JPH03137140A - Interior base material - Google Patents

Abstract

PURPOSE:To obtain an interior base material useful for ceiling, door trim, rear parcel, etc., having excellent rigidity, not requiring adhesion of reinforcing layer, comprising a plastic foam mixed with a filler. CONSTITUTION:A plastic foam which contains 10-70 wt.% based on plastic foam of a filler (inorganic fiber such as glass fiber or organic fiber such as polyester fiber) and is obtained by arbitrarily impregnating the filler with a synthetic resin. For example, in the case of polyurethane foam, a mixture of a polyfunctional isocyanate, a polyol and a curing agent which are mixed with the filler is cast into a mold, a polyurethane foam block is produced by foam molding, a lamellar or sheetlike foam is cut out from the block and at this stage, a synthetic resin (precursor) is arbitrarily impregnated into the foam having open cells, dried, heated and softened and molded into a desired shape to give the objective interior base material.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a base material for interior materials such as automobile ceilings, door trims, and rear parcels.

[Conventional technology]

Conventionally, automotive interior base materials made of plastic foams such as polystyrene foams and synthetic resin-impregnated polyurethane foams have been provided (for example, Japanese Patent Application Laid-Open No. 58-5346,
(Unexamined Japanese Patent Publication No. 61-51544) (Problem to be Solved by the Invention) However, since the automobile interior base material made of the plastic foam described above lacks rigidity, a reinforcing layer must be attached to one or both sides. This complicates the manufacturing process, and when a glass fiber layer is used as the reinforcing layer, glass fiber particles are scattered, creating a poor working environment.

[Means to solve the problem]

The present invention, as a means for solving the above-mentioned conventional problems,
The present invention provides an interior base material made of a plastic foam mixed with a filler.

The present invention will be explained in more detail.

[Plastic foam]

Plastic foams used in the present invention include polyethylene foams, polypropylene foams, polyvinyl chloride foams, polystyrene foams, polyurethane foams, and the like. When the plastic foam has open cells, it is formed of a synthetic resin such as styrene resin, acrylic resin, vinyl acetate resin, vinyl chloride resin, urethane resin, epoxy resin, melamine resin, phenol resin, or the above synthetic resin. A synthetic resin precursor such as a prepolymer, oligomer, or monomer may be impregnated. Examples of the synthetic resin precursors include unsaturated polyesters, styrene monomer-unsaturated polyester mixtures, epoxy prepolymers, urethane prepolymers, polyvalent isocyanates, methyl methacrylate monomers, and ethylene glycol dimethacrylate. After being impregnated into the plastic foam, it is cured to a synthetic resin by a curing means such as heat, light, a curing catalyst, or water.

[Filling material]

Fillers used in the present invention include inorganic fillers such as calcium carbonate, talc, bentonite, fly ash, blast furnace slag, and shirasu balloons, glass fibers, carbon fibers,
Ceramic fibers, metals [fibers, etc.] ! Weaving fibers include organic powder fillers such as plastic powder and organic fiber powder, and organic fibers such as polyester fiber, polyamide fiber, acetate fiber, and pulp.

The above filler is usually 10 to 7 for plastic foam.
Approximately 0 weight percent is added.

〔Production method〕

The above plastic foam is manufactured by conventional methods. Specifically, in the case of polyethylene foam, polypropylene foam, polystyrene foam, etc., a plastic foam block is manufactured by filling a mold with expandable beads mixed with the above-mentioned filler and foaming them under heating. A method of cutting out plate-like or sheet-like plastic foam from a polyurethane foam.For polyurethane foam, a mixture of a polyvalent isocyanate mixed with the above-mentioned filler, a polyol, and a curing agent is injected into a mold to form the foam. A method for producing a polyurethane foam block and cutting out a plate-like or sheet-like polyurethane foam from the polyurethane foam block. A method of manufacturing a polyvinyl chloride foam sheet by applying a paste onto a release paper and heating and foaming it into a gel is applied.

Plastic foams with open cells, such as polyvinyl chloride foams and polyurethane foams, may be impregnated with a synthetic resin or a synthetic resin precursor as described above, but in that case, the plastic foam is usually made into a plate. Impregnation is performed after cutting into shapes or sheets, and the amount of impregnation is usually 10 to 50% by weight.

[Molding]

The plastic foam of the present invention produced as described above is usually in the form of a plate or sheet, and is molded when used as a base material for automobile ceiling materials, door trims, rear parcels, etc. The molding method is heat-pressing molding. If the plastic foam is heated and softened and then subjected to cold pressing or vacuum forming, and the plastic foam is impregnated with a synthetic resin precursor, it is usually hardened by the above-mentioned curing method during molding. However, it may be cured before molding.

[Effect]

Mixing fillers into plastic foam improves the rigidity of the plastic foam. In particular, if inorganic or organic V&fiber is selected as the filler, a great reinforcing effect can be obtained.

When the plastic foam is impregnated with a synthetic resin, moldability and molded shape stability are improved.

〔Effect of the invention〕

Therefore, the interior base material of the present invention has high rigidity, and there is no need to attach a reinforcing layer.

〔Example〕

Example 1 40 parts by weight of glass fiber was added to 100 parts by weight of pre-expanded polystyrene expandable beads.
parts by weight and 10 parts by weight of polyester fibers are mixed, filled into a mold and heated at 150"C for 3 minutes to perform foam molding. The obtained filled polystyrene foam block is made into a plate-like body with a thickness of 15 mm+. Slice.The plate-shaped body has 13 slices.
It is softened by heating at 0"C for 5 minutes, and then vacuum formed into the shape of an automobile ceiling. The surface of the ceiling base material thus obtained is covered with a hot melt sheet such as a polyethylene sheet. Textile knitted fabric.

A covering material such as non-woven fabric, synthetic leather, or plastic sheet is attached to form the ceiling material.

Example 2 100 parts by weight of polypropylene glycol (molecular weight 3000), 1 part by weight of tolylene diisocyanate 44°, 3 parts by weight of water
．． 5 parts by weight, 10 parts by weight of trichloromonofluoromethane, 1.5 parts by weight of silicone dispersant, 0.5 parts by weight of stannath octoate, 40 parts by weight of glass fiber, and 20 parts by weight of calcium carbonate were mixed into a cream and molded. Inject into a mold and foam and harden. The filled polyurethane foam block obtained is sliced into plates with a thickness of 15 m. The plate is impregnated with 100% by weight of a 50% by weight solution of methylene diphenyl diisocyanate in trichloroethylene, dried, and then steam is blown out and molded into the shape of an automobile ceiling to obtain a ceiling base material. A covering material similar to that in Example 1 is attached to the ceiling base material to form a ceiling material.

Claims (1)

[Claims] 1. Interior base material 2 characterized by being made of a plastic foam mixed with a filler; Interior base material 3 according to claim 1, wherein the filler is an organic or inorganic fiber. , the interior base material according to claim 1, wherein the plastic foam is impregnated with a synthetic resin.