JP5249632B2 - Method for manufacturing vehicle ceiling material - Google Patents

Description

The present invention relates to a method for producing a vehicle ceiling material that can be suitably used, for example, as a ceiling material for automobiles and can exhibit good deodorizing properties.

  Conventionally, so-called deodorizing ceilings that exhibit a deodorizing function for removing odors in the passenger compartment are known as ceiling materials for automobiles. Specifically, a deodorant layer is formed by applying a scratch-preventing acrylic resin to which a deodorant is added to the surface of a surface material such as a polyester nonwoven fabric constituting the ceiling material. And the odor component is adsorbed and decomposed or chemically decomposed (oxidative decomposition) by the deodorant layer. However, in this automotive ceiling material, since the deodorant layer is formed on the surface of the surface material, the surface material is discolored or faded by the deodorant constituting the deodorant layer, or the deodorant There was a problem that the deodorant was easily volatilized from the layer, and clouding (fogging) occurred on the inner surface of the windshield or the like.

Then, the surface material for motor vehicle interior which formed the layer containing a deodorizer inside a skin material is proposed (for example, refer patent document 1). That is, a function-imparting agent layer is formed on the front part of each small bulge of the wadding material in which the tip of the filament bundle is formed as a small bulge between the front and back surfaces of the fiber web, and the function-imparting agent layer This is a surface material for automobile interior in which a skin material is bonded and integrated by a point-like bonded portion. According to this automotive interior surface material, a small amount of adhesive has sufficient adhesive strength, and an excellent texture can be obtained.
JP-A-8-289986 (2nd page, 3rd page and FIG. 1)

  However, in the automotive interior surface material described in Patent Document 1, since the function-imparting agent layer and the adhesive portion are provided in a dot shape so as not to impair the texture, they are included in the function-imparting agent layer. The deodorizing effect based on the deodorant could not be expressed satisfactorily.

  Moreover, when manufacturing the surface material for automobile interiors, a small ridge protruding from the surface must be formed between the front and back surfaces of the fiber web by needle stab processing, and a function-imparting agent layer is further formed on the small bulge portion. And a point-like adhesive portion must be formed thereon. For this reason, the manufacturing process of the surface material for automobile interiors is complicated, time is required for manufacturing, and production efficiency is poor.

Accordingly, an object of the present invention is to provide a method for manufacturing a vehicle ceiling material that can exhibit a better deodorizing effect than conventional ones and has high production efficiency.

In order to achieve the above object, a method for manufacturing a vehicle ceiling material according to claim 1 is characterized in that a reinforcing material layer that reinforces the base material is laminated on the base material formed by a polyurethane foam constituting the ceiling material. A method for producing a vehicle ceiling material provided with a surface material thereon, wherein the polyurethane foam of the base material is impregnated with polyisocyanate as an adhesive, a reinforcing material layer is laminated on the base material, On the reinforcing material layer, a deodorant aqueous solution diluted with an aqueous catalyst solution for promoting the reaction of polyisocyanate is applied, and then hot press molding is performed.

The method for manufacturing a vehicle ceiling material according to claim 2 is the invention according to claim 1, wherein the base material is formed of a soft polyurethane foam, and the reinforcing material layer is formed of a glass fiber layer and a nonwoven fabric layer thereon. A deodorant diluted with an aqueous catalyst solution is applied on the nonwoven fabric layer .

The method for manufacturing a vehicle ceiling material according to claim 3 is the invention according to claim 1 , wherein the base material is formed of a rigid polyurethane foam, the reinforcing material layer is formed of a glass fiber layer, and the glass fiber layer The deodorizer diluted with the catalyst aqueous solution is applied on the top.

According to the present invention, the following effects can be exhibited.
In the method for producing a vehicle ceiling material according to claim 1, a polyurethane foam as a base material is impregnated with polyisocyanate as an adhesive, a reinforcing material layer is laminated on the base material, and the polyisocyanate is formed on the reinforcing material layer. After applying the diluted deodorant aqueous solution to the aqueous catalyst solution that promotes the reaction, the hot press molding is performed. For this reason, it is only necessary to add a step of applying a deodorant aqueous solution in the conventional manufacturing process, and the deodorant is applied simultaneously with the catalyst aqueous solution application step, and it is necessary to add a new deodorant application step. There is no. Therefore, it is possible to manufacture a vehicle ceiling material that exhibits a better deodorizing effect than conventional ones with high production efficiency. Furthermore, since the deodorant is diluted with the catalyst aqueous solution, it can be evenly disposed on the ceiling material, and the deodorant function based on the deodorant can be sufficiently exhibited.

3. The method of manufacturing a vehicle ceiling material according to claim 2, wherein the base material is formed of a soft polyurethane foam, the reinforcing material layer is constituted by a glass fiber layer and a non-woven fabric layer thereon, and a catalyst aqueous solution is formed on the non-woven fabric layer. The deodorant diluted with is applied. Therefore, in addition to the effect of the invention according to claim 5, it is possible to prevent the adhesive from oozing out to the front side of the surface material, so that the appearance of the surface material is not deteriorated, and the sound absorption can be enhanced by the nonwoven fabric layer.

In the method for manufacturing a vehicle ceiling material according to claim 3 , the base material is formed of a rigid polyurethane foam, the reinforcing material layer is formed of a glass fiber layer, and the glass fiber layer is deodorized diluted with an aqueous catalyst solution. The agent is applied. Therefore, in addition to the effect of the invention according to claim 5, the adhesive between the base material and the glass fiber layer can be improved by the adhesive and its catalyst, and further the adhesiveness with the surface material can be improved. it can.

In the following, embodiments that are considered to be the best of the present invention will be described in detail.
First, the vehicle ceiling material will be described. As shown in FIG. 1 (a), a vehicular ceiling material 10 is a glass as a reinforcing material layer that reinforces the base material 11 on both surfaces of the base material 11 that constitutes the ceiling material and is formed from a rigid polyurethane foam. A fiber mat 12 is laminated, a deodorant is applied on the glass fiber mat 12 on the surface side (indoor side), and a surface material 14 is provided on the glass fiber mat 12. The deodorizer is diluted with an aqueous catalyst solution that promotes the reaction of polyisocyanate as an adhesive, and is uniformly disposed between the glass fiber mat 12 and the surface material 14. For this reason, the deodorizing function based on a deodorant can fully be expressed compared with the case where it is provided in the conventional dot shape.

  Moreover, as shown in FIG.1 (b), the ceiling material 10 for vehicles has laminated | stacked the glass fiber layer 15 on both surfaces of the base material 11 which comprises the ceiling material and was formed from the soft polyurethane foam, The surface side A nonwoven fabric layer 16 is formed on the glass fiber layer 15, a deodorant is applied on the nonwoven fabric layer 16, and a surface material 14 is provided on the nonwoven fabric layer 16. In this case, the glass fiber layer 15 and the nonwoven fabric layer 16 constitute a reinforcing material layer. The deodorant is uniformly disposed between the nonwoven fabric layer 16 and the surface material 14. A back material 13 is provided on the glass fiber layer 15 on the back side.

  The hard polyurethane foam constituting the substrate 11 generally means a foam having a closed cell structure in which cells (bubbles) are independent, plastically deforming with respect to compressive force, and having no resilience. Therefore, since the hard polyurethane foam has a higher hardness than the soft polyurethane foam, the amount of the curing agent (adhesive) used in molding the vehicle ceiling material can be reduced. On the other hand, the flexible polyurethane foam is lightweight, generally has an open cell structure in which cells communicate, is flexible, and has a restoring property. Accordingly, such a flexible polyurethane foam is suitable for forming a deep drawing shape or the like because of its good formability when the vehicle ceiling material 10 is formed.

The glass fiber mat 12 shown in FIG. 1A is formed by cutting a roving glass in which glass fibers are bundled and depositing them in a sheet shape. Similarly, the glass fiber layer 15 shown in FIG. 1B is formed by cutting the roving glass, spreading it on the substrate 11, and hardening it with an adhesive. Moreover, the nonwoven fabric which forms the nonwoven fabric layer 16 is a spun bond nonwoven fabric. The spunbonded nonwoven fabric is obtained by heating, melting and spinning a resin having a low melting temperature such as polypropylene, polyester, and polyamide, forming a web by superimposing the obtained long fibers, and heat-sealing with a hot roll. Is. Basis weight of the spunbonded nonwoven fabric is about 10 to 30 g / ^{m 2.}

  The polyurethane foam of the base material 11 is impregnated with, for example, polyisocyanate as an adhesive, and by adding a catalyst that promotes curing of the adhesive with heating to the adhesive, the base material 11 and the reinforcing material layer, The surface material 14 is bonded. The adhesive is cured by reacting with moisture. For example, in addition to 4,4-diphenylmethane diisocyanate (MDI) based adhesive, an isocyanate group obtained by reacting an excess amount of polyisocyanate and polyol. Urethane prepolymers having the following are used. In addition to an amine catalyst such as triethylamine, stannic chloride, ammonium chloride, or the like can be used as a catalyst for promoting the curing of the adhesive. As the polyisocyanate, 4,4-diphenylmethane diisocyanate (MDI) excellent in adhesion performance is preferable, and as the catalyst, an amine catalyst excellent in curing acceleration is preferable. Since the adhesive cures by reacting with moisture, the catalyst is used as an aqueous solution dissolved in water. Therefore, amine water in which an amine catalyst is dissolved in water is preferably used.

  The deodorant is not particularly limited, and examples thereof include amine compounds such as carbodidihydrazide and polyvinylamine, compounds having an acid anhydride group, compounds having a metal complex, and the like. This deodorant is an odorless component that reacts with odorous components such as formaldehyde and acetaldehyde, aldehydes such as acetaldehyde, acids such as ammonia and acetic acid, amines, sulfur compounds, etc. To change. As the deodorant, an amine compound that is excellent in the deodorizing effect of aldehydes and ammonia is preferable when considering a ceiling material for automobiles. The deodorant is diluted with a catalyst aqueous solution of the adhesive, adjusted to a predetermined concentration, and applied onto the reinforcing material layer. Thus, since the catalyst of an adhesive agent is used as a diluent for the deodorant, the deodorant can be applied efficiently.

The surface material 14 is formed of a knitted fabric, a woven fabric, a non-woven fabric, or the like, and is a breathable sheet material that allows gas such as odor to pass through.
Next, the manufacturing method of the vehicle ceiling material 10 described above will be described.

First, the case where the base material 11 is a rigid polyurethane foam is demonstrated. In this case, the vehicle ceiling material 10 is manufactured by batch operation. As shown in FIG. 2, a base material 11 having a predetermined size is impregnated with an adhesive in advance, and a laminate in which glass fiber mats 12 are laminated on both sides thereof is placed on a belt 18 of a conveyor 17 and conveyed. . Then, on the glass fiber mat 12 on the surface side of the base material 11, the catalyst aqueous solution is supplied from the nozzles 19 a of a plurality (two in this embodiment) of the deodorant spray devices 19 disposed above the conveyor 17. The diluted deodorant aqueous solution 20 is applied by spraying. The application amount of the deodorant aqueous solution 20 is, for example, 20 to 30 g / m ² . At this time, the deodorant aqueous solution 20 is uniformly sprayed over the entire surface of the glass fiber mat 12 because the deodorant is diluted with the catalyst aqueous solution and has a low viscosity at a predetermined concentration.

  Subsequently, on the glass fiber mat 12, the surface material roller 21 is disposed on the front side of the deodorant spray device 19 above the conveyor 17 and wound with the surface material 14, via the guide roller 22. A surface material 14 is supplied. The laminate 23 thus obtained is transferred between the lower mold 25 and the upper mold 26 of the hot press molding apparatus 24. In this state, the upper die 26 is lowered with respect to the lower die 25 and clamped, and press molding is performed by heating at a predetermined temperature for a predetermined time according to a conventional method. The lower mold 25 is formed with a molding concave portion 25a, and the upper mold 26 is provided with a molding convex portion 26a corresponding to the molding concave portion 25a so that the vehicle ceiling material 10 having a predetermined shape is molded. It has become.

  Next, the case where the base material 11 is a soft polyurethane foam is demonstrated. In this case, the vehicle ceiling material 10 is manufactured by continuous operation. As shown in FIG. 3, a glass fiber layer 15 formed by spreading roving glass cut on the surface side of a base material 11 preliminarily impregnated with an adhesive, and a back material 13 on the back side of the base material 11 A glass fiber layer 15 formed by spreading the cut roving glass is laminated on the base material 11 side of the back material 13. On the glass fiber layer 15 on the front surface side, a catalyst aqueous solution 28 is spray-applied from a nozzle 27a of a catalyst aqueous solution spray device 27 disposed above the glass fiber layer 15. Next, the spunbond nonwoven fabric 29 is disposed on the upper side through the first guide roller 31 and the pair of upper and lower squeezing rollers 32 from the nonwoven fabric roller 30 around which the spunbond nonwoven fabric 29 is wound. Supplied on top. Thus, the nonwoven fabric layer 16 is laminated | stacked through the glass fiber layer 15 on the surface side of the base material 11, and the laminated body 33 formed in predetermined thickness is obtained.

  Subsequently, the obtained laminated body 33 is guided in a V shape as shown in FIG. 3 by the second guide roller 34 and the third guide roller 35. On the nonwoven fabric layer 16 of the laminated body 33, the deodorant aqueous solution diluted with the catalyst from the deodorant spray device 19 disposed in a direction perpendicular to the laminated body 33 at a position close to the pair of squeezing rollers 32. 20 is sprayed. At this time, the deodorant aqueous solution 20 is uniformly applied over the entire surface of the nonwoven fabric layer 16 because the deodorant is diluted with a catalyst and has a reduced viscosity at a predetermined concentration.

  Thereafter, on the nonwoven fabric layer 16, the surface material roller 36 around which the surface material 14 is wound and disposed on the front side of the third guide roller 35 above the laminated body 33 is interposed via the fifth guide roller 37. A surface material 14 is supplied. The laminated body 40 thus obtained is continuously supplied between the lower mold 25 and the upper mold 26 of the hot press molding apparatus 24. In this state, the upper die 26 is lowered with respect to the lower die 25 and clamped, and press molding is performed by heating at a predetermined temperature for a predetermined time according to a conventional method. Although FIG. 3 is schematically drawn, the laminates 33 and 40 are continuously formed, and are supplied between the lower mold 25 and the upper mold 26 of the hot press molding apparatus 24 in a continuous state. Is done.

The effects exhibited by the above embodiment will be described collectively below.
In the vehicle ceiling material 10 of the present embodiment, the polyurethane foam of the base material 11 is impregnated with polyisocyanate as an adhesive, and the deodorant is diluted with an aqueous catalyst solution that promotes the reaction of the polyisocyanate to be reinforced. It is formed by applying on the material layer. For this reason, while being able to improve the adhesiveness between the base material 11 and a reinforcement material layer with an adhesive agent and a catalyst, the adhesiveness of the surface material 14 can also be improved. Furthermore, the deodorant can be applied efficiently, and the deodorant can be disposed uniformly. Therefore, the deodorizing function based on a deodorant can fully be exhibited compared with the case where it is provided in the conventional dot shape. That is, an odor component (gas) such as an odor due to cigarettes or an odor at the time of a new car is sewed and permeated between the surface materials 14, and is sufficiently brought into contact with the deodorant to exert an odor eliminating effect. Therefore, the vehicular ceiling member 10 can exhibit a better deodorizing effect than before.

  The polyisocyanate is 4,4-diphenylmethane diisocyanate (MDI) and the catalyst is an amine catalyst. Therefore, the adhesion between the base material 11 and the reinforcing material layer can be quickly performed, and the adhesive strength can be improved.

  The base material 11 is formed of a soft polyurethane foam, and the reinforcing material layer is composed of a glass fiber layer 15 and a nonwoven fabric layer 16 thereon, and the deodorant diluted with a catalyst aqueous solution on the nonwoven fabric layer 16. The agent is applied. For this reason, it is possible to prevent the adhesive from oozing out to the front side of the surface material 14, to prevent the appearance of the surface material 14 from being deteriorated, and to improve sound absorption by the nonwoven fabric layer 16.

  The base material 11 is formed of a hard polyurethane foam, and the reinforcing material layer is composed of a glass fiber mat 12, and a deodorant diluted with an aqueous catalyst solution is applied on the glass fiber mat 12. Therefore, the adhesiveness between the base material 11 and the glass fiber mat 12 can be improved by the adhesive and its catalyst, and the adhesiveness with the surface material 14 can also be improved. Furthermore, the deodorant can be applied efficiently, and the deodorant can be disposed uniformly. In addition, the reinforcing performance of the reinforcing material layer can be improved by the glass fiber mat 12.

  In the method for manufacturing the vehicle ceiling material 10, the polyurethane foam of the base material 11 is impregnated with polyisocyanate, a reinforcing material layer is laminated on the base material 11, and the reinforcing material layer is diluted with an aqueous catalyst solution. After spraying a deodorant aqueous solution, it is subjected to hot press molding. For this reason, the deodorant is applied simultaneously with the catalyst aqueous solution application step in the conventional manufacturing process, and it is not necessary to add a new deodorant application step. Moreover, even when a nonwoven fabric is added to the reinforcing material, it is only necessary to add a process of applying the deodorant aqueous solution on the molding line. Therefore, the vehicular ceiling member 10 having a better deodorizing effect than the conventional one can be manufactured with high production efficiency, and the manufacturing cost can be reduced. Furthermore, since the deodorizer is diluted with the catalyst aqueous solution, it can be evenly disposed on the vehicle ceiling material 10 and the deodorant function based on the deodorizer can be sufficiently exhibited. In addition, by spraying the deodorant aqueous solution 20 and immediately press-molding it, it is possible to omit the long drying process as in the prior art, leading to a reduction in drying equipment and a reduction in manufacturing costs. it can.

In addition, this embodiment can also be changed and embodied as follows.
In FIG. 3, spray application of the deodorant aqueous solution 20 onto the nonwoven fabric layer 16 is not limited to any position between the pair of squeezing rollers 32 and the third guide roller 35, and the squeezing roller 32 and the nonwoven fabric roller. You may apply | coat to the nonwoven fabric 29 between 30. That is, the deodorant spray device 19 is disposed so as to be substantially orthogonal to the laminate 33 or the nonwoven fabric 29 at a position from the squeezing roller 32 to the third guide roller 35 or a position from the squeezing roller 32 to the nonwoven fabric roller 30. The deodorant aqueous solution 20 can be sprayed onto the laminate 33 or the nonwoven fabric 29 from the deodorant spray device 19.

A semi-rigid polyurethane foam can also be used as the polyurethane foam forming the substrate 11.
O On the glass fiber mat 12 and the nonwoven fabric layer 16, a water-repellent or oil-repellent treatment is performed with a fluororesin, a silicone resin, or the like so that the adhesive impregnated in the base material 11 is prevented from soaking into the surface material 14 It is also possible to configure.

  As said adhesive, tolylene diisocyanate (TDI), xylylene diisocyanate (XDI), 1,5-naphthalene diisocyanate (NDI), etc. can also be used.

The vehicle ceiling material 10 is used as a ceiling material for vehicles such as buses, trucks, and trains in addition to passenger cars .

(A) And (b) is sectional drawing which shows the ceiling material for vehicles, (a) is sectional drawing at the time of using a rigid polyurethane foam as a base material, (b) is a flexible polyurethane foam as a base material. Sectional drawing when used. Explanatory drawing which shows typically the manufacturing apparatus of the ceiling material for vehicles in case a base material is a rigid polyurethane foam. Explanatory drawing which shows typically the manufacturing apparatus of the ceiling material for vehicles in case a base material is a flexible polyurethane foam.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Vehicle ceiling material, 11 ... Base material, 12 ... Glass fiber mat as a reinforcing material layer, 14 ... Surface material, 15 ... Glass fiber layer as a reinforcing material layer, 16 ... Nonwoven fabric layer as a reinforcing material layer, 20 ... deodorant aqueous solution, 28 ... catalyst aqueous solution.

Claims (3)

A method of manufacturing a vehicle ceiling material in which a reinforcing material layer for reinforcing the base material is laminated on a base material formed of a polyurethane foam constituting the ceiling material, and a surface material is provided thereon,
Polyurethane foam of the base material is impregnated with polyisocyanate as an adhesive, a reinforcing material layer is laminated on the base material, and an aqueous solution diluted with an aqueous catalyst solution that promotes the reaction of polyisocyanate is formed on the reinforcing material layer. A method for manufacturing a ceiling material for a vehicle, comprising applying a odorant aqueous solution and then heat press molding. The base material is formed of a flexible polyurethane foam, and the reinforcing material layer is composed of a glass fiber layer and a non-woven fabric layer thereon, and a deodorant diluted with an aqueous catalyst solution is applied on the non-woven fabric layer. The manufacturing method of the ceiling material for vehicles of Claim 1 characterized by the above-mentioned. The base material is formed of a rigid polyurethane foam, the reinforcing material layer is formed of a glass fiber layer, and a deodorant diluted with an aqueous catalyst solution is applied on the glass fiber layer. The manufacturing method of the ceiling material for vehicles of Claim 1 to do.

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