JP2007196382A - Integrated foamed urethane molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a three-layered integrated foamed urethane molding in which the degradation of a skin material caused by a volatile organic compound generated in a foamed urethane layer is prevented, and the scattering of the volatile organic compound is surely prevented and which is excellent in quality. <P>SOLUTION: In a panel constituting member 1 in which the foamed urethane layer 7 is molded integrally between the skin material 3 made of a resin and a substrate 5, a granular catcher material 13 catching the volatile organic compound generated in the foamed urethane layer 7 is adhered to a surface on the side of the foamed urethane layer 7 of the substrate 5 through an adhesive 15 so that a part of the catcher material 13 is not coated with the adhesive 15. A part of the catcher material 13 which is not coated with the adhesive 15 is contacted directly with the foamed urethane layer 7. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an improvement in a urethane-integrated foamed molded product and a method for producing the same, and particularly relates to measures for preventing scattering of volatile organic compounds generated in a urethane foam layer.

  As a urethane integrated foam molded article, there is a vehicle instrument panel having a three-layer structure in which a urethane foam layer is integrally formed between a resin skin material and a base material. In such an instrument panel having a three-layer structure, the volatile organic compound generated in the urethane foam layer is transferred to the skin material, so that the skin material is deteriorated and the appearance is impaired. For this reason, by forming a large number of vent holes in the base material, the volatile organic compounds generated in the urethane foam layer are released to the outside from the respective vent holes and transferred to the skin material of the volatile organic compounds. To improve the quality by suppressing deterioration of the skin material (see, for example, Patent Document 1).

  However, although the above-mentioned instrument panel can avoid deterioration of the skin material, volatile organic compounds are scattered from the urethane foam layer into the passenger compartment, causing health problems such as sick house syndrome and chemical sensitivity. Become. As long as the urethane-integrated foam-molded product has a structure as in Patent Document 1, such a problem also occurs when applied to a building material other than a vehicle interior product such as an instrument panel, for example. obtain.

On the other hand, for a sheet pad made of a flexible polyurethane foam in which a catcher material made of amines or the like is applied to the surface, or made of a foamed polyurethane material by injecting a foamed urethane raw material added with the above catcher material into a mold. Pads are known. According to these pads, volatile organic compounds generated in the urethane foam layer can be captured with a catcher material so that they do not splash outside, and health problems such as sick house syndrome and chemical sensitivity can be eliminated. (For example, refer to Patent Document 2).
Japanese Patent No. 3205671 (2nd page, FIG. 2) JP 2005-124743 A (pages 3 and 5)

  By the way, it is conceivable to apply a catcher material as disclosed in Patent Document 2 to a three-layer urethane integral foam molded product as described in Patent Document 1, but in Patent Document 1, a foamed urethane raw material is used between the skin material and the substrate. Since the urethane foam layer is molded by foaming, the molded urethane foam layer is integrally bonded to the skin material and the base material, and the catcher material can no longer be applied to the urethane foam layer surface. The former method of Patent Document 2 cannot be adopted.

  On the other hand, the method of adding the catcher material to the urethane foam raw material in the latter of Patent Document 2 is because the catcher material is a different material from the urethane foam raw material. It cannot be molded to a hardness of, and the quality deteriorates.

  The present invention has been made in view of such points, and the object of the invention is to prevent the deterioration of the skin material caused by the volatile organic compound generated in the urethane foam layer, and It is to provide a three-layer urethane integrated foam molded article that reliably performs anti-scattering measures and has excellent quality.

  In order to achieve the above object, the present invention is characterized in that the use of the catcher material has been devised to capture the volatile organic compound generated in the urethane foam layer so as not to be scattered outside. .

  Specifically, the solution provided by the invention of claim 1 is a urethane integrated foam molded product in which a urethane foam layer is integrally formed between a resin skin material and a base material, and the skin At least one urethane foam layer side surface of the material and the base material is sandwiched with the adhesive so that the granular catcher material that captures the volatile organic compounds generated in the urethane foam layer is not partially covered with the adhesive. And the non-covered portion of the catcher material by the adhesive is in direct contact with the urethane foam layer.

  The solution provided by the invention according to claim 2 is that, in the invention according to claim 1, the surface of the skin material terminal from the inside to the base material at the seal portion of the urethane foam layer terminal skin material and the base material. It is characterized by being in close contact.

  According to a third aspect of the present invention, there is provided a solution to the above-mentioned skin material by injecting a foamed urethane raw material into the molding die in a state where the resin skin material and the substrate are respectively set in the molding die. A urethane integrated foam molded product in which a urethane foam layer is integrally formed between a base material and a base material, wherein the foamed urethane raw material is set before or after setting the skin material and the base material to a molding die. Before injecting the adhesive, the adhesive is applied to the surface of the skin material and at least one urethane foam layer side of the base material, and then the volatile organic matter generated in the urethane foam layer before the adhesive is cured. A granular catcher material for capturing a compound is sprayed on the adhesive to cure the adhesive, whereby the skin material and the substrate are interposed through the adhesive so that the catcher material is not partially covered with the adhesive. Material At least one urethane foam layer is attached to the surface, and the urethane foam raw material is injected into a molding die to form a urethane foam layer that is in direct contact with the uncovered portion of the catcher material with an adhesive. And

  According to the first aspect of the invention, the volatile organic compound generated in the urethane foam layer is efficiently captured at the non-covered portion of the catcher material by the adhesive so as not to be scattered outside the urethane integrated foam molded product. As a result, it is possible to prevent deterioration of the skin material due to volatile organic compounds, and it is possible to eliminate health problems such as sick house syndrome and chemical sensitivity. In addition, since the catcher material is previously attached to at least one of the skin material and the base material, the catcher material added to the foamed urethane raw material as in Patent Document 2 does not hinder foaming of the foamed urethane raw material, as expected. It is possible to obtain a three-layer urethane integrated foam-molded article with excellent quality having a hardness of 5 mm. In addition, the catcher material is granular, that is, an aggregate of organic compounds and the like that capture volatile organic compounds, the average particle size is large, and the amount of volatile organic compounds captured per unit increases, thereby capturing volatile organic compounds. The function can be secured over a long period of time.

  According to the invention of claim 2, since the surface of the skin material terminal is pressed against the base material from the inside by the foaming pressure of the urethane foam layer, the airtightness of the sealing portion by the skin material and the base material is increased. Even if the volatile organic compound may move to the seal location, the volatile organic compound can be reliably prevented from scattering from the seal location to the outside.

  According to the invention of claim 3, the catcher material captures the volatile organic compound generated during the foaming of the urethane foam raw material not only after molding the urethane integrated foam molded product but also at the time of molding. It is possible to reduce the scattering of organic compounds into the factory and maintain a good working environment.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
FIG. 2 shows a panel constituent member 1 constituting the right half of the upper panel in the vehicle instrument panel, and this panel constituent member 1 is a urethane integrated foam molded article according to the first embodiment.

  As shown in FIG. 1, the panel constituent member 1 includes a resin skin material 3 that constitutes the front side of the panel constituent member 1 and a resin base material 5 that constitutes the back side of the panel constituent member 1. The urethane foam layer 7 is integrally formed between the skin material 3 and the base material 5. The skin material 3 is formed by slush molding or vacuum molding with a resin material such as PVC (polyvinyl chloride), TPO (thermoplastic olefin), TPU (thermoplastic urethane), or the like. The base material 5 is injection-molded with a resin material such as PP (polypropylene) or ABS (acrylonitrile / butadiene / styrene). The urethane foam layer 7 has a semi-rigid structure in which independent foaming and continuous foaming are distributed about half each.

  The skin material terminal 3a of the skin material 3 is formed to be bent at substantially right angles over the entire circumference on the base material 5 side. On the other hand, the base material terminal 5a of the base material 5 is formed with a recess 5b that opens on the skin material 3 side over the entire circumference. The surface of the outer skin material terminal 3a is in close contact with the inner surface of the outer vertical wall 5c of the recess 5b from the inner side, and a seal portion is formed by the skin material 3 of the urethane foam layer 7 terminal and the base material 5. Furthermore, a raw material injection port 9 for injecting a foamed urethane raw material is formed between the skin material 3 and the base material 5 at a substantially central portion of the base material 5, and the raw material injection port 9 is on the back side of the base material 5. The sealing material 11 is stuck and closed.

  On the surface of the base material 5 on the urethane foam layer 7 side, the adhesive 15 prevents the granular catcher material 13 that captures volatile organic compounds generated in the urethane foam layer 7 from being partially covered with the adhesive 15. The uncovered portion of the catcher material 13 with the adhesive 15 is in direct contact with the urethane foam layer 7. This is the greatest feature of the first embodiment.

  The catcher material 13 is composed of an aggregate of organic compounds that capture the volatile organic compounds. The organic compound constituting the catcher material 13 is not particularly limited as long as it captures a volatile organic compound such as holimaldehyde, acetaldehyde, toluene, xylene, and the like, and amines, imines, amidines, amides, Nitrogen-containing organic compounds such as carbides, hydrazides, azoles, azines, and amino acids are preferably used, but materials that physically capture volatile organic compounds such as activated carbon and silica gel may be used. In addition, such a physical trapping material and a nitrogen-containing organic compound can be used in combination. However, it is not limited to these. And the organic compound etc. which capture | acquire these volatile organic compounds are gathered to the granular form with an average particle diameter of 5-100 micrometers, for example using an acrylic resin or a urethane resin as a binder, and it is set as the catcher material 13. FIG. In addition, as the adhesive 15, a urethane-based or acrylic-based aqueous adhesive is used.

The panel constituent member 1 configured as described above is manufactured as follows. The numbers given in parentheses below indicate the order of the manufacturing process.
(1) As shown in FIG. 3, a clamp jig 19 that also serves as a mask for the set jig 17 with the surface of the base material 5 molded in advance in a predetermined shape facing the urethane foam layer 7 side upwards. Hold the clamp and set. The set jig 17 can be pivoted up and down on a pedestal 23 by a support shaft 21, and the set jig 17 is tilted obliquely by rotating downward around the support shaft 21, and an adhesive agent is applied by a spray gun 25. 15 is applied to the surface of the substrate 5 on the urethane foam layer 7 side.
(2) As shown in FIG. 4, the setting jig 17 is rotated upward around the support shaft 21, and is held in contact with a support member 27 projecting from the upper surface of the pedestal 23 and held horizontally. In this state, before the adhesive 15 is cured, a granular catcher material 13 that captures volatile organic compounds generated in the urethane foam layer 7 is sprayed from the spraying device 29 onto the adhesive 15 to bond the adhesive. By curing the agent 15, as shown in an enlarged detail in FIG. 5, the urethane foam layer 7 side of the base material 5 is interposed through the adhesive 15 so that the catcher material 13 is not partially covered with the adhesive 15. Adhere to the surface.
(3) As shown in FIG. 6, the upper mold 33 of the mold 31 is rotated upward around the hinge shaft 35 to open the mold 31. In this state, the skin material molded in advance into a predetermined shape 3 is set on the set surface 39a of the lower mold 39 provided on the base 37 of the molding die 31 so that the surface on the urethane foam layer 7 side faces upward. On the other hand, the base material 5 to which the catcher material 13 is attached in (2) is clamped and set on the set surface 33a of the upper mold 33 by a clamping device (not shown) so that the catcher material 13 attachment surface faces outward. In this set state, an injection nozzle 41 connected to an injection device (not shown) is inserted into the raw material injection port 9 of the substrate 5. The upper die 33 is supported by a support plate 43 so as to be movable by a hydraulic cylinder 45. At this stage, the hydraulic cylinder 45 is contracted and the upper die 33 approaches the support plate 43.
(4) After the upper die 33 is rotated downward about the hinge shaft 35 so as to approach the upper portion of the lower die 39, the hydraulic cylinder 45 is extended to lower the upper die 33 as shown in FIG. Then, the mold 31 is closed, and the surface of the skin material terminal 3a is brought into close contact with the inner surface of the outer vertical wall 5c of the recess 5b in the base terminal 5a from the inner side to seal the portion. Thereafter, the hook 49 at the tip of the arm 47 extending from the upper die 33 is engaged with the striker 53 at the tip of the arm 51 extending from the lower die 39, and the die 31 is held in the closed state. In this state, the urethane foam raw material is injected from the injection device into the space between the skin material 3 and the base material 5 in the molding die 31 through the injection nozzle 41 and the raw material injection port 9 of the base material 5. A panel constituent member 1 in which the urethane foam layer 7 is integrally formed with the base material 5 is obtained. As shown in FIG. 1, the urethane foam layer 7 of the panel component 1 is in direct contact with an uncovered portion of the catcher material 13 on the base material 5 side by the adhesive 15.

  Therefore, according to Embodiment 1 of the present invention, the volatile organic compound generated in the urethane foam layer 7 is efficiently captured by the uncovered portion of the catcher material 13 with the adhesive 15 and is not scattered outside the panel component 1. It is possible to prevent the skin material 3 from being deteriorated by volatile organic compounds, and it is possible to eliminate health problems such as sick house syndrome and chemical hypersensitivity.

  In addition, since the catcher material is attached to the base material 5 in advance, the catcher material added to the foamed urethane raw material as in Patent Document 2 does not hinder foaming of the foamed urethane raw material and has the expected hardness. It can be set as the panel structural member 1 of the 3 layer structure which was excellent.

  Furthermore, the catcher material 13 is a granular material composed of an aggregate of organic compounds or the like that captures volatile organic compounds, and the average particle size is large, so that the amount of captured volatile organic compounds per unit increases. The capturing function can be ensured over a long period of time.

  In addition, since the surface of the skin material terminal 3 a is pressed against the inner surface of the outer vertical wall 5 c of the base material terminal 5 a from the inside by the foaming pressure of the urethane foam layer 7, the sealing portion by the skin material 3 and the base material 5 The airtightness of the volatile organic compound can be reliably prevented from being scattered from the sealing portion.

  Furthermore, since the catcher material 13 captures volatile organic compounds generated during foaming of the foamed urethane raw material not only after molding the panel component 1 but also at the time of molding, the volatile organic compounds are introduced into the factory. Scattering can be reduced and a good working environment can be maintained.

(Embodiment 2)
FIG. 8 shows a panel component 1 according to the second embodiment. In this panel constituent member 1, the granular catcher material 13 that captures volatile organic compounds generated in the urethane foam layer 7 is not partially covered with the adhesive 15 on the surface of the skin material 3 on the urethane foam layer 7 side. It is made to adhere to this through the adhesive 15. The uncovered portion of the catcher material 13 with the adhesive 15 is in direct contact with the urethane foam layer 7. In addition, as for the catcher material 13 used here, it is desirable to use an average particle diameter of 5-50 micrometers and a smaller thing than Embodiment 1 so that it may not feel strange when touched from the surface of the skin material 3. This is also desirable from the viewpoint of preventing the skin material 3 from becoming hard due to the plasticizer contained in the skin material 3 being absorbed by the catcher material 13. The other parts are the same as those in the first embodiment, and the same components are denoted by the same reference numerals and the description thereof is omitted. Although the manufacturing method is omitted, it is the same as that of the first embodiment except that the adhesive 15 is applied to the skin material 3 and the catcher material 13 is sprayed and adhered thereon. .

  Therefore, in this Embodiment 2, there can exist an effect similar to the said Embodiment 1. FIG.

  In the first embodiment, the catcher material 13 is attached to the base material 5 side, and in the second embodiment, the catcher material 13 is attached to the skin material 3 side. However, the catcher material 13 is attached to both the skin material 3 and the base material 5. You may let them.

  In the first and second embodiments, the adhesive 15 is applied to the base material 5 before the base material 5 is set on the set surface 33a of the upper mold 33. For example, the skin material 3 is applied to the set surface 39a of the lower mold 39. The adhesive 15 may be applied to the skin material 3 after injecting the urethane foam material after setting. The application timing of the adhesive 15 to the skin material 3 and the base material 5 is not limited to these.

  Furthermore, in Embodiments 1 and 2, the foamed urethane raw material is injected into the mold 31 in the mold closed state, but the foamed urethane raw material may be injected into the mold 31 in the mold open state.

  In the first and second embodiments, the case where the urethane-integrated foam molded product is the panel component 1 of the instrument panel is shown. However, it may be a vehicle interior product such as a console box lid or door trim. It can also be applied to other building materials and other urethane integrated foam molded products.

  INDUSTRIAL APPLICABILITY The present invention is useful as a measure for preventing volatile organic compounds generated in a urethane foam layer from being scattered in a urethane-integrated foam-molded product applied to building materials, vehicle interiors, and the like.

It is sectional drawing in the II line | wire of FIG. It is a top view of the panel structural member (urethane integral foaming molding concerning Embodiment 1) which constitutes the right half of the upper panel in the instrument panel for vehicles. FIG. 3 is an adhesive application process diagram in the manufacturing method according to Embodiment 1; FIG. 4 is a catcher material spraying process diagram in the manufacturing method according to Embodiment 1; It is a cross-sectional enlarged view which shows the state which the catcher material adhered to the base material at the catcher material dispersion | distribution process in the manufacturing method which concerns on Embodiment 1. FIG. FIG. 3 is a mold diagram showing a state in which a skin material and a base material are set in a mold in an open state in the manufacturing method according to Embodiment 1. It is a model diagram which shows the state before demolding of the panel structural member shape | molded with the manufacturing method which concerns on Embodiment 1. FIG. FIG. 3 is a diagram corresponding to FIG. 2 of the second embodiment.

Explanation of symbols

1 Panel component (urethane integrated foam molding)
3 Skin material 3a Skin material terminal 5 Base material 7 Urethane foam layer 13 Catcher material 15 Adhesive 31 Mold 33 Upper mold 39 Lower mold

Claims (3)

A urethane integrated foam molded product in which a urethane foam layer is integrally formed between a resin skin material and a base material,
The adhesive on the surface of at least one urethane foam layer side of the skin material and the base material so that the granular catcher material that captures volatile organic compounds generated in the urethane foam layer is not partially covered with the adhesive. Is attached through
A urethane-integrated foam-molded article, wherein an uncoated portion of the catcher material by an adhesive is in direct contact with the urethane foam layer. In the urethane integrated foam molded article according to claim 1,
A urethane-integrated foam-molded product, wherein the surface of the skin material terminal is in close contact with the base material from the inside at the seal location of the urethane foam layer terminal with the skin material and the base material. A urethane foam layer is integrally formed between the skin material and the base material by injecting the foamed urethane raw material into the mold and foaming with the resin skin material and base material set in the mold. A method for producing a molded urethane integral foam product,
Before injecting the urethane foam raw material before or after setting the skin material and the base material into the mold, apply an adhesive to the surface of the skin material and the base material on the side of the urethane foam layer. Then, before the adhesive is cured, a granular catcher material that captures volatile organic compounds generated in the urethane foam layer is sprayed on the adhesive to cure the adhesive. Adhering the material to the surface on the urethane foam layer side of at least one of the skin material and the base material through the adhesive so as not to be partially covered with the adhesive,
A method for producing a urethane-integrated foam-molded product, comprising: injecting the urethane foam raw material into a mold and molding a urethane foam layer in direct contact with an uncoated portion of the catcher material by an adhesive.

Images