JP2601786B2 - Automotive interior base material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention
The present invention relates to a base material for an interior material such as a door trim and a rear parcel.

[0002]

2. Description of the Related Art Conventionally, an automobile comprising a synthetic resin-impregnated polyurethane foam sheet obtained by molding a polyurethane foam sheet impregnated with a polyvalent isocyanate by contact with moisture and curing the polyvalent isocyanate with the moisture. (Japanese Patent Application Laid-Open No. 58-534)
6). The above-mentioned interior base material is excellent in heat insulation and sound insulation.

[0003]

However, the synthetic resin-impregnated polyurethane foam sheet has a lack of rigidity, so that it is necessary to laminate a reinforcing layer such as a glass fiber layer and the like. There is a problem that air containing contaminants such as smoke permeates therethrough, the sheet acts as a filter, the contaminants accumulate on the surface of the interior material, and the surface of the interior material is significantly contaminated.

[0004]

According to the present invention, as a means for solving the above-mentioned conventional problems, a synthetic resin-impregnated polyurethane foam sheet is formed by impregnating a fiber sheet impregnated with a polyurethane elastomer having a crosslinked structure into a predetermined shape. The present invention provides an automotive interior base material.

[Synthetic resin-impregnated polyurethane foam sheet] The synthetic resin-impregnated polyurethane foam sheet used in the present invention is a soft polyurethane foam sheet formed of a urethane resin, a melamine resin, a phenol resin, a resorcin resin, an epoxy resin, a urea resin. A resin, a polyester resin, an acrylic resin, a styrene resin, a vinyl acetate resin, or a precursor of a synthetic resin such as a monomer, prepolymer, or oligomer of the above synthetic resin is usually impregnated with about 10 to 50% by weight, preferably about 20 to 40% by weight. In the case of impregnating a precursor of a synthetic resin, the resin is cured by an appropriate means such as heating, a catalyst, and moisture to form a synthetic resin.

[Urethane Elastomer] The urethane elastomer used in the present invention has a cross-linked structure and is composed of poly (1,4-oxybutylene) glycol,
Polyester, polyethylene adipate, polypropylene adipate, ethylene propylene adipate, etc. and TD
The terminal NCO is further reacted with a polyol, diamine, water, o-dichlorobenzidine, glycol, dicumyl peroxide or the like, if desired, by a polyaddition reaction with a polyvalent isocyanate such as I, MDI, 1.5NDI or the like. To form a crosslinked structure. The urethane elastomer of the present invention is mainly provided as an aqueous dispersion, and commercial products include, for example, Superflex 200 and 300 (registered trademark of Daiichi Kogyo Seiyaku Co., Ltd.).

[Fibre Sheet] As the fiber sheet used in the present invention, for example, organic fibers such as polyester fibers, polyamide fibers, acrylic fibers, acetate fibers, polyvinyl chloride fibers, polyvinylidene chloride fibers, and cotton fibers, or recycled fibers thereof. One or a mixture of two or more fibers,
Glass fiber, carbon fiber, ceramic fiber, whisker, rock wool, mixed fiber of two or more kinds of inorganic fibers such as slag wool, one or two or more kinds of mixed fibers of the above organic fibers, and one kind of the above inorganic fibers or There are fleeces, felts, non-woven fabrics, knitted fabrics, and the like of two or more types of mixed fibers, and two or more layers of the same or different types of the fiber sheet may be laminated. The fiber sheet usually contains 10 to 5 urethane elastomers having the crosslinked structure as pure components.
It is impregnated with 0% by weight, preferably about 20 to 40% by weight.

[Reinforcing Layer] In the present invention, a reinforcing layer may be polymerized on the upper and / or lower side of the fiber sheet. As the reinforcing layer, for example, a polyvalent isocyanate, a melamine resin, a phenol resin, a resorcin resin, an epoxy resin in place of the urethane elastomer in the fiber sheet,
There is a resin which is usually impregnated with urea resin or the like at a pure content of about 10 to 50% by weight, preferably about 20 to 40% by weight. Needless to say, the reinforcing layer is not essential in the present invention.

[Manufacture of Interior Base Material] The interior base material for automobiles of the present invention is formed by polymerizing the above-mentioned synthetic resin-impregnated polyurethane foam sheet, the above-mentioned fiber sheet and, if desired, the above-mentioned reinforcing layer into a predetermined shape. To manufacture. The synthetic resin-impregnated polyurethane foam sheet, the fiber sheet, and the reinforcing layer, if desired, may be molded and bonded before polymerization, respectively, but are usually integrally molded after polymerization. You.
Further, the skin material may be further polymerized and integrally formed and pressed. The synthetic resin-impregnated polyurethane foam sheet, the fiber sheet, and the reinforcing layer, if desired, include acrylic, vinyl acetate, and styrene-based ordinary adhesives and polyethylene, ethylene-vinyl acetate copolymer, and the like. The adhesive may be bonded using a hot-melt adhesive, but usually the above-mentioned adhesive is particularly necessary since the synthetic resin, urethane elastomer, etc., which are each impregnated, ooze out at the time of pressure bonding and act as an adhesive. do not do. The polymer of the synthetic resin-impregnated polyurethane foam sheet, the fiber sheet, and, if desired, the reinforcing layer is usually 100 to 180 ° C., ^{2 to 3} kg / cm ² ,
It is molded and pressed under conditions of about 30 to 180 seconds.

[0010]

The urethane elastomer having a crosslinked structure used in the present invention forms a rigid film having high gas barrier properties in a fiber sheet. Therefore, the synthetic resin-impregnated polyurethane foam sheet is prevented from breathing by such a fiber sheet and is given rigidity.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to an embodiment shown in FIGS. 1 to 3. In FIG.
A polyurethane foam sheet (2) impregnated with a mixture of 25% by weight of DI and 5% by weight of a hydroxyl group-containing acrylic resin; a glass fiber mat (3, 3) laminated on the front and back surfaces of the sheet (2);
A polyester nonwoven fabric sheet (4) laminated on the glass fiber mat (3) on the back side of the sheet (2), and a polyester cotton layer laminated on the glass fiber mat (3) on the surface of the sheet (2) (5)

The glass fiber mat (3, 3) and the polyester cotton layer (5) are each impregnated with about 30% by weight of melamine resin as a pure component, and the polyester nonwoven fabric sheet (4) is cross-linked. Superflex 200, a urethane elastomer having a structure, is 35
It is impregnated by weight percent.

As shown in FIG. 2, the interior base material (1) is polymerized with the skin material (6) via a heat-softened polyethylene sheet (7), and set on a press molding machine (8) at 160 ° C. 3kg
/ Cm ² molding pressure, 120 seconds hot press
It is molded into the ceiling material (9) of an automobile as shown in (1). The skin material (6) is made of, for example, a nonwoven fabric, a fiber knitted fabric, a synthetic leather, or the like.

By the above hot press, the MDI impregnated in the polyurethane foam sheet (2) of the base material (1) reacts and hardens with the hydroxyl group-containing acrylic resin to form a glass fiber mat.
The melamine resin impregnated in (3) and the polyester cotton layer (5) also hardens. Then, the polyurethane foam sheet (2), the glass fiber mat (3), the polyester nonwoven fabric sheet (4) and the polyester cotton layer (5) which constitute the base material (1)
Are adhered to each other by exudation of the synthetic resin impregnated with them, and the base material (1) and the skin material (6) are
Adhered by (7).

The urethane elastomer having a crosslinked structure impregnated in the polyester nonwoven fabric sheet (4) forms a uniform film having a high gas barrier property by the hot pressing, and prevents air permeability of the ceiling material (9). And imparts rigidity.

[0016]

Accordingly, in the present invention, the interior base material for automobiles is excellent in sound insulation and heat insulation, has no air permeability, is hard to adhere to pollutants such as dust and smoke of tobacco, and has high rigidity. Is obtained.

[Brief description of the drawings]

 1 to 3 show one embodiment of the present invention.

FIG. 1 is a cross-sectional view of an interior base material.

FIG. 2 Hot press state diagram

FIG. 3 is a perspective view of a ceiling material.

[Explanation of symbols]

1 Interior base material 2 Polyurethane foam sheet impregnated with synthetic resin 4 Polyester nonwoven fabric sheet impregnated with urethane elastomer having a crosslinked structure

Claims (1)

(57) [Claims] 1. An automotive interior substrate formed by molding a synthetic resin-impregnated polyurethane foam sheet into a predetermined shape by polymerizing a fiber sheet impregnated with a polyurethane elastomer having a crosslinked structure.