JPH06312474A - Interior finishing material and manufacture thereof - Google Patents

Abstract

PURPOSE:To absorb a crack, a wrinkle occurring at a single-faced corrugated fiberboard by a foamed layer having fluidity by adhering a liner to one side surface of a corrugated core material to form the fiberboard, and forming a hard or semicured urethane resin foamed layer on the core material side. CONSTITUTION:In the case of manufacturing an interior finishing material, a liner 11B is first adhered to one side surface of a corrugated core material 11A t form a single-faced corrugated fiberboard 11. Then, the material 11A side of the fiberboard 11 is coated with a raw material 12A of semicured urethane resin foam by a spray gun. Then, the fiberboard 11 is superposed on a front layer material 13 at the material 11A side, then set to press molds having an upper mold and a lower mold, heated to a low temperature and molded. The material 12A is foamed, cured by polymerization and crosslinking reactions thereby to form hard or semicured urethane resin foamed layer 12. Thus, a crack C, a wrinkle W occurring at the fiberboard 11 is absorbed by the layer 12 having fluidity to maintain its surface smooth.

Description

Detailed Description of the Invention

[0001]

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

[0002]

2. Description of the Related Art Conventionally, a corrugated cardboard (1) having liners (1B) attached to both sides of a corrugated core material (1A) as shown in FIG. 6 has been used as an interior material of this type.
Since (1) uses paper as a material, it does not have elongation and is poor in formability, and cracks and wrinkles occur in the deep-drawing part, and the cracks and wrinkles are detected from the outside through the skin material, and the appearance and feel are It was bad. Therefore, in order to absorb such cracks and wrinkles of the corrugated board (1) and conceal it from the outside, as shown in FIG. 6, the corrugated board (1) is provided with a resin-impregnated felt or a cushioning material such as a resin-impregnated soft urethane resin foam. (2) is laminated and the cushioning material
(2) A structure in which the surface covering material (3) is attached to the surface is disclosed. Further, there is provided an interior material formed by impregnating a soft urethane resin foam having good moldability with resin instead of corrugated board, but since the molded product of the resin-impregnated urethane resin foam has poor rigidity, the glass fiber layer It is necessary to laminate a reinforcing layer such as the above on the surface for reinforcement.

[0003]

However, in the above-mentioned prior art, a cushioning material is required to remove cracks and wrinkles in the corrugated board, which leads to an increase in weight and an increase in cost. It is time-consuming, and if a resin-impregnated soft urethane resin foam is used, the reinforcing layer such as the glass fiber layer will increase the weight and cost, and in the case of the laminated glass fiber layer, small glass fiber pieces can be used in the workplace. There is a problem in that it scatters and irritates the skin of the worker, which significantly deteriorates the working environment.

[0004]

Means for Solving the Problems As a means for solving the above-mentioned conventional problems, a single-sided corrugated board (11) having a liner (11B) attached to one side of a corrugated core material (11A),
A one-sided corrugated board (11), which comprises a hard or semi-rigid urethane resin foam layer (12) formed on the corrugated core material (11A) side, and provides an interior material (10) molded in a predetermined shape. Therefore, in order to manufacture the interior material (10), the hard or semi-rigid urethane resin foam raw material (12A) is applied to the corrugated core material (11A) side of the single-sided corrugated board (11), and heat-molded in a predetermined manner. A method in which the urethane resin foam raw material (12A) is foamed and cured to form a rigid or semi-rigid urethane resin foam layer (12) is applied.

[0005]

In the interior material of the present invention, the single-faced cardboard (11)
Is a carrier for the rigid or semi-rigid urethane resin foam raw material (12A). Then, the urethane resin foam raw material (12A) is foam-cured and molded into a predetermined shape by heat molding, but since the urethane resin foam raw material (12A) has fluidity, what kind of shape does it have before curing? Also, even if the single-faced corrugated board (11) has cracks or wrinkles during molding, the surface of the urethane resin foam layer (12) obtained by absorbing these becomes smooth. The hard or semi-rigid urethane resin foam layer (12) is a single-sided corrugated board (11)
Gives an interior material (10) reinforced by and having high rigidity.

[0006]

EXAMPLE The present invention will be described with reference to an example shown in FIGS.
And a liner (11A) attached to one side of the core material (11A).
B), and a raw material (12A) of a rigid or semi-rigid urethane resin foam is applied to the core material (11A) side of the single-sided corrugated board (11) by a spray gun (14). The coating amount of the above raw material is usually 200 to 250 g / m ² .

In the above single-sided corrugated board (11), the core material (11A)
Is made of paper, non-woven fabric, etc., and the paper, non-woven fabric, etc. may be impregnated with acrylic resin, urethane resin, vinyl acetate resin, urea resin, melamine resin, phenol resin, etc. The core material (11A) may be impregnated with the same resin as the core material (11A).

The above raw material (12A) is, for example, a polyol such as polyether polyol, polyester polyol, polyacrylic polyol, a mixture with a diisocyanate such as TDI or MDI, a mixture of a urethane prepolymer having a terminal hydroxyl group and a diisocyanate. , A mixture of a urethane prepolymer having a terminal isocyanate group and a polyol, etc., and water, a curing accelerator or the like may be added to the above mixture.

[0009] Single-sided corrugated board coated with the above raw material (12A)
(11) is the core material (11A) side with the facing material (13) superposed
As shown in Fig. 3, it is set in a press mold (15) consisting of a lower mold (15A) and an upper mold (15B), and is usually subjected to low temperature heat molding at about 70 to 100 ° C, and a predetermined shape as shown in Fig. 3. Is molded into. By the heat molding, the raw material (12A) is foamed and cured by a polymerization reaction and a crosslinking reaction,
As shown in FIG. 4, a rigid or semi-rigid urethane resin foam layer (12) is formed.

Even if cracks C or wrinkles W occur in the single-faced corrugated board (11) during the molding as shown in FIG. 4, the foam raw material (1
Since 2A) has fluidity, the cracks C and wrinkles W are absorbed by the foam layer (12) and the surface of the foam layer (12) becomes smooth. Further, the foam material (12A) can have any shape before being cured. In this way, for example, the molded ceiling (10) of an automobile as shown in FIG. 5 is obtained.

[0011]

Therefore, according to the present invention, there is provided an interior material which is lightweight, has excellent molding workability, and has high rigidity.

BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1 to 5 show an embodiment of the present invention.

FIG. 1 is an explanatory diagram of a urethane resin foam raw material coating process.

FIG. 2 is an explanatory diagram before the press molding process.

FIG. 3 is an explanatory diagram after the press molding process.

FIG. 4 is a partially enlarged sectional view of the interior material.

FIG. 5 is a perspective view of a molded ceiling

FIG. 6 is a partial cross-sectional view of a conventional example.

[Explanation of symbols]

 10 Molded ceiling 11 Single-sided corrugated board 11A Core material 11B Liner 12 Urethane resin foam layer 12A Urethane resin foam raw material

Claims (2)

[Claims] 1. A corrugated core material comprising a single-sided corrugated board having a liner attached to one side thereof, and a hard or semi-rigid urethane resin foam layer formed on the corrugated core material side of the single-sided corrugated board, and molded into a predetermined shape. Interior material characterized by 2. A hard or semi-rigid urethane resin foam raw material is applied to the corrugated core material side of a single-sided corrugated cardboard in which a liner is attached to one surface of the corrugated core material, and the urethane resin foam is molded into a predetermined shape by heat molding. A method for producing an interior material, characterized by foaming and hardening a body material to form a rigid or semi-rigid urethane resin foam layer.