JPH07256786A - Interior material and manufacture thereof - Google Patents

Abstract

PURPOSE:To eliminate continuous operations of a base raw fabric-forming process and a press molding process, facilitate management of manufacture, and eliminate preheating by a method wherein a polyurethane foaming solution is impregnated into a glass fiber so as to foam and the obtained glass fiber- foamed urethane composite sheet material is molded with heat. CONSTITUTION:To a base material of a urethane foam 2 reinforced by a glass fiber 1, a skin material 3 is adhered by an adhesive 4 such as a hot melt film. That is, a film 5 consisting of a polypropylene resin with a continuous strand mat 6 thereon is moved on a conveyor 12 and coated with a polyurethane foaming solution 7 by a spray. On the top of it, the hot melt film 4 is layered. While it is being compressed by upper and lower thickness adjusting rolls 13a and 13b, the glass mat is impregnated with resin, compressed by a belt conveyor 14, cured while it is foamed so as to obtain raw fabric 8. Further, an unwoven cloth skin 3 is layered on the hot melt film 4 and molded with heat.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to interior materials such as molded ceilings, door trims and trunk trims of automobiles and other vehicles, and a method of manufacturing the same.

[0002]

2. Description of the Related Art The following are examples of interior materials using polyurethane foam. 1) JP-B-63-7577 A flexible polyurethane foam is impregnated with an isocyanate compound and sprayed with water containing or not containing an amine to obtain a glass fiber, a plastic film, a non-woven fabric,
A method for manufacturing a composite panel, which comprises stacking skins and the like to form a base material sheet, and heat-molding this with a press die. 2) British Patent No. 2028714 (cold pressing method) A polyurethane foam sheet and / or a reinforcing sheet such as glass fiber is coated with an adhesive, and both are adhered to each other.
A method for producing a reinforced panel of polyurethane foam, which is preheated to 0 to 220 ° C. and then immediately molded in a press mold.

[0003]

Since the method 1) uses a flexible polyurethane foam, it requires a step of curing after impregnation with an isocyanate compound for the purpose of ensuring strength. Since the isocyanate compound reacts with the moisture in the air to proceed with curing, it is necessary to perform thermoforming immediately after impregnation, and in the intermediate step, the preservability is poor and it cannot be stocked. Therefore, it is necessary to make a series of continuous equipment from impregnation to press molding, resulting in large capital investment. Further, the method includes a step of spraying water containing or not containing an amine, the step is complicated, and corrosion of equipment is likely to occur. On the other hand, the method of 2) above requires a step of putting the heated composite of the polyurethane foam and the reinforcing sheet in the press mold immediately after taking it out from the heat source, that is, the step is complicated or short. The pressing process must be done in open time. Further, in each of the above 1) and 2), the glass fiber is exposed on the surface, so that it is necessary to cover with a surface material such as a nonwoven fabric, which is not preferable in terms of man-hours, material cost, and weight.
A main object of the present invention is to provide an interior material which does not require continuous steps of forming a base material sheet and press molding, and which can be pressed without preheating the base material sheet. Another object of the present invention is to provide an interior material which is excellent in weight, price and physical properties and has no splinter on the surface.

[0004]

Means for Solving the Problems As a result of extensive studies to solve the above problems, the present invention has been achieved. The present invention is a glass fiber obtained by impregnating a polyurethane foaming stock solution into glass fiber and then foaming the same. -It is an interior material for thermoforming a urethane foam composite sheet material, and succeeded in obtaining a desired interior material by impregnating a polyurethane foaming undiluted solution into glass fiber, followed by foaming and thermoforming.

The present invention will be described in detail. In the present invention, a glass fiber, for example, is placed as a glass fiber on a material such as a release film or paper, and a polyurethane foaming stock solution capable of hot press molding after foaming and hardening is uniformly stirred and applied, and then a hot melt film is formed on the upper surface thereof. Alternatively, a release film is overlaid, glass fibers are uniformly impregnated with a urethane material, and the urethane material is foamed and cured to obtain a mat-shaped base material fabric, and an interior material obtained by hot press molding the same. That is the manufacturing method.

The present invention will be illustrated and described with reference to the drawings.
The interior material of the present invention is, as shown in FIG. 1, a urethane foam 2 reinforced with the glass fiber 1 obtained as described above.
The base material 3 has a structure in which the skin material 3 is adhered by an adhesive 4 such as a hot melt film. The urethane material used in the present invention is one that can be hot-press molded after foaming and curing, and as such a urethane material, a raw material for a flexible polyurethane foam or a semi-flexible polyurethane foam is used. In order to make the foam flexible for the purpose of preventing cracking when molded, a polyol is blended so that the average molecular weight between the crosslinks is 500 to 2000, and water or fluorocarbons and A low-boiling material such as a hydrocarbon derivative is added, and other materials such as a catalyst and a foam stabilizer are usually used for urethane foaming. As for the expansion ratio, in terms of weight and price, and when the weight of urethane is large at the time of molding, it takes time to heat the inside of the material, and defects such as pocking are likely to occur at the time of molding. It is preferable, and the foaming agent is adjusted so as to have a concentration of about 0.005 to 0.030 g / cm ³ when free foaming.

As the isocyanate to be reacted with the above polyol component, a material such as MDI or TDI usually used for urethane foaming or a mixture of MDI and TDI can be used.

As the glass fiber to be dispersed in the foam of the present invention, a glass fiber non-woven fabric obtained by making a glass single fiber, a continuous strand mat, a chopped strand mat or a surface mat is used. Alternatively, one kind or two or more kinds of these may be used in combination, but a continuous strand mat, a chopped mat or the like which is well impregnated with a urethane resin is preferable. It is preferable to use a weight per unit area of 100 to 200 g / m ² for weight reduction. If the strength is required or if you want to take measures against warpage of the molded product, increase the basis weight to deal with it.

The film material sandwiching the material is PP or PE.
When using a film having releasability such as, peel off before molding, or if molding at low temperature, mold with the film attached. In the case of PET film and paper, it can be molded with the film attached. As the film material on the skin side, the above material is used when the skin is molded in a separate step after the base material is molded, but in the case of simultaneous molding of the skin, the film on the skin side is polyethylene, polypropylene, a resin film such as vinylidene chloride or polyamide. A hot melt film such as a polyester type or a polyester type is used.

When flame retardancy of interior materials is required, for example, when the US automobile safety standard (MVSS 302 pass) is required, non-combustible papers such as aluminum hydroxide paper, calcium carbonate paper and calcium silicate are used instead of synthetic resin film. Paper or the like is used.

The production method may be either batch production or continuous production as shown in FIG. 2, but the continuous process is preferred as the process for producing the base material. As a method of impregnating glass fibers with a urethane resin, the mixed urethane raw materials are sprinkled, and then strongly compressed through a film to impregnate them. It is preferable to spray-coat the urethane raw material because the resin can be easily uniformly impregnated.

When urethane is foamed after impregnation, a plate-like product is prepared by constraining the top and bottom with a constant gap in order to make the thickness uniform. Bubble nuclei It is preferable that the bubble nuclei are vertically elongated as in free foaming structurally, so after restraining the upper and lower sides for a certain period of time, it is preferable to release the restraint and foam in a tensionless state. . The coating amount of polyurethane foaming solution is 20
About 0 to 600 g / m ² is good, and the thickness of the plate-shaped product is 3 to
About 15 mm is good. After urethane foaming, it can be molded even if it is not completely cured, but since the heating time becomes long, it is preferable to mold after curing. There is no particular limitation on the time from curing to molding, and foaming heating can be produced by a batch method without using continuous equipment. Molding can be performed using a hot press mold at a molding temperature of 70 to 170 ° C.
At 130 ° C, molding can be performed for 30 seconds or more.

An example of the present invention will be described with reference to FIGS. Film made of polypropylene resin 5
150 g / m ² of continuous strand mat 6 is continuously placed on the conveyor 12 and moved. After foaming and curing, the polyurethane foaming undiluted solution 7 that can be thermoformed is evenly applied by spraying at 300 g / m ² ,
After laminating the hot melt film 4 made of a polyamide resin on it, the glass mat is impregnated with resin while being compressed by the upper thickness adjusting roll 13a and the lower thickness adjusting roll 13b from above and below, and then the upper and lower gaps ( Thickness)
3m endless belt conveyor 1 while maintaining 3mm
After being compressed at 4, the resin was cured while foaming in a tension-free state to prepare a base material 8 having a plate thickness of 10 mm on average. One day after foaming and curing, the PP film of the substrate raw material 8 was removed, and the nonwoven fabric skin 9 was further laminated on the hot melt film, and then heated to 130 ° C. The upper mold 10 is placed on 10b.
A base weight is 450 g / m after compression molding for 30 seconds.
The molded ceiling 11 of ² was created.

[0014]

[Function] While the glass fiber is placed on the resin film, the polyurethane foaming undiluted solution is applied, the hot melt film is placed and the thickness is adjusted while being compressed by the endless belt conveyor to form a base material stock, After a lapse of days, it is heat-molded with a mold, and the hot-melt film substitutes for the adhesive to obtain a desired molding material (for example, a molding ceiling).

[0015]

INDUSTRIAL APPLICABILITY According to the present invention, it is not necessary to continuously perform the step of forming the base material web and the press forming step, the manufacturing control is very easy, and the base material web is preheated. It is not necessary and can be manufactured with relatively simple equipment, and the equipment investment can be suppressed. In addition, since there is no step of curing the liquid material during molding, problems such as resin exudation into the skin do not occur, and stable quality is obtained. In the case of interior materials made of porous material such as resin felt or other urethane materials, when air passes through the material, the skin material acts as a filter and stains the skin, but this method creates a skin layer on the surface. No breathability and no dirt. In addition, since the glass fiber used for reinforcement is embedded in the urethane material, it does not scatter to the outside and the environment inside the vehicle is good. In terms of performance, the glass fibers are integrally foamed so that the dimensional change is extremely small, and the heat and moist heat resistance are good, which is advantageous for construction and can contribute to weight reduction.

[Brief description of drawings]

FIG. 1 is a cross-sectional configuration diagram of an interior material of the present invention.

FIG. 2 is a cross-sectional view showing an example of a continuous manufacturing method of a base material web for an interior material of the present invention.

FIG. 3 is a sectional view showing thermoforming by the mold of the present invention.

FIG. 4 is a cross-sectional view of a molded ceiling after thermoforming with the mold of the present invention.

[Explanation of symbols]

 1 Glass Fiber 2 Urethane Foam 3 Skin Material 4 Hot Melt Film 5 Resin Film 6 Continuous Strand Mat 7 Polyurethane Foaming Raw Liquid 8 Base Material Fabric 9 Nonwoven Fabric Skin 10a Molding Upper Mold 10b Molding Lower Mold 11 Molding Ceiling 12 Conveyor 13a Upper Thickness Adjusting roll 13b Lower thickness adjusting roll 14 Endless belt conveyor 15 Stirring machine

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Reference number within the agency FI technical display location B29K 105: 04 105: 08 (72) Inventor Shigeyoshi Fukushima Inakuchi, Inami-cho, Kako-gun, Hyogo Prefecture Kaike 1176 Toyo Tire & Rubber Co., Ltd. Hyogo Plant Hyogo Factory (72) Inventor Shiro Ozaki 3 Yoshigayama, Miyoshi Town, Nishikamo-gun, Aichi Toyo Tire & Rubber Co., Ltd. Automotive Parts Technology Center (72) Invention Person Shirito Mimura, 1/6 Uchigaike, 1/6, Inami-cho, Kako-gun, Hyogo Prefecture, Toyo Tire & Rubber Co., Ltd., Hyogo Plant, Hyogo Plant (72) Inventor, Tokuda Mana 6-character, Inami-cho, Kako-gun, Hyogo Prefecture Ike 1176 Toyo Tire & Rubber Co., Ltd. Hyogo Office Hyogo Factory

Claims (3)

[Claims] 1. An interior material characterized by thermoforming a glass fiber-foam urethane composite sheet material obtained by impregnating glass fiber with a polyurethane foaming stock solution and then foaming. 2. An interior material characterized in that glass fiber is impregnated with a polyurethane foaming stock solution, followed by foaming and thermoforming. 3. A method for producing an interior material, which comprises impregnating a glass fiber mat with a polyurethane foaming undiluted solution, followed by foaming and thermoforming.