JPH0636912Y2 - Interior base material - Google Patents

Description

[Detailed Description of the Invention] << Industrial Application Field >> The present invention relates to an interior base material excellent in weight reduction, rigidity, forming deep drawing and the like.

<< Conventional Technology >> For example, interior base materials for automobiles are often set to have a curvature or an uneven shape, so various characteristics such as rigidity, weight reduction, and heat resistance are required on the premise of moldability. cardboard,
Resin felt is often used.

Corrugated board is particularly excellent in lightening, but since corrugated corrugated core made of paper is fixed by a liner, problems easily occur in terms of rigidity and formability. In addition,
As for rigidity, it was reinforced by impregnating a cured resin in JP-A-56-127452, and for moldability in JP-B-53-47567, a corrugated core of paper quality and a liner were melted by heat. There is shown an improved example in which a resinous resin thin film is interposed to fix at a bonding point during molding.

In addition, since the resin felt is formed by pressure-molding a fiber layer, it is particularly excellent in moldability, and conversely tends to cause problems in terms of weight reduction and heat resistance. Regarding weight reduction, JP-A-54
-88368 and the like disclose improved examples in which fibers are specified.

<Problems to be solved by the invention> Thus, although the conventional corrugated board or resin felt base material has been improved to some extent, in the case of corrugated board, there is a limit to deep drawing, and in the case of resin felt Was easy to be limited in weight reduction.

Further, for example, only by stacking a corrugated board and a resin felt with an adhesive interposed, the advantages of both cannot be satisfied at the same time, and much more effects cannot be expected.

The present invention has been achieved through various tests based on the above background, and an object thereof is to provide an interior base material which is lightweight but has rigidity and is excellent in deep drawing. .

<Means for Solving the Problems> In order to achieve the above-mentioned object, the present invention, in an interior base material that is hot-press molded into a desired shape, has a corrugated core made of paper quality attached between upper and lower liners made of paper quality. A corrugated cardboard layer that is adhered and integrated, and a corrugated cardboard layer that is impregnated with a thermosetting resin to reinforce it, and has a resin felt layer that is adhered and integrated on the surface of each liner. There is.

<Operation> According to the interior base material having the above configuration, the corrugated board layer is sandwiched between the resin felt layers, and shape retention and rigidity are reinforced by the thermosetting resin, so that the conventional corrugated board and resin felt can be used. On the other hand, the shape-retaining characteristics and the rigidity are greatly improved.

<< Embodiment >> An embodiment of the present invention will be described below with reference to the drawings.

1 and 2 are cross-sectional views showing a main part of an interior base material to which the present invention is applied.

The interior base material 1 shown in the figure comprises a corrugated board layer 2 and a resin felt layer 3 disposed on the upper and lower surfaces of the corrugated board 2, and the corrugated board layer 2 is impregnated with a thermosetting resin 6 for reinforcement treatment.

The corrugated board layer 2 is a double-sided corrugated board in which a liner 5 is joined to the upper and lower sides of a corrugated core 4 with a glue such as coast tarch, and has a thickness t = 5.5 mm. In this way, by using the above-mentioned glue for joining the core 4 and the liner 5 above and below, good joining can be maintained even at a high temperature of 220 degrees.

As the corrugating medium 4 and the liner 5 is used plain paper such as kraft paper, the corrugated medium 4 to about 180 g / m ^2, the liner 5 has a basis weight of about 50 to 70 g / m ^2. The corrugated board layer 2 is impregnated with the thermosetting resin 6 by an appropriate method. As the thermosetting resin 6, a melamine / phenol / epoxy / unsaturated polyester resin was used and impregnated with a solid amount of 75 g / m ² as a guide.

The resin felt layer 3 is made by mixing powdered phenolic resin into the fiber (the mixing ratio is about 30% of the phenolic resin to 70% of the fiber), and the basis weight is about 300 g / m ² . I used the one.

Then, the interior base material 1 described above is press-molded into a ceiling surface shape of an automobile, for example, as shown in FIG. 2, by a hot-press molding die similar to the conventional one.

This figure shows a cross section of a deep-drawn portion of a molded product obtained by hot pressing the interior base material 1 under the conditions of a molding temperature of 220 degrees and a molding pressure of 3 kg / cm ² .

In the deep-drawn portion 1a, the surface has a good flat shape with no wrinkles or unevenness, and the joint point between the liner 5 and the core 4 is displaced, despite the high-temperature press of 220 degrees,
It was confirmed that the corrugated shape of the center core 4 was formed into a desired shape without being crushed.

This is because the liner 5 and the core 4 are bonded with the above-mentioned glue, so that the bonding point did not shift even at a high temperature of 220 degrees, the resin felt layer 3 was provided on the corrugated cardboard layer 2, and the thermosetting resin was used. 6 was impregnated so that it was sufficiently reinforced.

Therefore, the product after hot press molding becomes a lightweight / rigid base material of about 1 kg / m ² , and the joint between the liner 5 and the core 4 which has been apt to occur in the conventional deep drawing is misaligned. The problem of fine wrinkles on the surface is eliminated.

In addition, the press-formed product (A) and the conventional product (B: Unit weight is 1.4k)
The resin felt molded to g / m ² ) was subjected to a bending strength test and a moisture resistance test for comparison.

Here, in the bending strength test, the A of the present proposal and the conventional B are 50
The test piece was cut to a width of 150 mm, and an average value of 5 sheets was obtained. As shown in Fig. 3 (a), the test product is held on a pair of support members 11 arranged at 100 mm intervals, and a weight 12 is used at the center of the test product to apply a pressing speed of 20 mm / min. It was loaded with. It was carried out under the conditions of temperature of 20 degrees and humidity of 50%.

In the moisture resistance test, the A of the present proposal and the conventional B are 100 × 300 mm in width.
The test piece was cut into pieces, and the average value of three sheets was obtained. Each test product is held in a support member 13 installed as shown in Fig. 2B in a thermostatic chamber adjusted to a temperature of 70 ° C and a humidity of 95%, and three samples each are taken out after 4 hours and 24 hours. Ω
The amount of displacement was measured. The comparison results are as follows.

As for the maximum bending load, test product A is 8.0 kgf in length and 5.2 kgf in width.
On the other hand, the test product B was 4.0 kgf in length and 4.0 kgf in width.

As for the moisture resistance, ω of the test product A was −1 mm after 4 hours and -5 mm after 24 hours, whereas ω of the test product B was −82 m after 4 hours.
After 24 hours, it became −96 mm.

Therefore, from this result, the product of the present invention has the maximum bending load,
It was found that both the moisture resistance is excellent, and especially the moisture resistance strength can be greatly improved.

The resin felt layer 3 and the corrugated board layer 2 are usually formed by thermosetting resin 6 impregnated in the corrugated board layer 2 during hot press molding.
Also, the resin of the resin felt layer 3 can be integrated by using the phenol resin, but it may be separately attached and integrated by using an adhesive. Prior to the hot press molding process, for example, the resin felt layer 3 is formed on the upper and lower surfaces of the corrugated cardboard layer 2.
If the intermediate core 4 and the liner 5 are temporarily joined with the thermosetting resin 6 etc. by putting them in a dryer in a state of being stacked, the handling and workability in the hot press molding process can be performed efficiently. .

Further, although the case where the corrugated board layer 2 is a single layer has been described in the embodiment, the corrugated board layer 2 is not limited to this, and may be, for example, two or more layers in which cores are parallel or intersecting. Good. Further, the resin felt layer 3 is not limited to a single fiber, and a material mixed with glass fiber or the like can be used.

<< Advantages of the Invention >> As described above, the interior base material according to the present invention can improve shape retention characteristics, rigidity and the like as compared with the conventional base material made of corrugated board or resin felt alone.

Therefore, the interior base material not only has the advantages of corrugated cardboard and resin felt, but it is also an interior base material that fuses both, and it is particularly lightweight and has high rigidity, and is suitable for forming deep drawing. Even better.

[Brief description of drawings]

FIG. 1 is a longitudinal sectional view of an interior base material showing an embodiment of the present invention, FIG. 2 is an enlarged sectional view of an essential part of the interior base material after hot press molding, and FIGS. 3 (a) and 3 (b) are It is a figure which shows the outline of a bending strength test and a moisture resistance test. 1 ... Interior base material 2 ... Corrugated board layer 3 ... Resin felt layer 4 ... Core 5 ... Liner 6 ... Thermosetting resin

Claims (1)

[Scope of utility model registration request] 1. An interior base material which is hot-press molded into a desired shape, wherein a corrugated corrugated core made of paper material is adhered and integrated between upper and lower liners made of paper material, and a thermosetting resin is applied to the corrugated board layer. And a resin felt layer which is adhered to and integrated with the surface of each liner.