JPH09131743A - Manufacture of interior finish material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior finish base material for an automobile having a light weight, no air permeability and excellent appearance. SOLUTION: The method for manufacturing an interior finish material comprises the steps of superposing non-air permeable sheet 2 on one or both surfaces of a glass fiber sheet 1 immersed with synthetic resin and/or synthetic resin precursor to be partly adhered so that the orientation of the sheet 1 is not interfered with the sheet 2, superposing the sheet partly adhered with the sheet 2 on one or both surfaces of an air permeable base material 4, press molding it, and entirely adhering the material 4 to the sheets 1, 2 by the resin and/or cursor oozed from the sheet 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing interior materials for automobiles and the like.

[0002]

BACKGROUND OF THE INVENTION A foamed polyurethane sheet impregnated with diisocyanate is provided as a base material for an interior material such as an automobile ceiling material. Although such a breathable base material is lightweight, an interior material in which a breathable skin material such as a non-woven fabric is adhered to the base material is naturally breathable, and does not emit smoke or dust of cigarettes in the passenger compartment. There is a problem that the contained air easily passes through the interior material and becomes dirty. Therefore, conventionally, it has been proposed to laminate a non-breathable sheet on such a breathable substrate. The non-breathable sheet is laminated at the time of molding the base material, and at the same time as the molding of the base material, diisocyanate impregnated in the base material is exuded to the superposed surface of the sheet and cured to form the sheet. Adhere to the substrate.

[0003]

2. Description of the Related Art Since the above-mentioned non-breathable sheet is thin and flexible, if the non-breathable sheet is superposed on the breathable substrate when molding the breathable substrate, the work efficiency is remarkably high. descend. Therefore, conventionally, a method has been adopted in which the non-breathable sheet is entirely attached to a glass fiber sheet that reinforces the breathable substrate, and the glass fiber sheet is formed by superimposing the breathable substrate. There is.

[0004]

However, when a non-breathable sheet is entirely attached to the glass fiber sheet, the stretchability of the glass fiber sheet is impeded during press molding, and especially in the deep drawing part. There is a problem that the appearance of the interior material is deteriorated due to the occurrence of cracks.

[0005]

Means for Solving the Problems The present invention is, as a means for solving the above-mentioned problems, a non-breathable one or both surfaces of a glass fiber sheet (1) impregnated with a synthetic resin and / or a synthetic resin precursor. The sheet (2) is overlaid and partially adhered, and the one or both sides of the breathable substrate (4) are overlaid and press-molded to form the substrate (4) and the glass fiber sheet (1). And the glass fiber sheet
The non-breathable sheet (2) is formed by the synthetic resin and / or the synthetic resin precursor exuded from (1) to the glass fiber sheet.
The present invention provides a method for producing an interior material (9) which is entirely adhered to (1).

The glass fiber sheet used in the present invention is, for example, a knitted or woven fabric of glass fibers, or a glass fiber paper made from glass fibers.

Examples of the synthetic resin with which the glass fiber sheet is impregnated include urethane resins, melamine resins, thermosetting acrylic resins, urea resins, phenol resins, epoxy resins, thermosetting resins such as thermosetting polyesters, polyethylene, etc. Polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, fluororesin, thermoplastic acrylic resin, thermoplastic polyester, thermoplastic polyamide, thermoplastic urethane Resins, thermoplastic resins such as acrylonitrile-butadiene copolymer, styrene-butadiene copolymer, acrylonitrile-butadiene-styrene copolymer, and the like, and the synthetic resin precursor is, for example, polymerized and / or three-dimensionalized. By the above heat For example, a urethane resin prepolymer, an epoxy resin prepolymer, a melamine resin prepolymer, a urea resin prepolymer, a phenol resin prepolymer, a diallyl phthalate prepolymer, an acrylic oligomer, tolylene diisocyanate, which produces a volatile resin or the above synthetic resin, Paraphenylene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, hexamethylene diisocyanate, 1,4-naphthalene diisocyanate, 4,4 ′
-Diphenyl diisocyanate, 4,4'-diphenylmethane diisocyanate, 3,3'-dimethyl-4,
4'-diphenyldiisocyanate, 3,3'-dimethyl-4,4'-diphenylmethane diisocyanate,
3,3'-dimethoxy-4,4'-diphenyl diisocyanate, 2-chloro-1,4-phenyl diisocyanate, 1-chloro-2,4-phenylene diisocyanate, m-phenylene diisocyanate, p-phenylene diisocyanate, 2,2 ', 5,5'-tetramethyl-4,4'-biphenylene diisocyanate, m-xylylene diisocyanate, ω-xylylene diisocyanate, ω'-xylylene diisocyanate Examples thereof include polyvalent isocyanate such as nato, prepolymer such as (meth) acrylic acid ester monomer, diallyl phthalate monomer, oligomer, monomer and the like.

The non-breathable sheet of the present invention is, for example, a plastic sheet of polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyamide, polyester or the like, and the plastic sheet usually has a thickness of Those having a thickness of 10 to 50 μ are used.

The breathable substrate of the present invention is, for example, foamed polyurethane, felt, nonwoven fabric, fiber knitted woven fabric, etc., and the breathable substrate is made of the same synthetic resin and / or synthetic resin when impregnated with a glass fiber sheet. The resin precursor may be impregnated.

The non-breathable sheet is partially adhered by superimposing it on one side or both sides of the glass fiber sheet, and preferably the non-breathable sheet is adhered on both side edges of the glass fiber sheet. Adhesion between the glass fiber sheet and the non-breathable sheet uses an adhesive or a hot-melt sheet, or the hot-melt property of the non-breathable sheet itself is used without using the adhesive or the hot-melt sheet. May be welded together.

The glass fiber sheet on which one side or both sides of the non-breathable sheet is superposed and partially adhered is press-molded by superposing on one or both sides of the breathable base material. The synthetic resin and / or the synthetic resin precursor impregnated in the glass fiber sheet by the press molding exudes to the non-air-permeable sheet overlapping surface, and the synthetic resin and / or the synthetic resin precursor exuded in this way A non-breathable sheet is entirely adhered to the glass fiber sheet.

An adhesive or a hot melt sheet is used to bond the glass fiber sheet and the breathable substrate, but when the breathable substrate is impregnated with a synthetic resin and / or a synthetic resin precursor. The synthetic resin and / or the synthetic resin precursor exude to the superposed surface of the glass fiber sheet, and the synthetic resin and / or the synthetic resin precursor exuded in this manner causes the glass fiber sheet to pass through the breathable substrate. May be adhered to.

In the above press molding, since the non-breathable sheet is partially adhered to the glass fiber sheet, the elongation of the glass fiber sheet at the time of molding is not affected by the interference of the non-breathable sheet, and the deep drawing portion Also in the above, wrinkles do not occur in the glass fiber sheet.

[0014]

1 to 3 show one embodiment of the present invention. The glass fiber paper (1) shown in FIG.
The glass fiber paper (1) is impregnated with 4,4'-diphenylmethane diisocyanate in an amount of 1% by weight, and a polyester sheet (2) is superposed on one surface of the glass fiber paper (1). High frequency welding is applied to both side edges (3) of (1). (4) is a soft polyurethane foam sheet, the polyurethane foam sheet (4) has a thickness of 5 mm, and is impregnated with 4,4′-diphenylmethane diisocyanate in an amount of 30% by weight.
The glass fiber paper (1) is the expanded polyurethane sheet
(4) is laminated on one surface, and further, glass fiber paper (5) is laminated on the other surface of the foamed polyurethane sheet (4). The glass fiber paper (5) is not impregnated with synthetic resin and / or synthetic resin precursor.

In this way, the polyester sheet (2),
Glass fiber paper (1), polyurethane foam sheet (4)
, Glass fiber paper (5) is piled up and sandwiched between the upper mold (7) and the lower mold (8) of the press mold (6) as shown in FIG. 2, and the temperature is 150 ° C., 3 kgf / cm. Press-mold at a pressure of ² for 3 minutes.

The 4,4'-diphenylmethane diisocyanate impregnated in the glass fiber paper (1) and the foamed polyurethane sheet (4) by the above press molding is contacted with the moisture in the atmosphere to be thermally cured. The polyester sheet (2) is attached to the fiber paper (1) at both edges (3).
The glass fiber paper (1) is stretch-molded without interference with the polyester sheet (2) in the middle portion and is not wrinkled because it is adhered only to the glass sheet. Further, during the press molding, the polyester sheet (2) of the glass fiber paper (1) is overlaid on the glass fiber paper (1).
A polyester sheet (2) in which 4,4'-diphenylmethane diisocyanate impregnated in the glass is exudatively cured and pressed against the glass fiber paper (1) by the pressing pressure.
Is adhered entirely by the 4,4'-diphenylmethane diisocyanate.

Similarly, 4,4'-diphenylmethane diisocyanate impregnated in the foamed polyurethane sheet (4) is also exudatively cured on the superposed surface of the glass fiber paper (1,5), and thus glass fiber is obtained. The paper (1,5) is entirely adhered to the foamed polyurethane sheet (4),
An automobile ceiling base material (9) as shown in (3) is manufactured. The ceiling base material (9) has the polyester sheet (2) on the front side, and is made impermeable by the polyester sheet (2), but the surface of the ceiling base material (9) is also deep-drawn in the deep drawing part (10). I don't exist.

On the surface of the ceiling substrate (9), a non-woven fabric or knitted fabric of polyester fiber, polypropylene fiber, polyamide fiber, acrylic fiber or the like, or a polyurethane foam, polypropylene foam, polyethylene foam on the non-woven fabric or knitted fabric. A skin material such as a laminate obtained by laminating wadding materials such as the above is bonded with an adhesive or a hot melt sheet to form a ceiling material, and even if the skin material is bonded at the same time when the ceiling base material (9) is press-molded. Good.

[0019]

INDUSTRIAL APPLICABILITY According to the present invention, an interior material which is lightweight, has no breathability, and has an excellent appearance without wrinkles on the surface can be obtained.

[Brief description of the drawings]

 1 to 3 show an embodiment of the present invention.

FIG. 1 is a cross-sectional view of a superposed state.

[Fig. 2] Cross-sectional view of press-molded state

FIG. 3 is a perspective view of a ceiling base material.

[Explanation of symbols]

 1,5 Glass fiber paper (glass fiber sheet) 2 Polyester sheet (non-breathable sheet) 3 Edges on both sides 4 Polyurethane foam sheet (breathable base material) 9 Ceiling base material (interior material)

Claims (1)

[Claims] 1. A glass fiber sheet impregnated with a synthetic resin and / or a synthetic resin precursor, and a non-breathable sheet superposed on one side or both sides of the glass fiber sheet and partially bonded to the one side or both sides of the breathable base material. Together with press molding, the substrate and the glass fiber sheet are adhered to each other and the non-breathable sheet is entirely covered with the synthetic resin and / or the synthetic resin precursor exuded from the glass fiber sheet. A method of manufacturing an interior material characterized by bonding