JPH06210786A - Interior finishing material - Google Patents

Abstract

PURPOSE:To dispense with an adhesive and enhance the rigidity of an interior finishing material when adhering a skin material to a base by adding a thermoplastic fiber and/or a thermoplastic resin binder with a lower melting point than the molding temperature of the base as a fiber layer. CONSTITUTION:A fiber layer 16 is laminated on both surfaces or one surface of a base 12. The fiber layer 16 contains thermally plastic fibers and/or binder having a lower melting point than the molding temperature of the base 12. For example, resin felt using phenol resin as a binder or a polyurethane foam has a low molding temperature. During molding, the thermoplastic fibers and/or the thermoplastic resin binder of the fiber layer 16 melts to bond the base with the facing 15. In addition, the binding force of the fiber layer 16 increases to enhance rigidity.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to interior materials used for automobile ceiling materials, door trims, rear parcels and the like.

[0002]

2. Description of the Related Art As shown in FIG. 4, a ceiling material (1) for an automobile, for example, which uses a conventional synthetic resin-impregnated polyurethane foam as a base material (2), is used to reinforce the base material (2). A glass fiber layer (3) is laminated on both sides, a polyester cotton layer (4) is further laminated on the glass fiber layer (3), and a skin material (5) is laminated on the surface (Japanese Patent Publication No. 63-7577).
The glass fiber layer (3) and the polyester cotton layer (4) are each impregnated with a melamine resin, and the base material (2) and the glass fiber layer (3) are adhered to each other, and the glass fiber layer (3) and The above-mentioned impregnated melamine resin is used as an adhesive for adhesion with the polyester cotton layer (4).
A hot melt adhesive layer (6) is used for adhesion with (5).

[0003]

However, in the above conventional constitution, the softening point (about 240 ° C.) of the polyester cotton layer (4) is higher than the molding temperature (about 160 ° C.) of the substrate (2). The polyester cotton layer (4) did not soften during molding and therefore the hot melt adhesive layer (6) was required for laminating the skin material (5).

[0004]

The present invention provides a base material (12) having moldability as means for solving the above conventional problems.
And a fiber layer (1) laminated on both sides or one side of the base material (12).
6) and a skin material (15) attached on the fiber layer (16), the fiber layer (16) being a thermoplastic fiber having a melting point lower than the molding temperature of the substrate (12). And / or an interior material (11) containing a thermoplastic resin binder.

The moldable base material (12) used in the present invention is a resin felt, a cardboard, a polyurethane foam, a polystyrene foam or the like, and the base material includes a urethane resin, an acrylic resin, a melamine resin, A synthetic resin such as a urea resin, a phenol resin, an epoxy resin or a polyester resin, or a monomer, a prepolymer or an oligomer of the above synthetic resin may be impregnated.

A fiber layer is provided on both sides or one side of the base material (12).
(16) is laminated, and the fiber layer (16) contains a thermoplastic fiber having a melting point lower than the molding temperature of the base material (12) and / or
Alternatively, it contains a thermoplastic resin as a binder. For example, a resin felt using a phenol resin as a binder has a molding temperature of about 180 ° C, and a polyurethane foam impregnated with diisocyanate has a molding temperature of about 150 ° C.
Since the temperature is 0 ° C, the thermoplastic fibers and / or the thermoplastic resin contained in the fiber layer (16) have a melting point lower than that.

The fiber layer (16) is provided as a knitted woven fabric, a non-woven fabric using a synthetic resin as a binder, a needle punched non-woven fabric, a web, etc., and the fiber layer (16) is more than the molding temperature of the base material (12). Even if it is composed only of fibers having a low melting point, or the fiber layer (16) or a fiber or glass fiber having a melting point higher than the molding temperature of the substrate (12), carbon fiber,
Inorganic fibers such as ceramic fibers may be mixed, and a fiber having a melting point higher than the molding temperature of the base material (12) or a thermoplastic resin having a melting point of the inorganic fiber lower than the molding temperature of the base material May be bound as a binder. Further, fibers having a melting point lower than the molding temperature of the base material (12) may be bound with a thermoplastic resin having a melting point lower than the molding temperature of the base material (12) as a binder. When the binder is used, the fiber may be coated with the binder in advance. The fiber layer (16) may be impregnated with a thermosetting resin such as melamine resin, urea resin, phenol resin or epoxy resin. Above fiber layer
(16) is adhered to the base material (12) by fusion bonding or an adhesive.

The skin material (15) used in the present invention is a non-woven fabric of fibers such as polyester fiber, polypropylene fiber, polyamide fiber, knitted fabric, polyvinyl chloride leather, urethane synthetic leather, or the above skin material (15). It is lined with polyurethane foam, polyethylene foam, polypropylene foam and the like.

[0009]

In the present invention, the base material (1) is formed on the surface of the base material (12).
Fiber layer containing thermoplastic fiber and / or thermoplastic resin binder having a melting point lower than the molding temperature of 2)
Since the (16) is laminated, the thermoplastic fibers and / or the thermoplastic resin binder of the fiber layer (16) are melted during the molding to bond the base material (12) and the skin material (15). Further, by melting the thermoplastic fibers and / or the thermoplastic resin binder, the binding force of the fiber layer (16) is enhanced and the rigidity is improved.

[0010]

EXAMPLES The present invention will be described with reference to one example shown in FIGS. 1 to 3. The ceiling material (11) is a base material (12) made of polyurethane foam impregnated with diisocyanate, and the base material (12). 12) glass fiber layers (13, 13) laminated on both sides and polyester fiber layers (14) polymerized on the back surface of the glass fiber layers (13, 13)
And a fiber layer (16) to be polymerized on the surface and a skin material (15) attached via the fiber layer (16), and molded into an automobile ceiling shape as shown in FIG. .

The glass fiber layer (13, 13), the polyester fiber layer (14) and the fiber layer (16) are impregnated with melamine resin, and the fiber layer (16) is made of polypropylene fiber and the base material.
It is composed of a non-woven fabric of coated fibers coated with polyethylene (melting point 130 ° C.) having a melting point lower than the molding temperature (150 ° C.) of (12) as a binder.

As shown in FIG. 3, the ceiling material (11) is a base material (1
A laminate formed by laminating a glass fiber layer (13, 13), a polyester fiber layer (14) and a fiber layer (16) on 2) and a skin material (15) are overlaid and heated to about 150 ° C. to form a press molding machine ( Mold according to 17). In the above molding, the diisocyanate impregnated in the substrate (12) is polymerized and cured, and the glass fiber layer (1
3,13), the melamine resin impregnated in the polyester fiber layer (14) and the fiber layer (16) hardens, and the fiber layer (16) melts to bond the skin material (15).

[0013]

According to the present invention, therefore, a hot melt sheet or an adhesive is not particularly required when adhering the skin material to the base material side, the process is shortened, and the rigidity of the interior material is improved.

[Brief description of drawings]

 1 to 3 relate to an embodiment of the present invention.

FIG. 1 Sectional view

FIG. 2 is a perspective view

[Figure 3] Press process diagram

FIG. 4 is a conventional cross-sectional view.

[Explanation of symbols]

 11 Ceiling material 12 Base material 15 Skin material 16 Fiber layer

Claims (2)

[Claims] 1. A base material having moldability, a fiber layer laminated on both sides or one side of the base material, and a skin material attached on the fiber layer, the fiber layer being the base material. Interior material containing thermoplastic fiber and / or thermoplastic resin binder having a melting point lower than the molding temperature of 2. The interior material according to claim 1, wherein the fiber layer contains a thermosetting resin.