JPH07258486A - Blank board for interior trim of vehicle and its production - Google Patents

Abstract

PURPOSE:To produce a blank board for interior trim of vehicle having high quality at a low cost by recycling a waste material of injection molded PP article containing a bumper edge material and to provide a process for the production of the board. CONSTITUTION:This blank board 2 is produced from virgin PP and pellets obtained by crushing a bumper edge material 13 (waste material of injection molded PP article) as main raw materials. The board has high quality and excellent strength and moldability and is producible at a reduced cost corresponding to the reduction of the amount of expensive virgin PP. Since the main raw material of the blank board is compounded with 5-40% of talc, the board has excellent characteristics such as high heat-resistance (free from deformation at 90 deg.C for 10hr), rigidity, easy moldability owing to elongation in the molding of interior trim of vehicle, resistance to cracking of the blank by impact at a low temperature and the uniform thickness in extrusion molding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a material board constituting a vehicle interior product (for example, an inner wall of a trunk room) and a method for manufacturing the same.

[0002]

2. Description of the Related Art Recently, a PP board has been used as a material board in the above-mentioned vehicle interior parts in order to reduce the weight and cost of an automobile body or to supplement the strength of an outer plate. Particularly, in the case of a material board used for the inner wall of a luggage compartment, a synthetic fiber non-woven fabric made of PET or the like is often attached to the surface to give a cushioning property and a high-grade feeling.

[0003] However, the conventional material board for vehicle interior parts is a high quality one formed by using PP as a main raw material, so that it is very expensive in terms of cost. Therefore, recently, attempts have been made to use, as a raw material for the material board, PP injection molded product scraps (including bumper scraps and scraps) that have been disposed of by incineration or the like. PP here
Injection-molded product waste materials are used products, defective molding products (including defective coating products, defective products due to defects and stains), raw materials solidified from the sprue to the gate, scrap materials produced when the product is taken from the material board, etc. It includes those with a thermal history. In particular, the bumper after scrapping the car and the scraps discharged during the bumper molding are made of PP containing rubber for the purpose of improving the impact resistance, so it is a waste of resources to discard them by incineration or the like. There was a call for its effective use.

[0004]

However, when the waste material of the PP injection molded product, particularly the used bumper or the defective bumper is crushed and the raw material board is manufactured as the main raw material by itself, the material characteristic of the bumper is Therefore, the performance such as tensile strength, tear strength, tensile elongation strength and bending strength is not sufficient, and there is a problem that the moldability of the material board into a molded product is poor and the rigidity and heat resistance are reduced.

An object of the present invention is to solve the above-mentioned problems, and it is possible to significantly reduce the cost which is a drawback of a material board formed by using virgin PP as a main raw material, and a PP injection molded product. An object of the present invention is to provide a high-quality material board for vehicle interior parts, which has improved performance such as strength of a material board mainly made of waste material and improved moldability, and a manufacturing method thereof.

[0006]

In order to achieve the above-mentioned object, the present invention uses powder and granules obtained by pulverizing a waste material of PP injection molded product and virgin PP as main raw materials, and the main raw material contains talc of 5 to 5%.
The present invention provides a material board for vehicle interior parts, characterized by being molded by mixing 40%. In addition, the present invention is PP
At the stage of obtaining a main raw material by mixing virgin PP with powder particles obtained by pulverizing the waste material of the injection molded product, talc is added to the main raw material in an amount of 5 to 5.
The present invention provides a method for producing a material board for vehicle interior parts, which comprises mixing 40% and extruding the mixture. Further, the present invention provides a proper amount of a foaming agent in the step of mixing talc with the main raw material. The present invention provides a method for producing a material board for vehicle interior parts, which is characterized in that the material board is added.

[0007]

The material board for vehicle interior parts manufactured according to the present invention is mainly composed of powder and granules obtained by crushing waste material of PP injection molded product and virgin PP, and 5-40% of talc.
Since it is mixed and molded, the amount of virgin PP used can be greatly reduced compared to the conventional material board made only of virgin PP, and it can be manufactured at low cost, and it is made with only bumper scraps. Compared with the conventional material board
Since the content of P is increased, performances such as tensile strength, tear strength, tensile elongation strength and bending strength are further improved, and moldability, rigidity and heat resistance are further improved.
It will be possible to generally provide a good quality material board for vehicle interior parts.

[0008] It should be noted that the waste material of the PP injection molded product containing the scrap material of the bumper cannot be returned as a raw material of the same product because the coating film becomes a foreign matter after coating. In this respect, even in the present invention, even if the coating film becomes a foreign matter, there is no particular problem as a material board for vehicle interior parts.

[0009]

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.

In FIG. 1, reference numeral 1 denotes a vehicle interior part,
The vacuum formed parts a to g forming the inner wall of the luggage compartment are shown. This vehicle interior component 1 is formed by vacuum forming or press forming a material board 2 shown in the enlarged sectional view of FIG. The material board 2 is made of PET in order to give a cushioning property and a high-class feeling to the room-side surface of the board substrate 2a.
A synthetic fiber non-woven fabric 3 made of, for example, is attached.

Next, the manufacturing process of the material board 2 will be described with reference to FIG.
Shown in. First, a PP injection molded product waste material, for example, a defective product bumper or a used bumper (hereinafter referred to as bumper end material) 13 as shown in the drawing is prepared (step A). The bumper scraps 13 are made of PP, ethylene propylene rubber (E
PR) and talc. The ratio is PP: EP
R: Talc = 60: 30: 10 is good.

Next, the bumper scraps 13 are crushed (cut) by a crusher (step B), crushed (cut) to a desired size, and then crushed by a granulator 12 (step C) to form a powder or granular material. (First raw material) 32 is obtained. A well-known granulator 12 such as a Hensyl mixer can be used. It should be noted that the granulator 12 can be omitted if the crushing size by the crushing (cutting) machine 11 is appropriate.

Thus, the first raw material 32 obtained in the above process
And a virgin PP (second raw material) 31 prepared in advance are mixed by a mixer (for example, a ribbon mixer) 14 to obtain a main raw material. In this case, a cost reduction effect can be obtained by increasing the amount of PP injection molded product waste material relative to virgin PP, but considering the quality of the material board, PP injection molded product waste material: virgin PP = 40 to 65: 60 to 35 is suitable. At the stage of obtaining the main raw material, 5 to 40% of talc 33 is put into the mixer 14 and mixed (step D). The amount of talc charged and mixed here is limited to the range of 5 to 40%. The main reasons are as follows. The material board for vehicle interior parts manufactured with less than 5% has low heat resistance (deformation at 90 ° C x 10 hours).・ There is no rigidity.・ High cost (because virgin PP increases). The material board for vehicle interior parts manufactured with more than 40%:-Elongation at the time of molding decreases. -The base material is likely to crack due to cold shock.・ This is because thickness unevenness is likely to occur during extrusion molding.

The talc-containing main raw material mixed in the above process is extrusion-molded as the board 2a by the extruder 15 (step E), and the talc 33 is dispersed as shown in FIG. Then, while the board substrate 2a extruded from the extrusion molding machine 15 is still squeezable, the synthetic resin non-woven fabric 3 is supplied and bonded to one surface of the board substrate 2a to manufacture the material board 2. If a chemical foaming agent (for example, ADCA) is added and mixed as an additive at the stage of mixing the main raw material containing talc in the mixer 14, the board substrate 2a foams to reduce the weight and cost. Can be down.

The manufactured material board 2 is vacuum-formed or press-formed as a vehicle interior component and mounted on an automobile. The scraps of the material board itself provided for this interior item are collected. This scrap material is also recycled by crushing. At the time of this recycling, non-woven fabric 3 is applied to one side of the board substrate.
In the case of a laminated material board, the constituent fibers have a structure that remains in the recycled board substrate (composite effect with fibers such as reinforced plastic), resulting in better strength, dimensional stability, and shape. Maintainability and sound insulation can be obtained. In order to obtain such a composite effect with fibers, the heating temperature in the extruder 15 at the time of recycling is set to be lower than the melting point of the synthetic resin nonwoven fabric and higher than or equal to the melting point of the powder or granular material of the material board 2. is necessary.

Now, conventional products A and B shown in the following [Table 1]
Then, using the products 1 to 3 of the present invention, tests were conducted on four items of tensile strength, tensile elongation strength, tear strength, and heat shrinkage rate, and the results are shown in [Table 2]. The sizes of the conventional products A and B and the products 1 to 3 of the present invention are as follows: thickness = 0.9 m
m and tsubo 909 g / m ² .

[0017]

[Table 2] Invention product 1 Invention product 2 Invention product 3 Conventional product A Conventional product B Tensile strength Vertical 24.0 25.9 27.1 28.7 15.8 (kg / cm) Horizontal 20.0 20 .3 22.7 22.6 14.2 Tensile elongation Vertical 59 51 50 50 72 50 (%) Horizontal 67 61 61 62 68 32 Tear strength Vertical 17.5 18.3 19.2 22.3 11.4 (kg) Horizontal 14.9 15.0 16.3 15.4 9.5 Heat shrinkage ratio Vertical 0.5 0.4 0.5 0.5 0.4 0.3 (%) Horizontal 0.3 0.2 0.2 0.3 0.2 Formability ◎ ◎ ◎ ◎ ◎ ×

From the above table, the invention product 1 had the same moldability as the conventional product A, and the invention products 2 and 3 also had the property of satisfying the moldability as the vehicle interior parts. On the other hand, the conventional product B has a small elongation and has a problem of drawdown. Further, the conventional product B is not suitable as a vehicle interior product 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 due to the expansion rate. It was confirmed. As a result, the vehicle interior material board according to the present invention significantly reduced the virgin PP content. It has been proved that the product of the present invention has the same excellent strength as the conventional product A made of virgin PP.

The product 1 of the present invention was recycled 5 times (R-1 to R-5) to obtain its 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 11 12 11 13 11 (g / 10 min) Tensile strength Vertical 23.9 24.3 25.1 25.1 25. 2 (kg / cm) Horizontal 19.8 19.9 20.3 19.5 20.5 Tensile elongation Vertical 58 56 56 58 57 57 (%) Horizontal 66 60 60 58 58 58 Tear strength Vertical 17.0 17.1 17. 1 17.6 18.0 (kg) side 15.1 14.5 14.5 14.0 14.3

From the above table, the invention product 1 did not pose a problem in physical properties after being repeatedly recycled 5 times. In addition,
Inventive product 2 and inventive product 3 have not been subjected to repeated recycling experiments, but from the results of invention product 1, it can be conjectured that there is no problem.

In this embodiment, PET fibers are used as the synthetic fibers constituting the non-woven 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.

In the present embodiment, the trunk room is taken as an example of the vehicle interior component, but other vehicle interior components such as the inner wall of the hood, the dashboard and the like may be used.

[0025]

As described above, the material board for vehicle interior parts according to the present invention is composed mainly of the powder and granular material obtained by crushing the waste material of the PP injection molded product and the virgin PP, and therefore the expensive virgin PP. The amount used is suppressed, and accordingly, the cost is low, the quality is good, and excellent strength and moldability are obtained. Also,
The material board for vehicle interior parts of the present invention contains talc as the main raw material.
Since the mixture is -40%, the following effects can be obtained. High heat resistance (deforms at 90 ° C x 10 hours). It has rigidity.

According to the method for producing a material board for vehicle interior parts according to the present invention, talc is used as a main raw material in the step of mixing a granular material obtained by pulverizing a waste material of a PP injection molded product with virgin PP to obtain a main raw material. Since it is characterized by mixing 5 to 40% and extruding, talc has good dispersibility and mixability, there is no unevenness during extrusion as a board, sizing becomes good, and the manufacturing cost can be reduced. is there.

Furthermore, in the method for manufacturing a material board for vehicle interior parts according to the present invention, if an appropriate amount of a foaming agent is added at the stage of mixing talc with the main raw material, the dispersibility and mixing property of the foaming agent are improved. This contributes to weight reduction and cost reduction of the material board.

[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 11 Crusher 12 Granulator 13 Bumper End Material 14 Mixer 15 Extruder 31 Second Raw Material (Virgin PP) 32 First Raw Material (Bumper) Scrap powder) 33 Talc

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Izumi Komatsuzaki 3607 Santanda, Katsuta City, Ibaraki Prefecture (72) Inventor Masatoshi Hayashi 33-2 Inaoka-cho, Inage-ku, Chiba City, Chiba Prefecture

Claims (3)

[Claims] 1. A powdery material obtained by crushing a waste material of a PP injection molded product and virgin PP as a main raw material, and talc 5
A material board for vehicle interior parts, characterized by being molded by mixing up to 40%. 2. Extruding by mixing 5 to 40% of talc with the main raw material at the stage of mixing the powder and granules obtained by pulverizing the waste material of PP injection molded product with virgin PP to obtain the main raw material. A method of manufacturing a material board for vehicle interior parts, characterized by: 3. In the step of mixing talc with the main raw material,
The method for manufacturing a material board for vehicle interior parts according to claim 2, wherein an appropriate amount of a foaming agent is added.