JPH07223284A - Production of interior material - Google Patents

Abstract

PURPOSE:To simply produce an interior material in a resources saving manner without requiring a surface material by molding corrugated cardboard the surface liners of which are formed of an uncolored nonwoven fabric into a specific shape and dyeing the uncolored nonwoven fabric with a specific color. CONSTITUTION:The liners 13 laminated to the upper and rear surfaces of the core 12 of corrugated cardboard 11 are a needle punched nonwoven fabric composed of a fiber mixture consisting of a low m.p polyester fiber with an m.p. of about 140 deg.C and a usual polyester fiber with an m.p. of about 180 deg.C in a 1:1wt. ratio. This corrugated cardboard 11 is heated to 160 deg.C and subjected to cold press molding in a press mold consisting of upper and lower molds to be molded into a specific shape. This molded corrugated cardboard is immersed in the dyeing soln. 9 of a dyeing tank 8 and the uncolored nonwoven fabric of the corrugated cardboard 11 is dyed with a specific color. By this constitution, an interior material wherein the surface dyed liners function as surface materials can be simply produced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention mainly relates to a method of manufacturing interior materials such as automobile ceiling materials, door trims and rear parcels.

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 7, a base material (2) made of cardboard, resin board or the like is attached to the surface of a base material (4) with a hot melt adhesive (3) attached to the interior of the interior. It constitutes the material (1).

[0003]

However, in the above-described conventional structure, the base material (2) must be attached to the base material (4) with the hot melt adhesive (3). A material called an agent is required, and in addition to the step of forming the base material, the step of pressure bonding the cover material is required.

[0004]

As means for solving the above-mentioned conventional problems, the present invention forms a cardboard (11) having a liner (13) at least on the surface side made of uncolored non-woven fabric into a predetermined shape. The present invention provides a method for producing an interior material (14) for dyeing the uncolored nonwoven fabric in a predetermined color.

The corrugated cardboard of the present invention comprises, for example, a corrugated core (12) shown in FIG. 1 with liners (13, 13) attached to both sides, and a corrugated core (22) shown in FIG. Cardboard with liner (23) on one side
(21), as shown in FIG. 3, the core (32) may have a honeycomb shape other than the corrugated shape.

In the present invention, at least the liner on the front surface side of the cardboard is made of a non-colored non-woven fabric, but the core and the back liner may be made of a non-colored non-woven fabric of the same material as the front liner. It may also be made of a material such as paper, glass mat or glass paper.

The non-colored non-woven fabric used in the present invention is a needle punched non-woven fabric in which fibers such as polyester fiber, polyamide fiber, acrylic fiber, acetate fiber, cotton fiber and the like are entwined with each other by needle punching, or the above fibers are bound with a synthetic resin binder. It is a non-woven fabric or the like that has been worn, and one having a basis weight of about 20 to 60 g / m ² is usually used.

As means for imparting moisture resistance and shape retention to the above cardboard, for example, polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyester, polyamide, fluororesin, heat Thermoplastic synthetic resin such as plastic acrylic resin, thermoplastic urethane resin, urethane resin, melamine resin, thermosetting acrylic resin, urea resin, phenol resin, epoxy resin, thermosetting synthetic resin such as thermosetting polyester, Urethane resin prepolymer, epoxy resin prepolymer, melamine resin prepolymer, urea resin prepolymer, phenol resin prepolymer, diallyl phthalate prepolymer, acrylic oligomer,
A polyvalent isocyanate, a methacrylic ester monomer, a prepolymer such as a diallyl phthalate monomer, a means for impregnating an oligomer, a monomer, etc., and / or when the whole cardboard is made of a non-woven fabric or the like, polyethylene fiber, polypropylene fiber, There are means for mixing low melting point fibers such as low melting point polyester fibers and polyamide fibers, and / or means for using a hot melt adhesive or a thermoplastic resin adhesive for bonding the liner and the core. When the cardboard is impregnated with the synthetic resin, the monomer, the prepolymer, the oligomer or the like, the liner and the core are separately impregnated and then assembled into the cardboard, or the cardboard is impregnated.

The cardboard is molded into a predetermined shape and dyed in a predetermined color. The above dyeing may be carried out either before or after molding, but when molding is carried out at a high temperature, it is preferably carried out after molding in order to prevent discoloration. Dyeing is performed by spraying a dye on the uncolored non-woven fabric on the surface of the cardboard or by immersing the entire cardboard in a dyeing solution.

[0010]

In the present invention, since the liner (13) on at least the surface side of the cardboard (11) used for the interior material (14) is composed of a non-colored nonwoven fabric, the liner (13) is dyed in a predetermined color. Then, the liner (13) functions as a cover material, and it is not necessary to separately attach the cover material.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to an embodiment shown in FIGS. 4 to 6. The cardboard (11) having the structure shown in FIG.
(12), Liners (13,13) attached to the front and back sides, melting point 1
It is composed of a needle-punched non-woven fabric which is a mixed fiber of a low melting point polyester fiber of 40 ° C. and a normal polyester fiber of melting point 180 ° C. in a 1: 1 weight ratio. The cardboard (11) is 160
It is heated to ℃ and cold-pressed by a press molding die (5) consisting of an upper die (6) and a lower die (7) as shown in FIG. The corrugated cardboard (11) thus formed is then immersed in the dyeing solution (9) in the dyeing tank (8) to dye it in a predetermined color as shown in FIG. After dyeing, if necessary, it is further immersed in a fixative and a washing solution and then dried. Thus, as shown in FIG. 6, the ceiling material (14) in which the dyed liner (13) on the surface side functions as a covering material is manufactured.

[0012]

Therefore, according to the present invention, it is possible to obtain an interior material which does not require a covering material, saves resources and has a simple manufacturing process.

[Brief description of drawings]

 1 to 3 show types of cardboard.

FIG. 1 is a partial sectional view of a double-faced cardboard.

FIG. 2 is a partial sectional view of a single-sided cardboard.

FIG. 3 is a perspective view of a honeycomb-shaped core. FIGS. 4 to 6 show an embodiment of the present invention.

FIG. 4 is an explanatory diagram of a molding process

FIG. 5: Illustration of dyeing process

FIG. 6 Perspective view of ceiling material

FIG. 7 is a conventional cross-sectional view.

[Explanation of symbols]

 11,21 Cardboard 12,22,32 Core 13,23 Liner 14 Ceiling material (interior material)

Claims (1)

[Claims] 1. A method for producing an interior material, comprising forming a cardboard having a liner on at least a surface side of a non-colored non-woven fabric into a predetermined shape and dyeing the non-colored non-woven fabric in a predetermined color.