JPH0365267B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to an automobile interior material used as an automobile ceiling material, etc., and a method for manufacturing the same. Conventionally, interior materials for automobiles, especially ceiling materials, have been molded by heating and pressurizing cardboard, or by pasting a pair of deformed polystyrene resin films on both sides of a deformed polystyrene resin foam, which is then heated and subjected to secondary foaming. It is known to be molded by pressing,
Although the former has the advantage of being inexpensive, it has the disadvantage of not being able to be deep drawn, while the latter can be deep drawn, but there is a problem of thermal deformation due to the rise in vehicle temperatures in the summer, so improvements in heat resistance are required. was. In view of such conventional drawbacks, the present invention has been developed by bonding a polyester nonwoven fabric to the back side of a composite laminated sheet in which a pair of modified polystyrene resin films are adhered to both sides of a deformed polystyrene resin foam. An object of the present invention is to efficiently produce an interior material for an automobile, which has a good surface appearance and excellent heat resistance, by adhering a skin material such as a vinyl chloride sheet or a woven fabric with a nonwoven fabric interposed therebetween. Embodiments of the present invention will be described below with reference to the drawings. In the figure, 1a is a modified polystyrene resin foam that is formed into a plate shape by adding a foaming agent and extruding it under heating to foam a part of the foaming agent (this foaming is generally referred to as primary foaming). A pair of modified polystyrene resin films 1 are placed on both sides of the modified polystyrene resin foam 1.
Composite laminated sheet 1 is created by pasting b and 1b.
(hereinafter referred to as "PS resin composite sheet 1"). The modified polystyrene resin herein generally refers to a copolymer of styrene and maleic anhydride, methacrylic acid, acrylic acid, or the like. Therefore, the automobile interior material shown in FIG.
3 is adhered, and a skin material 4 of polyvinyl chloride sheet with foamed urethane is further adhered to the surface side of the PS resin composite laminate sheet 1 so that the foamed urethane layer 5 faces the polyester nonwoven fabric 2. It is. The skin material 4 of the vinyl chloride sheet may be replaced with a woven fabric as the same skin material. Next, an example of the manufacturing method will be described with reference to the manufacturing process diagram shown in FIG. 2. 1' is the above
The PS resin composite laminate sheet 1 is the basis of the PS resin composite laminate sheet 1. The PS resin composite laminate sheet 1' is made by extruding polystyrene resin to which a foaming agent has been added into a plate shape under heating to remove a portion of the foaming agent. It is foamed and a pair of modified polystyrene resin films 1b, 1b are attached to both sides of the foam. Further, the polyester non-woven fabric 2 to be adhered to the surface of the PS resin composite laminate sheet 1 is immersed in a bath 6 of a heat-resistant synthetic resin adhesive to impregnate the polyester non-woven fabric 2 with the heat-resistant synthetic resin adhesive,
Thereafter, the polyester nonwoven fabric 2 is adhered to the upper surface 7 of the PS resin composite laminate sheet 1'. The coating method may be a dipping method as shown in the figure, or other methods such as double-sided spraying or double-sided roll coating. On the other hand, the heat-resistant synthetic resin adhesive is applied to one side of the polyester nonwoven fabric 3 that contacts the back side of the PS resin composite laminate sheet 1.
It is adhered to the lower surface 8 of the PS resin composite laminate sheet 1'.
In this case, the adhesive application method may be not only the spray coating method shown in the figure, but also other methods such as a roll coating method. thus
The PS resin composite laminated sheet 1' with the polyester nonwoven fabrics 2 and 3 adhered to both the front and back surfaces is then transported into a heating chamber 9 where the temperature is higher than that at the time of primary foaming.
Heating in an atmosphere of 105° C. to 140° C. causes secondary foaming of the PS resin composite laminate sheet 1′ to expand its volume and bring it into a semi-molten state, while at the same time thermally activating the heat-resistant synthetic resin adhesive. At this time, since the polyester nonwoven fabrics 2 and 3 usually have a heat resistance of at least 180° C. or higher, the sheet-like shape is maintained without deterioration at this ambient temperature. Next, the skin material 4 such as the polyvinyl chloride sheet with foamed urethane is superimposed on the upper surface 7 side of this laminated material and carried into the press 10, and pressurized by the male and female molds 11 and 12 to form a solid shape of a predetermined shape. It is deep drawn into shape. Next, another manufacturing method of the present invention will be explained with reference to the manufacturing process diagram shown in FIG. In the manufacturing process diagram shown in the figure, one of the polyester nonwoven fabrics 2 impregnated with a heat-resistant synthetic resin adhesive is placed in a drying chamber.
3 and heated with infrared rays to evaporate the solvent, thereby drying and curing in one step. Further, the other polyester nonwoven fabric 3 is also carried into the drying chamber 14 after a heat-resistant synthetic resin adhesive is applied to its upper surface, and the solvent is similarly evaporated and dried. Next, one polyester nonwoven fabric 2 is superimposed on the upper surface of the PS resin composite laminate sheet 1', and the other polyester nonwoven fabric 3 is superimposed on the lower surface 8 of the PS resin composite laminate sheet 1' in a non-adhered state. After that, as in the case of Fig. 2, this is carried into the heating chamber 9, and the PS resin composite laminate sheet 1' is secondarily foamed to a semi-molten state, and at the same time, the heat-resistant synthetic resin adhesive is thermally activated. Then, the skin material 4 is superimposed on the upper surface 7 side of this and pressure-molded using a press machine 10. FIG. 4 shows a manufacturing process diagram according to yet another manufacturing method. In this case, a heat-resistant synthetic resin adhesive is not applied to the polyester nonwoven fabric 3, but instead a heat-resistant synthetic resin adhesive is applied to the lower surface 8 of the PS resin composite laminate sheet 1', and the heat-resistant synthetic resin adhesive The resin adhesive is dried and hardened in the drying chamber 15, and the rest is the same as in the case of FIG. 3. The automobile interior material obtained in this way is PS
Since it is an integrated composite material made by pasting polyester nonwoven fabrics 2 and 3 on both the front and back surfaces of the resin composite laminate sheet 1, and further adhering a skin material 4 to the front side of the PS resin composite laminate sheet 1, It is resistant to impact, and even if it is used as a ceiling material in a car and left in the high temperature inside the car for a long time, the ceiling will not sag or otherwise deform, and its heat resistance has been significantly improved. The following table shows the heat resistance of the conventional automobile interior material (PS resin composite laminate sheet described above) and the automobile interior material manufactured by the manufacturing method of the present invention. When attached to an automobile body and left in an atmosphere with a temperature of 50℃ and humidity of 95% for 24 hours, and then in an atmosphere with a temperature of 85℃ for 24 hours and repeating this for 2 cycles, the amount of sagging at each point ( mm). (Note) In the table, Example 1 refers to the interior material manufactured by the manufacturing process shown in Figure 2, and Example 2 refers to the interior material manufactured by the manufacturing process shown in Figure 3.

【table】

[Table] Furthermore, Example 3 refers to an interior material manufactured by the manufacturing process shown in FIG. As described above, in the present invention, since the sagging can be reduced, it is possible to prevent the design of the ceiling material for an automobile from becoming deformed or wrinkled.
The sagging of the interior materials of Examples 2 and 3 was even less than that of Example 1 because polyester nonwoven fabric was not bonded to both the front and back surfaces of the PS resin composite laminate sheet during the manufacturing process. This is thought to be due to the fact that by pressure forming the PS resin composite laminate sheets in a loose state by simply overlapping them, the residual strain of the PS resin composite laminate sheet during pressure forming can be reduced, and the return of the shape after molding can be reduced. As explained in the examples above, the automotive interior material according to the present invention is produced by bonding polyester nonwoven fabric to both the front and back surfaces of a PS resin composite laminated sheet.
Since a surface material such as polyvinyl chloride sheet with foamed urethane or woven fabric is further attached to the surface side of the PS resin composite laminated sheet, it not only has a good surface appearance and tactility, but also has structural strength. High heat resistance and particularly excellent strength. In addition, regarding the manufacturing method, the skin material is made by bonding a polyester nonwoven fabric with heat-resistant synthetic resin adhesive on both sides to the surface of the PS resin composite laminate sheet, or stacking it in a non-adhesive state. Since the adhesive is heat-activated and then laminated on top of the adhesive and then press-molded, the adhesive surface of the skin material has a high peel strength and may peel off during use. Moreover, it has many advantages such as simplifying the manufacturing process and achieving efficient manufacturing, and is extremely useful industrially.

[Brief explanation of drawings]

The drawings relate to the present invention; FIG. 1 is a partially cutaway external perspective view of the interior material, FIG. 2 is a manufacturing process diagram showing one embodiment, and FIG. 3 is a diagram showing another embodiment. FIG. 4 is a manufacturing process diagram showing still another example, and FIG. 5 is a perspective view of the interior material showing the measurement position of the sagging test. 1, 1'...PS resin composite laminated sheet, 2, 3...
...Polyester nonwoven fabric, 4...Skin material, 11,
12... Male and female type.

Claims (1)

[Scope of Claims] 1. A polyester nonwoven fabric is adhered to the back side of a composite laminated sheet in which a pair of modified polystyrene resin films are adhered to both sides of a modified polystyrene resin foam, and a polyester nonwoven fabric is adhered to the front side of the composite laminated sheet. is an automobile interior material made by pasting a skin material such as a vinyl chloride sheet or woven fabric with a polyester nonwoven fabric interposed therebetween. 2 A composite laminated sheet is formed by pasting a pair of modified polystyrene resin films on both sides of a plate-shaped modified polystyrene resin foam that has been subjected to primary foaming with the addition of a foaming agent, and a heat-resistant synthetic resin adhesive is applied to both sides. The applied polyester nonwoven fabric is adhered to the surface of the composite laminate sheet, and the same polyester nonwoven fabric is adhered to the back side of the composite laminate sheet, and the composite laminate sheet is heated to a temperature higher than that during primary foaming. At the same time, the heat-resistant synthetic resin adhesive is thermally activated, and then a skin material such as a vinyl chloride sheet or woven fabric is applied to the polyester nonwoven fabric on the surface side of the composite laminated sheet. A method for manufacturing an automobile interior material, which comprises stacking the materials and pressing them with male and female molds to form a three-dimensional shape into a predetermined shape. 3 A composite laminated sheet is formed by attaching a pair of modified polystyrene resin films to both sides of a plate-shaped modified polystyrene resin foam that has been subjected to primary foaming with the addition of a foaming agent, and a heat-resistant composite sheet is formed on both sides of the polyester nonwoven fabric. After applying a resin adhesive and drying and curing the heat-resistant synthetic resin adhesive, the polyester nonwoven fabric is superimposed on the surface of the composite laminate sheet in a non-adhered state, and the back side of the composite laminate sheet is coated with a heat-resistant synthetic resin adhesive. A polyester nonwoven fabric is laminated in a non-adhesive state with a synthetic resin adhesive interposed by drying and curing, and then the composite laminated sheet is secondarily foamed by heating this to a higher temperature than that during the primary foaming. At the same time, the heat-resistant synthetic resin adhesive is heat-activated to make it into a semi-molten state, and then a skin material such as a vinyl chloride sheet or woven fabric is overlaid on the surface side of the composite laminated sheet, and applied with male and female molds. A method for producing an interior material for an automobile, which comprises pressing and forming the material into a three-dimensional shape having a predetermined shape.