist of the present invention lies below.
【0006】リサイクル材料から製造された表皮材を使
用することを特徴とする自動車内装材。発泡プラスチッ
クを芯材として、この芯材の少なくとも片側、又は全体
をリサイクル材料から製造された表皮材により覆うこと
を特徴とする自動車内装材。フロア嵩上材、天井材、ダ
ッシュインシュレーター、ドアトリム、ピラートリム、
パーセルシェルフ、トランクトリム、トランクマット、
フロアマットから選ばれることを特徴とする上記記載の
自動車内装材。An automobile interior material characterized by using a skin material manufactured from a recycled material. An automobile interior material comprising a foamed plastic as a core material, and at least one side or the whole of the core material is covered with a skin material manufactured from a recycled material. Floor bulk material, ceiling material, dash insulator, door trim, pillar trim,
Parcel shelf, trunk trim, trunk mat,
The automobile interior material described above, which is selected from floor mats.
【0007】また、該内装材の製法である第2発明は以
下に存する。リサイクル材料を長さ5mm以下のサイズ
に細かく粉砕し、この粉砕品に熱可塑性樹脂繊維を混合
して熱風加熱によりシート状に成形することを特徴とす
る、自動車内装材の製法。The second invention, which is a method of manufacturing the interior material, is as follows. A method for producing an automobile interior material, characterized in that a recycled material is finely pulverized to a size of 5 mm or less, and the pulverized product is mixed with a thermoplastic resin fiber to form a sheet by heating with hot air.
【0008】本発明に使用するリサイクル材について説
明する。リサイクル材の原材料としては、自動車のカー
ペットや天井材、シート等の内装材、建築廃材などを挙
げることができる。これらを細かく切削、粉砕して長さ
5mm以下の粉状物にする。The recycled material used in the present invention will be described. Examples of raw materials for recycled materials include carpets and ceiling materials for automobiles, interior materials such as sheets, and construction waste materials. These are finely cut and pulverized to form a powdery substance having a length of 5 mm or less.
【0009】この粉状物を主成分として、必要形状に接
着固化させるためのバインダー成分を混合する。バイン
ダー成分としては特に限定されないが、熱可塑性樹脂、
あるいはこの熱可塑性樹脂による繊維等が好適に使用で
きる。熱可塑性樹脂としては、ポリエステル、ポリプロ
ピレン、ポリエチレン、ポリスチレン、酢酸ビニル、塩
化ビニル、これらのモノマーから重合、共重合されてな
るポリマー、コポリマー、これらから作られる繊維が使
用でき、特にポリエステル繊維が好ましく使用できる。
ポリエステル繊維は、繊維径2〜10デニール、長さ5
〜70mmに加工されたものが適当である。A binder component for adhering and solidifying into a required shape is mixed with the powdery substance as a main component. The binder component is not particularly limited, but a thermoplastic resin,
Alternatively, fibers made of this thermoplastic resin can be preferably used. As the thermoplastic resin, polyester, polypropylene, polyethylene, polystyrene, vinyl acetate, vinyl chloride, a polymer obtained by polymerizing or copolymerizing these monomers, a copolymer, or a fiber made from these can be used, and a polyester fiber is particularly preferably used. it can.
Polyester fiber has a fiber diameter of 2 to 10 denier and a length of 5
Those processed to 70 mm are suitable.
【0010】主成分に対するバインダー成分の配合割合
としては、5〜30質量%が適当であり、特に好ましく
は10〜20質量%である。5質量%未満であるとリサ
イクル材に必要な形状保持、硬さが得られず、30質量
%を超えて配合しても、接着効果は変わらず、コスト的
には不利となる。The mixing ratio of the binder component to the main component is appropriately 5 to 30% by mass, and particularly preferably 10 to 20% by mass. If the amount is less than 5% by mass, the shape retention and hardness required for the recycled material cannot be obtained, and if the amount exceeds 30% by mass, the adhesive effect does not change, which is disadvantageous in terms of cost.
【0011】主成分にバインダーを混合するには、従来
公知のミキサー、攪拌機等を使用する他、密閉容器中に
て空気混合するなどの方法がある。均一に混合されない
と、部分的に接着不良となったり、硬くなり過ぎて脆く
なってしまう虞れがある。In order to mix the binder with the main component, conventionally known mixers, stirrers and the like are used, and there are methods such as air mixing in a closed container. If they are not mixed uniformly, there is a risk that adhesion may be partially lost or they may become too hard and brittle.
【0012】主成分とバインダーの混合物を任意の形状
に成形するには、加熱が可能な金属型、樹脂型に混合物
を投入して加熱、成形するといった方法があるが、その
他にも、混合物を通気性を有するネット状物により、上
下から挟み込み、これにネット状物の上から熱風を送り
加熱成形する方法がある。この方法であると連続生産が
可能である。加熱温度はバインダー樹脂繊維の種類によ
り変わるが、100〜250℃程度であり、加熱硬化時
間は1〜10分程度である。加熱成形後、適当な手段に
より冷却して、成形型、あるいはネット状物から脱型し
て出来あがる。In order to mold the mixture of the main component and the binder into an arbitrary shape, there is a method of charging the mixture into a heatable metal mold or resin mold and heating and molding the mixture. There is a method in which a net-like material having air permeability is sandwiched from above and below, and hot air is sent from above the net-like material to perform heat molding. With this method, continuous production is possible. The heating temperature varies depending on the type of binder resin fiber, but is about 100 to 250 ° C., and the heating and curing time is about 1 to 10 minutes. After heat-molding, it is cooled by an appropriate means and released from the molding die or the net-shaped material to complete.
【0013】又、全く別のリサイクル材の成形方法とし
ては、リサイクル材の粉砕品とホットメルト接着剤、ア
クリルエマルジョン等の水溶性の接着剤などを成形型、
あるいはネット状物の上に敷いた不織布の上に、交互に
散布し、層状に積層して、要すれば熱風加熱する事でシ
ート化が可能である。必要に応じて、散布量を加減する
ことで、リサイクル材の厚さを調節することができる。
ホットメルト接着剤であれば加熱は不要であり、水溶性
接着剤を使用した場合には、その種類により加熱温度が
変わるが、100〜250℃程度であり、加熱硬化時間
は1〜10分程度である。加熱成形後、適当な手段によ
り冷却して、成形型、あるいはネット状物から脱型して
出来あがる。As a completely different method of molding recycled materials, crushed recycled materials and hot-melt adhesives, water-soluble adhesives such as acrylic emulsions, etc.
Alternatively, it can be formed into a sheet by alternately spraying on a non-woven fabric laid on a net-like material, laminating them in layers, and heating with hot air if necessary. The thickness of the recycled material can be adjusted by adjusting the amount of spraying, if necessary.
If it is a hot-melt adhesive, heating is not necessary. When a water-soluble adhesive is used, the heating temperature changes depending on the type, but it is about 100 to 250 ° C, and the heat curing time is about 1 to 10 minutes. Is. After heat-molding, it is cooled by an appropriate means and released from the molding die or the net-shaped material to complete.
【0014】上記により出来あがったリサイクル材を表
皮材として、これを芯材の少なくとも片面、要すれば両
面を覆うことにより、自動車内装材を形成する。芯材と
しては、各種の発泡プラスチック、すなわちポリスチレ
ン、ポリエチレン、ポリプロピレン、塩化ビニル、酢酸
ビニル、ポリウレタン、尿素樹脂等を公知の方法にて発
泡成形した軽量低比重のフォーム材などが好適に使用で
きる。その他にも、嵩高性フェルトなど、軽量低比重で
あり、必要な強度、剛性を備えているものがあれば、芯
材として使用できる。The recycled material produced as described above is used as a skin material, and at least one surface of the core material, and if necessary both surfaces thereof, are covered to form an automobile interior material. As the core material, various foamed plastics such as polystyrene, polyethylene, polypropylene, vinyl chloride, vinyl acetate, polyurethane, urea resin, and the like can be suitably used, which are light and low specific gravity foam materials formed by foaming by a known method. In addition, if there is a material such as bulky felt that is lightweight and has a low specific gravity and has required strength and rigidity, it can be used as a core material.
【0015】芯材と表皮材は、ホットメルト接着剤等の
接着剤によって接着一体化するか、エアタッカー等によ
りステープル止めを要所に行い、部分的に固定する方法
も使用できる。あるいは、リサイクル材を表皮材として
成形するのではなく、芯材の必要個所に予めホットメル
ト接着剤等の常温硬化する接着剤を塗布しておき、この
塗布面に粉砕品のリサイクル材を吹付けることで、リサ
イクル材の表皮層を形成することができる。このよう
に、必要に応じて各種の方法が選択可能である。It is also possible to use a method in which the core material and the skin material are bonded and integrated with an adhesive such as a hot-melt adhesive, or a method of partially fixing them by stapling with an air tacker or the like. Alternatively, instead of molding the recycled material as a skin material, a room temperature curing adhesive such as a hot-melt adhesive is applied in advance to a necessary portion of the core material, and a crushed recycled material is sprayed on the coated surface. Thus, the skin layer of the recycled material can be formed. As described above, various methods can be selected as needed.
【0016】[0016]
【発明の実施の形態】本発明の理解に供するため、以下
に実施例を記載する。いうまでもなく、本発明は以下の
実施例に限定されるものではない。BEST MODE FOR CARRYING OUT THE INVENTION In order to provide an understanding of the present invention, examples will be described below. Needless to say, the present invention is not limited to the examples below.
【0017】[0017]
【実施例1】廃車となった自動車の内装材を分離し、裁
断、粉砕を行って、長さ5mm以下の粉砕品を得た。こ
の粉砕品全量に対して、繊維径2デニールのポリエステ
ル繊維を10質量%の割合で添加、混合し、通気性のあ
るネットにて上下を挟み、120℃の熱風により1分間
加熱し、更に冷却装置により冷風を送り、厚さ5mmの
シート形状のリサイクル材を得た。発泡ポリスチレンフ
ォームを芯材として、表皮材に上記リサイクル材を積層
し、要所をエアタッカーでステープル止めし、自動車フ
ロア嵩上げ材を得た。Example 1 The interior material of a scrapped automobile was separated, cut and pulverized to obtain a pulverized product having a length of 5 mm or less. A polyester fiber having a fiber diameter of 2 denier was added and mixed at a ratio of 10% by mass with respect to the total amount of this crushed product, and the upper and lower sides were sandwiched by a breathable net, which was heated for 1 minute with hot air at 120 ° C and further cooled Cool air was sent by the device to obtain a sheet-shaped recycled material having a thickness of 5 mm. Using the expanded polystyrene foam as the core material, the above-mentioned recycled material was laminated on the surface material, and stapled at the key points with an air tacker to obtain an automobile floor raising material.
【0018】[0018]
【実施例2】ポリウレタンフォーム材を芯材として、実
施例1と同じリサイクル材を表皮材として使用し、成形
天井材を得た。Example 2 A molded ceiling material was obtained by using a polyurethane foam material as a core material and the same recycled material as in Example 1 as a skin material.
【0019】[0019]
【実施例3】熱可塑性樹脂繊維をバインダーとして原反
を作成した、熱可塑性フェルトを芯材として、実施例1
と同じリサイクル材を表皮材として使用し、両者を加熱
成形金型に積層載置し、加熱加圧成形によりダッシュイ
ンシュレーターを得た。[Example 3] Example 1 was prepared using a thermoplastic felt as a core material, in which a raw fabric was prepared using thermoplastic resin fibers as a binder.
Using the same recycled material as the skin material, both were placed on a heat-molding die in a laminated manner, and a dash insulator was obtained by heat-pressure molding.
【0020】[0020]
【実施例4】熱可塑性樹脂繊維をバインダーとして原反
を作成した、熱可塑性フェルトを芯材として、実施例1
と同じリサイクル材を表皮材として使用し、両者を加熱
成形金型に積層載置し、加熱加圧成形によりドアトリム
を得た。[Example 4] Example 1 was prepared using a thermoplastic felt as a core material, in which a raw fabric was prepared using a thermoplastic resin fiber as a binder.
Using the same recycled material as the skin material, both were placed on a heat-molding die in a laminated manner, and a door trim was obtained by heat-pressing.
【0021】[0021]
【実施例5】熱可塑性樹脂繊維をバインダーとして原反
を作成した、熱可塑性フェルトを芯材として、実施例1
と同じリサイクル材を表皮材として使用し、両者を加熱
成形金型に積層載置し、加熱加圧成形によりピラートリ
ムを得た。[Example 5] Example 1 was prepared using a thermoplastic felt as a core material, in which a raw fabric was prepared using a thermoplastic resin fiber as a binder.
Using the same recycled material as the skin material, the two were laminated and placed on a heat-molding die, and a pillar trim was obtained by heat-pressing.
【0022】[0022]
【実施例6】熱可塑性樹脂繊維をバインダーとして原反
を作成した、熱可塑性フェルトを芯材として、実施例1
と同じリサイクル材を表皮材として使用し、両者を加熱
成形金型に積層載置し、加熱加圧成形によりトランクル
ームトリムを得た。[Example 6] Example 1 was prepared by using a thermoplastic felt as a core material to prepare an original fabric using a thermoplastic resin fiber as a binder.
Using the same recycled material as the skin material, both were laminated and placed on a heat-molding die, and a heat and pressure molding was performed to obtain a trunk room trim.
【0023】[0023]
【結果】実施例1〜6にて作成した自動車内装材は、い
ずれも十分な強度、剛性を有し、外観上従来の原材料を
使用した内装材と比較しても、問題のないものであっ
た。Results: The automobile interior materials prepared in Examples 1 to 6 all have sufficient strength and rigidity, and there is no problem in appearance in comparison with interior materials using conventional raw materials. It was
【0024】[0024]
【発明の効果】本発明は、廃車となった自動車や建築廃
材からの粉砕品を利用して表皮材を作成し、各種の自動
車内装材を得られ、かつその製法を開発したものである
が、従来のものと同等以上の外観、強度、剛性を有する
ものを得ることができ、この結果、今後増加が予想され
る自動車廃棄物の有効利用に道を開くものである。INDUSTRIAL APPLICABILITY According to the present invention, various kinds of automobile interior materials can be obtained by producing a skin material by using a crushed product from an abandoned automobile or construction waste material, and a manufacturing method thereof has been developed. It is possible to obtain a product having an appearance, strength, and rigidity that are equal to or higher than those of conventional products, and as a result, it will open the way to the effective use of automobile waste, which is expected to increase in the future.
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.7 識別記号 FI テーマコート゛(参考) B29L 9:00 B29L 9:00 Fターム(参考) 3D023 BA01 BB01 BE02 BE04 4F100 AK01A AK01B AK01C AK04 AK07 AK12 AK22 AK41 BA02 BA03 BA06 BA10B BA10C DG03B DG03C DJ01A GB33 JB16B JB16C JK01 JL16B JL16C 4F203 AA50 AB25 AG01 AG03 AG20 AH26 DA14 DB01 DB02 DC01 DF02 DL01 ─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. 7 Identification code FI theme coat (reference) B29L 9:00 B29L 9:00 F term (reference) 3D023 BA01 BB01 BE02 BE04 4F100 AK01A AK01B AK01C AK04 AK07 AK12 AK22 AK41 BA02 BA03 BA06 BA10B BA10C DG03B DG03C DJ01A GB33 JB16B JB16C JK01 JL16B JL16C 4F203 AA50 AB25 AG01 AG03 AG20 AH26 DA14 DB01 DB02 DC01 DF02 DL01
Claims (4)
用することを特徴とする自動車内装材1. An automobile interior material characterized by using a skin material manufactured from a recycled material.
の少なくとも片側、又は全体をリサイクル材料から製造
された表皮材により覆うことを特徴とする自動車内装材2. An automobile interior material, characterized in that foamed plastic is used as a core material, and at least one side or the whole of the core material is covered with a skin material manufactured from a recycled material.
レーター、ドアトリム、ピラートリム、パーセルシェル
フ、トランクトリム、トランクマット、フロアマットか
ら選ばれることを特徴とする請求項1又は請求項2に記
載の自動車内装材3. The automobile according to claim 1 or 2, wherein the material is selected from a floor raising material, a ceiling material, a dash insulator, a door trim, a pillar trim, a parcel shelf, a trunk trim, a trunk mat, and a floor mat. Interior material
に細かく粉砕し、この粉砕品に熱可塑性樹脂繊維を混合
して熱風加熱によりシート状に成形することを特徴とす
る、請求項1〜請求項3に記載された自動車内装材の製
法4. The recycled material is finely crushed to a size of 5 mm or less, and the crushed product is mixed with thermoplastic resin fibers to be molded into a sheet by heating with hot air. Manufacturing method of automobile interior material described in item 3
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2001255954A JP4197586B2 (en) | 2001-08-27 | 2001-08-27 | Automotive interior materials using skin materials made from recycled materials |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2001255954A JP4197586B2 (en) | 2001-08-27 | 2001-08-27 | Automotive interior materials using skin materials made from recycled materials |
Publications (2)
Publication Number | Publication Date |
---|---|
JP2003063319A true JP2003063319A (en) | 2003-03-05 |
JP4197586B2 JP4197586B2 (en) | 2008-12-17 |
Family
ID=19083844
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP2001255954A Expired - Lifetime JP4197586B2 (en) | 2001-08-27 | 2001-08-27 | Automotive interior materials using skin materials made from recycled materials |
Country Status (1)
Country | Link |
---|---|
JP (1) | JP4197586B2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2009208473A (en) * | 2009-04-27 | 2009-09-17 | Idemitsu Technofine Co Ltd | Manufacturing method of regenerated resin layer/fiber layer composite material, manufacturing apparatus for the same and powdery material manufacturing apparatus |
WO2012147422A1 (en) | 2011-04-27 | 2012-11-01 | 株式会社イノアックコーポレーション | Mat and manufacturing method therefor |
Citations (8)
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JPS61235278A (en) * | 1984-11-26 | 1986-10-20 | Ikeda Bussan Co Ltd | Floor structure for vehicle, and the like |
JPH02286241A (en) * | 1989-04-26 | 1990-11-26 | Kanai Hiroyuki | Interior skinmaterial for automobile |
JPH0585629U (en) * | 1992-04-27 | 1993-11-19 | 本田技研工業株式会社 | Resin skin material |
JPH11192635A (en) * | 1998-01-06 | 1999-07-21 | Toyoda Spinning & Weaving Co Ltd | Production of soundproof material |
WO1999044817A1 (en) * | 1998-03-03 | 1999-09-10 | Rieter Automotive (International) Ag | Sound absorbent thin-layer laminate |
JP2001225704A (en) * | 2000-02-16 | 2001-08-21 | Nippon Tokushu Toryo Co Ltd | Sound isolating part for automobile and manufacturing method therefor |
JP2002178397A (en) * | 2000-12-14 | 2002-06-26 | Kasai Kogyo Co Ltd | Soundproofing material for vehicle and manufacturing method therefor |
-
2001
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JPS6018863U (en) * | 1983-07-18 | 1985-02-08 | 林テレンプ株式会社 | Soundproofing materials for automobiles |
JPS61235278A (en) * | 1984-11-26 | 1986-10-20 | Ikeda Bussan Co Ltd | Floor structure for vehicle, and the like |
JPH02286241A (en) * | 1989-04-26 | 1990-11-26 | Kanai Hiroyuki | Interior skinmaterial for automobile |
JPH0585629U (en) * | 1992-04-27 | 1993-11-19 | 本田技研工業株式会社 | Resin skin material |
JPH11192635A (en) * | 1998-01-06 | 1999-07-21 | Toyoda Spinning & Weaving Co Ltd | Production of soundproof material |
WO1999044817A1 (en) * | 1998-03-03 | 1999-09-10 | Rieter Automotive (International) Ag | Sound absorbent thin-layer laminate |
JP2001225704A (en) * | 2000-02-16 | 2001-08-21 | Nippon Tokushu Toryo Co Ltd | Sound isolating part for automobile and manufacturing method therefor |
JP2002178397A (en) * | 2000-12-14 | 2002-06-26 | Kasai Kogyo Co Ltd | Soundproofing material for vehicle and manufacturing method therefor |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2009208473A (en) * | 2009-04-27 | 2009-09-17 | Idemitsu Technofine Co Ltd | Manufacturing method of regenerated resin layer/fiber layer composite material, manufacturing apparatus for the same and powdery material manufacturing apparatus |
WO2012147422A1 (en) | 2011-04-27 | 2012-11-01 | 株式会社イノアックコーポレーション | Mat and manufacturing method therefor |
JP5478779B2 (en) * | 2011-04-27 | 2014-04-23 | 株式会社イノアックコーポレーション | Mat and its manufacturing method |
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