JPH0349942A - Preparation of base material of interior material - Google Patents

Abstract

PURPOSE:To achieve wt. reduction, cost reduction and the enhancement of quality by providing a reinforcing layer formed by impregnating glass long fibers with an urethane modified unsaturated polyester resin in a cut/dispersed/ laminated state to both surfaces of a polyurethane foam sheet to form a raw base material and applying heat press molding to said base material. CONSTITUTION:An urethane modified unsaturated polyester resin 3 is uniformly applied to a release film 5 by a doctor blade 6 and glass fiber 2 cut into a definite length are uniformly laminated to the resin layer in a dispersed state and a heat-moldable polyurethane foam sheet 1 is placed thereon. Next, glass fibers 2 cut into a definite length are uniformly laminated to the upper surface of the polyurethane foam sheet in a dispersed state and the release film 5 uni formly coated with the resin 3 on the inside by the doctor blade 6 is laminated to the fiber layer. This raw base material is sealed by a cellophane film 8 and the volatilization of a styrene monomer is prevented to thicken the resin. The release films 5 are removed from the raw base material whose resin is thickened and the raw base material is inserted in a heat press mold 9 to be subjected to heat press molding.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention is applicable to interior materials, particularly for automobiles such as molded ceilings, door trims, pillar pawnishes, trunk trims, etc.
@Related to methods for manufacturing base materials for interior materials such as vehicles and furniture.

(Prior Art) Examples of methods for manufacturing interior material base materials using polyurethane foam include the following.

(1) Japanese Patent Publication No. 63-7577 A flexible polyurethane foam is impregnated with an isocyanate compound, and water containing or not containing amine is sprayed on it to form glass fibers, plastic films, non-woven fabrics, etc.
A method for manufacturing composite panels in which skins, etc. are laminated and heated and formed using a press mold.

(2) G B 2028714 B (Cold press method) Apply adhesive to a polyurethane foam sheet and/or a reinforcing sheet such as plus fiber, and bond them together, 17
A method for producing a reinforced panel of polyurethane foam, which is preheated to 0 to 220°C and then immediately molded with a press mold.

Since the method (1) above uses flexible polyurethane foam, a step of impregnating it with an isocyanate compound and then curing it is necessary to ensure strength. Incyanate compounds react with moisture in the air and begin to harden, so they must be thermoformed immediately after being impregnated, and they have poor storage stability and cannot be stocked. Therefore, it is necessary to use a series of continuous equipment from impregnation to press molding, which requires a large investment in equipment. In addition, the process is cumbersome as it includes a step of spraying water with or without amine.

On the other hand, the method (2) above includes the step of taking out the heated composite of polyurethane foam and reinforcing sheet from the heat source and immediately putting it into a press mold, that is, within 3 to 10 seconds,
The process is complicated or the pressing process must be performed in a short open time.

Furthermore, in both (1) and (2) above, the resin used for adhesion does not have sufficient strength even after curing, and is not hard enough to harden the plus fibers and prevent them from moving, so if left as is, the surface will become sticky. Therefore, a skin material (non-woven fabric) is necessarily required, which is also undesirable in terms of weight and cost.

(Problems to be Solved by the Invention) The purpose of the present invention is to eliminate the need for a continuous process from impregnation to pressing because the resin to be impregnated has a long pot life. An object of the present invention is to provide a method for producing an interior material base material that can be press-formed without preheating the base material material.

Another object of the present invention is to provide a method for producing an interior material base material that is excellent in terms of weight, cost, and physical properties, and can also omit the skin material because it only has spikes on the surface.

(Means for Solving the Problems) The present invention is a thermoformable polyurethane foam sheet with urethane-modified unsaturated fibers cut into a certain pressure and uniformly distributed and laminated in a random direction on both sides of a thermoformable polyurethane foam sheet. Production of an interior material base material, which is characterized in that a reinforcing layer impregnated with polyether 0g fat is provided to create a base material material, and then this base material material material is shaped and cured by hot press molding. Regarding the method.

The interior material base material of the present invention comprises a thermoformable polyurethane foam sheet 1 and a reinforcing layer 4 of a urethane-modified unsaturated polyester resin 3 reinforced with plus fibers 2, as shown in FIG.

As the polyurethane foam of the present invention, a conventionally well-known thermoformable polyurethane foam is used,
For example, density 20-50kHz/m', preferably 30-4
Semi-rigid or rigid polyurethane foam having a closed cell ratio of 0 kg/+a' of 0 to 80%, preferably 0 to 10% is preferably used. Specific examples of such polyurethane foam include, for example, the above-mentioned GB 2028714 B
Or Modern P 1stiesInter
Examples include polyurethane foams described in National, 6 (3) IL1978 and the like.

Also, the thickness of the polyurethane foam sheet is 3-15am.
is preferable, and 4 to 101 is more preferable.

Plus fibers are made by bundling tens to hundreds of single fibers with a sizing agent and then cutting the strands as they are or several strands (roving) into a certain length (25 to 60 m+s) while dispersing and laminating them in a random direction. (50 to 150 g/m2, preferably 70 to 100 g/m2), and add 100 to 25 g/m2 of urethane-modified unsaturated polyester resin.
It is used by impregnating it at a rate of 0 g/2 ounces, preferably 140 to 160 g/2 ounces.

The urethane-modified unsaturated polyester resin used in the present invention is a polyol component that is a mixture of a polyester polyol having unsaturated groups, a urethane catalyst, and a crosslinking agent for unsaturated groups (usually styrene monomer) (if polyether polyol, etc. is added to this) ) and an isocyanate component which is a mixture of isocyanate and peroxide. In the reaction, first, the polyol and incyanate form a urethane bond under the influence of a urethane catalyst, resulting in chain extension. Thereafter, under heating under the influence of a peroxide catalyst, the unsaturated groups in the molecule and a crosslinking agent such as a styrene monomer undergo radical polymerization, resulting in a highly crosslinked cured resin.

Since all raw materials are of low molecular weight, the initial viscosity is low and easy to handle. Unless the liquid resin is heated to high temperatures, only the urethane reaction will proceed and the crosslinking reaction of unsaturated bonds will not occur. Since the urethane reaction can be controlled with a catalyst, thickening can be delayed for a long time.

Even when the urethane reaction progresses and gradually thickens and loses its tackiness, it remains soft because it is diluted with styrene monomer, and when heated, it melts and then hardens over a long period of time. It can be thermoformed even after The cured resin has better physical properties such as impact resistance and strength than ordinary unsaturated polyester, has less shrinkage during molding, and has heat resistance not found in polyurethane.

Taking advantage of the processability and physical properties of this urethane-modified unsaturated polyester resin, the initial viscosity is low, so it has good impregnation into lath A fibers, and even a small amount of resin can be sufficiently impregnated, making it possible to reduce weight. (Since the pot life of the fat is long, it can be stored for a long time, so there is no need for continuous processing, and since the resin is highly hardened, the lath fibers can be completely hardened, eliminating the need for a skin material, reducing weight, This makes it possible to lower prices.

In addition, by combining with a thermoformable polyurethane foam, it is possible to produce a shaped and hardened interior material base material by hot press molding the raw base material without preheating.

In the present invention, hot press molding may be performed immediately after glass fibers are impregnated with the turethane-modified unsaturated polyester resin on both sides of the thermoformable polyurethane foam sheet, but the resin may be thickened after the impregnation operation. It can also be molded with the surface tacky, and in this case handling becomes much easier.

In addition, methods for providing reinforcing layers on both sides of a thermoformable polyurethane foam sheet include a method in which resin is applied to a 7-ohm urethane sheet in advance and then plus fibers are dispersed and laminated, and a method in which F-7 fibers are layered on a 7-ohm urethane sheet is applied. A method of applying resin after dispersion and lamination, or a method of directly spraying resin and plastic fibers simultaneously onto a 7-ohm urethane sheet, or a method of uniformly applying resin on a release film such as polyethylene film and then applying plastic fibers. Various methods can be considered, such as dispersion lamination and then placing a urethane 7-ohm sheet on top of it. When providing reinforcing layers on both sides, among these methods, IMi methods can be used to perform both sides, and two types of methods can be used. can be implemented in combination.

An example of the manufacturing method for the interior material base material of the present invention will be explained with reference to FIG. 2.

■First, urethane-modified unsaturated polyester resin 3 is uniformly applied onto the lower mold release film 5 such as polyethylene film or polypropylene film using a doctor blade 6, etc., and then the plus fiber 2 cut into a certain length is applied. A thermoformable polyurethane foam sheet 1 is placed on the uniformly dispersed and laminated layer. Next, glass fibers JI2 cut to a certain length are uniformly dispersed and laminated on the upper surface of the 7-ohm urethane sheet, and a release film 5 on which resin 3 is uniformly coated on the inside with a doctor blade 6 is laminated thereon.

(2) The base fabric prepared in step (a) above is sealed with cellophane film 8 or the like to prevent volatilization of the styrene monomer and allowed to thicken under mild conditions at 20 to 40°C for one day or more.

■(1) From the base material with thickened fat to the female mold film 5
is removed and heated to 130-160℃, preferably 14℃.
Insert into a hot press mold 9 at 0 to 150°C and heat to 0.5 to 3
Hot press molding is performed for 0.5 to 2 minutes, preferably 0.5 to 2 minutes.

■Remove the mold and take out the molded interior material base material.

The skin may be bonded after molding or may be bonded at the same time as the molding, and this will be adjusted depending on the type of skin.

(Effects of the invention) - It is relatively lightweight and has high rigidity because it consists of a reinforcing layer that combines high-strength resin and plus fiber and a core material of low specific gravity polyurethane foam.

■As it combines highly heat-resistant resin and glass fiber, it is heat-resistant and has extremely high dimensional stability.

■Since it is a resin with excellent moisture resistance, it has high humidity and heat resistance of -1°. ■Since it uses thermoplastic hard or semi-rigid urethane 7 ohm, it has good moldability and a high degree of freedom in design.

■Since the resin is highly hardened, the glass fiber can be completely hardened, making it possible to omit the skin material.

(Example) The present invention will be explained below with reference to Examples.

Example 1 On one side of a thermoformable rigid polyurethane foam sheet with a specific gravity of 0,030 and a thickness of 7 mm, a roving of long glass fibers was attached to a roll of urethane rubber with a knife at a spacing of 30 mm on the outlet of a spray gun. By inserting the blade into the gap between the rolls and rotating them, Q 30mwn
At the same time as cutting is continuously carried out at 1 yen intervals, the polyol component and the incyanate component of the urethane-modified unsaturated polyester resin are mixed in a spray gun and sprayed uniformly at the same time. At this time, the amount of plus fiber should be 100g/m2, and the amount of fat should be 150g/m2. Next, the other side is similarly sprayed with resin and plus fiber at the same time. Furthermore, this was inserted into a heat press mold for molded ceilings at 150°C and press-molded to a standard wall thickness of 611 Tsuru.
The mold was removed after 1 minute to obtain a molded ceiling base material weighing 710 g/-''.

Example 2 While uniformly applying urethane-modified unsaturated polyester resin containing a polyol component and incyanate component onto a polyethylene film using a doctor blade at a coating amount of 150 g/Ken2, the polyethylene film was continuously and uniformly coated. move at speed. On top of that, a roving of plus long fibers was inserted between a roll of urethane rubber and a roll with knife blades attached at 30 mm intervals, and these were rotated. Then, a thermoformable rigid polyurethane foam sheet with a specific gravity of 0.030 and a thickness of 7 mm was placed on top of it, and 100 g/m2 of lath fibers were uniformly distributed and laminated in a random direction. On top of that, uniformly add 100 pieces of plus fiber cut into 30 pieces in the same way as above.
g/m" dispersed and laminated, and on top of that, a polyethylene film coated with 150 g/m2 of resin evenly on the inside in the same manner as above was laminated, and then lightly compressed with a press roll with a clearance set to 7-. After that, the product is cut to match the product size.The created base material is packed into 30 sheets, sealed with cellophane film, and left at 25°C for 7 days.Before molding, the cellophane film and polyethylene film are is removed, and then this base material is 1
Press molded with a hot press mold for molded ceilings at 50°C to a standard wall thickness of 61 mm, removed from the mold after 1 minute, and finished with a mold of 710 g/m2.
A base material for a molded ceiling was obtained.

[Brief explanation of drawings]

FIG. 1 shows a cross-sectional view of the base material obtained by the present invention. FIG. 2 shows an example of the manufacturing method of the present invention. 1...Thermoformable polyurethane foam, 2...
Plus fiber, 3... Urethane modified unsaturated polyester resin, 4... Reinforcement layer, 5... Release sheet, 6...
- Doctor blade, 7... Roll, 8... Cellophane film, 9... Hot press mold. (Above) Applicant Toyo Rubber Industries Co., Ltd. Agent Patent attorney 1) Iwao Mura Diagram ■ =--5=-1--1 Procedural amendment (method) 1. Presentation of the case 1999 Patent No. 186323 2゜Name of the invention Method for manufacturing interior material base material 3 Relationship with the case of the person making the amendment Patent applicant (314) Toyo Tires & Rubber Industries Co., Ltd. 4, Substituted in Kita, Osaka City, Osaka Prefecture, 530 Ward Sonezaki 1-2-8 Heisei 1
October 16, 1999 (Shipping date: October 31, 1999) 6.
Target of correction “Drawing” 7. Contents of correction Figure (4) qton ===nnn2

Claims (2)

[Claims] (1) A reinforcing layer impregnated with urethane-modified unsaturated polyester resin is applied to both sides of a thermoformable polyurethane foam sheet, with bundled long glass fibers cut to a certain length and uniformly distributed and laminated in random directions. 1. A method for producing an interior material base material, which comprises: preparing a base material material, and then shaping and curing the base material material material by hot press molding. (2) The method for producing an interior material base material according to claim 1, wherein after the impregnation operation with the urethane-modified unsaturated polyester resin, the viscosity is thickened under mild conditions to lose surface tackiness, and then hot press molding is carried out.