JPH08112875A - Corrugated board interior finishing material - Google Patents

Abstract

PURPOSE: To paste a skin material to a base material under the condition that the forming of the base material and the design properties of the skin material are maintained simultaneously by a method wherein both corrugated board based material impregnated with a binder having heat softening properties and glass paper impregnated with resorcin-based resin are heated up to the temperature not more than the specified value under the condition being piled up so as to pressure-form them under the condition that the skin material is put upon them. CONSTITUTION: A corrugated board base material 50 impregnated with a binder having heat softening properties and glass paper 30 impregnated with a resorcin-based resin are put one upon the other and then heated up to the temperature not more than 150 deg.C, under which the binder infiltrated in the corrugated board base material 40 softens, the curing reaction of the resorcin-based resin in the glass paper 30 can proceed and no skin material 20 is damaged by heat. Next, after the skin material 20 is put upon the glass paper 30, the resultant assembly is arranged between a male and female press forming molds so as to be integrally fixed under pressure by being pressed together. Since the press forming molds are cold pressing ones, the binder in the corrugated base material 40 and the resorcin-based resin in the glass paper 30 are cooled down and solidified, resulting in fixing the formed shape.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior material using a cardboard as a base material, and more particularly to an interior material to which a skin material is attached at the time of molding the base material.

[0002]

2. Description of the Related Art Conventionally, interior materials have been laid for interior decoration of automobiles. Most of the interior materials of this type are molded so as to fit the laid position that is not flat, and a decorative skin material is attached to a base material with a certain rigidity so that the molded shape is maintained. There are many things that become. Of such interior materials,
In order to establish a lightweight structure while maintaining rigidity, there is a corrugated paper material, so-called cardboard. That is, in terms of rigidity, since it depends on the apparent thickness of the base material, a cardboard having a hollow region inside and having a large apparent thickness while being lightweight is suitable for use. By the way, this kind of interior material is required to have heat resistance and dimensional stability in addition to the required characteristics such as the above-mentioned light weight and a certain rigidity. This is a vehicle 8
It is assumed that it will be exposed to an atmosphere of 0 ° C or higher. If the interior material lacks heat resistance, the shape will dull, and if it does not have dimensional stability and expands or contracts depending on the temperature, it will become This is because there is a gap in the mating part and it does not look good.
The conventional method of solving this has been to weaken the dependence on temperature with a thermosetting resin and to secure dimensional stability by using glass fibers.
The problem with performing the conventional method is that considerable heating is required in order to proceed with the curing reaction of the thermosetting resin during molding, which is much higher than 150 ° C and close to 200 ° C. The base material molding at such a high temperature not only has poor thermal efficiency but also makes simultaneous adhesion of the skin material impossible.
That is, under such a high temperature, since the non-woven fabric, which is generally composed of a thermoplastic resin, and the skin material such as a sheet are considerably softened, when the skin material in this state is pressed against the base material, the skin material is This is because the material is crushed and the design is greatly impaired.

[0003]

SUMMARY OF THE INVENTION The present invention has been conceived in view of the above problems, and is a cardboard interior material having a thermosetting resin and glass fibers with improved heat resistance and dimensional stability. It is possible to attach a skin material while maintaining the design, at the same time as molding of

[0004]

[Means for Solving the Problems] The means for solving the problems according to the present invention is to impregnate a cardboard base material impregnated with a binder having a heat-softening property and a resorcin resin disposed on at least one surface of the base material. A glass paper and a skin material, the cardboard base material and the glass paper are overlaid and heated to a temperature of 150 ° C. or lower, and then the skin material is overlaid and press-molded to integrate the skin material and It depends on the cardboard interior material that is molded in the shape of.

[0005]

According to the present invention, a thermosetting resin for imparting heat resistance and dimensional stability to a cardboard base material and glass fiber are added to the cardboard base material, which has excellent heat resistance and dimensional stability. It can be applied in a single process by stacking glass paper impregnated with sol. Also, it can be molded at a relatively low temperature because the curing reaction of resorcin resin progresses below 150 ° C. Therefore, it is possible to attach the skin material at the same time as molding.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A preferred embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a sectional view showing an embodiment of a cardboard interior material of the present invention, in which a cardboard base material 40, a glass paper 30 impregnated with a resorcin-based resin, and a skin material 20 are stacked and integrated. And is formed into a shape that fits the installation position. The cardboard substrate 40 is composed of a corrugated core 40a and liners 40b on both sides of the corrugated core. As the corrugated cardboard, a general corrugated core roll core type or honeycomb core type can be used, and the thickness is about 5 mm, and the base material of paper quality is a softening binder (corn starch, polyethylene resin, rubber type). It is preferable that the coating weight is about 300 g / m ² after impregnation with a resin or the like. The glass paper 30 impregnated with the resorcin-based resin preferably has a fiber length of 13 to 25 mm,
A glass paper having a basis weight of 30 g / m ² obtained by bonding and arranging glass fibers having a fiber diameter of 9 micrometers in a mixed paper-making method, and a dry weight of 100 g / m of a resorcin resin having a property of curing at a relatively low temperature. ² Impregnated. Here, the resorcin-based resin refers to a thermosetting resin that contains a condensate of resorcin and formaldehyde as a main component and contains phenol and formaldehyde condensate, melamine condensate and the like as other components. When the temperature of the glass paper becomes 100 ° C. or higher, the impregnated resin is first softened so that the glass paper itself is in a state suitable for press molding, and the curing reaction of the resin proceeds by being further heated. Then, it is cured during press molding and the molded shape is stabilized. As the skin material, it is possible to use a material that is generally used as a skin material for this type of interior material having a certain design property and heat resistance, and needle-punched nonwoven fabric (made of polyester fiber, basis weight 200 g / m 2 ² ) is most preferable, but other woven fabrics, knitted fabrics, resin sheets, etc. are also possible. This skin material is lined with a low melting point thermoplastic resin (polyolefin, thickness: 0.
1 mm) is most suitable. Next, a preferable molding method of this interior material will be described. First, the cardboard base material and the glass paper are overheated, the binder impregnated in the cardboard softens, the curing reaction of the resorcin resin in the glass paper can proceed, and the skin material is not damaged by heat. It is heated with a heater or the like so that the temperature is preferably 130 to 140 ° C. Next, after overlaying the skin material on the glass paper, the skin material is placed between the male and female press molds and press-pressed to integrally press them together. Since this press mold is a cold mold, the binder impregnated in the cardboard and the resorcin resin in the glass paper are cooled and solidified to fix the molded shape. FIG. 2 shows another embodiment of the present invention, which is an example in which a spunbonded nonwoven fabric 50 of a thermoplastic resin is interposed on the outside of a base material. This is a suitable structure particularly when it is necessary to improve the releasability from the mold during molding or when it is necessary to give the base material a ventilation stop function. Particularly preferred as this spunbond nonwoven fabric is
Polyolefin resin, weight is 10-15g / m ²
Is. The spunbonded nonwoven fabric also has a function of softening and melting the thermoplastic resin film at the time of molding to enhance the adhesiveness between the glass paper and the skin material. As a result of evaluating heat resistance and dimensional stability of the interior material according to this example, 8
No abnormalities such as deformation and deterioration after being heated at 5 ° C. for 24 hours were observed, and the dimensional change rate was 0.15%, which is one-third of that of the conventional cardboard interior material of this type. It was a level.

According to the present invention, in the step of molding the interior material, the cardboard, the glass paper and the skin material are integrated at a relatively low temperature, and the number of steps can be reduced. It has excellent heat resistance and dimensional stability.

[Brief description of drawings]

1 shows a cross-sectional view of an embodiment of the present invention.

FIG. 2 shows a cross-sectional view of another embodiment.

[Explanation of symbols]

 10 ... Interior material 20 ... Skin material 30 ... Glass paper 40 ... Base material (Danball) 40a ... Core 40b ... Liner 50 ... Spunbond nonwoven fabric

Claims (1)

[Claims] 1. A cardboard base material comprising a cardboard base material impregnated with a binder having a heat-softening property, a glass paper impregnated with a resorcin resin disposed on at least one surface of the base material, and a skin material. A corrugated cardboard interior characterized by being formed into a specific shape as well as being integrated with the skin material by press-molding after stacking the glass paper with glass paper and heating to a temperature of 150 ° C. or less. Material.