JP2676156B2 - Elastic lining material for automobile and method for manufacturing the same - Google Patents

Description

TECHNICAL FIELD The present invention relates to a lining material for automobiles, particularly a lining material excellent for a ceiling and a method for producing the same.

[Prior Art and its Problems] Conventionally, a lining material for automobiles, particularly a ceiling material, is used as a core material of glass fiber, polystyrene, corrugated board,
Although many felt-based materials are used, generally, for ceilings, many excellent performances such as sound absorption, heat insulation, workability and dimensional stability are required. However, there was no one that fulfilled the requirements for a ceiling lining material, and it was difficult to realize it.

Therefore, in recent years, a lining material for automobiles, which is made of polyurethane foam, which is excellent in sound absorption, functionality, lightness, and ease of assembly, is being developed.

Polyurethane-based foams have a good foam structure in which the shape of the foam is open-celled, and if possible, it is considered that the foam cells are ideally non-uniform and complex shapes, rather than uniform shapes. Since the shape does not have self-holding property, the polyurethane foam itself is treated with a thermosetting resin such as epoxy, polyester, melamine, or an isocyanate, or various non-woven fabrics, glass paper, and various film sheets are used on the front and back of the foam. Or a method of forming a sandwich structure by pasting and laminating in a state of being impregnated with resin, both of which used continuous polyurethane foam as the core material, and thus the shape retention was slightly inferior and the shape with deep drawing property was used. In the molding of, the appearance of the shape was insufficient.

Therefore, an object of the present invention is to provide an elastic lining material for automobiles which is lightweight and economical, can be sufficiently formed even in a deep-drawn shape, and has excellent performance, and a manufacturing method thereof. I am trying.

[Means for Solving the Problems] In order to achieve the above-mentioned object, the present invention is to attach a foamable thermosetting resin to both front and back surfaces of a thermoformable semi-rigid polyurethane foam having open cells and at the same time, use a gauze cloth or A coarse sheet such as a glass fiber mat formed by interlacing glass fibers in a mesh shape was attached, and thermocompression molding was performed at a predetermined temperature to foam and cure the thermosetting resin to form a desired shape. It constitutes a lining material for automobiles having elasticity,
Further, in the production of this lining material for automobiles, a foamable thermosetting resin is sprayed or applied on both front and back surfaces of a thermoformable semi-rigid polyurethane foam having open cells to heat the thermosetting resin. In a melted state, further attach a rough sheet such as a glass cloth or a glass fiber mat formed by interlacing glass fibers in a mesh shape on both sides, and then heat compression molding to cure the semi-rigid polyurethane foam and heat it. The curable resin is foamed and cured to form a desired shape.

Further, in the present invention, in the above method, sheets may be adhered to both front and back surfaces of a semi-rigid polyurethane foam, and then a skin material such as a non-woven fabric may be polymerized on one surface to integrally perform heat compression molding.

[Operation] In the automobile lining material configured as described above, a foamable thermosetting resin is attached to both front and back surfaces of a thermoformable semi-rigid polyurethane foam having open cells, and a rough sheet is attached. It is formed by wearing and heat-compressing, but the heat-compressing cures the polyurethane foam to increase the foam density and deform the cells of the foam to increase the sound absorption.
Further, since the foam is a semi-hard thermoformable material having open cells, it is possible to perform molding with a high degree of freedom, that is, deep-drawing molding. Furthermore, by providing a foamable thermosetting resin layer on both sides of the foam, heat resistance, In addition to flame retardancy, the above-mentioned sheet is also adhered to exert excellent effects on dimensional stability and shape retention.

Embodiment An embodiment of the present invention will be described below with reference to the drawings. In the drawing, FIG. 1 shows a production flow sheet according to the present invention, in which 1 is a heating furnace, and conveyors 4a, 4b, 4c are arranged in the heating furnace 1 and before and after its inlet 2 and outlet 3, respectively. Above the conveyor 4a arranged in front of the entrance 2, a hopper 5 storing a powdery material of a foamable thermosetting resin P is provided. Further, a conveyor 4d is provided continuously with the conveyor 4c provided at the outlet 3 of the heating furnace 1, and the sheet is provided above the conveyor 4d.
A pair of rolls around which 6 and 6 are wound and a roll around which a skin material 7 such as a non-woven fabric is wound are arranged side by side, and a cutter 8 which operates in the vertical direction is arranged at the tip of the conveyor 4d. Reference numeral 9 is a compression molding machine including a pair of concave and convex molds 10a and 10b. The sheets 6 and 6 are coarse and thin sheets such as a glass cloth or a glass fiber mat formed by interlacing glass fibers in a net shape.

Then, the thermoformable semi-rigid polyurethane foam F having open cells is placed on the upper surface of the conveyor 4a and sent to the heating furnace 1. Before that, the polyurethane foam F is transferred and the hopper 5 is placed on the upper surface thereof. The foamable thermosetting resin P is sprayed at a spraying rate of 50 to 300 g / m ² , and then heated in the heating furnace 1 to adhere to the surface of the polyurethane foam F in a semi-molten state. Since the thermosetting resin P is sprayed on both sides, the polyurethane foam F heated in the heating furnace 1 is turned over and the thermosetting resin P is sprayed again and heated.

Next, on the conveyor 4d, the sheets 6, 6 wound in a roll shape are attached to both the front and back surfaces of the polyurethane foam F, and the skin material 7 is attached only to the front surface, and a cutter 8 having a predetermined length is attached. Cut by. Then, it is loaded into a pair of molds 10a, 10b in the compression molding machine 9 and compression-molded into a desired shape while being heated to 120 ° C to 220 ° C.

The automobile lining material thus formed is used as an automobile lining material, particularly as a ceiling lining material.
Is adhered by foaming of a thermosetting resin, and the polyurethane foam F is cured to increase the foam density of itself and the cells of the foam are deformed so that the cells of the foam on the front and back sides are impregnated with the thermosetting resin. The deformation density is further increased, the sound absorption is increased, and deep drawing is possible. In FIG. 4, the refraction portion by the deep drawing is shown in a cross section. As shown in this drawing, the thermosetting resin permeates the rough sheet 6 to the outside along with the refraction, and is filled and cured in the narrow curvature portion. . For this reason, the sharp refraction part due to deep drawing is also finished neatly. FIG. 5 is a diagram comparing the sound absorption characteristics of the conventional range felt system and the product of the present invention, and the product of the present invention is particularly excellent in the sound absorption characteristics in the low sound range and the high sound range.
Furthermore, by providing thermosetting resin layers on both the front and back surfaces of polyurethane foam F, heat resistance and flame retardancy, and also by sticking rough sheets 6 and 6, together with dimensional stability,
Exhibits excellent effect on shape retention.

The foamable thermosetting resin may be melted and applied, and the resin may be a phenolic resin, a urea resin, a melamine resin, an acrylic resin, a polyamide resin, or a mixture thereof. To be Further, the foamed form may be an independent continuous foam alone or as a mixture thereof, and it is desirable that the expansion ratio is lower than that of polyurethane foam. The above-mentioned sheet may be made of natural or chemically synthetic fiber, and may be of a thin cloth having a coarse mesh through which a thermosetting resin can pass. Although not shown, a reinforcing material such as non-woven fabric or glass paper may be polymerized on the back surface to further enhance the reinforcing effect.

[Effects of the Invention] According to the present invention as described above with reference to the embodiments, by using a thermoformable semi-rigid polyurethane foam having open cells as a core material, a deep drawing degree of freedom is provided and excellent sound absorption is achieved. In addition, it exhibits moisture resistance, heat resistance, flame retardancy and heat retention by forming a thin layer of phenol foam on both the front and back sides of the foam by foaming thermosetting resin Together with the attachment of the sheet, it has excellent dimensional stability and shape retention, can supply the product at low cost, and is lightweight, so that it has many useful effects such as easy handling when mounted in a vehicle.

[Brief description of the drawings]

FIG. 1 shows an embodiment of the present invention. FIG. 1 is a manufacturing flow sheet shown for explaining a method for manufacturing an automobile lining material according to the present invention, and FIG. 2 is a manufacturing flow sheet for an automobile lining material. FIG. 3 is an exploded perspective view showing the laminated state, FIG. 3 is an enlarged view showing a part of the automobile lining material in section, FIG. 4 is a sectional view of the deep drawing portion, and FIG. It is a diagram showing the sound absorption characteristics. 6,6 ... Sheet, P ... Thermosetting resin, F ... Semi-rigid polyurethane foam.

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Claims (3)

(57) [Claims] 1. An eye such as a glass fiber mat formed by adhering foamable thermosetting resin on both front and back surfaces of a thermoformable semi-rigid polyurethane foam having open cells and by interlacing gauze or glass fiber in a net shape. A lining material for an automobile having elasticity, which is obtained by sticking a rough sheet and performing heat compression molding at a predetermined temperature to foam and cure the thermosetting resin to form a desired shape. 2. A thermoformable semi-rigid polyurethane foam having open cells is sprayed or applied with a foamable thermosetting resin on both front and back surfaces to heat the thermosetting resin to a semi-molten state, and then the front and back surfaces. A rough sheet such as a glass fiber mat formed by interlacing a gauze or glass fiber on both sides is attached, and then heat compression molding is performed to cure the semi-rigid polyurethane foam and foam cure the thermosetting resin. A method of manufacturing an automobile lining material having elasticity so as to be molded into a desired shape. 3. The elastic automobile for automobiles according to claim 2, wherein sheets are attached to both front and back surfaces of the semi-rigid polyurethane foam, and then a skin material such as a non-woven fabric is polymerized and thermocompression-molded integrally on one surface. Method of manufacturing liner.