JPH01280552A - Moulding of panel board - Google Patents

Abstract

PURPOSE:To obtain a light panel board which is excellent in rigidity, heat insulation, noise absorption, and thermal moisture resistance and can be deeply drawable, by a method wherein a polyol component and an isocyanate component are discharged on a moisture nonpermeable film by making the isocyanate component react excessively under a presence of water and an organic foaming agent, a nonwoven fabric is pressed and then, this laminated material is brought into contact with water to be heated. CONSTITUTION:When a polyol component is made to react on an isocyanate component under a presence of either or both of water and organic foaming agent of monochloro trichloromethane or the like, they are made to react under a state in which the isocyanate component exists more excessively than a reaction equivalent and foam is generated. When it is used as a foam raw material and foaming and moulding are successively in a panel form performed on double conveyors, a moisture non-permeable film 2 is laid on the conveyor, and a cream 3, stirring mixing liquid, is made to flow uniformly from above the conveyor traversing it to be moulded into a continuous block form of a low foaming height. Further at a time when some tack remains on an upper surface of this block, a continuous panel board of a controlled thickness of which both surfaces are covered by the moisture non- permeable film and the nonwoven fabric can be moulded by compressing above-mentioned continuous block on the conveyor via the nonwoven fabric 6.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is a molded ceiling material for automobiles. It is a lightweight panel board that can be suitably used for door panels, etc. and has excellent rigidity, heat insulation properties, sound absorption properties, and moisture resistance properties. It is about the method.

[Prior Art] In recent years, interior materials such as molded ceiling materials and door panels for automobiles have tended to use rigid or semi-rigid plastic foam as a base material in view of weight reduction, sound absorption, and heat insulation properties.

As such materials, rigid or semi-rigid foams such as urethane foam and phenol foam made by stage foaming have been known, and these are generally produced in the form of blocks, which are then cut out. When molding, cracks occur during press molding.

This had the disadvantage that it could not be followed particularly by deep drawing because cracks etc. occurred.

In order to solve this problem, there is a method of pouring these foaming stock solutions into a mold and foaming and hardening them in the mold, but according to this method, when filling a gap of 8 to 10 mm, There is a problem with the flowability of the foaming liquid, which not only causes problems with moldability such as poor surface conditions during molding, but also increases the density of the surface of the molded product, which increases the overall weight of the product. This method has some problems, such as difficulty in forming a composite surface material.

Furthermore, recently, flexible porous materials (
A method in which A) is impregnated with the isocyanate component (B) and then reacted with water to form a network (Japanese Patent Publication No. 61-5154
4, USP44S1310, Special Publication No. 57-22013,
JP-A-58-'d46) has been proposed, but this method also has problems in that the impregnation step with the inocyanate component (B) deteriorates the working environment, and when (A) is a soft urethane foam, the isocyanate component (B) is impregnated with the isocyanate component (B). Not only does impregnation cause (A) to become wet and the foam strength decreases, causing problems in workability and dimensional stability, but the amount of isocyanate component (B) impregnated must be increased in order to obtain the final strength of the cured foam. Not,
As a result, there was a disadvantage that the weight increased.

Moreover, this mold hardening mechanism is based on the constituent materials (A) and (B).
) are separate components that do not react chemically and are simply physical composites. Therefore, the flexibility required for moldability depends on the separately completed porous body (A), and the isocyanate component (B
) uniquely reacts with water and hardens, so the final product can be thought of as a physical composite of a flexible material (A) and a hard material.

Furthermore, in conventional technology, when forming final products such as molded ceiling materials and door panels by press molding in a mold with a complex pattern, the skin material, glass fiber reinforcement material, foam core material, non-woven material, etc. A backing material such as, and a material such as an adhesive coating or a hot melt adhesive sheet were used to fix these together. This requires an extremely complicated lamination process, which poses major problems in terms of work efficiency and work environment (i.e., scattering of glass fiber powder, environmental pollution caused by solvents when using adhesives, etc.).

[Problems to be Solved by the Invention] The present invention solves the problems in the conventional method, and provides a lightweight, rigid, heat-insulating, sound-absorbing, and moisture-heat resistant material that can be suitably used for automobile molded ceiling materials, door panels, etc. A method for forming panel boards that can produce panel boards that do not crack or break even during deep drawing using an extremely simplified process and with excellent work safety and quality stability. The purpose is to provide

[Means for Solving the Problems] As a result of intensive studies in order to solve the above problems, the present inventors have found that the polyol component and the isocyanate component are mixed with either water or an organic blowing agent such as monochloro or trifluoromethane. When the reaction is carried out in the presence of one or both of the isocyanate components in excess of the reaction equivalent, the resulting foam is substantially thermoplastic, and the foam is free from water or They discovered that when heated with water vapor, unreacted isocyanate reacts with water and hardens, resulting in a hard or semi-hard foam that no longer softens even when heated. They used this as a foam material pigment and transferred the foam material pigment to a double conveyor. When continuously foaming and forming panels into panels, a moisture-impermeable film is laid on the conveyor, and the cream, which is the stirred and mixed liquid, is flowed uniformly over the film while traversing, resulting in continuous foaming with a low foaming height. When molded into a block, there is no contamination of the conveyor due to penetration of the pigment cream, healthy foam is generated as the foam is communicated, and it becomes a stable continuous foam.Furthermore, when there is some tack left on the top of the block, the conveyor is not contaminated by penetration of the pigment cream. We have discovered that by compressing the above continuous block on a conveyor, it is possible to form a continuous panel board with controlled wall thickness, both sides covered with moisture-impermeable film and nonwoven fabric.

In the present invention, a moisture-impermeable film is laid on the conveyor when the foam material pigment is continuously foam-molded into a panel shape on a double conveyor, but a glass fiber nonwoven fabric may be further laid on the moisture-impermeable film. By traversing and uniformly pouring the stirred mixed liquid cream over this mixture and forming it into a continuous block with a low foaming height, there is no contamination of the conveyor due to penetration of the jXX cream, and the laid glass fiber nonwoven fabric is placed in the center of the block. It becomes an intervening state.

The material obtained by cutting such continuous panel material is a rigid and stable plate-shaped molded product, but it has thermoplasticity that quickly softens when heated to 100°C or more, and it also has a thermoplastic property that quickly softens when heated above 100°C. It was also confirmed that this thermoplasticity changes to thermosetting property when heated in the presence of water vapor.

That is, by simply heat-press molding this continuous panel material and skin material in the presence of water or steam, final products such as molded ceiling materials, door panels, etc. can be molded in extremely good and simple steps.

It is important that the polyurethane resin foam or polyurethane polyurea resin foam as an intermediate in the present invention is a substantially open-cell thermoplastic rigid foam. More preferably, a reaction progress form (profile) in which cream rise progresses far from pigment mixing and stirring.
It is desirable for practical line design to have formulation conditions that have
In addition, the property that the obtained thermoplastic foam changes from a thermoplastic type to a thermosetting type when it comes into contact with water or steam in the final molding process is important for providing the final molded product with rigidity and stable permanent deformation properties. This is important, and as a result, a molded article with stable quality and good final shape can be obtained.

It is necessary to provide air permeability to the foam, which is essentially an open-cell system, in order to (1) ensure the dimensional stability of the continuous panel board formed by the double conveyor (preventing the shrink phenomenon), and (2) the final Imparting sound absorbing properties to molded products such as molded ceiling materials, etc., obtained in This is due to the following three reasons: to make the entire system uniformly thermosetting by diffusing into the thermosetting resin.

Also, the reason why it is necessary for the intermediate form itself to be thermoplastic is that it can provide good formability to molds with complex deep drawing patterns in the final process. However, when forming a continuous panel board to be produced as an intermediate material with controlled thickness, it is preferable that the foam itself is thermoplastic.In other words, thermoplastic foam is better when pressed at the final stage of the double conveyor. This is because there is a wide margin of timing when doing so.

Such a substantially open-celled thermoplastic rigid foam is formed, for example, from the following formulation.

That is, the polyol component and the isocyanate component are mixed with water and/or
Or, when reacting in the presence of an organic blowing agent such as monochloro-trifluoromethane to produce a polyurethane resin foam or a polyurethane-polyurea resin foam, the reaction is performed in a state in which the isocyanate component is present in excess of the reaction equivalent. The basic idea is to use a hard foam with thermoplastic properties.

Examples of the polyol component used in the present invention include dihydric alcohols such as ethylene glycol, propylene glycol, 1,4-butanediol, and diethylene glycol; trihydric alcohols such as glycerin and trimethylolpropane; pentaerythritol, sorbitol, and Addition polymerization of alkylene oxides such as propylene oxide and ethylene oxide to tetravalent or higher alcohols such as sugars, or these polyhydric alcohols, and addition polymerization of alkylene oxides to aliphatic or aromatic polyamines and alkanolamines. General urethane foams include polyether polyols, so-called polymer polyols obtained by graft polymerizing monomers with vinyl groups to polyether polyols, and polyester polyols obtained by condensation polymerization of polybasic acids and polyhydric alcohols. One type or a combination of two or more of the polyol components used can be used as the pace polyol. Furthermore, in order to improve the degree of interconnection of the foam, a polyol obtained by addition-polymerizing a larger amount of ethylene oxide to the above-mentioned polyhydric alcohol, aliphatic or aromatic polyamine, or alkanolamine is added to the blended system to bring about a foam-breaking effect. It is desirable to do so.

Further, as the isocyanate component, a general aliphatic or aromatic isocyanate or a mixture thereof is used, and if necessary, a terminal -NCO prepolymer obtained by partially reacting these isocyanates with a polyol is used. can also be used.

The mixing ratio of the polyol component and the incyanate component is set so that a large amount of unreacted isocyanate component remains in the foam made by using a larger amount of isocyanate component than the amount of isocyanate component that reacts chemically equivalently with the polyol component used. Make it.

The amount of isocyanate component used is 1 of the amount of isocyanate component that reacts chemically equivalently with the polyol component used.
．． It is good to set it as 2 times - 5 times, preferably 1.5 - 2.5 times.

When reacting in the presence of wood, the amount of the isocyanate component used is 1.2 to 5 times the amount of the isocyanate component that reacts chemically equivalently with the polyol component and water used,
Preferably it is 1.5 to 2.5 times.

Water and an organic blowing agent are added to foam the resulting polyurethane resin or polyurethane-polyurea resin into an open-celled foam.

As the organic blowing agent, all known organic blowing agents can be used, such as fluorocarbons such as monochloro and trifluoromethane, and methylene chloride, and is not limited to one type.

In the present invention, the ratio of these polyol components to isocyanate components and the amount of water and organic blowing agents such as monochlorotrifluoromethane may be arbitrarily set depending on the intended use of the final product. Not limited.

Further, in one foaming process, catalysts, surfactants, etc. can also be used as necessary. The type and amount of additives used may be the same as those used for general urethane foams, and are not particularly limited.

The pigment cream formulated in this way, which gives a substantially open-celled thermoplastic hard foam, is placed on a moisture-impermeable sheet placed on a double conveyor moving at a constant speed, or on a moisture-impermeable sheet. It is injected with a uniform thickness onto a two-layer sheet made of glass fiber non-woven fabric, and in an appropriate temperature range, smooth foaming, foam rise, and healthy foam generation progress.

At the final stage of the double conveyor, a plate-like foam block continuous molded product is completed with a surface condition that does not allow liquid to seep out even when a nonwoven fabric is placed on it.

Here, the roles of the moisture-impermeable sheet and the glass fiber nonwoven fabric will be explained.

The stirred cream formulated with the above formula has a low viscosity.

If poured onto a non-woven fabric, etc., it will not only easily pass through the holes in the non-woven fabric and stain the double conveyor with pigment cream, but also leave a large amount of unreacted isocyanate remaining after foaming and curing. Moisture can easily enter the interior of the panel from outside during storage, and there is a risk that it will lose its important thermoplastic properties, aided by the breathable foam.

Therefore, it is desirable to pour the pigment cream onto a moisture-impermeable sheet and store the panel in that state even after forming the continuous molded product.

Moisture-impermeable films used for this purpose include:
For example, a general polyolefin film such as polyethylene film or polypropylene film, which can be easily peeled off after the urethane foam is cured, may be used, but considering that it will be bonded to various skins in the final product molding process, moisture-impermeable sheets may be used. It is extremely convenient to use films such as polyolefin hot melt films such as ethylene vinyl acetate or polyamide hot melt films.In other words, these hot melt films are used as pigment creams when producing thermoplastic continuous panel moldings. To prevent contamination of the conveyor by itself, and when storing this thermoplastic panel molded body as an intermediate material, use an external sil! This is because it plays a multi-functional role, preventing the inconvenience of loss of thermoplastic properties due to intrusion into the foam, and acting as an adhesive when bonding various skins in the final product molding process.

In addition, when hot melt film is used, when the thermoplastic panel board is hot press-formed with water or steam in a mold with a complex deep drawing shape in the final product forming process,
Even if water or steam is sprayed onto the hot melt, the hot melt film will melt preferentially and proceed instantly, and then the water will freely spread into the thermoplastic rigid foam.
The reaction between water and unreacted isocyanate proceeds uniformly without any problems, and after the final product is demolded, the thermoplastic rigid foam becomes a thermosetting rigid foam, resulting in a permanently deformed final product such as a molded ceiling material. .

Furthermore, the glass fiber nonwoven fabric is effective not only in increasing the rigidity of the final product but also in maintaining the dimensional stability of the product.

Originally, the glass mttii reinforcing material used to increase the rigidity of the panel board is most effective when bonded to both sides of the core material form in a sandwich form. Considering that a panel is made as a panel and then heat press molded in a mold with a complex deep drawing shape in the final product forming process, a sandwich structure panel structure in which glass fiber reinforcement is bonded to both surfaces of the panel is considered. No matter how thermoplastic the core material foam is, it is a monolithic structure in which the glass fiber itself loses its free movement, resulting in large wrinkles in the deep drawing part, leading to poor appearance. Not only this, but also the mold followability becomes insufficient.

In the present invention, we fundamentally reviewed the glass fiber reinforcement form from the viewpoint of imparting good post-processability.As a result, we decided to either uniformly disperse the glass fibers throughout the foam block, or to place the glass fibers in the center of the foam block. It has been found that only a panel-shaped thermoplastic rigid foam intermediate material with a nonwoven fabric interposed therein is a panel that has good post-processability.

In order to interpose glass fiber inside the foamed product, a glass fiber non-woven fabric is laid on the moisture-impermeable sheet mentioned above,
This is achieved by pouring foaming cream over it.

Whether it is better to interpose the glass fibers in a uniformly dispersed state inside the foam block or to interpose them in the form of glass fiber nonwoven fabric in the center of the block depends on the shape and required characteristics of the final product. .

Normally, if the shape of the final product is not very complicated and the degree of deep drawing is not too large, it is preferable to use the glass fiber uniform distribution type inside the block.If the shape of the final product is complex and the degree of deep drawing is large, the central part of the glass fiber inside the block is preferable. A fiber nonwoven fabric interposed type is preferred.

Whether the glass am is uniformly dispersed inside the block or interposed in the center in the form of a nonwoven fabric is determined by the type of binder of the glass fiber nonwoven fabric used.

It is not specified here.

With nonwoven fabrics that quickly unravel when they come into contact with urethane pigment cream, the glass fibers will be uniformly dispersed inside the block as the foaming cream reaction progresses, while with other nonwoven fabrics, the cream will pass through the holes of the nonwoven fabric and go under the nonwoven fabric. The amount of cream remaining on the non-woven fabric is almost the same,
After the reaction is completed, a panel molded body is completed with a nonwoven fabric interposed in the center of the inside of the block.

The glass fiber mat-like structured sheet used in the present invention as a glass fiber non-woven fabric may be a non-woven sheet such as a so-called glass fiber chopped strand mat or a glass fiber filament mat. As a final product, it is lightweight and has stable quality.
In order to finish high-rigidity molded ceiling materials for automobiles, door panels, etc., glass fiber mats with a small basis weight exhibit high reinforcing properties. ! The taste is glassy! Shun filament mat is recommended. That is, the basis weight is 20 to 100 g/rn
2. Preferably, a filament mat of 30 to 80 g/m2 is good, and the type of binder constituting the mat is determined by whether a glass fiber uniformly dispersed block or a glass fiber nonwoven central intervening layer block is selected. The present invention is not particularly limited.

The moisture-impermeable sheet selected as described above, or a two-layer sheet of a moisture-impermeable sheet and a nonwoven glass fiber fabric, is laid on a double conveyor, and a pigment cream that gives an open-cell, thermoplastic hard foam is applied on top of this. In order to produce a continuous block with a low foaming height through uniform flow, it is desirable to adjust the conveyor temperature to an appropriate temperature according to the formulation, i.e. in the range of 25°C to 50"C; the temperature is too low. As the density of the bottom surface of the foam block increases, the density distribution changes greatly in the height direction of the block, making it impossible to obtain a thermoplastic panel molded body with uniform density as a medium IR material. If the temperature is too high, the reaction balance between the block's foaming reaction and crosslinking reaction will be disrupted, resulting in an unstable foamed foam with cell disorder.

The feed speed of the conveyor is determined by considering factors such as the cream injection speed, the width of the thermoplastic panel board, the foam density, and the compression ratio during the pressing performed in the final process of the double conveyor. It is recommended that the conveyor feed rate is such that a foaming height of 1.5 to 10 times the thickness, preferably 2.0 to 4.0 times, is obtained.

If the foam height is less than 1.5 times the wall thickness that should be controlled, slight irregularities on the top surface of the foam will deteriorate the appearance of the panel board, which is the intermediate material; In this case, the density of the intermediate material increases, making it impossible to provide a lightweight panel board, which is a feature of the present application.

Pigment cream that gives an open-cell thermoplastic rigid foam is continuously stirred on a moisture-impermeable sheet or a two-layer sheet of a moisture-impermeable sheet and a glass fiber nonwoven fabric, which is constructed as described above, laid on a double conveyor. A foaming machine capable of pouring is used to uniformly pour the water, but there are no particular restrictions on the type of foaming machine.Also, any method such as the traverse method or toctoring method may be used as the uniform pouring method, and the foam can be poured uniformly to a uniform height. It is enough if the cream can flow.

The injected cream undergoes a foaming reaction, and just before it gels, the foam becomes open with the generation of healthy foam, but when the gas generation is finished, the surface of the foam undergoes a gelling reaction, and there is still some stickiness. At the remaining point, a nonwoven fabric is laid and adhered to the surface of the foam, and pressed to a predetermined thickness to make the adhesion safer and at the same time form a panel material with good surface smoothness. At this time, pressing can be done at room temperature (25℃), but by taking advantage of the thermoplasticity of the foam,
A double conveyor continuous press method heated at 70° C. is more preferable.

After press forming, the continuous molded panel material is cooled to room temperature to create a panel with enough rigidity to be cut.

In the next step, this a-cut panel material can be hot-pressed in a mold with a complex deep-drawing pattern to form the final product shape with good formability. It's what you do.

The excess incyanate component present inside the reform causes a reaction that changes the thermoplasticity of the panel material to thermosetness, thus ensuring the thermal stability of the complex deep-drawn part after hot press forming. Then, it is applied to a so-called permanently deformed shaped body, that is, a final shaped product.

An example of an embodiment of the first half process of the present invention will be described with reference to FIG. 1. A pigment cream 3 having a composition defined by the present invention is discharged onto a moisture-impermeable film 2 laid on a conveyor 1 heated to an appropriate temperature. Then, the cream is leveled to a certain height by doctoring 4, and the cream foams into a continuous foam 5. When the generation of healthy foam is finished, a nonwoven fabric 6 is layered on the upper surface of the foam, and it is continuously pressed with a press 7. As a result, a structure in which a moisture-impermeable film 2, a foam 5, and a nonwoven fabric 6 are sequentially laminated as shown in FIG.

A substantially thermoplastic laminate is obtained.

FIG. 3 shows another example of the embodiment of the first half of the present invention, in which a glass fiber nonwoven fabric 8 is further laid on the moisture-impermeable film 2 laid on the conveyor 1 heated to an appropriate temperature, Pigment cream 3 having a composition defined by the present invention is discharged onto the pigment cream, the cream is leveled to a certain height by doctoring 4, and the cream foams into a continuous foam 5 and foams when the generation of healthy foam is completed. By laminating the nonwoven fabric 6 on the upper surface of the body and continuously pressing it with the press 7, the moisture-impermeable film 2, the film 5, and the nonwoven fabric 6 as shown in FIG. 4 can be formed depending on the type of glass fiber nonwoven fabric used. A substantially thermoplastic laminate having a sequentially laminated structure in which glass fibers #18' are uniformly dispersed inside the foam, or a moisture-impermeable film 2, a foam 5, and a nonwoven fabric as shown in FIG. A substantially thermoplastic laminate having a structure in which the nonwoven fabrics 8 are successively laminated in the center of the foam is obtained.

The present invention will be specifically explained below using Examples.

Table 1 [Example 1] A hot melt film (polyamide hot melt film M31 manufactured by Daicel Chemical Industries, Ltd.
0:27g/m2) and 7A with the composition shown in Table 1.
A three-component foaming machine that can continuously mix prepared raw materials is stirred and
The cream obtained by mixing was poured onto the hot melt film while traversing, and the height of the cream was leveled to 1.0 mm using a doctoring method. The cream was foamed to form an open foam board with a height of about 25 to 30 mm, and at the same time, the cream was made into open cells while generating healthy foam. When the generation of healthy foam is finished, a nonwoven fabric (polyester nonwoven fabric 90303WSO manufactured by Unitika: 30g/
m2) was laid down and continuously fed to a double conveyor heated to 50°C and equipped with a 10 mm thick spacer for continuous pressing. The resulting 10 m
The m-thick molded panel is continuously cooled to room temperature (25℃), and! &, We obtained a rigid panel board that can be cut. This panel board is a panel material with a cross-sectional structure as shown in Figure 2, and is a foam board covered with hot melt film on one side and non-woven fabric on the other side, and is a rigid panel with a surface weight of 860 g/m2. Ta.

Water was sprayed on both sides of this panel material, and a skin material of 300 g/m2 was layered on the hot melt film surface in such a way that it overlapped with the surface material. When press-molded in a mold with 8 types of drawing,
A foam two-skin integrally molded panel with good formability and permanent deformation was obtained.

In addition, water was sprayed on both sides of the above panel material, and a nonwoven fabric (polyester nonwoven fabric 90303WSO manufactured by Unitika: 30g/m2) was laminated on the hot melt film surface.
In the same way, hot press molding was carried out at 110°C for 2 minutes using a flat plate mold with a spacer of m thickness attached, and the bending rigidity of the panel plate after molding was measured using the method shown in Figure 7 for test piece 9. Surface weight 890 g/m2
The bending strength is 3.06 kg, the width is 75 cm, and the initial bending slope is 1.

It is a lightweight board material with excellent rigidity, measuring 35g / 5 cm width / mm, and has good other physical properties.As shown in Table 2, it is a panel that is excellent in terms of both 8-dimensional stability and 1-dimensional stability. It was confirmed that the material was

Table 2 [Example 2] On the double conveyor (40"C heat retention) shown in Figure 3,
A hot melt film (polyamide hot melt film M3 manufactured by Daicel Chemical Industries, Ltd.) is used as a moisture-impermeable film.
10: 27g/m2) was laid, and a glass ttaya filament mat (Nittobo && Co., Ltd. filament mat MF-60P: 60g/m2) was placed on top of it, and the raw materials prepared according to the composition shown in Table 11 were continuously poured. The cream obtained by stirring and mixing with a three-component foaming machine capable of mixing was poured onto the above glass fiber filament mat while traversing, and the height of the cream was leveled to 1.0 mm by a toctoring method. The cream was made into open cells by loosening glass fiber filaments. ! !
When the generation of bubbles is finished, a nonwoven fabric (polyester nonwoven fabric 90303WSO manufactured by Unitika V4) is applied to the surface of the foam.
30 g/m2), heated to 50°C, and 1
The material was continuously supplied to a double conveyor equipped with a 0 mm thick spacer and continuously pressed. The result was 1
0mmpi0mm Lumi molded panel is continuously heated to room temperature (25
℃) to obtain a rigid panel material that can be cut. This panel material had a cross-sectional structure as shown in FIG. 4, and was a rigid panel with a surface weight of 920 g/m2, consisting of a foam board covered with a hot melt film on one side and a nonwoven fabric on the other side.

Water was sprayed on both sides of this panel material, and a skin material of 300 g/m2 was layered on the hot melt film surface in such a way that it overlapped, and deep drawing was performed at 110°C for 2 minutes in a complex manner as shown in Figure 6. When press-molded in a patterned mold, a foam-skin integrated molded panel with good 1cE moldability and permanent deformation was obtained.

In addition, water was sprayed on both sides of the panel material, and a nonwoven fabric (polyester nonwoven fabric 90303WSO manufactured by Unitika: 3 og/m') was laminated on the hot melt film surface.
Heat press molding was performed for 110" CXZ in the same manner using a flat plate mold with a spacer of mm thickness attached, and the bending rigidity of the panel plate after molding was measured using the method shown in the t57 diagram, and the surface weight was 950 g / m 2 has a bending strength of 4.35K
g15cm width, initial bending slope 2.00Kg15cm width”
It was confirmed that the panel material was a lightweight panel material with excellent rigidity of mm, and other physical properties were also good.As shown in Table 2, it was confirmed that the panel material was excellent in terms of thermal and dimensional stability.

[Example 3] On a glass fiber filament mat on a double conveyor configured in the same manner as in Example 2, raw materials prepared according to the composition shown in Table 1 were stirred and mixed using a three-component foaming machine capable of continuous mixing. The resulting cream was poured while traversing, and the height of the cream was reduced to 0.7 mm by doctoring.
It became a sound.

As in Example 2, the cream foams while forming open cells to form a continuous foam board with a height of approximately 25 to 30 mm. When the generation of healthy foam is complete, a non-woven fabric is laid and press molded, and as in Example 2, it is 620 g/m. A rigid panel material with a surface weight of ' was obtained. This panel material has good deep drawing formability as shown in Figure 6.

When the bending rigidity of a panel plate formed under the same conditions as in Example 1 was measured, the bending strength was 2.75, g15cm width, initial bending slope position, 20Kg15cm width mm, and other physical properties are shown in Table 2. It was confirmed that this is an excellent lightweight panel material with no problems.

[Example 4] Nittobo #! as glass m miscellaneous mat on double conveyor!
Using a chopped strand mat made by A (cutting length 50 mm, surface weight 100 g/m2), same compounding conditions as Example 3,
When a panel board was molded under foam molding conditions, a rigid panel material (face weight 690 g/m2) with a glass fiber mat in the center of the foam was obtained as shown in FIG. Deep drawing 1 of this panel material: The layering properties were good, and when the bending rigidity of the panel plate formed under the same conditions as in Example 1 was measured, the bending strength was 2.95 kg, 15 cm width, initial bending slope device, 35
It was confirmed that it was an excellent lightweight panel material with no problems in terms of K g/5 cm width/mm and other values as shown in Table 2.

[Example g45] A panel board was molded using the formulation shown in Example 5 in Table 1 and under the same molding conditions as Example 2. As shown in Figure 4, a rigid panel with glass fibers dispersed inside the foam was obtained. A plate (face weight 645 g/m2) was obtained.

The deep drawability of this panel was good, and Example 1
The bending rigidity of the panel board was measured under the same molding conditions as 1 bending strength: 3.00Kg/5c
m 11, initial bending slope position, 35Kg 15cm width/m
m and other physical properties as shown in Table 2, it was confirmed that it was an excellent lightweight panel material with no problems.

[Example 6] A polyethylene film with a final thickness of 35 mm was used as a moisture-impermeable film on a double conveyor, and a glass RAM filament mat was laid on top of it in the same manner as in Example 3. A rigid panel material having a surface weight of 660 g/m 2 was obtained under the same molding conditions as in Example 1 by pouring a cream having the same formulation. To evaluate the deep drawing formability of this panel material, the polyethylene film on the panel surface was peeled off, the isocyanate shown in Table 1 (Sumidur 44V-20) was used as an adhesive, and after spraying wood on the panel, Example 300g/m as in 1
A place where the skin materials from 2 are laminated and hot press molded.

A form with good shapeability: a skin-integrated molded article was obtained. In addition, when a panel board was formed in a flat plate mold using the same nonwoven fabric as in Example 1 and using isocyanate as an adhesive, the surface weight was 750 g/m2 and the bending strength was 3.3.
5Kg15cm width, initial bending slope position, 50Kg15cm
As shown in Table 2, it was confirmed that the material was an excellent lightweight panel material with no problems in terms of width "mm" and other physical properties.

[Comparative Example 1] A panel board was molded using the formulation shown in Comparative Example 1 in Table 1 under the same conditions as Example 2. As shown in Figure 4, a rigid panel material with glass fibers dispersed inside the foam was obtained. (face weight 92
017 m2) was obtained.

However, when this panel material was hot press-molded in a mold with a complicated deep-drawing pattern as shown in FIG. 6, form failure occurred at the deep-drawn portion, and a good molded product could not be obtained.

[Function] ■The panel material obtained in the first process exhibits thermoplasticity because the unreacted isocyanate in the foam itself that makes up the panel has not yet reached final hardening. To provide a molded product with good shapeability without cracking during press molding.

(2) When the foam is brought into contact with water or steam during hot pressing, unreacted isocyanate in the foam reacts and final hardening occurs, changing from thermoplastic to thermosetting, resulting in permanent deformation of the molded product.

■When glass fiber nonwoven fabric is used in combination, the glass fibers that are uniformly dispersed inside the foam or interposed in the center not only exert an effective reinforcing effect without impairing the formability of the panel material, but also strengthen the panel itself. Maintain dimensional stability.

■The moisture-impermeable film used during panel manufacturing not only prevents contamination of the conveyor by foamed cream stock solution during panel material molding, but also prevents moisture from entering the inside of the panel after molding, thereby preventing unreacted isocyanate from being stored. When a hot melt film is used as a moisture-impermeable film, the film itself becomes an adhesive and works effectively when applied to the skin in the second step.

■ The foam itself is basically open-celled and has excellent dimensional stability and sound absorption properties.

[Effects of the invention] Extremely simplified form material that is lightweight, rigid, has excellent 'tR8 properties, sound absorption properties, moisture and heat resistance, and has no cracks even when deep drawing, which can be suitably used for automobile molded ceiling materials, door panels, etc. It is possible to manufacture a vine panel board or a complex-shaped molded product using a process that guarantees excellent work safety and quality stability.

[Brief explanation of the drawing]

FIG. 1 is a diagram showing an example of an embodiment of the first half process of the present invention,
FIG. 2 is a diagram showing a cross-sectional structure of a substantially thermoplastic m-layer body obtained by the embodiment shown in FIG. 1, and FIG. 3 is a diagram showing another example of implementation IIB of the first half of the present invention. , FIG. 4 and FIG. 5 are diagrams showing the cross-sectional structure of a substantially thermoplastic laminate obtained by the embodiment of FIG. 3, and FIG. 6 is a diagram showing the shape of a deep-drawn product in the example. , FIG. 7 is a diagram showing a means for measuring the bending rigidity of the panel plate after molding.

Claims (1)

[Claims] A polyol component and an isocyanate component are reacted in the presence of water and/or an organic blowing agent in a state in which the isocyanate component is present in excess of the reaction equivalent amount.The pigment is discharged onto a moisture-impermeable film to form a foam. The laminate is molded into a substantially thermoplastic laminate by pressing the top surface of the foam with a nonwoven fabric, and then the laminate is brought into contact with water and/or steam and heated to remove the contents of the laminate. A method for forming a panel board having a skin, which comprises a step of reacting unreacted isocyanate with water and curing and forming a laminate.