JPH0141503B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention mainly relates to a method for manufacturing interior materials used for automobiles, houses, etc.

This type of interior material has conventionally used a reinforced structural material made of paper such as cardboard as a base material. These reinforced structural materials are lightweight and are desirable as base materials in today's world where improvements in fuel efficiency are demanded for automobiles, etc. However, when molded, especially when deep drawn, they cause wrinkles on the surface of the base material. , cracks, etc. occur, and such wrinkles and cracks cause the appearance of irregularities on the surface of the covering material superimposed on the surface of the base material, which is extremely undesirable in terms of appearance. In order to prevent such drawbacks, a method has been proposed in which a layer capable of absorbing irregularities is polymerized on the surface of the base material, and a facing material is polymerized through the layer. However, the facing material is made of a polymer of plastic foam and plastic sheet as a cushion layer, and in the end it has a four-layer structure of base material + layer capable of absorbing unevenness + plastic foam + plastic sheet. It takes time and effort to manufacture and is also expensive. However, if the layer capable of absorbing unevenness is omitted from this structure, unevenness will appear on the surface of the plastic sheet. This is because plastic foam is essentially perfectly elastic and cannot absorb irregularities.

The purpose of the present invention is to improve these conventional drawbacks and manufacture interior materials that have a simple structure and do not have uneven surfaces. The main idea is to thermally bond a covering material made of a cushion layer made of a thermoplastic fiber aggregate and a plastic sheet polymerized to the surface thereof.

To explain the present invention with reference to an embodiment shown in the drawings, a corrugated cardboard 1 in which surface layers 1B and 1B are attached to both sides of a corrugated core 1A with an adhesive or the like is a heated press type consisting of an upper mold 20A and a lower mold 20B. 20 to heat form the desired shape. The molding temperature at this time is 150
-250°C, and about 2-5 kg/cm ² during molding. The above steps are illustrated in FIGS. 1 and 2.

A cushion layer 2 made of a thermoplastic fiber aggregate is formed on the surface of the heat-formed cardboard 1 by a compression die 21 consisting of an upper die 21A and a lower die 21B.
A facing material 2 made of polymerized plastic sheet 2B is adhered to A. At this time, since the surface of the cardboard 1 is in a high temperature state due to heating during hot press molding, the thermoplastic fibers constituting the cushion layer 2A of the covering material 2 are fused to the surface of the cardboard 1, so the adhesive is Not necessary. It is desirable that the compression mold 21 be cooled. The above steps are illustrated in FIGS. 3 and 4. Thermoplastic fiber aggregates include fibers made of thermoplastic fibers such as polyethylene and polypropylene, synthetic fibers such as ordinary polyamide, polyester, and acrylic, or natural fibers bound with thermoplastic synthetic resin. A fiber aggregate that can be heat-fused.
Such a fiber aggregate exhibits viscoelastic behavior and can cause permanent deformation, so it is capable of absorbing irregularities such as cracks and wrinkles on the surface of the cardboard 1. On the other hand, it has cushioning properties, so it is not suitable for plastics. It also functions as a cushion layer of the covering material in place of the foam. A plastic sheet 2B is further superposed on the surface of the cushion layer 2A, and the plastic sheet 2B is made of plastic such as polyvinyl chloride, polyamide, polyurethane, etc., and its surface may be embossed. In order to polymerize the cushion layer 2A and the plastic sheet 2B, the plastic sheet 2B may be bonded to the surface of the cushion layer 2A using an adhesive, polymerized by thermal welding, or the cushion layer 2A may be polymerized by thermal welding. Plastic sheet 3 is formed by applying plastisol or paste resin on the surface of layer 2A and heating it to gel, or applying plastisol or paste resin on transfer paper, heating it to gel, and then transferring it to the surface of cushion layer 2. urge

In this way, for example, a molded ceiling material 10 for an automobile as shown in FIG. 5 is obtained, the structure of which is as shown in FIG.
The part A and the peripheral part are deep-drawn parts with a small radius of curvature, and the tambour 1 is more prone to wrinkles and cracks.
It is absorbed by A and does not affect the surface of the plastic sheet 2B.

Other than this example, for example, cardboard 1 and facing material 2
During the compression bonding, the residual heat from the heating and forming of the cardboard 1 may be used, but the surface of the cardboard 1 may be heated again. Further, as shown in FIG. 7, for example, as a cardboard which is a reinforced structural material, a cushion layer 12A is placed on the surface layer 11B side of a cardboard 11 in which a surface layer 11B is adhered to only one side of a corrugated core 11A.
Covering material 12 made of plastic sheet 12B
As shown in FIG. 8, a cushion layer 12A is formed on the core 11A side of the cardboard 11 in FIG.
Covering material 12 made of plastic sheet 12B
Polymerized products can also be used. In addition, examples of reinforced structures other than the cardboard structure include a honeycomb structure. Furthermore, such reinforced structural materials include phenolic resin,
Synthetic resins such as aminoplast resin, epoxy resin, urethane resin, acrylic resin, vinyl acetate resin, styrene resin, and polyvinyl chloride may be impregnated.

As described above, in the present invention, the reinforcing structure material made of paper is press-molded into a predetermined shape and then the facing material is bonded. No heat pressure is applied, and the cushion layer maintains good cushioning properties without being crushed by such heat pressure. Further, as described above, the cushion layer can be thermally bonded to the covering material made of the thermoplastic fiber aggregate to the reinforcing structural material without using an adhesive.

[Brief explanation of drawings]

The drawings show one embodiment of the present invention, and FIG. 1 is a front view showing the state before the cardboard is molded, FIG. 2 is a front view showing the state after the cardboard is molded, and FIG. 3 is the cardboard and the facing material. 4 is a front view showing the state after crimping the cardboard and the facing material, FIG. 5 is a perspective view of the resulting molded ceiling, and FIG. 6 is the interior material. An enlarged side sectional view, FIG. 7 is an enlarged side sectional view of the interior material of another embodiment, FIG.
The figure is an enlarged side sectional view of an interior material of still another embodiment. In the figure, 1, 11... cardboard, 2A, 12A
...Cushion layer, 2A, 12A...Plastic sheet, 20...Heat pressing type, 21...Crimping type.

Claims (1)

[Claims] 1. An interior material characterized in that a reinforcing structural material made of paper is press-molded into a predetermined shape, and a covering material made of a cushion layer made of a thermoplastic fiber aggregate and a polymerized plastic sheet is thermally bonded to the surface thereof. manufacturing method.