JPH06270342A - Material board for interior trimming of vehicle and production threof - Google Patents

Abstract

PURPOSE:To reduce cost to a large extent and to obtain a material board of high quality for the interior trimming of a vehicle by bonding a synthetic fiber nonwoven fabric to one surface of a board molded using the end material of the interior trimming of the vehicle and a bumper waste material as main raw materials. CONSTITUTION:A mixture of a first raw material 31 and a second raw material 32 is used as a main raw material and a small amt. of an auxiliary raw material (e.g. mixture of virgin PP and talc or talc alone) 33 and all of them are mixed in a mixer (e.g. ribbon mixer) 14 to be subjected to extrusion molding using an extrusion molding machine 15 as shown by a step I to obtain a board 2a. A synthetic resin nonwoven fabric 3 is supplied to one surface of the board 2a during a period when the board 2a is still held to a plastic state to be bonded thereto and the obtained trimming is again returned to a step A as a material board 2 for the interior trimming of a vehicle and the end material 10 thereof is recycled to a step B.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle interior part, and more particularly to a material board for a plurality of molded parts constituting an inner wall of a luggage compartment and a method for manufacturing the same.

[0002]

2. Description of the Related Art Recently, the above-mentioned vehicle interior parts are provided with a cushioning property and a high-class feeling on the surface of a PP board for the purpose of reducing the weight of the automobile body and reducing the cost, and supplementing the strength of the outer plate. For this reason, a material board made of laminated synthetic fiber nonwoven fabric made of PET or the like is used.

The above material board is a high-quality material containing a large amount of virgin. Therefore, it is a waste of resources to discard the scraps generated during the vacuum forming of the vehicle interior parts by incineration, and it is necessary to protect the global environment. Is also not preferable. Therefore, the applicant has developed a recycling method in which the end material of the material board and the virgin PP are recycled as the main material for the substrate of the material board for vehicle interior parts for the purpose of effective use of resources and environmental protection.

The board substrate thus regenerated is mixed with the constituent fibers of the synthetic fiber nonwoven fabric pasted on the surface of the end material which is the raw material thereof, so that the strength such as tensile strength, tear strength, tensile elongation strength, bending strength, etc. Had the advantage of being strengthened.

[0005]

However, the board substrate of the recycled material board is expensive virgin PP.
There is a problem that sufficient cost reduction cannot be achieved because a large amount of is used.

An object of the present invention is to solve such a problem, and to provide a high quality material board for vehicle interior parts and a method for manufacturing the same, which greatly reduces the cost. To aim.

[0007]

In order to achieve this object, the present invention has a synthetic fiber non-woven fabric bonded to one surface of a substrate formed by using a scrap material of a vehicle interior part and a bumper scrap material as main raw materials. In addition, the present invention provides a material board for vehicle interior parts, which is characterized by crushing and granulating the end material of vehicle interior parts, and crushing and granulating bumper waste materials to this and extruding as the main raw material. Provided is a method for manufacturing a material board for vehicle interior parts, which comprises molding and adhering a synthetic fiber non-woven fabric on one surface of the obtained substrate. further,
The end material of vehicle interior parts is pulverized and granulated, and the bumper waste material is pulverized and granulated and added to this as the main raw material, and a chemical foaming agent is added as an additive to this, and extrusion foam molding is performed. Another object of the present invention is to provide a method for producing a material board for vehicle interior parts, which comprises laminating a synthetic fiber nonwoven fabric on one surface of a foam board substrate.

[0008]

According to the present invention, the recycled material board has virgin PP instead of the scrap material of the vehicle interior parts and the scrap material of the bumper, and the scrap material of the bumper has impact resistance. It has a high quality that contains a large amount of PP and rubber for the purpose of enhancing it, so it is possible to manufacture a good quality board substrate at low cost in combination with the characteristics of the end material of vehicle interior parts. is there.

The waste bumper material can be returned as a raw material for the bumper itself before coating, but cannot be returned as a raw material for the bumper itself because the coating film becomes foreign matter after coating. In this respect, even in the present invention, even if the coating film becomes a foreign matter, it is a mixture with a raw material composed of a scrap material of a vehicle interior component and does not pose a problem as a board substrate.

[0010]

Embodiments of the present invention will now be described with reference to the drawings. FIG. 1 is a perspective view of a vehicle interior product (component of a trunk room) made of a material board according to the present invention, and FIG. 2 is a partially enlarged sectional view of the material board according to the present invention.
FIG. 3 is a schematic explanatory view showing a manufacturing process of the material board according to the present invention.

A vehicle interior component 1 shown in FIG. 1 shows vacuum-molded parts a to g constituting an inner wall of a luggage compartment. This vehicle interior component 1 is made of a material board 2 as shown in FIG.
The material board 2 has a synthetic fiber non-woven fabric 3 made of PET or the like attached to the room-side surface of the board substrate 2a.

Next, the process of recycling the material board 2 is shown in FIG. First, the material board 2 as in step A
The vehicle interior component 1 is vacuum-formed and trimmed using. As a result, the mill ends 10 remaining as in step B are crushed (cut) to a desired size by the crusher (cutting) machine 11 as in step C, and are used as the first raw material 31 in the granulator 12 as in step D. Granulated.

On the other hand, the crusher (cutting) machine 1 is also used for the scraper 13 of the bumper 13 which has become a defective coating product or a defective molding product at the manufacturing stage as in the step E, as in the case of the above-mentioned scrap 10.
1 is crushed (cut) to the desired size, and step G
As described above, the second raw material 32 is granulated by the granulator 12.
The crushing (cutting) machine 11 and the granulating machine 12 for the scrap material 10 and the bumper waste material 13 are separate from each other in the drawing, but may be separate or common as shown in the drawing. . Further, as the granulator 12, a known one, for example, a Hensyl mixer can be used.

The components of the bumper waste material 13 are those which are defective in coating or defective in molding at the manufacturing stage as described above, and include PP, ethylene propylene rubber (hereinafter referred to as "EP").
R ”) and talc. The ratio is P
P: EPR: talc = about 60:30:10.

Next, as in step H, the first raw material 31
And a second raw material 32 are used as a main raw material, and a small amount of an auxiliary raw material (for example, a small amount of a mixture of virgin PP and talc or talc alone) 33 is added thereto and mixed by a mixer (for example, a ribbon mixer) 14. Then, as in step I, extrusion molding is performed using the extruder 15. As a result, the board substrate 2a
To get While the substrate 2a still retains its stickiness, the synthetic resin non-woven fabric 3 is supplied to one surface of the substrate 2a and bonded to the substrate 2a to be regenerated as the material board 2 for vehicle interior parts. Then, the process returns to step A again, and the scrap 10 is recycled through step B.

When the raw materials are mixed in the mixer 14,
A chemical foaming agent (such as ADCA) may be added as an additive to foam the board 2a. This is effective for reducing the weight and cost of the board 2a.

The heating and melting temperature of the raw material in the extruder 15 is lower than the melting point of the synthetic resin non-woven fabric attached to the surface of the board 2a, and is higher than the melting points of the vehicle interior material board 2 and the bumper waste material 13. Done in. Therefore, the constituent fibers 3 of the non-woven fabric 3 are included in the recycled material board 2.
The structure a remains as it is as shown in FIG. 2, and excellent strength, dimensional stability, shape retention, sound insulation, etc. can be obtained by the combined effect of fibers such as reinforced plastic.

Now, using the current product, the products 1 to 3 of the present invention and a comparative product shown in the following [Table 1], the four items of tensile strength, tensile elongation strength, tear strength and heat shrinkage ratio are tested. The results are shown in [Table 2]. The sizes of the current product, the products of the present invention 1 to 3 and the comparative product are as follows: thickness = 0.
It is 9 mm and the basis weight is 909 g / m ² .

[Table 1] Current product Vehicle interior product scraps 50% Virgin PP 40% Talc 10% Invention product 1 Vehicle interior product scraps 25% Bumper waste material 50% Virgin PP 20% Talc 5% Invention product 2 Vehicle Interior scraps 40% Bumper waste 50% Virgin PP 5% Talc 5% Invention 3 Vehicle interior scraps 45% Bumper scrap 50% Virgin PP 0% Talc 5% Comparative product Bumper scrap 100%

[Table 2] Inventive product 1 Inventive product 2 Inventive product 3 Current product Comparative product Tensile strength Vertical 294 276 272 311 189 (kg / cm ² ) Horizontal 231 218 220 255 255 133 Vertical elongation 350 370 370 300 150 150 (% ) Horizontal 70 80 80 80 80 120 Tear strength Vertical 205 198 187 222 222 133 (kg / cm) Horizontal 183 171 146 167 987 98 Heat shrinkage rate Vertical 0.5 0.4 0.4 0.5 0.5 0.1 (%) Horizontal 0 6.6 0.6 0.6 0.7 0.4 Formability ◎ ◎ ◎ ◎ ◎ ×

From the above table, the invention product 1 had the same moldability as the current product, and the invention products 2 and 3 also had the property of sufficiently satisfying the conditions as the vehicle interior parts. on the other hand,
The comparative product had low growth and had a problem of drawdown. In addition, it is confirmed to be unsuitable for vehicle interior parts because the rigidity is low due to the large proportion of EPR, and the thickness of the deep-drawn portion is greatly reduced when vacuum forming, and the thickness difference easily occurs depending on the expansion rate. It was As a result, the material board for vehicle interior parts according to the present invention significantly reduces the content of virgin PP, or is a product of the present invention that does not contain virgin PP at all and is as excellent as the current product containing a large amount of virgin PP. It has been proved that excellent strength can be obtained.

The product 3 of the present invention containing no virgin PP is recycled 5 times (R-1 to R-5).
Repeatedly, the physical properties (MRF, tensile strength, elongation, tear strength) were tested, and the results are shown in [Table 3]. Test conditions MRF; 230 ° C, load 2160 kg, tensile and elongation test; dumbbell No. 1 type, 200 mm / m
in Tear test; B type, 200mm / min

[Table 3] R-1 R-2 R-3 R-4 R-5 MFR 2.0 2.1 2.2 2.0 2.0 (g / 10 min) Tensile strength Vertical 264 275 267 272 271 (kg / cm ² ) horizontal 206 215 210 213 211 211 tensile elongation vertical 350 350 330 350 340 340 (%) horizontal 80 70 70 60 60 60 tear strength vertical 185 187 187 189 191 (kg / cm) horizontal 150 145 143 148

From the above table, Invention 3 did not cause any problems in physical properties after repeated recycling of 5 times. In addition,
Inventive products 1 and 2 have not been subjected to repeated recycling experiments, but from the results of invention product 3, it can be conjectured that there is no problem.

In this embodiment, PET fibers were used as the synthetic fibers constituting the nonwoven fabric 3, but the present invention is not limited to this, and other thermoplastic synthetic fibers such as a mixture of PET fibers and PP fibers or PP fibers alone may be used. You may.

Further, in this embodiment, the trunk room has been described as an example of the vehicle interior component, but other vehicle interior components may be used.

[0027]

As described above, the material board for vehicle interior parts according to the present invention has a synthetic fiber non-woven fabric attached to one surface of a substrate formed by using scrap materials of vehicle interior parts and waste bumper material as main raw materials. Since they are combined, the properties of both raw materials are combined to obtain excellent strength and moldability.

Further, in the manufacturing method according to the present invention, virgin PP is not used at all as the main raw material, and even if virgin PP is used as the auxiliary raw material, the amount is small, so that there is an advantage that the manufacturing cost can be reduced.

Further, in the manufacturing method according to the present invention, when a chemical foaming agent is used as an additive, there is an advantage that the weight and cost of the board can be further reduced.

[Brief description of drawings]

FIG. 1 is a perspective view of a vehicle interior product (component of a trunk room) made of a material board according to the present invention.

FIG. 2 is a partially enlarged cross-sectional view of a material board according to the present invention.

FIG. 3 is a schematic explanatory view showing a manufacturing process of the material board according to the present invention.

[Explanation of symbols]

 1 Vehicle Interior Parts 2 Material Board for Vehicle Interior Parts 2a Board Substrate 3 Synthetic Resin Nonwoven Fabric 3a Nonwoven Fiber Constituent Fiber 10 Vehicle Interior Parts End Material 11 Crusher 12 Granulator 13 Bumper Waste Material 14 Mixer 15 Extruder 31 1st Raw material 32 Second raw material 33 Auxiliary raw material

Claims (3)

[Claims] 1. A material board for vehicle interior products, characterized in that a synthetic fiber non-woven fabric is bonded to one surface of a board substrate formed by using scrap materials of vehicle interior products and waste bumper materials as main raw materials. 2. An end material of a vehicle interior product is pulverized and granulated, and a material obtained by pulverizing and granulating a bumper waste material to the pulverized product is extruded as a main raw material. A method for manufacturing a material board for vehicle interior parts, which comprises bonding non-woven fabrics. 3. A main raw material is obtained by pulverizing and granulating end material of a vehicle interior product, and pulverizing and granulating bumper waste material to this.
A method for producing a material board for vehicle interior parts, characterized in that a chemical foaming agent as an additive is mixed with this and extrusion foaming is performed, and a synthetic fiber nonwoven fabric is bonded to one surface of the foamed board substrate obtained thereby.