JPH03227210A - Manufacture of internal trim - Google Patents

Abstract

PURPOSE:To enable the rigidity of internal base material to be regulated simply by the small pressure of a press by a method in which the glass fiber-layer coated with an adhesive and/or unwoven fabric and skin material are laminated on the foam layer impregnated with uncured thermosetting resin, and then said laminate is clamped with a plate-mold and is sent to a curing furnace, and further the laminate is integrally formed with said adhesive by curing under heating the thermosetting resin. CONSTITUTION:A foam layer 25 may be molded by the pressure of 0.2-0.5kg/cm<2>, and the foam layer 25 is impregnated with thermosetting resin 26 such as uncured melamine resin etc. of about 10wt.%. The glass fiber layers 31, 32 coated with an adhesive and/or unwoven fabric 35 and skin material 23 are laminated on said foam layer 25. Said laminate 41 is inserted between the bottom force and the top force of a plate mold, and is sent to a curing furnace in the state of mold-clamping. The laminate is integrally molded with the adhesive by curing under heating. Accordingly, burrs do not occur, and the regulation of the rigidity is simply achieved by selecting glass fiber or unwoven fabric with thermosetting resin.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for manufacturing an interior material. More specifically, the present invention relates to a method for manufacturing an interior material. Specifically, a reinforcing fiber layer is laminated on an interior material made of a foam layer, and The present invention relates to a method for manufacturing an interior material in which an interior material having a desired shape is formed by bonding a skin material to the surface of the material.

[Conventional technology]

Conventionally, there have been molded ceilings, door trims, trunk trims, etc. as interior materials for vehicles, etc., and it is known that resin felt, cardboard, polyurethane foam, and other foam layers are used as interior base materials for these interior materials. . Although the interior base material made of resin felt and corrugated poles has sufficient rigidity, the interior base material made of a foam layer lacks rigidity. Laminated ones are known. Also known is an interior base material impregnated with a thermosetting resin to impart rigidity to the foam layer (Japanese Patent Publication No. 5852495).
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In addition, a hot press mold is used to mold the resin felt and corrugated poles, and a pressure of around 3 kg/c is applied.

[Problems to be Solved by the Invention] However, when using resin felt or cardboard as in the past, it is necessary to use a hot press mold with a large pressing pressure during hot pressing, which increases the size of the equipment and increases costs. In addition, it has the disadvantage that flakes are generated during hot pressing, and the process for removing flakes is complicated. Furthermore, when reinforcing nonwoven fabric or glass fiber is bonded to the foam layer using an adhesive, the lamination process is complicated and work efficiency cannot be improved. If it is not possible to impregnate the resin, it is difficult to obtain uniform rigidity, and it is also extremely difficult to adjust the rigidity.

The object of the present invention is to be able to mold an interior base material using a foam layer that requires only a small press pressure, to be able to mold the interior material simply and quickly using a sheet metal mold, and to significantly improve work efficiency. , the rigidity of the interior base material can be easily adjusted, there is no need to use a hot press mold when molding the interior material, it is highly economical, and it can be manufactured using a line process suitable for mass production. The present invention provides a method for manufacturing interior materials.

[Means for Solving the Problems] The present invention has been made in view of the above-mentioned problems, and includes laminating a reinforcing fiber layer on an interior base material made of a foam layer, and applying a skin material to the surface of the interior base material. In a method for manufacturing an interior material that is bonded to form an interior material of a desired shape, the foam layer is impregnated with an uncured thermosetting resin, and the back side of the foam layer is coated with an adhesive. A lower mold and an upper mold each having a shape corresponding to the shape of an interior material to be formed by laminating layers and/or nonwoven fabrics, and laminating a skin material coated with an adhesive on the surface side of the foam layer, and molding these laminated products. Insert it into a sheet metal mold consisting of, transfer the sheet metal mold to a curing furnace with the mold clamped,
The method is characterized in that the uncured thermosetting resin impregnated into the foam layer is heated and cured to form an interior material having a desired shape.

[Effect]

According to the present invention, a glass fiber layer and/or nonwoven fabric, and a skin material, are obtained by impregnating an uncured thermosetting resin into a foam layer that can sufficiently reduce the press pressure, and applying an adhesive to the foam layer. These laminated products are inserted between the lower and upper molds of a sheet metal mold that does not require large press pressure,
Transfer the sheet metal mold in a clamped state to a curing furnace, heat cure the uncured thermosetting resin of the foam layer to integrate the laminate with the adhesive, and obtain an interior material with a desired shape. Since the interior material of the desired shape can be obtained by clamping the sheet metal mold and heating, there is no occurrence of flaking, and the rigidity can be easily adjusted by selecting a glass fiber layer or nonwoven fabric in addition to the thermosetting resin. It is something.

〔Example〕

The method for manufacturing interior materials according to the present invention will be described in detail below with reference to the drawings.

FIG. 1 and FIG. 2 show a sheet metal mold 1 applied to the method of the present invention.
The outline of one embodiment of 1 is shown, and this sheet metal mold 1
1 includes a lower mold 12 and an upper mold 13 attached to the lower mold 12 via a hinge 14 so as to be freely openable and closable, and is configured to be clamped by a clamp mechanism 16 in a state where the upper mold 13 is clamped. .

The lower mold 12 and the upper mold 13 are each formed into a shape corresponding to the external shape of the interior material to be molded. Further, the lower mold 12 is placed on a base 18 and is configured to be transferred to a curing furnace which will be described later.

FIG. 3 shows an example of the laminated state of the interior base material 22 and the skin material 23 inserted into the sheet metal mold 1, and the interior base material 22 is made of polyol having a thickness of 4 to 10 mm and a density of 20 kg/rrf. It has a foam layer 25 having open cells made of urethane, slab urethane, etc.
2 to 0.5) can be molded at a pressure of cg/cil,
In addition, the foam layer 25 has an uncured thermosetting resin 26.
is impregnated. As the thermosetting resin 26, melamine resin, urethane resin, urea resin, thermosetting acrylic resin, etc. can be used, and the foam layer 25 is impregnated with about IO weight %.

Glass fiber layers 31 and 32 coated with reinforcing adhesive are laminated on both the front and back surfaces of the foam layer 250. On the back side of the glass fiber layer 31 on the back side (top side in this embodiment) of the foam layer 25, a nonwoven fabric 35 made of polyester nonwoven fabric or the like with a weight of 10 to 50 g/rd is laminated.

Further, on the front side of the glass fiber layer 32 on the front side of the foam layer 25, a hot melt sheet 37 as an adhesive is provided on the back side.
A skin material 23 is laminated.

A laminated product 41 shown in FIG. 3 is cut into a desired shape and inserted into the lower mold 12 of the sheet metal mold 11, and the upper mold 13 is clamped and clamped by the clamping mechanism 16 to create a pressurized state. The sheet metal mold 11 is transferred to a curing furnace (not shown). The curing furnace is heated to 150° C., and by heating for about 60 seconds, the uncured thermosetting resin 26 impregnated into the foam layer 25 is cured. Also,
The hot melt sheet 37 laminated on the skin material 23 is heated and melted, the skin material 23 is joined to the foam layer 25 via the glass fiber layer 32, and the laminated product 41 is integrated into the sheet metal mold 1
The interior material 21 is formed into a desired shape along the shape of the interior material 21.

Alternatively, the end of the skin material 23 may be formed longer than the end of the interior base material 22, and after the interior material 21 is molded, the end of the skin material 23 may be folded back to the back side of the interior base material 22 for end treatment.

Note that either one of the glass fiber layers 31 and 32 may be omitted, or either the glass fiber layer 31 or the nonwoven fabric 35 may be omitted.

〔Effect of the invention〕

The above is an embodiment of the method for manufacturing interior materials according to the present invention. According to this method, an uncured thermosetting resin is impregnated into a foam layer that can be molded with a small molding pressure. Then, a glass fiber layer and/or non-woven fabric coated with adhesive, and a skin material are laminated on the foam layer, and these laminated products are inserted between the lower mold and the upper mold of a sheet metal mold, and the sheet metal mold is pressed with a small pressure. The mold is transferred to a curing furnace in a clamped state, and in this state, the uncured thermosetting resin of the foam layer is heated and cured to integrate the laminate together with the adhesive, and an interior material having a desired shape is obtained. Since the interior material is obtained by clamping and heating the sheet metal mold, there is no generation of flakes, and the rigidity can be easily adjusted by selecting a glass fiber layer or non-woven fabric in addition to the thermosetting resin. It is an extremely economical interior material that can be easily obtained with high rigidity, and since it does not use a hot press mold, the equipment can be miniaturized and mass production can be carried out in a line process. A manufacturing method can be obtained.

[Brief Explanation of the Drawings] Figures 1 to 3 each schematically show an embodiment of the method for manufacturing interior materials according to the present invention, and Figure 1 shows a state in which a laminate is inserted into a sheet metal mold. 2 is a sectional view showing a state in which the sheet metal mold is clamped, and FIG. 3 is a sectional view showing a laminated state of a laminated product. In the figure, 11... Sheet metal mold, 12... Lower mold, 13...
Upper mold, 16... Clamp mechanism, 18... Base, 21
... Interior material, 22 ... Interior base material, 23 ... Skin material, 25 ... Foam layer, 26 ... Thermosetting resin, 31
．． 32...Glass fiber layer, 35...Nonwoven fabric, 37.
...Hot melt sheet, 41...Laminated product. Figure 3

Claims (1)

[Claims] (1) A method for producing an interior material, in which a reinforcing fiber layer is laminated on an interior base material made of a foam layer, and a skin material is bonded to the surface of the interior base material to form an interior material of a desired shape. The body layer is impregnated with an uncured thermosetting resin, the back side of the foam layer is laminated with a glass fiber layer and/or a nonwoven fabric coated with an adhesive, and the adhesive is applied on the front side of the foam layer. These laminated products are inserted into a sheet metal mold consisting of a lower mold and an upper mold having a shape corresponding to the shape of the interior material to be molded, and the sheet metal mold is placed in a curing furnace with the mold clamped. A method for producing an interior material, which comprises transferring the uncured thermosetting resin impregnated into the foam layer to heat and cure it to form an interior material having a desired shape.