JP2008045228A - Glass chopped strand mat, method for producing the same and automotive moldeed ceiling material using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a glass chopped strand mat which can ensure rigidity needed for GFRP, can sufficiently control a defect called a sink mark, and can prevent damages caused, when the mat is pulled out from a mat roll, to provide a method for producing the same, and to provide an automotive molded ceiling material using the mat. <P>SOLUTION: The glass chopped strand mat 19 contains 5 mass% of ethylene-vinyl acetate copolymer resin in a binder P. The method for producing the glass chopped strand mat 19 includes spraying the binder P. The automotive molded ceiling material has the glass chopped strand mat applied with the binder P on the skin side of a foamed resin sheet. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

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

  The glass chopped strand mat is a glass strand of long glass fibers by applying and bundling various adjusted sizing agents to the surface of a large number of glass filaments so as to have an adhesion amount of about 0.1 to 2% by mass. 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 a uniform and random manner, a suitable amount of powdered polyester resin is sprayed as a binder from above. Then, the powdered polyester resin is heated and melted and then press-molded to cool and solidify, or an emulsion of the emulsified resin is applied to a sheet-like deposit and then dried.

The production of this glass chopped strand mat will be specifically described. For example, a glass strand having a single fiber diameter of 11 μm and a strand count of 35 tex (or tex, also described as tex, the weight in grams per 1000 m) is used. Cut with a cutter so that the dimension is about 50 mm long. 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 automobile molded ceiling material, it is used for the purpose of reducing the weight of the entire automobile in addition to characteristics such as rigidity, dimensional stability, heat insulation, or sound insulation. The material to be used is required to reduce the weight per unit area. In addition, when a glass chopped strand mat is bonded to a foamed resin sheet such as a foamed polyurethane sheet, an adhesive such as phenol, melamine, or isocyanate resin is used. If it does not penetrate to the back side, there is a problem that the rigidity of the molded automotive ceiling material is insufficient, or there is a problem that peeling occurs between the mat and the foamed resin sheet or skin after bonding. It is necessary to sufficiently penetrate the adhesive.

  In order to reduce the weight of the automobile molded ceiling material and improve the permeability of the adhesive to the mat, the basis weight of the glass chopped strand mat may be reduced. The smaller the basis weight, the more the strand of the glass chopped strand mat The distribution becomes inhomogeneous and the tensile strength of the mat is lowered. As a result, after the mat is wound on 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.

  Further, 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. From about 10 to several hundreds of glass filaments having a diameter of 13 to 10 μm, glass chopped strands cut to a length of 3 to 25 mm are dispersed into monofilaments in white water, and paper is made. However, glass continuous strand mats have the problem of low production efficiency per glass raw material and are therefore expensive, and glass paper has a small reinforcing effect because glass fibers are in a monofilament state. However, there is a problem that rigidity is insufficient.

For this reason, various attempts to improve the strength of the chopped strand mat have been made so far. For example, in Patent Document 1, the shape of the glass chopped strand is specified, thereby preventing collapse from the conveyor. Inventions have been made that only the strength can be realized. Further, Patent Document 2 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.
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, 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 250 g / m ² is used on at least one surface thereof. It has become so. The glass chopped strand 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 into a length of about 50 mm, and the basis weight is in the range of 50 g / m ² to 250 g / m ² . The powder polyester resin is sprayed so as to be in the range of 8% by mass to 14% by mass, and then heated and melted to cool and solidify, or an emulsion in which the resin is emulsified is deposited. The glass chopped strands are applied to each other and dried so that the adhesion amount is in the range of 6 mass% to 10 mass%.

  In such a glass chopped strand mat, when the adhesive such as phenol, melamine, or isocyanate is applied to the mat, the mat is partially broken due to a problem in the dispersion state of the glass chopped strand. May be easier. And in order to superimpose the chopped strand mat coated with the adhesive in such a state, from the inner skin of the automobile, the glass chopped strand mat, the foamed resin sheet, the glass chopped strand mat and the protective sheet on the ceiling side of the automobile in this order, When pulling out the mat from the mat roll, there is a problem that the mat is torn, that is, may be broken.

Moreover, when producing the above-mentioned automobile molded ceiling material, the glass chopped strand mat is impregnated with an adhesive such as phenol, melamine or isocyanate resin, and the skin (the interior of the automobile), the glass chopped strand mat, the foam When the resin sheet, glass chopped strand mat, and protective sheet (car ceiling side) are layered in order and pressed into the shape of the molded ceiling, the corner of the deep-drawn part such as the shade of the molded ceiling material and the assist grip Skin wrinkles called sinks may occur. The rate of occurrence of such a sink defect is, in particular, a thin non-woven fabric having a basis weight of 50 g / m ² or less is used for the skin for the purpose of cost reduction, or the skin of a knit material without raising is used with emphasis on design. It has become remarkable in recent years.

  The present invention has been made in view of the above circumstances, and prevents the problem that the mat is partially damaged when the mat is pulled out from the mat roll after ensuring the necessary rigidity after becoming a GFRP molded product. It is an object of the present invention to provide a glass chopped strand mat that can be suppressed and sufficiently suppress the occurrence of a defect called sink in a molded product, a manufacturing method thereof, and an automotive 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 contains 5% by mass or more of an ethylene vinyl acetate copolymer resin. It is characterized by.

  The present inventor has an effect that an unsaturated polyester resin generally used as a binder in various studies on glass chopped strand mats can easily bond glass chopped strands. I found that there was a point. In other words, the glass chopped strand mat becomes harder and the flexibility of the thick-weighted portion due to unevenness in the weight of the glass chopped strand mat is lost. When a thick portion is constructed, a defect called wrinkle called a sink may occur in the epidermis. In order to prevent wrinkles called sinks from entering the skin, the mat roll is used to apply an adhesive such as phenol, melamine, or isocyanate resin to the glass chopped strand mat when the amount of the binder is reduced to soften the mat. Adhesive for stacking the skin (car interior side), glass chopped strand mat, foamed resin 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 mat roll formed by the chopped strand mat coated with the chopped strand mat, there may be a problem that the mat is torn from a portion having a low basis weight due to unevenness in the basis weight of the chopped strand mat, that is, torn off.

  Therefore, the present inventor has realized the most preferable performance that the binder contains 5% by mass or more of ethylene vinyl acetate copolymer resin in order to solve the performance problems of the glass chopped strand mat described above. Find out what you can do and present it here.

  In the present invention, the binder contains 5% by mass or more of an ethylene vinyl acetate copolymer resin as a binder used for binding glass chopped strands when the mass of the binder is 100 In addition, it is a glass chopped strand mat formed by using a material containing 5 or more ethylene vinyl acetate copolymer resins and bonding glass chopped strands having a predetermined length to each other.

  When the content of the ethylene vinyl acetate copolymer resin is less than 5% by mass, the effect of adding the ethylene vinyl acetate copolymer resin, that is, even when the amount of the binder is large, the glass chopped strand mat is softened and molded as an automobile ceiling material. Sometimes even when the thick and hard part of the glass chopped strand mat has to be applied to the opening of the shade or the corner of the deep drawing due to unevenness of the glass chopped strand mat, a defect called wrinkles called sink marks occurs in the skin. This is not preferable because it has a poor effect of deterring.

  About this binder, it does not prevent containing components other than ethylene vinyl acetate copolymer resin. However, it is not preferable that the component which suppresses the performance obtained by containing ethylene vinyl acetate copolymer resin is contained.

  In addition to the above, the glass chopped strand mat of the present invention has an ethylene vinyl acetate copolymer resin melt flow rate of 40 g / 10 min or more when the binder is melted in order to produce a chopped strand mat. It is preferable because the fluidity of the binder is good and the adhesive strength is improved.

  In the present invention, the melt flow rate of the ethylene vinyl acetate copolymer resin is 40 g / 10 min or more is a measure of the fluidity of the ethylene vinyl acetate copolymer resin in a liquid state, using an extrusion plastometer, JIS K7210. : According to 1999 (or ISO 1133: 1997), the amount flowing out from a nozzle (orifice) having a prescribed size under a constant pressure and a constant temperature is measured, and an index representing the value in units of g / 10 min is This means that the melt flow rate is 40 g / 10 min or more, and this melt flow rate is also called a melt flow index or a solution index.

  When the melt flow rate of the ethylene vinyl acetate copolymer resin is less than 40 g / 10 min, the flowability of the binder is poor when the binder is melted to produce a chopped strand mat, and the adhesive strength is weak. This is not preferable because the tensile strength of a chopped strand mat cannot be obtained. On the other hand, when the value of the melt flow rate of the ethylene vinyl acetate copolymer resin exceeds 1500 g / 10 min, the fluidity may become too high, resulting in troubles in workability. Therefore, a more preferable value of the melt flow rate of the ethylene vinyl acetate copolymer resin is in the range of 40 g / 10 min to 1500 g / 10 min.

  As such a binder, it does not prevent the inclusion of other additive components, but in order to fully exhibit the performance of the polyethylene resin, the main components other than the ethylene vinyl acetate copolymer resin are unsaturated polyester. It is preferable to use a resin. Here, the main component means that the ethylene-vinyl acetate copolymer resin and the unsaturated polyester resin are 50% or more based on the total mass of the binder.

In addition to the above, the glass chopped strand mat of the present invention has a binder adhesion amount in the range of 8% to 25% by mass, an average strand count in the range of 10 tex to 30 tex, and a basis weight of 50 g / m ^2. If it is in the range of 250 g / m ² , excellent quality can be realized in each process from spinning of glass fibers to glass chopped strand mats before use.

In the present invention, the adhesion amount of the binder is in the range of 8% to 25% by weight, the average strand count is in the range of 10 tex to 30 tex, and the basis weight is in the range of 50 g / m ² to 250 g / m ^2. The strength of the glass cake used in the production of the chopped strand mat was determined from the ignition loss value of the chopped strand mat measured by the ignition loss measurement method described in JIS R3420 (1999). By subtracting the heat loss value, the average strand count representing the mass of the glass strand corresponding to a length of 1000 m is within the range of 8 to 25% by mass, and the unit area is within the range of 10 to 30 tex. The basis weight corresponding to the weight of the glass chopped strand per unit is 50 g / m ² to 25 It represents being in the range of 0 g / m ² .

  As for the amount of binder adhering in the range of 8% by mass to 25% by mass, the amount of binder adhering to less than 8% by mass is sufficient because a sufficient amount of binder does not adhere to the glass chopped strands. High tensile strength is not obtained, and an adhesive such as phenol, melamine, or isocyanate resin is applied to a glass chopped strand mat. Inner), glass chopped strand mat, foamed resin sheet, glass chopped strand mat, and protective sheet (car ceiling side), so that the mat is pulled out sequentially from the mat roll formed by the chopped strand mat coated with adhesive The fabric weight is thin due to uneven fabric weight of the chopped strand mat. I know mat rupture, i.e., is not preferable because it may problem torn arises. On the other hand, when the adhesion amount of the binder exceeds 25% by mass, the portion where the basis weight becomes thick due to the unevenness of the basis weight of the chopped strand mat becomes hard, and the hard portion becomes a corner portion that requires deep drawing such as a shade. When used for construction, the chopped strand mat is not sufficiently stretched at the time of pressing, and wrinkles on the skin called sinks occur, resulting in appearance defects.

  Further, if the average strand count of the glass chopped strand mat is in the range of 10 tex to 30 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 converging glass filaments per strand. When producing such a glass strand, it is used during spinning. Either the number of holes in the bushing is reduced or the yarn is split into more strands. When 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 30 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, which is not preferable.

Moreover, if the basis weight of the glass chopped strand mat is in the range of 50 g / m ² to 250 g / m ² , the distribution of the glass chopped strands can be maintained in a uniform state, and the weight can be reduced as in the case of automobile molded ceiling materials. It can be set as the mat applicable also to the use made into a subject. 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 250 g / m ² , the achievement of the object of reducing the weight of the automobile molded ceiling material and improving the permeability of the adhesive will be 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 for bonding glass chopped strands of sheet-like deposits to each other, characterized in that the binder is dispersed.

  In the present invention, the production of the above-mentioned glass chopped strand mat means that the molten glass adjusted to have a predetermined material is drawn out from the bushing and spun, and the obtained glass strand having a predetermined diameter is cut into a predetermined length. This means that after the glass chopped strand is formed, the glass chopped strands are bonded to each other using the binder described above to form a glass chopped strand mat.

  The ethylene vinyl acetate copolymer resin contained in the binder for bonding the glass chopped strands according to the present invention may have any form, and any spraying method is adopted. May be. That is, the form is not limited to powder, and various forms such as granules, fibers, sheets, and films are possible. Further, as a specific method for adjusting the dispersion state of the binding material, a method of supplying a predetermined amount of binding agent from above the mat by adjusting the flow rate from a supply nozzle or the like is generally used. Anyway, what is necessary is just to be able to eliminate the variation in the final content by adopting an arbitrary spraying method. Moreover, the method of using together ethylene vinyl acetate copolymer resin and resin other than ethylene vinyl acetate copolymer 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 as described above is bonded to the skin side of the foamed resin sheet.

Here, the above-mentioned glass chopped strand mat is bonded to the skin side of the foamed resin sheet. In order to realize the molding material of the present invention, at least one surface of the foamed resin sheet constituting the automobile molded ceiling material The glass chopped strand mat of the present invention, that is, a glass chopped strand mat characterized in that the binder contains 5% by mass or more of ethylene vinyl acetate copolymer resin, preferably, the melt flow rate of the ethylene vinyl acetate copolymer resin is 40 g / 10min or higher, the average strand count is in the range of 30tex from 10Tex, glass chopped strand mat basis weight is in the range of 50 g / m ² of 250 g / m ² have indicates that a bonded configuration. When adopting only one surface of the foamed resin sheet, there is no particular limitation as to whether or not another coating material is used on the other surface.

  In addition, the automobile molded ceiling material of the present invention is not limited to the skin side of the foamed resin sheet. Naturally, the glass chopped strand mat of the present invention having the above-mentioned binder attached to both surfaces thereof is adhered. It may be.

  A known bonding method can be used for bonding the glass chopped strand mat and the foamed resin sheet, and the glass chopped strand mat is impregnated with one or a plurality of adhesives such as phenol, melamine, or isocyanate resin. Can be used.

  In addition to the above, the automobile molded ceiling material of the present invention is free from sink marks even when it is a deep-drawn portion having a curvature radius smaller than 10 mm when it is press-formed into the shape of the molded ceiling. preferable.

  (1) As described above, since the glass chopped strand mat of the present invention contains 5% by mass or more of ethylene vinyl acetate copolymer resin in the binder, it is in the process of releasing the mat from the mat roll. It has excellent quality that can eliminate the fear of strength and is difficult to rupture, and can be applied to parts with a small radius of curvature, such as shades for automotive ceiling materials and assist grips. Even in the case of adopting the above-mentioned design, it has a stable quality with a small probability that an appearance defect called sink will occur after molding.

  (2) The glass chopped strand mat of the present invention can be bonded when the binder is melted to produce a chopped strand mat if the melt flow rate of the ethylene vinyl acetate copolymer resin is 40 g / 10 min or more. The fluidity of the agent is good and the adhesive strength can be improved.

(3) Further, in the glass chopped strand mat of the present invention, the adhesion amount of the binder is in the range of 8% by mass to 25% by mass, the average strand count is in the range of 10 tex to 30 tex, and the basis weight is from 50 g / m ^2. If it is in the range of 250 g / m ² , it can be used as a component of deep-drawn molding or automotive molded ceiling material having a complicated shape, and is a highly versatile and lightweight component material with excellent performance. It can be realized at low cost.

  (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. Then, a glass chopped strand mat manufacturing method for bonding the glass chopped strands of the sheet-like deposits to each other, and since the above binder is dispersed, it is possible to efficiently form the mat, It is possible to quickly form a glass chopped strand mat in which defects are suppressed.

  (5) The automobile molded ceiling material of the present invention is a wide variety because the glass chopped strand mat to which the binder is attached as described above is bonded to the skin side of a foamed resin sheet such as a foamed polyurethane sheet. It can be easily applied to various automobile molded ceiling materials that require a special design, and defects such as sink marks are unlikely to occur even in the case of a ceiling material having 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, the manufacturing process of a glass chopped strand mat is demonstrated below.

  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 as shown in FIG. 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, as shown in FIG. 1, the glass strand 10 is continuously unwound from the inner layer of the glass cake 5 after the drying step, and sent to a cutting device 12 provided with a plurality of cutters, and is chopped with a length of 50 mm. Cut into strands 10a. At this time, the strand 10 made of 1200 glass filaments that has been wound by being divided into 18 yarns becomes a chopped strand 10a in a state of being 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 by the dimension of length 50mm is disperse | distributed so that it may become uniform on the 1st conveyance conveyor 13, and after becoming the sheet-like deposit 10b of the state accumulated on the sheet form, it is 1st. It is conveyed out of the chamber 11 by a single conveyor 13. Next, the sheet-like deposit 10b is conveyed onto the next second conveyor 14, and the melt flow rate is applied by the spreader 15 onto the glass chopped strand 10a of the sheet-like deposit 10b moving on the second conveyor 14. Mixed resin P in which ethylene vinyl acetate copolymer resin of 75 g / 10 min and bisphenol A ethylene oxide adduct-based polyester resin are mixed at a ratio of 1: 1, that is, 50% in terms of mass percentage, is chopped strand 10a. As a binder, it is sprayed after adjusting to a uniform state so that a predetermined adhesion amount (13 mass%) is obtained.

Then, the glass chopped strands 10a uniformly dispersed on the belt conveyor 14 and the dispersed mixed resin P are conveyed from the second conveyor 14 to the third conveyor 16 while maintaining a state where they are dispersed. . 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 resin P is dispersed moves into the heating furnace 17 and is predetermined. By being heated at the temperature, the dispersed powdered mixed resin P is heated and softened, and becomes a molten state on the surface of the glass chopped strand 10a. Next, the sheet-like deposit 10 b to which the softened mixed resin P is adhered is moved to the outside of the heating furnace 17, cooled and pressed through the water-cooled roll 18. As a result, the melted powder mixed resin P is solidified and then wound up by the winder 20 to finally obtain the glass chopped strand mat 19 (weight per unit area: 107 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. A total of 7 types of samples 6 and 7 were prepared. That is, after impregnating a glass chopped strand mat 19 having a predetermined dimension of the E glass material, which is the strand count of Table 1, and adjusted to have 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, the ethylene vinyl acetate copolymer resin with respect to the total amount (A + B) of the mass of the ethylene vinyl acetate copolymer resin (A) and the mass of the bisphenol A ethylene oxide adduct polyester resin (B) is shown. The percentage ratio of mass (A) is expressed as (A / (A + B)). Here, sample No. Nos. 2 and 3 contain only ethylene vinyl acetate copolymer resin (A). 6 and 7 contain only the bisphenol A ethylene oxide adduct polyester resin 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 After measuring (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.

  For the ethylene vinyl acetate copolymer resin, the melt flow rate of the ethylene vinyl acetate copolymer resin was measured by the method described in JIS K7210: 1999 (or ISO 1133: 1997).

  As for the automobile molded ceiling material, a skilled worker inspected the number of sinks generated on the skin side of the 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. 1 has a strand count of 20 tex, a mat basis weight of 107 g / cm ² , and the total amount (A + B) of the mass (A) of ethylene vinyl acetate copolymer resin and the mass (B) of bisphenol A ethylene oxide adduct polyester resin as a binder. The percentage of the mass (A) of the ethylene vinyl acetate copolymer resin with respect to) is 50%, and the amount of adhesion is 13%. However, the mat is not broken when the mat is pulled out from the mat roll, and it is defective due to sink. Was 0.5%.

Sample No. No. 2 is a sample having a strand count of 18 tex, a mat basis weight of 130 g / cm ² , and an ethylene vinyl acetate copolymer resin as a binder, and its adhesion amount is 13%. However, when the mat is pulled out from the mat roll, There was no tearing, and no defects due to sink marks were observed.

Furthermore, sample no. 3 to sample no. For sample No. 5, sample no. 3 is a sample having a strand count of 20 tex, a mat basis weight of 100 g / cm ² , a binder (A / (A + B)) × 100 value of 100%, and an adhesion amount of 15%. No. 4 has a strand count of 22 tex, a mat basis weight of 105 g / cm ² , and the binder (A / (A + B)) × 100 has a value of 75%, and its adhesion amount is 12%. 5 is a sample having a strand count of 19 tex, a mat basis weight of 108 g / cm ² , a binder (A / (A + B)) × 100 value of 25.0%, and an adhesion amount of 11%. Although a defect due to sinking was slightly recognized, the value was 1.0% or less, and the mat was not torn when the mat was pulled out from the mat roll.

On the other hand, sample No. which is a comparative example. No. 6 is a sample having a strand count of 18 tex, a mat basis weight of 107 g / cm ² , and containing only a bisphenol A ethylene oxide adduct polyester resin as a binder and an adhesion amount of 10%. Since it is a binder containing only a bisphenol A ethylene oxide adduct polyester resin that does not contain a polymerized resin, 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. No. 7 is a sample having a strand count of 20 tex, a mat basis weight of 107 g / cm ² , containing only a bisphenol A ethylene oxide adduct polyester resin as a binder, and an adhesion amount of 13%. Since it is a binder containing only a bisphenol A ethylene oxide adduct polyester resin that does not contain a polymerization resin, tearing did not occur, but the glass chopped strand mat became hard and the basis weight of the glass chopped strand mat was uneven. The flexibility of the part was lost, and the incidence of defects due to sink marks was as high as 16%.

  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-cooled roll 19 Glass chopped strand mat (mat roll)
20 Winder P Mixed 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 5% by mass or more of an ethylene vinyl acetate copolymer resin.   The glass chopped strand mat according to claim 1, wherein the melt flow rate of the ethylene vinyl acetate copolymer resin is 40 g / 10 min or more. The adhesion amount of the binder is in the range of 8% by mass to 25% by mass, the average strand count is in the range of 10 tex to 30 tex, and the basis weight is in the range of 50 g / m ² to 250 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,
The manufacturing method of the glass chopped strand mat characterized by spraying the binder in any one of Claims 1-3.   An automotive molded ceiling material, wherein the glass chopped strand mat according to any one of claims 1 to 3 is bonded to a skin side of a foamed resin sheet.

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