JPH02258239A - Manufacture of composite base material for trim - Google Patents

Abstract

PURPOSE:To improve mold release properties by imparting favorable rigidity and making handling of raw fabric favorable, by a method wherein foaming phenolic resin powder is held temporarily on a surface material through heating, the surface material is laminated on both sides of a glass wool mat into which thermosetting resin infiltrated and foam molding is performed with a hot press mold. CONSTITUTION:Foaming phenolic resin powder 2 is spread over one side of a surface material 1 by making use of a spreading device 3. The surface material 1 is heated on both sides with a heater 4. In this instance, heating on the surface of the foaming phenolic resin powder 2 is constituted so that a temperature of the same will not raise up to the decomposition temperature of a foaming agent of the same nor to the reacting temperature of a curing agent of the same in the foaming phenolic resin powder. On the one hand, heating on the surface material 1 is performed so that the foaming phenolic resin powder 2 is cured. With this construction, the foaming phenolic resin powder 2, which has come into contact with the surface material 1, is cured and a thin filmy layer 10 is formed. The temporarily held surface materials 1 are laminated respectively and the same is set up to a hot press mold 9 constituted of a top and bottom forces 7, 8 for pressure molding. The foaming phenolic resin powder 2 held on to the surface material 1 is reacted for foaming and curing.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a method for producing an interior composite base material used as an interior material, particularly as a ceiling material or door trim of a vehicle such as an automobile. The present invention relates to a method for manufacturing a composite base material for interior use on which a foamed phenol layer is formed.

[Conventional technology]

Conventionally, glass wool mats have been used as composite base materials for automobile interiors because they have excellent sound absorption and heat resistance, are lightweight, and can be formed by deep drawing. There is. Although this glass wool mat has the above-mentioned characteristics, it has the disadvantage that the glass wool mat is brittle and easily breaks during transportation or handling.

In order to solve this problem, it is possible to improve the rigidity of the base material by impregnating the glass wool mat with foamed phenol resin powder to form a foamed phenol layer on the glass wool mat.

Conventionally, a foamed phenol layer was formed on a composite base material for interior use using a glass wool mat as a base material by the following method. That is, foamed phenol resin powder is spread on one side of a glass wool mat, then this glass wool mat is turned over, and foamed phenol resin powder is spread on the other side, and the foamed phenol resin powder is spread on both sides of the glass wool mat by heat pressing. A composite base material for interior use was produced by foaming resin powder to form a foamed phenol layer and molding it into a desired shape.

[Problem to be solved by the invention]

However, in this manufacturing method, foamed phenolic resin powder is sprinkled on both sides of the glass wool mat, so
When handling this raw fabric, the sprayed foamed phenolic resin powder may fall off and cause a tingling sensation to the operator.

Furthermore, the foamed phenolic resin powder foams during hot pressing and adheres to the mold surface, resulting in poor mold releasability after molding.

It is an object of the present invention to overcome the above-mentioned problems and provide a method for producing a composite base material for interiors, which has good rigidity, is easy to handle as a raw material, and has excellent mold releasability.

[Means to solve the problem]

The means of the present invention for solving the problem is that after spraying foamed phenolic resin powder on a surface material, the foamed phenolic resin powder is heated from the foamed phenolic resin powder side at a temperature at which the foamed phenolic resin powder does not foam and harden. From the material side, the foamed phenolic resin powder is temporarily fixed to the surface material by heating at a temperature that hardens the foamed phenolic resin powder in the thin part that has come into contact with the surface material to form a film-like hardened layer. are laminated on both sides of a glass wool mat impregnated with a thermosetting resin such as phenol, and each layer is molded and integrated using a pair of heat press molds heated to a desired temperature, and the foamed phenol resin on both sides of the glass wool mat is laminated. A composite substrate for interior use was manufactured by foaming the powder to form foamed phenol layers on both sides of the glass wool mat.

[For production]

Since the surface of the foamed phenolic resin powder sprinkled on the surface material is heated at a temperature at which the foamed phenolic resin powder does not foam or harden, the foamed phenolic resin powder becomes temporarily fixed to the surface material. Therefore, the surface material can be made into a roll, which is easy to handle, and the foamed phenolic resin powder will not fall off because it is in a temporarily fixed state.

Further, since the surface material side is heated at a temperature that hardens the foamed phenol resin powder in contact with the surface material and forms a thin film-like layer, a thin film of foamed phenol is formed on the surface material. For this reason, even if it is laminated on both sides of the glass wool mat and heat press molded, the foamed phenol resin powder will not foam and ooze out to the surface of the surface material.Therefore, the foamed phenol layer will adhere to the surface of the heat press mold. Excellent mold releasability.

〔Example〕

An embodiment of the present invention will be described in detail with reference to the drawings.

1 to 3 are process schematic diagrams of the manufacturing method of the present invention.According to the manufacturing method of the present invention, first, foamed phenolic resin powder 2 is sprayed on one side of the surface material 1 using a spraying device 3. . This surface material 1 is heated from both sides using a heater 4 or the like. At this time, the heating from the two sides of the foamed phenolic resin powder should not be raised to the decomposition temperature of the foaming agent in the foamed phenolic resin powder 2 and the reaction temperature of the curing agent.
A temperature in the range of 0 to 100°C is preferable. On the other hand, the heating from the skin material 1 side is heated to about 200°C so as to harden the thin portion of the foamed phenolic resin powder 2 in contact with the skin material 1. As a result, the foamed phenolic resin powder 2 that has come into contact with the surface material 1 is hardened to form a thin film-like layer 10.

A cross-sectional view of this surface material 1 is shown in FIG.

As the surface material 1 used in the present invention, woven fabric, non-woven fabric (made of polyester, polyamide), raised knit, woven fabric, glass paper, etc. can be used.The basis weight of the surface material 1 is 15 to 120 g/rd. is suitable. If the basis weight is small, the surface material 1 will increase when the pressing pressure of the mold is increased.
In addition, if the basis weight is too large, it is difficult to stretch and may easily wrinkle or tear.The amount of spraying depends on the thickness of the foamed phenol layer 5, but the 200g/rrr is appropriate.

The foamed phenolic resin powder 2 used in the present invention is a novolac type, and a tri-blend of this novolac with a curing agent and a foaming agent is used.

As the curing agent, hexamethylenetetramine or the like is used, and as the blowing agent, dinitrosopentamethylenetetramine, P-toluenesulfonic acid amide, or the like is used.

Next, the temporarily fixed skin material 1 is laminated on both sides of the glass wool Matsutoro so that the skin material 1 is exposed on the surface. The foaming agent and curing agent of the foamed phenolic resin powder 2 temporarily fixed to the surface material 1 set in a hot press mold 9 composed of 8 and pressure-molded react with each other during pressure-molding to foam and harden. On the other hand, the thin film-like layer 10 that was previously hardened and formed on the surface material 1 does not react, and the temporarily fixed foamed phenolic resin powder 2 foams and does not ooze into the surface material 1, causing it to separate after molding. Excellent formability. The pressing time was within 3 minutes, depending on the weight of the glass wool Matsutoro and the content of the binder.

The thickness of the interior composite base material at this time was 4 to 1 tnrx.

In addition, if necessary, one side of the surface material 1 may be provided with a cushion layer such as polyurethane foam, polyethylene foam, polypropylene foam, polyvinyl chloride foam, nonwoven fabric, felt, or a layer of two or more layers of these. It is also possible to laminate a facing material in which breathable facing materials such as woven fabric, nonwoven fabric, knit, tricot, moquette, etc. are laminated by a known method such as frame lamination.

This facing material is bonded using another mold after the interior composite base material is molded.

〔Effect of the invention〕

The present invention has the following effects.

(1) 0 foamed phenolic resin powder is sprinkled on the surface material and heated from the foamed phenolic resin powder side at a temperature at which the foamed phenolic resin powder does not foam or harden, so the surface material to which the foamed phenolic resin powder is temporarily fixed is heated. can. Therefore, it can be kept in a roll, making it easier to handle.

(2) The foamed phenolic resin powder in the part that came into contact with the surface material hardens to form a film-like layer, and the foamed phenolic resin powder in the other parts spreads between the glass wool mat and the temporarily fixed surface material. Since it is laminated on 6 sides and hot press molded, even if the temporarily fixed foamed phenolic resin powder is foamed, it does not ooze out onto the surface of the surface material and has excellent mold releasability.

(3) By laminating the surface material to which foamed phenolic resin powder is temporarily fixed on both sides of the glass wool mat, foamed phenol layers can be formed on both sides of the glass wool mat. A foamed phenol layer is formed uniformly. Therefore, a composite base material for interior use having good rigidity can be manufactured.

[Brief explanation of drawings]

1 to 3 are schematic process diagrams of the manufacturing method of the present invention. DESCRIPTION OF SYMBOLS 1... Surface material, 2... Foamed phenolic resin powder 3... Spraying device, 4... Heater, 5... Foamed phenol layer, 6... Glass wool mat, 7... Upper mold , 8...
Lower mold, 9...Press mold, 10...Thin film-like layer. Resin powder: Heater Thin film layer 2 Upper mold nibbles mold: Lower mold Fig. 3

Claims (1)

[Claims] After spraying foamed phenolic resin powder on the surface material,
heating from the foamed phenolic resin powder side at a temperature at which the foamed phenolic resin powder does not foam or harden;
Temporarily fix the foamed phenolic resin powder to the surface material by heating from the surface material side at a temperature that hardens the foamed phenolic resin powder in a thin portion that has come into contact with the surface material to form a film-like hardened layer. A surface material is laminated on both sides of a glass wool mat impregnated with a thermosetting resin such as phenol, and each layer is molded and integrated using a pair of heat press molds heated to a desired temperature, and both sides of the glass wool mat are foamed. A method for producing a composite base material for interior use, which comprises foaming phenolic resin powder to form foamed phenol layers on both sides of the glass wool mat.