JPH0262387B2 - - Google Patents

Info

Publication number
JPH0262387B2
JPH0262387B2 JP56154499A JP15449981A JPH0262387B2 JP H0262387 B2 JPH0262387 B2 JP H0262387B2 JP 56154499 A JP56154499 A JP 56154499A JP 15449981 A JP15449981 A JP 15449981A JP H0262387 B2 JPH0262387 B2 JP H0262387B2
Authority
JP
Japan
Prior art keywords
modified polystyrene
polystyrene resin
nonwoven fabric
foam
heat
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
JP56154499A
Other languages
Japanese (ja)
Other versions
JPS5871154A (en
Inventor
Seiji Kawaguchi
Susumu Hayashi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Motor Corp
Howa Co Ltd
Original Assignee
Howa Textile Industry Co Ltd
Toyota Motor Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Howa Textile Industry Co Ltd, Toyota Motor Corp filed Critical Howa Textile Industry Co Ltd
Priority to JP56154499A priority Critical patent/JPS5871154A/en
Publication of JPS5871154A publication Critical patent/JPS5871154A/en
Publication of JPH0262387B2 publication Critical patent/JPH0262387B2/ja
Granted legal-status Critical Current

Links

Landscapes

  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Body Structure For Vehicles (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Laminated Bodies (AREA)

Description

【発明の詳細な説明】[Detailed description of the invention]

本発明は軽量で熱変形性がなくしかも成形が容
易な自動車用天井内装材とその製造方法に関する
ものである。 従来から自動車の天井用内装材としては、段ボ
ールを加熱、加圧して成形したものや、変性ポリ
スチレン樹脂発泡体の上下両面に変性ポリスチレ
ンを貼着しこれを加熱加圧して成形したものが知
られているが、前者は安価である利点を有するも
のの深絞りが出来ない欠点があり、また、後者は
深絞りは可能であるが、車内の100℃近くの高温
度に長時間放置されると変形するおそれがあり耐
熱性の改善が特に必要とされていた。 本発明の自動車用天井内装材は上記欠点を解消
せんとするもので、スチレンと無水マレイン酸と
の共重合体よりなる変性ポリスチレン樹脂の発泡
体の両面に、該変性ポリスチレン樹脂を含浸させ
たポリエステル不織布を熱融着してなることを特
徴としたものである。 また本発明に係る自動車用天井内装材の製造方
法は、スチレンと無水マレイン酸との共重合体よ
りなる変性ポリスチレン樹脂を溶解したトルエン
等の溶剤中にポリエステルを原料とする不織布を
浸漬するか、又は、該不織布に変性ポリスチレン
樹脂シートをホツトプレスすることにより、該不
織布中に変性ポリスチレン樹脂を予め含浸せし
め、該不織布を変性ポリスチレン樹脂に発泡剤を
加えて押出することにより一次発泡させた板状の
発泡体の両面に熱融着することにより板状の一次
成形品を製造し、さらにこの一次成形品を加熱す
ることにより発泡体を二次発泡させて半溶融状態
としこれを所定の雄雌型にて天井に沿う立体形に
加圧成形することを特徴としたものである。 以下に本発明の実施例を図面と共に説明する。
一般に変性ポリスチレン樹脂は、スチレンと無水
マレイン酸との共重合体、または、スチレンとメ
タアクリル酸との共重合体、または、スチレンと
アクリル酸との共重合体を指称するが、スチレン
と無水マレイン酸との共重合体は、米国アムコア
社より販売され日本では積水化成品工業株式会社
または日本スチレンペーパー株式会社から商品名
ダイラークとして市販されている。この変性ポリ
スチレン樹脂をポリエステル不織布に含浸させる
に際しては第1図に示したデイツピング方法又は
第2図に示したラミネート方法を使用する。第1
図のデイツピング方法では、トルエン、キシレ
ン、テトラヒドロフラン、塩素系溶剤等の各種溶
剤に変性ポリスチレン樹脂を5〜25重量%使用し
た変性ポリスチレン溶液1を水槽2中に用意する
と共に、ロール状に巻回されたポリエステルを原
料とする不織布3をガイドローラ4,5,6に通
してこの不織布3を変性ポリスチレン溶液1中に
浸透させる。そしてこれを乾燥室7中に搬入して
フアンの回転により100℃〜200℃の温風を吹付け
てその溶剤を蒸発させることにより変性ポリスチ
レン樹脂を不織布3中に含浸させる。また、第2
図のラミネート方法による場合には、押出機8か
ら押出された薄い変性ポリスチレン樹脂シート9
とポリエステル不織布3とを重合しこれを表面に
テフロン樹脂加工した一対のホツトプレスロール
10,10間に挾入して加熱加圧した後フアン1
1により空冷する。 このようにして変性ポリスチレン樹脂を繊維間
に予め含浸させたポリエステルの不織布3′を変
性ポリスチレン樹脂に発泡剤を加えて押出成形す
ることにより一次発泡させた板状の発泡体の両面
に熱融着する。即ち第3図に示したように、押出
成形機12中に発泡剤を加えた変性ポリスチレン
樹脂を入れて加熱によりその変性ポリスチレン樹
脂を一次発泡させて板状の発泡体13を押出成形
すると同時に、前記のようにして変性ポリスチレ
ン樹脂を予め含浸した不織布3′,3′をホツトプ
レスロール14,14によつて発泡体13の両面
に熱融着させる。このとき不織布3′,3′中に含
浸されている変性ポリスチレン樹脂は発泡体13
表面の変性ポリスチレン樹脂と融合し同一樹脂に
よる完全一体的な接着状態が得られる。15はこ
のようにして得られた板状の三層の一次成形品1
6を空冷し硬化させるフアンを示す。 次にこの一次成形品16を第4図に示したよう
に電熱ヒータを備えた加熱室17内に搬入して
105〜140℃の雰囲気により加熱して該一次成形品
16の不織布によつて被われた発泡体13を二次
発泡させ体積を膨脹させると共に溶融状態とす
る。このとき表面に接着されているポリエステル
の不織布は普通少なくとも180℃以上の耐熱性を
備えているため変性ポリスチレン樹脂が溶融する
100〜140℃の温度では変質なくシート状形態が保
持される。このようにして内部が柔軟に溶融した
一次成形品16を所定の雄雌金型18,18が取
付られたプレス機19にて加圧成形し、自動車の
天井面に沿う立体形に深絞り成形するものであ
る。第5図は前記のように加熱室17内に搬入し
て一次成形品16を加熱するのに代えて、プレス
機20に設定された一対の平担な熱板21,21
を105〜140℃に保ちその熱板間に一次成形品16
を挾着することにより該一次成形品16を加熱す
るようにしたものを示し、この場合には熱伝導体
たる熱板21,21のほうが熱容量を大きく一次
成形品16を所定温度に確実に加熱できる利点が
ある。なおその後のプレス機19による加圧成形
の際、成形品周縁部の不要部分は切り落とされる
が、その端材は前記デイツピング法における溶剤
中に溶解することにより変性ポリスチレン樹脂を
無駄なく再使用できるので、端材を焼却処理する
必要がなく公害防止上有効的であると共に、経済
的にも有益である。 このようにして得られた自動車用天井内装材
は、発泡体の表面にポリエステル不織布が一体に
貼着した複合材となるので衝撃に強く、また、自
動車内の高温に長時間放置されても天井がたれ下
る等の変形がなく耐熱性が顕しく改善された。 次表は従来の天井内装材(前述の変性ポリスチ
レン樹脂発泡体の上下両面に変性ポリスチレンシ
ートを貼着してなるもの)と本発明に係る天井内
装材との耐熱性を比較するため、第6図に示した
1000mm×1500mmの大きさの平板の周囲を普通の自
動車天井のように止着して水平に保持し、それを
85℃の雰囲気で23時間放置した後1時間常温とし
これを三回繰り返した場合の〜の各点のたれ
下り距離(mm)を表わしたものである。
The present invention relates to an automotive ceiling interior material that is lightweight, has no heat deformability, and is easily molded, and a method for manufacturing the same. Traditionally, interior materials for automobile ceilings have been known, such as those made by heating and pressurizing corrugated cardboard, and those made by pasting modified polystyrene on both the top and bottom surfaces of a modified polystyrene resin foam and then heating and pressuring it. Although the former has the advantage of being inexpensive, it has the disadvantage that it cannot be deep drawn, while the latter can be deep drawn, but will deform if left in the high temperature of nearly 100℃ inside a car for a long time. There was a particular need for improvement in heat resistance. The ceiling interior material for automobiles of the present invention is intended to solve the above-mentioned drawbacks, and is made by impregnating both sides of a foam of a modified polystyrene resin made of a copolymer of styrene and maleic anhydride with a polyester resin. It is characterized by being made by heat-sealing nonwoven fabric. In addition, the method for producing an automobile ceiling interior material according to the present invention includes immersing a nonwoven fabric made of polyester in a solvent such as toluene in which a modified polystyrene resin made of a copolymer of styrene and maleic anhydride is dissolved; Alternatively, the nonwoven fabric is pre-impregnated with the modified polystyrene resin by hot-pressing a modified polystyrene resin sheet onto the nonwoven fabric, and the nonwoven fabric is first foamed by adding a foaming agent to the modified polystyrene resin and extruding it. A plate-shaped primary molded product is manufactured by heat-sealing both sides of the foam, and this primary molded product is further heated to cause the foam to be secondarily foamed to a semi-molten state, which is then molded into a predetermined male and female mold. It is characterized by being press-formed into a three-dimensional shape that follows the ceiling. Embodiments of the present invention will be described below with reference to the drawings.
Generally, modified polystyrene resin refers to a copolymer of styrene and maleic anhydride, a copolymer of styrene and methacrylic acid, or a copolymer of styrene and acrylic acid. The copolymer with acid is sold by Amcor Corporation in the United States, and in Japan by Sekisui Plastics Co., Ltd. or Nippon Styrene Paper Co., Ltd. under the trade name Dilark. When impregnating a polyester nonwoven fabric with this modified polystyrene resin, the dipping method shown in FIG. 1 or the laminating method shown in FIG. 2 is used. 1st
In the dipping method shown in the figure, a modified polystyrene solution 1 containing 5 to 25% by weight of modified polystyrene resin in various solvents such as toluene, xylene, tetrahydrofuran, and chlorinated solvents is prepared in a water tank 2, and is wound into a roll. A nonwoven fabric 3 made of polyester is passed through guide rollers 4, 5, and 6 to penetrate into a modified polystyrene solution 1. Then, this is carried into the drying chamber 7, and the nonwoven fabric 3 is impregnated with the modified polystyrene resin by blowing hot air at 100° C. to 200° C. by rotating a fan to evaporate the solvent. Also, the second
In the case of the lamination method shown in the figure, a thin modified polystyrene resin sheet 9 extruded from an extruder 8
and polyester nonwoven fabric 3 are polymerized, and this is sandwiched between a pair of hot press rolls 10, 10 whose surfaces are treated with Teflon resin, heated and pressed, and then fan 1
Cool in air according to step 1. In this way, the polyester nonwoven fabric 3' with modified polystyrene resin pre-impregnated between the fibers is heat-sealed on both sides of a plate-shaped foam that is primarily foamed by extrusion molding by adding a foaming agent to the modified polystyrene resin. do. That is, as shown in FIG. 3, a modified polystyrene resin to which a foaming agent has been added is put into an extrusion molding machine 12, and the modified polystyrene resin is primarily foamed by heating to extrude and mold a plate-shaped foam 13. The nonwoven fabrics 3', 3' impregnated in advance with modified polystyrene resin as described above are heat-sealed to both sides of the foam 13 by hot press rolls 14, 14. At this time, the modified polystyrene resin impregnated into the nonwoven fabrics 3' and 3' is
It fuses with the modified polystyrene resin on the surface, creating a completely integrated adhesive state using the same resin. 15 is the plate-shaped three-layer primary molded product 1 obtained in this way.
6 shows a fan for air cooling and curing. Next, this primary molded product 16 is carried into a heating chamber 17 equipped with an electric heater as shown in FIG.
The foam 13 covered by the nonwoven fabric of the primary molded product 16 is heated in an atmosphere of 105 to 140° C. to cause secondary foaming, expand its volume, and bring it into a molten state. At this time, the polyester nonwoven fabric bonded to the surface usually has a heat resistance of at least 180°C, so the modified polystyrene resin melts.
At temperatures of 100 to 140°C, the sheet-like form is maintained without deterioration. The primary molded product 16 whose interior has been molten flexibly in this way is pressure-formed in a press 19 equipped with predetermined male and female molds 18, 18, and deep-drawn into a three-dimensional shape that follows the ceiling surface of the automobile. It is something to do. FIG. 5 shows a pair of flat hot plates 21, 21 set in a press machine 20 instead of heating the primary molded product 16 by carrying it into the heating chamber 17 as described above.
The primary molded product 16 is kept at 105 to 140℃ between the hot plates.
In this case, the heat plates 21, 21, which are heat conductors, have a larger heat capacity and can reliably heat the primary molded product 16 to a predetermined temperature. There are advantages that can be achieved. Note that during the subsequent pressure molding using the press 19, unnecessary portions of the periphery of the molded product are cut off, but by dissolving the scraps in the solvent used in the dipping method, the modified polystyrene resin can be reused without waste. It is not necessary to incinerate the scraps, which is effective in preventing pollution, and is also economically beneficial. The automobile ceiling interior material obtained in this way is a composite material in which polyester nonwoven fabric is adhered to the surface of the foam, so it is resistant to impact, and even if left in the high temperature of a car for a long time, the ceiling There was no deformation such as sagging, and the heat resistance was significantly improved. The following table compares the heat resistance of the conventional ceiling interior material (made by pasting modified polystyrene sheets on both the upper and lower surfaces of the above-mentioned modified polystyrene resin foam) and the ceiling interior material according to the present invention. shown in the figure
The periphery of a flat plate measuring 1000mm x 1500mm is fixed and held horizontally like a normal car ceiling, and then
This graph shows the sag distance (mm) at each point when the sample was left in an atmosphere of 85°C for 23 hours, then brought to room temperature for 1 hour, and this process was repeated three times.

【表】 このように本発明ではたれ下りが約半分近くに
まで少なくできたので、自動車天井面のデザイン
の型くずれ又はしわの発生等が防止できるもので
ある。 以上実施例について説明したように本発明に係
る自動車用天井内装材の製造方法は、変性ポリス
チレン樹脂を不織布に予め含浸せしめそれを一次
発泡した変性ポリスチレン樹脂発泡体の両面に熱
融着させるので、同一材料による一体的な接着状
態が得られ、複合材としての優れた製品強度が達
成される。またこのようにして両面に融着された
不織布は、加熱により二次発泡し発泡体が半溶融
状態になつたときの取扱いを容易ならしめる。そ
して雄雌型により加圧成形された際半溶融状態の
発泡体は上下面の不織布間にて自由に流動し天井
面に沿つた所期の深絞り形状も難なく成形される
ものである。またこうして製造された自動車用天
井内装材は、変性ポリスチレン樹脂発泡体の両面
に耐熱性の高いポリエステル不織布が一体的に融
着されてなるので、耐熱性が高く高温度に長時間
放置しても変形が少ないので自動車用として極め
て有益な利点がある。
[Table] As described above, in the present invention, the sag can be reduced to about half, so that it is possible to prevent the design of the automobile ceiling surface from becoming deformed or from forming wrinkles. As described above in the embodiments, the method for manufacturing an automotive ceiling interior material according to the present invention involves impregnating a nonwoven fabric with a modified polystyrene resin in advance and heat-sealing it to both sides of a primary foamed modified polystyrene resin foam. An integral bonding state using the same material is obtained, and excellent product strength as a composite material is achieved. Furthermore, the nonwoven fabric fused on both sides in this way undergoes secondary foaming by heating and becomes easier to handle when the foam is in a semi-molten state. When press-molded by male and female molds, the semi-molten foam flows freely between the nonwoven fabrics on the upper and lower surfaces, and the desired deep-drawn shape along the ceiling surface can be formed without difficulty. In addition, the automobile ceiling interior material manufactured in this way has highly heat-resistant polyester nonwoven fabric integrally fused to both sides of the modified polystyrene resin foam, so it has high heat resistance and can be left at high temperatures for long periods of time. It has the advantage of being extremely useful for automobiles because of its low deformation.

【図面の簡単な説明】[Brief explanation of the drawing]

図面は本発明の実施例を示したもので、第1図
及び第2図は樹脂含浸工程の説明用略図。第3図
は熱融着工程の説明用略図、第4図及び第5図は
加圧成形工程の説明用略図、第6図はたれ下り試
験の測定位置を示した天井内装材の平面図であ
る。 1……変性ポリスチレン溶液、3……ポリエス
テル不織布、9……変性ポリスチレン樹脂シー
ト、10……ホツトプレスロール、12……押出
成形機、13……発泡体、14……ホツトプレス
ロール、16……一次成形品、17……加熱室、
18……雄雌金型、21……熱板。
The drawings show an embodiment of the present invention, and FIGS. 1 and 2 are schematic diagrams for explaining the resin impregnation process. Figure 3 is a schematic diagram for explaining the heat fusion process, Figures 4 and 5 are schematic diagrams for explaining the pressure forming process, and Figure 6 is a plan view of the ceiling interior material showing the measurement position for the sagging test. be. DESCRIPTION OF SYMBOLS 1... Modified polystyrene solution, 3... Polyester nonwoven fabric, 9... Modified polystyrene resin sheet, 10... Hot press roll, 12... Extrusion molding machine, 13... Foam, 14... Hot press roll, 16... ...Primary molded product, 17...Heating chamber,
18... Male and female molds, 21... Hot plate.

Claims (1)

【特許請求の範囲】 1 スチレンと無水マレイン酸との共重合体より
なる変性ポリスチレン樹脂の発泡体の両面に、該
変性ポリスチレン樹脂を含浸させたポリエステル
不織布を熱融着してなることを特徴とした自動車
用天井内装材。 2 スチレンと無水マレイン酸との共重合体より
なる変性ポリスチレン樹脂を溶解したトルエン等
の溶剤中にポリエステルを原料とする不織布を浸
漬するか、又は、該不織布に変性ポリスチレン樹
脂シートをホツトプレスすることにより、該不織
布中に変性ポリスチレン樹脂を予め含浸せしめ、
該不織布を変性ポリスチレン樹脂に発泡剤を加え
て押出することにより一次発泡させた板状の発泡
体の両面に熱融着することにより板状の一次成形
品を製造し、さらにこの一次成形品を加熱するこ
とにより発泡体を二次発泡させて半溶融状態とし
これを所定の雄雌型にて天井面に沿う立体形に加
圧成形することを特徴とした自動車用天井内装材
の製造方法。
[Claims] 1. A polyester nonwoven fabric impregnated with the modified polystyrene resin is heat-sealed to both sides of a foam made of a modified polystyrene resin made of a copolymer of styrene and maleic anhydride. Automotive ceiling interior material. 2. By immersing a nonwoven fabric made of polyester in a solvent such as toluene in which a modified polystyrene resin made of a copolymer of styrene and maleic anhydride is dissolved, or by hot pressing a modified polystyrene resin sheet onto the nonwoven fabric. , pre-impregnating the nonwoven fabric with a modified polystyrene resin,
A plate-shaped primary molded product is produced by heat-sealing the nonwoven fabric to both sides of a plate-shaped foam that is primarily foamed by extruding a modified polystyrene resin with a foaming agent added thereto. A method for producing a ceiling interior material for an automobile, which comprises secondarily foaming the foam by heating to bring it into a semi-molten state, and press-molding it into a three-dimensional shape along the ceiling surface using predetermined male and female molds.
JP56154499A 1981-09-28 1981-09-28 Ceiling interior finish material for automobile and its manufacture Granted JPS5871154A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP56154499A JPS5871154A (en) 1981-09-28 1981-09-28 Ceiling interior finish material for automobile and its manufacture

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP56154499A JPS5871154A (en) 1981-09-28 1981-09-28 Ceiling interior finish material for automobile and its manufacture

Publications (2)

Publication Number Publication Date
JPS5871154A JPS5871154A (en) 1983-04-27
JPH0262387B2 true JPH0262387B2 (en) 1990-12-25

Family

ID=15585576

Family Applications (1)

Application Number Title Priority Date Filing Date
JP56154499A Granted JPS5871154A (en) 1981-09-28 1981-09-28 Ceiling interior finish material for automobile and its manufacture

Country Status (1)

Country Link
JP (1) JPS5871154A (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6166641A (en) * 1984-09-04 1986-04-05 モンサント コンパニ− Thermoformable laminated structure
JPS6375162A (en) * 1986-09-16 1988-04-05 積水化学工業株式会社 Fiber sheet molded body
NL8703138A (en) * 1987-12-28 1989-07-17 Schreiner Luchtvaart SANDWICH MATERIAL AND USE THEREOF.
JP6937185B2 (en) * 2017-08-03 2021-09-22 林テレンプ株式会社 Interior materials for vehicles

Also Published As

Publication number Publication date
JPS5871154A (en) 1983-04-27

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