JP2007113142A - Glass chopped strand mat, method for producing the same and automotive molded ceiling material using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a glass chopped strand mat which can ensure rigidity necessary for GFRP molded articles, can sufficiently reduce the formation of defects called sink marks, and can prevent damages, when drawn out from a mat roll, to provide a method for producing the same, and to provide an automotive molded ceiling material using the same. <P>SOLUTION: This glass chopped strand mat is characterized by containing a bisphenol A propylene oxide-added polyester resin and a bisphenol A ethylene oxide-added polyester resin in a binder. The method for producing the same is characterized by adhering the binder to produce the glass chopped strand mat. The automotive molded ceiling material is characterized in that the binder-adhered automotive molded ceiling material is adhered to the skin side of a foamed polyurethane sheet. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a glass chopped strand mat used as a reinforcing material for foamed polyurethane such as a reinforcing material for glass fiber reinforced plastic (hereinafter referred to as GFRP) and an automotive molded ceiling material, a method for producing the same, and an automotive molded ceiling material using the same. About.

  The glass chopped strand mat is obtained by applying and bundling the adjusted sizing agent onto the surface of a large number of glass filaments so that the attached amount is about 0.1 to 2% by mass, thereby obtaining glass strands of long glass fibers. Then, after cutting this with a cutting device so as to have a predetermined length, and depositing a large number of the obtained glass chopped strands in an even and disordered manner, a suitable amount of powdered polyester resin is dispersed as a binder from above, Then, the powdered polyester resin is heated and melted and then press-molded to cool and solidify, or the emulsion of resin emulsified in a sheet-like deposit is applied and dried.

The production of this glass chopped strand mat will be described in detail. For example, a glass strand having a single fiber diameter of 11 μm and a strand count of 45 tex (tex is the weight in grams per 1000 m of length) has a length of about 50 mm. Cut with a cutter. Next, deposit evenly and randomly so that the basis weight is 300 to 900 g / m ² , spray it so that the amount of powdered polyester resin adheres to 1 to 6% by mass, and cool and solidify after heating or melting, or adhere the resin emulsion emulsion After apply | coating so that quantity may be 1-6 mass%, the method of drying and adhere | attaching each glass strand is employ | adopted.

  The glass chopped strand mat produced in this way is used in various applications as a reinforcing material for GFRP molded products such as bathtubs and septic tanks, and mainly impregnated with an unsaturated polyester resin generally called a hand lay-up method. It has been used extensively in molding methods. In recent years, as an alternative to automotive molded ceiling materials that have been molded with corrugated cardboard, felt, etc., the rigidity and dimensional stability have been improved by bonding glass chopped strand mats to both surfaces of the polyurethane foam sheet. Has been developed.

  When a glass chopped strand mat is used as an alternative material for automotive molded ceiling materials, its performance is intended to reduce the overall weight of the vehicle in addition to characteristics such as rigidity, dimensional stability, thermal insulation, and sound insulation. The material used is required to reduce the weight per unit area. Also, when bonding the glass chopped strand mat with the foamed polyurethane sheet, an adhesive such as phenol, melamine, or isocyanate will be used, but if this kind of adhesive does not penetrate to the back of the glass chopped strand mat, There is a problem that the molded automobile ceiling material is insufficient in rigidity, and there is a problem that peeling occurs between the mat and the foamed urethane sheet or skin after bonding, so the adhesive should be sufficiently penetrated to the back of the mat. There is a need.

  In order to reduce the weight of the molded ceiling material of automobile molded ceiling material and to improve the permeability of the adhesive to the mat, the basis weight of the glass chopped strand mat may be reduced, but the smaller the basis weight, the more glass chopped strand The strand distribution of the mat becomes uneven, and the tensile strength of the mat decreases. As a result, after the mat is wound around the winding core, the mat breakage rate increases during the unwinding by pulling the mat from its outer layer, and work is performed with attention to the mat breakage etc. There is a problem that is significantly reduced.

  As a general lightweight glass fiber reinforcing material, a glass continuous strand mat in which about 50 to 100 glass filaments (single fibers) having a diameter of about 15 μm to 24 μm are bundled and deposited in a continuous fiber state, or a diameter of 6 μm is used. Generally, a glass paper made by bundling several tens to several hundreds of 13 μm glass filaments and dispersing glass chopped strands cut to a length of 3 mm to 25 mm into monofilaments in white water is generally known. However, the glass continuous strand mat has a problem that its production efficiency is low and therefore expensive, and the glass paper has a small reinforcing effect because the glass fiber is in a monofilament state, and has a rigidity as an automobile molded ceiling material. There is a problem of shortage.

For this reason, various attempts to improve the strength of the chopped strand mat have been made so far. For example, Patent Document 1 discloses a fiber composite having both compression strength and bending strength applicable to needle punching treatment. The invention is disclosed. Moreover, in patent document 2, the invention which can implement | achieve the intensity | strength only to prevent collapse from a conveyance conveyor is performed by prescribing | regulating the form of a glass chopped strand. Further, Patent Document 3 discloses an invention in which the tensile strength can be increased to 150 kgf or more by increasing the ignition loss value. In addition to the above, the present inventor has been conducting research on the causal relationship with the basis weight and strength in order to reduce the defects of the molded ceiling material called glass eyes and scratches.
JP-A-5-24781 Japanese Patent Laid-Open No. 6-93546 JP 2003-175777 A

However, the inventions disclosed so far are not sufficient to provide a glass chopped strand mat having stable quality and performance. For example, an automobile molded ceiling material has a single fiber diameter of 10 μm to 14 μm, a glass strand having an average strand count of 18 tex to 30 tex is cut to a length of about 50 mm, and the basis weight is 50 g / m ² to 150 g / m ² . Emulsions deposited evenly and randomly so as to be in a range, and sprayed with a powdered polyester resin in a range of 8 mass% to 14 mass%, then heated and melted to cool and solidify or emulsify resin A glass chopped strand mat obtained by applying and drying so that the adhesion amount is in the range of 6% by mass to 10% by mass and bonding the glass chopped strands to each other has been used.

In an automotive ceiling material having a structure in which chopped strand mats are bonded to both surfaces of a foamed polyurethane sheet, a chopped strand mat having a basis weight in the range of 50 g / m ² to 150 g / m ² is used on at least one surface thereof. It is like that. In such a mat, when applying an adhesive such as phenol, melamine, or isocyanate to the glass chopped strand, the mat is likely to be partially broken due to a problem in the dispersion state of the glass chopped strand. There is a risk of becoming. And in order to stack the chopped strand mat coated with the adhesive in such a state in the order of the skin (the interior of the automobile), the glass chopped strand mat, the foamed polyurethane sheet, the glass chopped strand mat and the protective sheet (the ceiling of the automobile), When pulling out the mat from the roll, there is a problem that the mat is torn, that is, may be broken.

In the above-described mat, a glass chopped strand mat is impregnated with an adhesive such as phenol, melamine, or isocyanate, and the skin (inside the vehicle interior), glass chopped strand mat, foamed polyurethane sheet, glass chopped strand mat, and protection When the sheet (car roof side) is stacked in order and press-molded into the shape of the molded ceiling, there is a disadvantage that skin wrinkles called sinks occur at the corners corresponding to deep drawn parts such as shades of molded ceiling materials There is. And the incidence of such a sink defect has become more prominent in recent years, especially with the aim of reducing costs, using thin non-woven fabrics with a basis weight of 50 g / m ² or less.

  The present invention has been made in view of the above circumstances, and after securing the necessary rigidity after becoming a GFRP molded product, prevents the mat from being partially damaged when pulled out from the roll. It is an object of the present invention to provide a glass chopped strand mat capable of suppressing the occurrence of a defect called sink in a molded product, a manufacturing method thereof, and an automobile molded ceiling material using the mat.

  The glass chopped strand mat of the present invention is a glass chopped strand mat in which glass chopped strands deposited in a sheet form are bonded to each other with a binder, and the binder is combined with a bisphenol A propylene oxide adduct polyester resin and bisphenol A ethylene. It is characterized by containing an oxide adduct polyester resin.

  Here, the binder contains a bisphenol A propylene oxide adduct polyester resin and a bisphenol A ethylene oxide adduct polyester resin as a binder used to bond glass chopped strands. A glass chopped strand mat formed by bonding glass chopped strands having a predetermined length to each other using a polyester resin containing an A propylene oxide adduct polyester resin and a bisphenol A ethylene oxide adduct polyester resin. Represents.

  About this binder, it does not prevent containing a component other than bisphenol A propylene oxide adduct polyester resin and bisphenol A ethylene oxide adduct polyester resin. However, it is not preferable to contain a component that suppresses the performance obtained by containing both of these components.

  In the various studies on the glass chopped strand mat, the present inventor, when the bisphenol A propylene oxide adduct polyester resin and the bisphenol A ethylene oxide adduct polyester resin are each contained alone in the binder. Although all have the effect of easily bonding glass chopped strands, they have found problems. In other words, when only bisphenol A ethylene oxide adduct polyester resin is used, the glass chopped strand mat becomes hard and the flexibility of the thick portion of the glass chopped strand mat due to uneven weight per unit area is lost. If this part has to be constructed at the opening of the shade or the corner of the deep drawing and a wrinkle defect called a sink may occur in the skin. In addition, if only bisphenol A propylene oxide adduct-based polyester resin is used as a binder, the tensile strength of the chopped strand mat is lowered, and therefore, a roll is used to apply an adhesive such as phenol, melamine, or isocyanate to the glass chopped strand. Adhesive for stacking the skin (car interior side), glass chopped strand mat, foamed polyurethane sheet, glass chopped strand mat and protective sheet (car ceiling side) in order in order to pull out the mat from the ceiling and to form the ceiling material When the mat is sequentially pulled out from the roll formed by the chopped strand mat coated with the matt, the mat may be broken, that is, may be broken.

  Therefore, in order to solve the above-mentioned problems in performance of the glass chopped strand mat, the present inventor used both a bisphenol A propylene oxide adduct polyester resin and a bisphenol A ethylene oxide adduct polyester resin as a binder. It is found that it is possible to achieve the most preferable performance when both are contained.

  Further, in the glass chopped strand mat of the present invention, in addition to the above, the binder is bisphenol A propylene oxide addition to the total mass of the bisphenol A propylene oxide adduct polyester resin and the bisphenol A ethylene oxide adduct polyester resin. If the mass percentage of the physical polyester resin is in the range of 16% to 84%, the mat can be provided with sufficient flexibility even if there is a portion where the basis weight is thick due to uneven basis weight of the chopped strand mat, It is possible and preferable to provide sufficient tensile strength that does not break when pulling out the chopped strand mat.

  Here, the binder has a mass percentage of 16% of the mass of the bisphenol A propylene oxide adduct polyester resin and the total mass of the bisphenol A propylene oxide adduct polyester resin and the mass of the bisphenol A ethylene oxide adduct polyester resin. Is within the range of 84% from 100%, the total mass value of the bisphenol A propylene oxide adduct polyester resin and the bisphenol A ethylene oxide adduct polyester resin in the binder used for the glass chopped strand is 100. Then, it represents a glass chopped strand mat using a binder containing a bisphenol A propylene oxide adduct-based polyester resin in an amount corresponding to a mass value in the range of 16 to 84.

  If the mass percentage of bisphenol A propylene oxide adduct polyester resin is less than 16% of the total mass of bisphenol A propylene oxide adduct polyester resin and bisphenol A ethylene oxide adduct polyester resin, bisphenol A propylene oxide Even if the addition effect of the polyester resin, that is, when the glass chopped strand mat is softened and this part has to be constructed at the corner of the opening or the deep drawing of the shade when molded as an automobile ceiling material, This is not preferable because the effect of suppressing generation of a wrinkle defect called a sink is generated in the epidermis.

  Further, when the mass percentage of the bisphenol A propylene oxide adduct polyester resin exceeds 84% with respect to the total mass of the bisphenol A propylene oxide adduct polyester resin and the mass of the bisphenol A ethylene oxide adduct polyester resin, In some cases, the strength of the glass chopped strand mat may decrease, and it is not preferable because the rate of occurrence of problems such as tearing of the mat when the mat is sequentially pulled out from the roll, that is, tearing, is increased.

  As a binder, it does not preclude containing other additive components, but in order to fully demonstrate the performance of bisphenol A propylene oxide adduct polyester resin and bisphenol A ethylene oxide adduct polyester resin, It is preferable to contain only these components as a main component. Here, the main component means that the sum of the bisphenol A propylene oxide adduct polyester resin and the bisphenol A ethylene oxide adduct polyester resin is 50% or more of the total mass of the binder.

  The glass chopped strand mat of the present invention has a mass ratio of bisphenol A propylene oxide adduct polyester resin to bisphenol A ethylene oxide adduct polyester resin of 1: 5 to 5 for realizing higher performance. Bisphenol A propylene oxide adduct-based polyester resin and bisphenol A propylene oxide adduct-based polyester resin in the binder, assuming that the total mass value of the bisphenol A ethylene oxide adduct-based polyester resin is 100. The mass value of the resin is preferably in the range of 16.67% to 83.33%. Furthermore, from this point of view, more preferably, when the total mass value of the bisphenol A propylene oxide adduct polyester resin and the bisphenol A ethylene oxide adduct polyester resin in the binder is 100, bisphenol A propylene oxide addition The mass value of the physical polyester resin is in the range of 20% to 80%, more preferably in the range of 25% to 75%, and most preferably in the range of 30% to 70%. It is to be inside.

In addition to the above, the glass chopped strand mat of the present invention has an adhesion amount of the binder in the range of 6% by mass to 12% by mass, the average strand count in the range of 10 tex to 20 tex, and the basis weight from 50 g / m ^2. If it is in the range of 150 g / m ² , excellent quality can be realized in each process from spinning of glass fibers to glass chopped strand mats before use.

Here, the adhesion amount of the binder is in the range of 6% by mass to 12% by mass, the average strand count is in the range of 10 tex to 20 tex, and the basis weight is in the range of 50 g / m ² to 150 g / m ² . The amount of binder on the glass chopped strand mat is measured by the ignition loss measurement method described in JIS R3420 (1999). By subtracting the weight loss value, the average strand count representing the mass of the glass filament corresponding to a length of 1000 m is in the range of 10 to 20 tex, and the average strand count is in the range of 10 to 20 tex. The basis weight corresponding to the mass of the glass chopped strand of 50 g / m ² to 15 It represents being in the range of 0 g / m ² .

  As for the amount of binder adhering in the range of 6% by mass to 12% by mass, if the amount of adhering binder is less than 6%, a sufficient amount of binder is not adhering to the glass chopped strands. The tensile strength cannot be obtained, which is not preferable. On the other hand, when the adhesion amount of the binder exceeds 12%, the portion where the basis weight becomes thick due to unevenness in the weight of the chopped strand mat becomes hard, and the thick portion becomes suitable for the construction of a corner portion that requires deep drawing such as a shade. When used, the chopped strand mat is not sufficiently stretched during pressing, causing wrinkles on the skin called sinks, resulting in defects in appearance.

  Moreover, if the average strand count of the glass chopped strand mat is in the range of 10 tex to 20 tex, no problem occurs during production and use of the mat. That is, in order to produce a glass strand having an average strand count of less than 10 tex, it is necessary to reduce the number of glass filaments bundled per strand, and when producing such a glass strand, it is used during spinning. The number of bushing holes to be reduced will be reduced, or the yarn will be split into more strands. If the number of holes in the bushing is reduced, the production amount of glass fiber per bushing is reduced, leading to an increase in material cost. Further, when the number of split yarns is increased, the strands are easily cut at the time of spinning, which also leads to an increase in material cost. Further, when the strand count is reduced, the strand becomes soft, and there is a problem that the rigidity required for the automobile molded ceiling material cannot be obtained. On the other hand, when the average strand count exceeds 20 tex, the width of the strand becomes wide, the strand becomes hard, and glass eyes may be generated on the skin of the automobile molded ceiling.

If the basis weight is in the range of 50 g / m ² to 150 g / m ² , the distribution of the glass chopped strands is maintained in a uniform state, and it is also applicable to applications where weight is a problem, such as automobile molded ceiling materials. Can with mat that can. The basis weight represents the mass of the glass chopped strand per unit area, but if the basis weight is less than 50 g / m ² , the strand distribution of the glass chopped strand mat becomes uneven and the tensile strength of the mat decreases, When the mat is wound around the core and then pulled out from the outer layer, there is a high risk of the mat breaking in the middle of the process. Problem arises. On the other hand, if the basis weight is larger than 150 g / m ² , the achievement of the purpose of reducing the weight of the automobile molded ceiling material and improving the permeability of the adhesive is jeopardized.

  In the method for producing a glass chopped strand mat of the present invention, glass chopped strands are deposited in a sheet shape to form a sheet-like deposit, and a binder is sprayed on the sheet-like deposit, and then the binder is solidified to form the sheet-like deposit. A method for producing a glass chopped strand mat in which glass chopped strands of sheet deposits are bonded to each other, wherein the binder is attached to produce the glass chopped strand mat.

  Here, the above-mentioned glass chopped strand mat is manufactured by drawing a molten glass adjusted to be a predetermined material from a bushing and spinning it, and cutting the obtained glass strand having a predetermined diameter into a predetermined length. It means that, after the chopped strand is formed, the glass chopped strands are bonded to each other using the above-described binder to form a glass chopped strand mat.

  As a binder for bonding the glass chopped strands according to the present invention to each other, the bisphenol A propylene oxide adduct polyester resin and the bisphenol A ethylene oxide adduct polyester resin may be of any form. Any spraying method may be employed. That is, the form is not limited to powder, and various forms such as granules, fibers, sheets, emulsions or films are possible. In addition, as a specific method for adjusting the dispersion state of the binder, for example, a simple dipping method or the like may be adopted as a method of impregnating the mat with the binder. The binder may be supplied by adjusting the flow rate from a supply nozzle or the like. There is no problem in using these together. In any case, it is only necessary that the dispersion of the final content can be eliminated by adopting a predetermined spraying method. Moreover, the method of using together a bisphenol A propylene oxide adduct type polyester resin and a bisphenol A ethylene oxide adduct type polyester resin may apply | coat after mixing both, or may apply | coat both separately.

  The automobile molded ceiling material of the present invention is characterized in that the glass chopped strand mat to which the binder is attached is adhered to the skin side of the foamed polyurethane sheet.

Here, the above-mentioned glass chopped strand mat is adhered to the skin side of the foamed polyurethane sheet.To realize the molding material of the present invention, at least one surface of the foamed polyurethane constituting the automobile molded ceiling material, The glass chopped strand mat of the present invention, that is, a glass chopped strand mat characterized by comprising a bisphenol A propylene oxide-attachable polyester resin and a bisphenol A ethylene oxide-attachable polyester resin as a binder, preferably Bisphenol A propylene oxide adduct-based polyester resin relative to the total mass of bisphenol A propylene oxide adduct-based polyester resin and bisphenol A ethylene oxide adduct-based polyester resin The weight percentage of fat is in the range of 16% to 84%, more preferably the amount of binder attached is in the range of 6% to 12% by weight, the average strand count is in the range of 10 tex to 20 tex, Represents that the glass chopped strand mat having a thickness of 50 g / m ² to 150 g / m ² is bonded. In the case of adopting only one surface, there is no particular limitation on whether or not another coating material is used on the other surface.

  Further, the automobile molded ceiling material of the present invention is not limited to the foamed polyurethane skin side, but may be configured such that the glass chopped strand mat of the present invention having the above-mentioned binder attached to both surfaces is adhered. Good.

  Adhesion between the glass chopped strand mat and the foamed polyurethane sheet can employ a known method, and impregnate the glass chopped strand mat with one or a plurality of adhesives such as phenol, melamine or isocyanate. Can do.

  In addition to the above, the automobile-molded ceiling material of the present invention is preferable because, when it is press-molded into the shape of the molded ceiling, even if the radius of curvature of the molded ceiling material is less than 10 mm, there is no sink.

  (1) As described above, the glass chopped strand mat of the present invention contains bisphenol A propylene oxide adduct polyester resin and bisphenol A ethylene oxide adduct polyester resin in the binder. It has an excellent quality that can hardly cause tearing during the operation of releasing the mat from the mat roll, and can solve the anxiety in terms of strength.

  (2) In the glass chopped strand mat of the present invention, the binder is bisphenol A propylene oxide relative to the total amount of the bisphenol A propylene oxide adduct polyester resin and the bisphenol A ethylene oxide adduct polyester resin. If the mass percentage of the adduct-based polyester resin is within the range of 16% to 84%, a deep drawing design is adopted for application to a portion having a small curvature radius, for example, a shade of an automobile ceiling material or an assist grip portion. Even if it is a case, it has a stable quality with a low risk of appearance defects called sink after molding.

(3) Further, in the glass chopped strand mat of the present invention, the adhesion amount of the binder is in the range of 6% by mass to 12% by mass, the average strand count is in the range of 10 tex to 20 tex, and the basis weight is from 50 g / m ^2. If it is in the range of 150 g / m ² , it can be used as an automotive molded ceiling material having deep drawing or complex shapes, and is a highly versatile and lightweight component material that can realize excellent performance at low cost. It can be done.

  (4) The method for producing a glass chopped strand mat of the present invention is such that glass chopped strands are deposited in a sheet form to form a sheet deposit, and a binder is sprayed on the sheet deposit, and then the binder is solidified. A glass chopped strand mat for bonding the glass chopped strands of the sheet-like deposits to each other, and the glass chopped strand mat is manufactured by adhering the above-mentioned binder. Thus, a glass chopped strand mat in which defects are suppressed can be rapidly formed.

  (5) The automobile molded ceiling material of the present invention is formed by bonding the glass chopped strand mat to which the above-mentioned binder is attached to the skin side of the foamed polyurethane sheet. It can be easily applied to automobile molded ceiling materials, and defects such as sink marks are less likely to occur even in the case of a complicated shape.

  Hereinafter, based on an Example and a comparative example, the glass chopped strand mat of this invention, its manufacturing method, and the ceiling material for motor vehicles using the glass chopped strand of this invention are demonstrated in detail. In addition, FIG. 1 is explanatory drawing which shows the manufacturing process of a glass chopped strand mat.

  First, it shows below about the manufacturing process of a glass chopped strand mat.

  A glass fiber made of E glass is formed as a glass filament having a diameter of 11.6 μm from a platinum bushing having 1200 nozzles. At this time, the polyvinyl acetate emulsion having a solid content of 50% by mass was 6% by mass, γ-methacryloxypropyltrimethoxysilane was 0.3% by mass, the quaternary ammonium salt was 0.5% by mass, and ion-exchanged water was 93%. The sizing agent adjusted to 2 mass% is applied to the surface of the molded glass filament so that the adhesion amount is 0.4 mass%. The glass strand thus obtained is wound up by being divided into 18 pieces by a carbon shoe to form a glass cake 5. Thereafter, the glass cake 5 is dried for a predetermined time, and the sizing agent is fixed on the surface of the glass filament.

  Next, the glass strand 10 is continuously unwound from the inner layer of the glass cake 5 after the drying step, fed into a cutting device 12 provided with a plurality of cutters, and cut into chopped strands 10a having a length of 50 mm. The strand composed of 1200 glass filaments is divided into 18 strands. Each cutting machine 12 includes a cutter roller 12a and a rubber roller 12b, and the glass strand 10 is continuously cut by feeding the glass strand 10 between the rotating cutter roller 12a and the rubber roller 12b. The cutting device 12 is attached to the ceiling portion of the chamber 11, and the chopped strand 10 a cut to a size of 50 mm falls on the first transport conveyor 13 disposed at the bottom of the chamber 11. .

  And the glass chopped strand 10a cut | disconnected to the dimension of 50 mm in length is disperse | distributed so that it may become uniform on the 1st conveyance conveyor 13, and after it will be in the state accumulated on the sheet form, it will be a chamber by the 1st conveyance conveyor 13 11 is conveyed outside. Next, the dispersed glass chopped strand 10a is conveyed to the next second conveyor 14, and is spread on the sheet-like deposit 10b of the glass chopped strand 10a moving on the second conveyor 14 by the spreader 15. A powder polyester resin P in which an oxide adduct polyester resin and a bisphenol A ethylene oxide adduct polyester resin are mixed at a ratio of 1: 1, that is, 50% in terms of mass percentage, is used as a binder for the chopped strand 10a. It is sprayed after adjusting to a uniform state so that a predetermined adhesion amount (10% by mass) is obtained.

Then, the glass chopped strands 10a uniformly dispersed on the belt conveyor 14 and the dispersed mixed polyester resin P dispersed therein are conveyed from the second conveyance conveyor 14 to the third conveyance conveyor 16 while being maintained in a mutually dispersed state. The A heating furnace 17 is arranged in the middle of the third conveyor 16, and the sheet-like deposit 10 b of the glass chopped strand 10 a on which the powdered mixed polyester resin P is dispersed moves into the heating furnace 17. By being heated at a predetermined temperature, the dispersed powdered mixed polyester resin P is heated and softened, and becomes a molten state on the surface of the glass chopped strand 10a. Next, the glass chopped strand 10 a is moved to the outside of the heating furnace 17, cooled and pressed through the water-cooled roll 18. As a result, the melted powdered polyester resin P is solidified and then wound by the winder 20 to finally obtain the glass chopped strand mat 19 (weight per unit area: 100 g / m ² ).

  An investigation was conducted to examine the performance of the automobile ceiling material manufactured using the glass chopped strand mat 19 thus obtained. The contents will be described below.

  First, as shown in Table 1, sample No. 1 to sample no. 5 and comparative sample No. 6 and sample no. 7. A total of 7 types of samples were prepared. That is, after impregnating a glass chopped strand mat 19 having a predetermined dimension of an E glass material as a strand count in Table 1 and adjusting to a predetermined mat basis weight with an isocyanate-based adhesive, Indoor side), glass chopped strand mat 19, foamed polyurethane sheet, another glass chopped strand mat 19 and protective sheet (on the ceiling side of the automobile) are stacked in this order. Subsequently, this laminate is put into a press die having a shape of a molding ceiling with a cemented carbide blade attached around the laminate, and press molding is performed in that state. Finally, the periphery was trimmed and trimmed at the same time. Here, regarding the binder, in Table 1, bisphenol A propylene oxide relative to the total amount (A + B) of the mass (A) of the bisphenol A propylene oxide adduct polyester resin and the mass (B) of the bisphenol A ethylene oxide adduct polyester resin. The percentage ratio of mass (A) of the adduct-based polyester resin is represented as (A / (A + B)). Here, sample No. 6 contained only the bisphenol A propylene oxide adduct polyester resin (A). No. 7 contains only the bisphenol A ethylene oxide adduct polyester resin (B) in the binder.

  The strand count (tex) in the glass chopped strand mat 19 was measured by incinerating the chopped strand mat 19 at 620 ° C. for 30 minutes, and then extracting 50 strands constituting the chopped strand mat 19 and measuring the average length L ( mm), 50 total masses W (g) are measured using a scale having a sensitivity of 0.1 mg or less, and can be calculated by the equation shown in Equation 1. Since this equation represents the weight of a strand length of 1000 m, the unit is converted from mm (millimeter) to m (meter).

  Each sample prepared by the above procedure was investigated by the following evaluation method.

  Regarding the glass chopped strand mat, the amount of the binder used in the glass chopped strand mat was measured by the method described in JIS R3420 (1999). Obtained by subtracting loss on ignition.

  Moreover, about the automobile molded ceiling material, the expert inspected the number of sinks generated on the skin side of 1000 automobile molded ceiling materials by visual observation. The above results are shown in Table 1.

As is apparent from Table 1, the sample No. No. 1 has a strand count of 18 tex and a mat basis weight of 110 g / cm ^{2. As} a binder, the mass of bisphenol A propylene oxide adduct polyester resin (A) and the mass of bisphenol A ethylene oxide adduct polyester resin (B) The percentage of the mass (A) of the bisphenol A propylene oxide adduct-based polyester resin with respect to the total amount (A + B) is 50%, and the adhesion amount is 10%. However, when the mat is pulled out from the roll, the mat is torn off. There was no defect due to poor sink marks.

Sample No. No. 2 has a strand count of 17 tex and a mat basis weight of 108 g / cm ^{2. As} a binder, the mass of the bisphenol A propylene oxide adduct polyester resin (A) and the mass of the bisphenol A ethylene oxide adduct polyester resin (B) The percentage of the mass (A) of bisphenol A propylene oxide adduct-based polyester resin with respect to the total amount (A + B) is 60%, and the amount of adhesion is 9%. However, when the mat is pulled out from the roll, the mat is torn off. There is no defect due to the sink defect. Similar to 1, it was not recognized at all.

Furthermore, sample no. 3 to sample no. For sample No. 5, sample no. 3 has a strand count of 19 tex, a mat basis weight of 106 g / cm ² , and the binder (A / (A + B)) × 100 has a value of 62.5%, and its adhesion amount is 11%. No. 4 has a strand count of 19 tex, a mat basis weight of 107 g / cm ² , a binder (A / (A + B)) × 100 value of 37.5%, and an adhesion amount of 10%. 5 is a sample having a strand count of 20 tex, a mat basis weight of 108 g / cm ² , a binder (A / (A + B)) × 100 value of 40.0%, and an adhesion amount of 12%. Although a defect due to sinking was slightly observed, the value was 0.3% or less, and the mat was not torn off when the mat was pulled out from the roll.

On the other hand, sample No. which is a comparative example. No. 6 is a sample having a strand count of 22 tex, a mat basis weight of 107 g / cm ² , containing only (A) as a binder, and an adhesion amount of 14%, but a bisphenol A ethylene oxide adduct polyester resin is used. Since it is a binder containing only the bisphenol A propylene oxide adduct polyester resin not contained, the tensile strength of the chopped strand mat was lowered and tearing occurred when the mat roll was pulled out.

Sample No. which is a comparative example. 7 is a sample having a strand count of 22 tex, a mat basis weight of 107 g / cm ² , containing only (A) as a binder, and an adhesion amount of 12%, but a bisphenol A propylene oxide adduct polyester resin is used. Because it is a binder that contains only bisphenol A ethylene oxide adduct polyester resin that does not contain, the glass chopped strand mat becomes hard, the flexibility of the thick portion of the glass chopped strand mat due to unevenness in the weight of the glass chopped strand is lost, and the occurrence of sink defects The rate was as high as 6%.

  As described above, the glass chopped strand mat and the automobile molded ceiling material of the present invention can be reduced in weight without causing problems due to insufficient strength, and excellent quality without causing sink defects in terms of appearance quality. It became clear that it has.

  The glass chopped strand mat of the present invention is preferably used as an automotive molded ceiling material formed using the glass chopped strand mat as its application, but in addition, various precision housing components such as electronics industry etc. It can be used in various ways such as construction materials, various structural members for industrial use, etc., and can be used in combination with other members to achieve a desired function.

Explanatory drawing which shows the manufacturing process of the glass chopped strand mat of this invention.

Explanation of symbols

5 Glass cake 10 Glass strand 10a Glass chopped strand 10b Sheet deposit 11 Chamber 12 Cutting device 12a Cutter roller 12b Rubber roller 13 First transport conveyor 14 Second transport conveyor 15 Spreader 16 Third transport conveyor 17 Heating furnace 18 Water cooling roll 19 Glass chopped strand mat 20 Winder P Mixed polyester resin (binder)
L Average length of glass chopped strands W Total mass of 50 glass chopped strands

Claims (5)

A glass chopped strand mat in which glass chopped strands deposited in a sheet form are bonded to each other by a binder,
A glass chopped strand mat, wherein the binder contains a bisphenol A propylene oxide adduct polyester resin and a bisphenol A ethylene oxide adduct polyester resin.   As for the binder, the mass percentage of the bisphenol A propylene oxide adduct polyester resin relative to the total mass of the bisphenol A propylene oxide adduct polyester resin and the bisphenol A ethylene oxide adduct polyester resin is from 16% to 84%. The glass chopped strand mat according to claim 1, wherein the glass chopped strand mat is within a range of%. The adhesion amount of the binder is in the range of 6% by mass to 12% by mass, the average strand count is in the range of 10 tex to 20 tex, and the basis weight is in the range of 50 g / m ² to 150 g / m ^2. The glass chopped strand mat according to claim 1 or 2. Glass chopped strands are deposited in a sheet form to form a sheet deposit, and a binder is applied to the sheet deposit, and then the binder is solidified to bond the glass chopped strands of the sheet deposit together. A method of manufacturing a glass chopped strand mat,
A glass chopped strand mat is produced by attaching the binder according to any one of claims 1 to 3 to produce a glass chopped strand mat.   An automotive molded ceiling material, wherein the glass chopped strand mat to which the binder according to any one of claims 1 to 3 is attached is adhered to the skin side of a foamed polyurethane sheet.