JP2710004B2 - Automotive interior molding material and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a low-cost automotive interior molding material having excellent properties such as light weight, rigidity, sound absorption, dimensional stability, and recyclability, and a method for producing the same.

[0002] The interior molding material according to the present invention can be widely used for molded ceilings, door trims, rear packages, rear parcels, trunk rooms, dashboards and the like of automobiles.

[0003]

2. Description of the Related Art The recent automobile industry is also focusing on environmental issues.
There is a demand for lightweight and rigid materials that are recyclable.

Conventionally, as a base material for forming interior parts, a wide variety of materials such as waste felt, pulp, glass wool, wood board, and plastic foam have been used. In addition, it was necessary to increase the weight per unit area (weight per square meter), which inevitably increased the cost and made the product heavy.

[0005]

DISCLOSURE OF THE INVENTION The present invention has improved the disadvantages of the conventional molding base which are heavy and cannot be regenerated,
It is an object of the present invention to provide a low-cost base material that is light, strong, and easy to work with a composite material configuration, and a method for manufacturing the same.

[0006]

Means for Solving the Problems The interior molding material for automobiles of the present invention comprises a surface of a substrate obtained by impregnating a resin into a nonwoven fabric made of vegetable fiber.
Composed of PVA woven fabric of synthetic fiber as reinforcing material
It is intended to provide an automotive interior molded material.

In the present invention, a material composed of palm fiber, coconut fiber or hemp fiber is used as the base material.

[0008] Palm fiber, coconut fiber or hemp fiber has a length of 100 to 300 mm and a thickness of 0.2 to 1.5 mm.
It is preferred to use In the substrate, these fibers are entangled non-directionally and have a substrate density of 50 to 1,
Plate thickness 2-10m to be 500kg / cubic meter
Preferably, it is compressed to m.

Further , it is preferable that these fibers are bonded at the intersection of the fibers with an adhesive.

As the adhesive, a powdery adhesive and a liquid adhesive are used, and in consideration of impregnation, a liquid adhesive which can be uniformly impregnated is preferable.
0-100% is preferred.

[0011] Palm fiber, coconut fiber or hemp fiber has flammability. However, when a thermosetting resin adhesive or a thermoplastic resin adhesive is used as a resin impregnated in these plant fibers, self-extinguishing is included in the adhesive. Materials can be blended, and the base material can be made flame-retardant.

In terms of formability, there is no difference in properties between palm fiber, coconut fiber and hemp fiber in terms of shape stability and flexibility.

[0013] Table 1 shows a comparison of the performance of a substrate made of palm fiber, coconut fiber or hemp fiber and a conventionally used substrate.

In the table, ○ indicates good, Δ indicates acceptable, and × indicates unacceptable.

[0015]

[Table 1] PVA fabric has low elongation, is lightweight and has excellent strength.
The construction method is also simple and preferable.

A surface material layer may be provided on the fiber reinforcing material layer to smooth the surface of the molding base material. As the surface material in this case, a fluororesin film, a urethane foam sheet, a polyester film, or the like is used. A foamed urethane sheet having a thickness of 2 to 8 mm is preferable in consideration of moldability and mold release properties. If a polyester film is used according to the purpose of use, a molded part substrate having no air permeability can be obtained.

Further, the present invention is palm fiber, a substrate made of coconut fibers or hemp fibers, a liquid or powdered thermosetting resin adhesive or a thermoplastic resin adhesive is coated impregnated, thereon The present invention also provides a method for producing an automotive interior molding material, which comprises laminating PVA fabrics and hot-press molding.

The interior molding material for an automobile of the present invention can be suitably produced by the following method.

[0019] First of all, palm, coconut, or a hemp fiber raw materials by the fiberizer to fibrillation. The defibration is suitably performed by crushing a raw material of palm or coconut fruit or hemp fiber with a crusher and then using a defibrator to take out fibers around the fruit.

[0020] Then, to the resulting fibers in the sheet form impregnated with a thermosetting or thermoplastic resin binder. Immediately
Lethal over preparative like fiber, uniformly impregnated with 10-100% of the thermosetting resin adhesive Weight. At this time, the liquid thermosetting resin adhesive is diluted with a solvent such as water or alcohol so that the weight ratio of the thermosetting resin adhesive and the solvent is 1: 1 to 1: 3, and the sheet-like fiber is formed. Is preferably impregnated.

As a method of impregnation, usually, a method of spraying and impregnating a diluted thermosetting resin adhesive with high-pressure air from the upper and lower surfaces of the sheet is preferably used. In the case of a powdery adhesive, it is preferable to mix them at the time of fiber opening.

From the upper and lower surfaces of the obtained fiber sheet,
Spraying a liquid thermosetting resin adhesive diluted with high-pressure air and applying a PVA fabric on the bare or one or both surfaces of the impregnated base material and performing hot pressing, the liquid impregnated in the base material The thermosetting adhesive permeates and adheres to the PVA fabric, and a molded base material for interior parts having sufficient rigidity is obtained.

[0023] At this time, liquid thermosetting resin adhesive to improve the permeability, water-soluble liquid thermosetting or thermoplastic resin adhesive by water, also liquid thermosetting resin adhesive alcohol soluble It is preferable to dilute each with an alcohol to adhere to and impregnate the fiber reinforcing agent.

The dilution ratio is water in the case of a water-soluble liquid thermosetting resin adhesive, and alcohol in the case of an alcohol-soluble liquid thermosetting resin adhesive.
The ratio is preferably set to 1: 1 so that the solid content of the liquid thermosetting resin adhesive is 10 to 100% by weight with respect to the fiber base material.

Next, by thermal molding overlapping a surface material such as urethane foam sheet on top of the PVA fabric. The surface material layer has an effect of eliminating irregularities on the surface of the obtained interior component molding base material and facilitating release of the molding die from the molded product. In addition, by using a flame-retardant urethane foam sheet, the flame retardant standard of MVSS-302 can be satisfied.

The molding conditions are as follows :
It is preferable to heat and press for 3 minutes. In this way, a lightweight, flexible and excellent rigid base material for automobile interior parts can be obtained.

[0027]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to embodiments shown in the drawings, but the present invention is not limited thereto.

FIG . 1 is a perspective view showing a cross section of a state where a PVA woven fabric is bonded to a base material, wherein 1 is a base material and 2 is a PVA woven fabric.

The fibrillating the destination Dzu palm or fiberizer a hemp fiber material, palm fibers or hemp fibers obtained, the weight ratio of 1: 1 fiber a liquid thermosetting resin adhesive diluted by adding water It is impregnated with a spray at a weight ratio of 0.2 to 1 and compressed to obtain a palm fiber base and a hemp fiber base.

At this time, compression is performed by a hot press
C. for 90 seconds.

[0031] Next, as shown in Table 2, basis weight of 500g
(Example 1) A PVA fabric is laminated on both front and back surfaces of each resin-impregnated palm fiber base material of 700 g (Example 2) and 800 g (Example 3) via a binder, and is placed at 170 ° C. for 2 minutes.
3mm thick by hot pressing at kgf / square centimeter
A molded base material for automobile interior parts was obtained. The weight ratio of each binder to the material is 1: 0.25.

[0032] A product weight and bending strength of this compound in Table 2.

[0033]

By adhering a 10-20 μm polyester film to the surface of the PVA fabric, an air-impermeable molding substrate for interior parts to which dirt was not adsorbed was obtained.

[0034] Table 3 is a table of physical properties of the case the plant fibers of hemp.

In Table 3, Examples 4, 5 and 6 show that the basis weight of the resin-impregnated hemp fiber base material is 500 g, 70 g, respectively.
0 g and 800 g.

[0036]

FIGS. 2 and 3 are tables showing the bending strengths of Tables 1 and 2, respectively.

From these figures, it can be seen that the heavier the weight of the product, the higher the bending strength.

Further, when a product such as a molded ceiling is assembled into a line, the product may be broken only with rigidity. On the other hand, palm and coconut fibers have a larger fiber diameter, and thus have a better flexural rigidity than hemp.

Next, the resin-impregnated palm fiber or molding substrate obtained by heat pressure molding superposed PVA fabric on the front and back of the hemp fiber substrate thickness (mm) and the bending strength of the product (kg / Table 4 shows the relationship with the distance of 50 mm).

[0040]

Table 4 shows comparative data obtained by measuring the strength of a bare palm felt product of the present invention obtained by impregnating a resin into a nonwoven fabric of a palm fiber and hot-pressing the same, and a conventional bare glass wool while changing the basis weight. (The test measuring machine is TENSILON
VTM1-2500).

[0041]

Table 5 shows that palm fiber is not inferior to glass wool in strength.

[0042] naked products such as palm is suitable for the door around the interior moldings of the car, the front and back to that piled up PVA fabric is suitable for interior moldings that require the strength of the ceiling or the like.

[0043]

In summary, according to the present invention, a nonwoven fabric of plant fibers such as palm, coconut or hemp is molded with a resin-impregnated base material, which is lightweight.

Further, these plant fibers are entangled non-directionally when formed into a non-woven fabric, and are polymerized with a PVA fabric, so that the flexibility and rigidity of the plant fibers are increased as a whole.

[0045] Further raw vegetable fibers cheaper cost because easy spontaneous or cultivated, superior as they are easy to manufacture because easily impregnated with resin, yet does not contaminate the combustion possible waste can easily incinerated environmental It has the effect.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a cross section of a part of an automotive interior molding material embodying the present invention.

FIG. 2 is a table showing the relationship between product weight and bending strength of Examples 1, 2, and 3 in which a PVA fabric is attached to the front and back of palm fiber. In the data plots in the charts, open circles represent Example 1, black circles represent Example 2, and triangles represent Example 3.

FIG. 3 is a table showing the relationship between the product weight and the bending strength of Examples 4, 5 and 6 in which a PVA fabric is bonded to the front and back of hemp fiber. In the data plots in the charts, open circles represent Example 4, black circles represent Example 5, and triangles represent Example 6.

[Explanation of symbols]

 1 base material 2 PVA fabric

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification number Agency reference number FI Technical display location // B29K 29:00 B29L 31:58

Claims (2)

(57) [Claims] 1. An interior molding material for automobiles wherein a PVA woven fabric is polymerized on a surface of a substrate obtained by impregnating a resin into a nonwoven fabric made of vegetable fiber . 2. A preparation of automobile interior molding material, characterized in that the heat pressure molded superimposed PVA fabric to the surface of the plant fiber nonwoven fabric in a thermosetting or thermoplastic resin-based adhesive base material impregnated with Method.