JP2004066629A - Molded interior material and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded interior material which is constituted of a paper material layer impregnated with an adhesive composed of a thermosetting resin, formed between a reinforcing layer and a back layer and enables the reinforcing layer to be molded and joined simultaneously with the molding of the molded interior material inside a molding die and improves the rigidity of the material with high productivity and enables the realization of manufacturing cost reduction. <P>SOLUTION: This molded interior material is constituted of a base material layer 11 formed of a hard foam, the reinforcing layer 12 joined to both sides of the base material layer 11 and a skin layer 13 and the back layer 14 joined to the outside of both reinforcing layers 12 respectively. The paper material layer 10 impregnated with the adhesive composed of the thermosetting resin is arranged between the reinforcing layer 12 and the back layer 14. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a lightweight molded ceiling material, a molded door trim, a rear package tray, a tonneau board, a vehicle floor material and the like having excellent shape stability and a method of manufacturing the same.
[0002]
[Prior art]
Conventionally, a reinforcing layer such as a glass fiber layer for reinforcing and reinforcing the base layer is formed on both sides of a base layer made of a thermoformable rigid foam or the like, and a skin layer is formed on both sides of the reinforcing layer. BACKGROUND ART Molded interior materials such as molded ceiling materials for vehicles provided with a back surface layer are known.
[0003]
As a method for manufacturing these molded interior materials, a sheet for reinforcement or a substrate layer coated with a thermosetting resin is prepared, and a skin and a back paper are stacked on this, and pressure-molded with a heated press mold. Hot pressing methods are known. It is also known that a film is inserted between the skin and the reinforcing layer in order to prevent permeability. As examples of such molded interior materials, for example, JP-A-08-246315, JP-A-09-277415, and JP-A-10-000716 are known.
[0004]
[Problems to be solved by the invention]
By the way, recently, an overhead console is provided on a ceiling in a leisure car, a one-box car, or the like. For example, in a molded ceiling 21 of a vehicle as shown in FIG. 3, an opening 23 for providing an overhead console and portions 22 for providing sun visors on both sides thereof form a shape greatly deformed in the vertical direction as shown in FIG. Need to be molded. Since the opening 23 where the overhead console is provided needs to be extremely stretched, the thickness of the molded ceiling 21 is reduced as shown by an arrow a, the rigidity is insufficient, and it is difficult to obtain a predetermined shape. Note that, in FIG. 3, an arrow indicated by a symbol F indicates that the vehicle is on the front side of the vehicle.
[0005]
Also in the vicinity of the opening 25 of the sliding roof as shown in FIG. 5, the thickness of the molded ceiling 21 becomes thin similarly to the above, and the rigidity when the molded ceiling 21 is attached to the vehicle body is insufficient, so that the molded ceiling 21 is broken. In some cases, bending was caused, and wrinkles, damages, and the like were generated in the skin layer.
[0006]
Therefore, in order to compensate for the lack of rigidity of the overhead console portion, generally, a resin reinforcing structure having a shape along the peripheral shape of the overhead console is prepared in advance, and is formed on the back surface of the corresponding portion after molding the molded ceiling. This resin-made reinforcing structure is attached with an adhesive.
[0007]
In addition, in order to compensate for the lack of rigidity of the sliding roof, generally, an iron plate or resin plate molded in the shape of the part with insufficient rigidity is prepared, and an adhesive is applied to the iron plate or resin plate to form a molding die. There are methods such as setting and bonding at the same time as molding, or bonding with an adhesive after molding the molded ceiling.
[0008]
However, in these conventional techniques, in order to reinforce a portion where strength is insufficient, an iron plate, a resin material, or the like must be formed in advance in a shape corresponding to the reinforced portion. In addition, it is necessary to apply an adhesive and set it in a molding die, or to attach the adhesive later, which complicates the process. Also, component costs and manufacturing costs were high.
[0009]
[Means for Solving the Problems]
The present invention has been made in consideration of the above-described problems of the related art, and it is an object of the present invention to ensure reinforcement of a necessary portion, and at the same time, easily manufacture a reinforcing member and set the reinforcing member at the necessary portion. In particular, the present invention is characterized in that the reinforcing member can be formed and joined at the same time as forming the formed ceiling material or the like in the forming die, instead of separately forming and preparing the reinforcing member.
[0010]
Specifically, the invention according to claim 1 includes a base layer made of a rigid foam, a reinforcing layer bonded to both sides of the base layer, and a skin layer bonded to the outside of each of the reinforcing layers. A molded interior material including a back surface layer, wherein a paper material layer impregnated with an adhesive made of a thermosetting resin is disposed between the reinforcing layer and the back surface layer.
[0011]
With this configuration, since the molding and joining of the reinforcing layer can be performed simultaneously with the molding of the molded interior material in the molding die, the production process is easy and the production can be performed at low cost.
[0012]
According to a second aspect of the present invention, in the molded interior material according to the first aspect, the thermosetting resin is an isocyanate-based resin. Can be maintained, and the rigidity can be improved. Further, the bonding strength between the paper material layer and the reinforcing layer can be secured.
[0013]
According to a third aspect of the present invention, in the molded interior material according to the first or second aspect, the paper material layer has a thickness of 0.1 mm to 3.0 mm. Shape can be maintained and rigidity can be improved.
[0014]
According to a fourth aspect of the present invention, in the molded interior material according to the third aspect, the paper material layer has a thickness of 0.2 mm to 2.0 mm. Can be maintained, and the rigidity can be improved.
[0015]
According to a fifth aspect of the present invention, in the molded interior material according to any one of the first to fourth aspects, the plant fiber comprises at least one of hemp, kenaf, bamboo fiber, wood fiber, cactus fiber, and sugarcane fiber. No harmful components are generated at the time of incineration, and it can be obtained at low cost.
[0016]
According to a sixth aspect of the present invention, in the molded interior material according to any one of the first to fourth aspects, the plant fiber is made of sisal fiber. This sisal fiber is a natural material and does not generate harmful components during incineration. In addition, sisal fiber is a material that is already used as a raw material for ropes, hemp bags, and the like, and can be easily obtained at low cost. Also, when used in a large amount such as a molded ceiling for a vehicle, a predetermined amount can be secured with stable quality, which is preferable.
[0017]
According to a seventh aspect of the present invention, in the molded interior material according to any one of the first to sixth aspects, the molded interior material is a molded ceiling material, and the paper material layer is provided around the overhead console portion provided on the ceiling. Since it is arranged in the vicinity, it is possible to reinforce the lack of rigidity in the vicinity of the periphery and to reduce problems such as bending.
[0018]
The invention according to claim 8 is the molded interior material according to any one of claims 1 to 6, wherein the molded interior material is a molded ceiling material, and the paper layer has a sunroof that can be opened and closed. Since it is arranged near the periphery of the part, insufficient rigidity near the periphery can be reinforced, and problems such as bending can be reduced.
[0019]
According to a ninth aspect of the present invention, a reinforcing material is laminated on both sides of a sheet-like base material made of a rigid foam via an adhesive, and then a skin material is arranged on one side of the reinforcing material, and a thermal material is arranged on another side. A paper material impregnated with an adhesive made of a curable resin is laminated, and then a back material is laminated on the outside of the paper material. Thereafter, the laminated body is placed in a mold and integrally molded by heating and pressing. Configuration.
[0020]
According to the method for manufacturing a molded interior material, the paper material layer can be molded simultaneously with the molding of the molded interior material, so that the number of production steps can be reduced and the productivity is excellent.
[0021]
As the paper material used in the present invention, various paper materials such as recycled paper, horse dung paper, good quality paper, and hard paper can be used. The paper material in the present invention needs a predetermined thickness in order to obtain necessary strength when the contained isocyanate-based adhesive is cured. However, the strength originally possessed differs depending on the paper quality of paper such as recycled paper and high quality paper. In addition, when used as a molded ceiling material, there is a difference in required rigidity depending on the shape and size of the molded ceiling material, the presence / absence of the overhead console and its shape / size, and the presence / absence of the sunroof and its shape / size. On the other hand, if the thickness of the paper material layer is too large, it becomes difficult to mold, and if it is too thin, the rigidity after molding becomes insufficient. Therefore, the thickness of the paper material layer is preferably from 0.1 mm to 3.0 mm, and more preferably the thickness of the paper material layer is from 0.2 mm to 2.0 mm.
[0022]
Also, the amount of the isocyanate-based adhesive impregnated in the paper material may be such that it slightly oozes out of the paper material layer in the mold and can join this paper material layer to the reinforcing material layer. May be applied with a brush. In particular, when the amount of isocyanate is large, it protrudes during molding and overflows into the mold to deteriorate the releasability. On the other hand, a large amount of isocyanate is not preferable because it may protrude to the urethane foam side or the skin side and deteriorate the appearance of the surface shape.
[0023]
The molded interior material of the present invention can be used for molded interior materials for automobiles, for example, molded ceiling materials for automobiles, molded door trims, rear package trays, floor materials, and the like. The present invention is applicable not only to automobiles but also to other vehicles. When used as a molded ceiling material, the thickness of the layer made of urethane foam is 3 to 10 mm, and the thickness of the layer made of vegetable fiber and thermosetting adhesive is 0.2 to 2 mm. Things are used.
[0024]
As the reinforcing material layer of the present invention, vegetable fibers can be used in addition to glass fibers. The plant fiber is obtained by branch cutting or pulverizing a plant mainly composed of cellulose, and includes hemp, kenaf, sisal fiber, bamboo fiber, wood fiber and sugarcane fiber. Wood fibers are obtained from wood. Trees include cedar, pine, keyaki, cypress, cypress, cherry, cherry blossom, poplar, and fir. In particular, sisal fibers are preferred from the viewpoint of productivity, cost, and the like. Vegetable fibers, and below the urethane foam layer, it is preferable to be uniformly distributed as reinforcement 60~300g / ^{m 2,} for example 100 to 200 g / ^{m 2.}
[0025]
The plant fiber preferably has a diameter adjusted to 1.0 mm or less (for example, 0.2 to 0.8 mm) and a length of 10 to 100 mm (for example, 30 to 50 mm). In this case, the shorter length of the fiber cross section was defined as the diameter. When fibers having a diameter of more than 1.0 mm are used as a reinforcing material, irregularities of the fibers appear on the surface of the molded product, which significantly impairs the appearance. These fibers can be cut to a length of 10 to 100 mm with simple equipment. If the length is 10 mm or less, the required reinforcing effect cannot be obtained, and if the fibers are too long, they are entangled with each other and cannot be uniformly dispersed on the foam. A size of 10 to 100 mm is preferable in order to be able to relatively easily and uniformly spray a molded product having a large area such as an automobile ceiling material and to obtain a sufficient reinforcing effect.
[0026]
The base material layer is preferably a rigid urethane foam. The urethane foam may be in the form of a sheet, and its thickness varies depending on the application. In the case of a molded ceiling, a thickness of 3 to 10 mm is usually used. The thermosetting adhesive is an adhesive comprising an aromatic polyisocyanate, water, a catalyst, and, if necessary, a polyol. As the thermosetting adhesive, those described in JP-A-2001-047544 or an adhesive generally used can be used. The amount of thermosetting adhesive agent with respect to the mat material for the reinforcing layer of 100 g / ^{m 2,} the adhesive of 10 to 150 g / ^{m 2,} preferably by applying an adhesive 15~70g / ^{m 2} using Is done. More preferably, it is 15 to 40 g / m ² . When the amount is 15 g / m ² or less, particularly 10 g / m ² or less, the amount of the adhesive is insufficient. When the amount is 150 g / m ² or more, the amount of the adhesive is too large, and handling becomes difficult. In particular, when the amount is 40 g / m ² or less, there is an advantage that there is no excess protrusion of the adhesive, the handling is easy, and there is no need to provide a film for preventing the protrusion of the adhesive.
[0027]
If necessary, an adhesive seepage prevention film may be disposed between the reinforcing material layer and the skin layer. Examples of the surface decoration skin include woven or non-woven fabric of polyolefin, polyester, or polyamide, and vinyl leather.
[0028]
As a manufacturing method, a reinforcing material sheet prepared by applying a thermosetting adhesive to the reinforcing material is prepared, laminated on both sides of the urethane foam, and then a skin material is laminated on one outer side of the reinforcing material sheet, and the other is laminated. A paper material impregnated with an isocyanate-based adhesive is laminated on the outside, then a back material is laminated on the outside of the paper material, and then the laminate is placed in a heated mold and integrated by heating and pressing Mold. Further, a thermosetting adhesive is applied to both surfaces of the urethane foam (for example, spray application), fibers for reinforcing material are sprayed on both surfaces, a skin material is laminated on one side, and an isocyanate-based adhesive is impregnated on the other side. The laminated paper and back material may be placed in a heated mold, the adhesive may be cured by heating and pressing, and the molded product may be taken out of the mold.
[0029]
In the present invention, it is essential that the paper material is disposed between the reinforcing material and the back material. The reason is described below. When the paper is disposed between the reinforcing material and the urethane foam, the reinforcing material and the urethane foam need to be bonded with the isocyanate-based adhesive contained in the paper, but the bonding cannot be sufficiently secured due to the presence of the paper. . For this reason, if the amount of isocyanate contained in the paper material is increased, it oozes out and causes a problem as described above. In addition, when a paper material is disposed between a reinforcing material and a skin material, a small amount of isocyanate may protrude to the surface side, and a small amount of isocyanate may cause poor adhesion. On the other hand, between the reinforcing material and the back surface material, the amount of isocyanate can be easily controlled, and there is no fear that the appearance on the front surface side is deteriorated. When a paper material is arranged between the reinforcing material and the back surface material, it is possible to provide an isocyanate and a paper material necessary for securing rigidity after molding.
[0030]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, examples of the present invention will be described, and the present invention will be specifically described. FIG. 1 is a partial view of a molded ceiling of an automobile, and FIG. 2 is a diagram illustrating a laminated state of molded ceiling materials used in FIG. Note that, in FIG. 1, an arrow indicated by a symbol F indicates that the vehicle is on the front side.
[0031]
A recess 2 for a sun visor is formed on both sides on the front side of the molded ceiling 1, and an opening 3 for an overhead console is formed at an intermediate position thereof. The cross section of this portion is formed so as to be greatly depressed from a normal plane, similarly to FIG. 4 of the prior art. In the present invention, the paper material layer 10 is arranged in a hatched area in FIG. As shown in FIG. 2, the cross section of this portion is such that a reinforcing layer 12 made of glass fiber or vegetable fiber is arranged on both sides of a base material layer 11 made of urethane foam, and a skin layer 13 is arranged on one of the outer sides. The other has a structure in which a paper material layer 10 and a back surface layer 14 are arranged.
[0032]
As shown in FIG. 1, since the paper material layer 10 is disposed near the opening 3 for the overhead console where the cross-sectional shape of the molded ceiling 1 greatly changes, insufficient rigidity can be compensated.
[0033]
Next, a method for producing a molded ceiling material as a molded interior material according to the present invention will be described.
[0034]
Providing a thermoformable rigid urethane foam sheet having open cells of the unit area weight ^{180g / m 2 (1200mm × 1600mm} × thickness 5.5 mm). Glass fibers having a diameter of 0.5 mm or less and a length of 30 to 50 mm were uniformly spread with a basis weight of about 100 g / m ² , and a reinforcing material bonded to each other with a binder was prepared. An isocyanate-based adhesive is applied to the reinforcing material. Then, a paper material having both sides coated with an isocyanate-based adhesive is prepared. Further, a tricot skin material and a back material are prepared.
[0035]
The materials prepared as described above are laminated in a molding die so as to be arranged in the order of skin material-reinforcement material-urethane foam sheet-reinforcement material-paper material-back material. Pressure molding is performed in a molding die, and they are adhered to each other. After molding and bonding, the molded product was taken out of the molding die, and a molded ceiling having a width of 1200 mm × 1600 mm and a total thickness of 7.5 mm including all the materials forming the ceiling was manufactured.
[0036]
As the paper material, 2 mm of recycled paper, 1 mm of high quality paper, and 0.2 mm of hard paper were prepared, and isocyanate-based adhesive was lightly applied to both surfaces thereof with a brush. These paper materials were arranged at the positions as shown in FIG. 1 and were molded by a molding die for a molded ceiling. As a result of comparing the rigidity of these molded products, the rigidity was remarkably improved as compared with the conventional one, and particularly, the rigidity near the opening 3 was improved.
[0037]
In the above example, the molded ceiling was made of glass fiber which is often used as a reinforcing material. However, in the case of using a glass fiber, in the disposal operation of the molding terminal at the time of molding the product, there is a possibility that the working environment is deteriorated if the terminal is scattered. On the other hand, plant fibers such as sisal fibers are easy to handle and do not have this problem. Therefore, various studies on the movement of adopting this material have been studied. Therefore, for the reinforcing layer using sisal fiber instead of glass fiber, a molded ceiling was formed using paper as described above.
[0038]
However, since sisal fibers are natural fibers, they are more hygroscopic than glass fibers, and may absorb moisture over time to reduce rigidity and cause problems such as a part of the molded ceiling hanging down. . For this purpose, in this embodiment, the paper material is provided not only in the vicinity of the opening 3 for the overhead console but also over substantially the entire molded ceiling. Then, not only the rigidity in the vicinity of the opening 3 for the overhead console was improved, but also the rigidity of the entire molded ceiling 1 could be improved, and the problem of sagging could be eliminated.
[0039]
In the above embodiment, the paper material is provided only in the vicinity of the opening 3 for the overhead console. However, if there is another location where rigidity is insufficient, the paper material may be received there. Further, it may be provided on the entire molded ceiling 1. Further, it may be provided around the opening for the sliding roof.
[0040]
In addition, it is also possible to provide a specially thick paper material in a portion where the rigidity of the paper material is strongly required. As another method, a reinforcing fiber such as carbon fiber may be added. In that case, it may be laminated with a paper material or may be a mixture.
[0041]
The isocyanate adhesive to be impregnated in the paper material may be brush-coated on the surface of the paper material as in the above embodiment, and various impregnation means such as roller coating, roll coater, spraying and the like can be applied.
[0042]
【The invention's effect】
In the present invention, a molded interior material comprising a base layer made of a rigid foam, a reinforcing layer bonded to both sides of the base layer, and a skin layer and a back layer bonded to the outside of the two reinforcing layers, respectively. Since the paper material layer impregnated with an adhesive made of a thermosetting resin is disposed between the reinforcing layer and the back surface layer, the molding of the molded interior material is performed in a molding die. At the same time, the reinforcing layer can be formed and joined, so that the rigidity of the formed interior material can be improved, the productivity is excellent, and the cost can be reduced.
[0043]
In particular, when the reinforcing layer is made of vegetable fiber, the rigidity at the time of molding is high, and even if the vegetable fiber absorbs moisture and causes expansion or contraction or a decrease in rigidity, deformation as a molded product can be suppressed to an allowable range, and after use. When incinerated, no harmful components are generated, and there is no risk of causing a pollution problem.
[Brief description of the drawings]
FIG. 1 shows a partial view of a molded ceiling of a motor vehicle.
FIG. 2 is a view for explaining a laminated state of a molded ceiling material used in FIG. 1;
FIG. 3 shows a partial view of a conventional molded ceiling.
FIG. 4 is a sectional view taken along the line AA of FIG. 3;
FIG. 5 shows a partial view of another conventional molded ceiling.
[Explanation of symbols]
REFERENCE SIGNS LIST 1 molded ceiling 10 paper material layer 11 base material layer 12 reinforcing layer 13 skin layer 14 back layer

Claims (9)

A base layer made of a rigid foam,
A reinforcing layer joined to both sides of the base material layer,
A molded interior material comprising a skin layer and a back surface layer respectively bonded to the outside of the two reinforcing layers,
A molded interior material, wherein a paper material layer impregnated with an adhesive made of a thermosetting resin is disposed between the reinforcing layer and the back surface layer. The molded interior material according to claim 1,
A molded interior material, wherein the thermosetting resin is an isocyanate-based resin. The molded interior material according to claim 1 or 2,
A molded interior material, wherein the paper material layer has a thickness of 0.1 mm to 3.0 mm. The molded interior material according to claim 3,
A molded interior material, wherein the paper layer has a thickness of 0.2 mm to 2.0 mm. The molded interior material according to any one of claims 1 to 4,
A molded interior material characterized in that the reinforcing layer comprises at least one of hemp, kenaf, bamboo fiber, wood fiber, cactus fiber, and sugarcane fiber. The molded interior material according to any one of claims 1 to 4,
A molded interior material, wherein the reinforcing layer is made of sisal fiber. The molded interior material according to any one of claims 1 to 6,
A molded interior material, wherein the molded interior material is a molded ceiling material, and the paper material layer is disposed near the periphery of an overhead console portion provided on the ceiling. The molded interior material according to any one of claims 1 to 6,
A molded interior material, wherein the molded interior material is a molded ceiling material, and the paper material layer is arranged near the periphery of the sunroof portion of a vehicle having an openable sunroof. Laminating a reinforcing material on both sides of a sheet-like base material made of a rigid foam via an adhesive,
Next, a skin material is arranged on one side of the reinforcing material, and a paper material impregnated with an adhesive made of a thermosetting resin is laminated on the other side,
Then, the back material is laminated on the outside of the paper material,
Thereafter, the laminate is placed in a mold and integrally molded by heating and pressing, thereby producing a molded interior material.

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