JPH04216030A - Manufacture of base material of interior material - Google Patents

Abstract

PURPOSE:To provide comparatively light weight and high rigidity and upgrade resistance to heat and dimension stability by integrating a reinforced layer composed of the combination of specified resin and glass fiber and a porous non-woven core material. CONSTITUTION:Urethane modified unsaturated polyester resin is applied uniformly on a film 6 for releasing such as a polypropylene film by a doctor blade 7 or the like. Glass fiber 2 is cut into the given length and dispersed and laminated on said film. Further, propylene films are laminated thereon and wound in the roll shape after being compressed by a press roll 8 of given pressure. The polypropylene films on the surface and the back face are removed, and then prepregs 9 are laminated on both faces of a non-woven cloth composed of a copolymer of acrylonitril and viny chloride, and hot press molding is carried out to solidify and integrate.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to interior materials, especially molded ceilings,
The present invention relates to a method for producing base materials for automobiles such as door trims, trunk trims, pillar garnishes, and interior materials for other vehicles and furniture.

0002

BACKGROUND OF THE INVENTION Heretofore, examples of interior material base materials mainly used for molded ceilings include the following.

[0003]Resin Felt An original fabric made of recycled cotton impregnated with phenolic resin is compression molded using a hot press mold, and the resin is cured to produce a molded ceiling with a certain shape. ■Polystyrene foam sheet A polystyrene foam sandwiched between non-foamed polystyrene sheets is softened by preheating and then immediately molded using a press mold. ■Cardboard made of corrugated paper is compressed and molded using a hot press mold to produce molded ceilings with a certain shape.

However, in the method (2), before molding, the resin and the fiber material are not bonded, so there is a lot of dust and the workability is poor. Moreover, in order to obtain the necessary and sufficient strength, the weight becomes large. Another drawback is that it tends to sag under high temperature and high humidity conditions.

Furthermore, in method (2), dimensional changes are large under high-temperature conditions, and a mounting structure that can absorb the dimensional changes must be provided, which poses significant design constraints.

Furthermore, in method (2), since the paper does not stretch, it cannot accommodate complicated shapes and tears occur, so the degree of freedom in design is low. Furthermore, there are limitations to the surface material because the corrugated board has unevenness on its surface.

[0007]

SUMMARY OF THE INVENTION An object of the present invention is to provide an interior material base material that is lightweight, has great strength and freedom of design, and exhibits small dimensional changes with good workability.

[0008]

[Means for Solving the Problems] The present invention involves cutting bundled long glass fibers to a certain length and uniformly dispersing them in random directions, impregnating them with a urethane-modified unsaturated polyester resin, and then applying the resin under mild conditions. The product is thickened and aged until the surface loses its tackiness, then it is laminated on both sides of a bulky nonwoven fabric made from thermoformable fibers, and is cured and integrated by hot press molding. It relates to a method for manufacturing interior material base materials.

As shown in FIG. 1, the interior material base material of the present invention includes a core material layer (4) of a bulky nonwoven fabric (1) made of thermoformable fibers, and a urethane layer reinforced with glass fibers (2). Reinforcing surface material (5) of modified unsaturated polyester resin (3)
Consisting of

The bulky nonwoven fabric used in the present invention is a nonwoven fabric made from fibers that can be thermoformed and has shape retention properties. Specific examples include nonwoven fabrics made of polyacrylonitrile synthetic fibers such as Kanekalon (registered trademark, a copolymer of acrylonitrile and vinyl chloride) alone or in combination with such fibers and polyester. As for the manufacturing method of non-woven fabric, ■
Mechanical bonding methods represented by needle punching; ■Chemical bonding methods in which sheet fibers are directly sprayed or impregnated with adhesive. ■After opening a long single fiber aggregate, it is made into a layered product made by laminating spread cotton. There is a method of impregnating and drying a thermoplastic or thermosetting synthetic resin binder. Kanekalon has the property of being hardened by heating, and combining this property with the addition of a thermosetting resin (melamine, epoxy, phenol resin, etc.) to the binder component increases the rigidity of the core material after molding, which is preferable. The basis weight is 100 to 1000
g/m2, preferably 200 to 600 g/m2. Glass fibers are made by bundling tens to hundreds of single fibers with a sizing agent, either as is or by aligning several strands (roving) to a certain length (25 to 60 m).
Distributed lamination (50 to 1 m) in a random direction while cutting
50 g/m2, preferably 100 g/m2 or less), and a total amount of 50 g/m2 of urethane-modified unsaturated polyester resin.
0-300g/m2, preferably 70-200g/m2
Use after soaking to some extent.

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) (in addition to polyether polyol, etc. ) and an isocyanate component which is a mixture of isocyanate and peroxide. In the reaction, the polyol and isocyanate first form a urethane bond under the influence of a urethane catalyst, resulting in chain length extension. Then, under the influence of a peroxide catalyst,
The unsaturated group in the molecule and a crosslinking agent such as a styrene monomer undergo radical polymerization to form 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 as the urethane reaction progresses and gradually increases in viscosity and loses its tackiness, it remains soft because it is diluted with styrene monomer, and when heated, it melts and then hardens for a long time. It can be thermoformed even after the lapse of time. 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.

[0012] Taking advantage of the processability and physical properties of this urethane-modified unsaturated polyester resin, it has a low initial viscosity, so it has good impregnation into urethane foam and glass fiber, and even a small amount of resin can be sufficiently impregnated, resulting in weight reduction. Since it is a reinforcing material layer made of a combination of thermosetting resin and glass fiber, it is heat resistant and has high dimensional stability, and there are no restrictions on the mounting method. Furthermore, since a stretchy nonwoven fabric is used as the core material, it can be formed into a deep-drawn shape without tearing, providing a high degree of freedom in design. Furthermore, since the glass fibers are impregnated with resin, they do not scatter, and interior material base materials can be produced with good workability.

An example of the method for manufacturing the interior material base material of the present invention will be explained with reference to FIG. ■Urethane-modified unsaturated polyester resin is uniformly and continuously applied with a doctor blade (7) on a release film (6) such as polyethylene film or polypropylene film, and then glass fiber (2) is applied on top of it. are cut to a certain length and distributed and stacked. A release film coated with the resin (3) on the inside is covered with a doctor blade or the like from above, and the entire prepreg (9) is uniformly impregnated with a roll (8) or the like. It may be wound up and then cut at the time of use, or it may be cut to match the product shape immediately after impregnation. At this time, the resin (3) may be applied uniformly onto the release film (6) by spraying. Alternatively, the resin (3) may be applied in a required amount to only one side of the release film (6) to impregnate the entire film. ■ Seal the prepreg (9) with cellophane film (10), etc. to prevent the volatilization of the styrene monomer.
Thicken for 1 day or more under mild conditions at 0°C. ■Remove the release film (6) from the prepreg (9) with thickened impregnated resin. ■Prepreg (9) on both sides of thermoformable nonwoven fabric (1)
) is laminated at 130 to 160°C, preferably 1
Insert into a hot press mold (11) at 40 to 150°C
．． Hot press molding is performed for 5 to 3 minutes, preferably 0.5 to 2 minutes. ■Remove the mold to obtain a molded interior material base material. The skin may be bonded after molding or may be bonded simultaneously during molding. This is adjusted depending on the type of epidermis.

[0014]

【Example】

Example 1 On a polypropylene film, a urethane-modified unsaturated polyester resin containing a polyol component and an isocyanate component was uniformly applied with a doctor blade to a coating amount of 120 g/m2, while the polypropylene film was continuously moved at a constant speed. to move it. On top of that, a roving of long glass fibers is inserted between a urethane rubber roll and a roll with knife blades attached at 30 mm intervals, and these are rotated to continuously supply glass fibers cut at 30 mm intervals, Glass fibers of 80 g/m2 are uniformly distributed and laminated in random directions. A polypropylene film is laminated on top of this, compressed with a press roll at a constant pressure, and then wound up into a roll. The wound roll was sealed with cellophane film and kept at 23℃ for 7 days.
I left it for days. The cellophane film was removed before molding, and the prepreg, which had lost its stickiness, was cut to match the length of the product, and the polypropylene film on the front and back sides was also removed.
Based on a copolymer of acrylonitrile and vinyl chloride (4:6) with thermoformability, basis weight 370g/m2
prepreg is laminated on both sides of the nonwoven fabric, and this laminated product is
Press molded with a heat press mold for molded ceilings at 50℃ to a general thickness of 2 mm, and removed from the mold after 1 minute to 770 g/m2
A base material for a molded ceiling was obtained.

[0015]

【Effect of the invention】

■The interior material base material obtained by the method of the present invention is composed of a reinforcing layer made of a combination of high-strength resin and glass fiber, and a core material of porous nonwoven fabric, so it is relatively lightweight and has a high cost. It is rigid.

[0016] Since the interior material base material obtained by the method of the present invention combines a highly heat-resistant resin and glass fiber,
It is heat resistant and has very high dimensional stability.

(2) The interior material base material obtained by the method of the present invention has high moisture and heat resistance because a resin with excellent moisture resistance is used.

[0018] Since the interior material base material obtained by the method of the present invention uses a stretchable nonwoven fabric material, it has good moldability and a high degree of freedom in design.

[Brief explanation of the drawing]

FIG. 1 is a sectional view of an interior material base material obtained by the present invention.

FIG. 2 is an explanatory diagram showing an example of the manufacturing method of the present invention.

[Explanation of symbols]

1 Thermoformable nonwoven fabric 2 Glass fiber 3 Urethane-modified unsaturated polyester resin 4 Core layer 5 Reinforcing surface material 6 Release film 7 Doctor blade 8 Roll 9 Prepreg 10 Cellophane film 11 Hot press mold

Claims (1)

[Claims] Claim 1: The bundled long glass fibers are cut to a certain length and uniformly dispersed in random directions, and then impregnated with urethane-modified unsaturated polyester resin, and the resin is thickened under mild conditions to form a surface layer. A method for producing an interior material base material, which is characterized by laminating the material that has been aged until it loses its stickiness on both sides of a bulky nonwoven fabric made from thermoformable fibers, and curing and integrating the material by hot press molding. .