JPH0919983A - Backing for interior decoration and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To heat efficiently during molding in the production of a non-gas- permeable interior decoration material. SOLUTION: A thermoplastic fiber layer 3 is placed on a gas permeable backing 2, and hot air is supplied to heat the backing 2 and the fiber layer 3 to soften or cure the backing 2 and to fluidize the fiber layer 3 by melting to make a non-gas-permeable layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior base material used as a base material for interior materials such as a molded ceiling of an automobile.

[0002]

2. Description of the Related Art For example, when an interior material such as an automobile ceiling material has air permeability, air inside the vehicle circulates through the interior material, and dust or cigarette smoke contained in the air causes a surface of the interior material. Is polluted. Therefore, conventionally, when a breathable base material such as a resin felt or a synthetic resin-impregnated polyurethane foam is used as an interior material, a structure in which a non-breathable film is attached is provided (for example, Japanese Patent Application Laid-Open No. HEI 7). -40484
issue).

[0003]

The above interior base material is produced, for example, by a method of blowing hot air during molding to soften or cure the binder resin contained in the base material and mold it into a predetermined shape. When a non-breathable film is attached to the base material, hot air cannot pass through the base material,
There is a problem in that it is impossible to perform heating uniformly, which hinders molding.

[0004]

Means for Solving the Problems As a means for solving the above-mentioned conventional problems, the present invention provides a non-woven fabric formed by heating and melting a breathable base material (2) and a thermoplastic fiber layer (3). Provided is an interior base material (17) comprising a polymer with a ventilation layer (16), wherein the interior base material (17) is a thermoplastic fiber layer (1) on one side or both sides of the breathable base material (2). 3) is overlaid and the base material
(2) is heated by blowing hot air into the base material (2) and the thermoplastic fiber layer (3) is melted to form a non-venting layer (16) and molded into a predetermined shape. It

The breathable substrate used in the present invention is, for example, polyethylene, 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 resin, acrylonitrile-butadiene copolymer, styrene-butadiene copolymer, thermoplastic resin such as acrylonitrile-butadiene-styrene copolymer, urethane Resin, melamine resin, thermosetting acrylic resin, urea resin,
Thermosetting resin such as phenol resin, epoxy resin, thermosetting polyester, or urethane resin prepolymer, epoxy resin prepolymer, melamine resin prepolymer, urea resin prepolymer, phenol resin prepolymer that produces the thermosetting resin Polyurethane impregnated with a synthetic resin or a synthetic resin precursor such as a prepolymer such as a diallyl phthalate prepolymer, an acrylic oligomer, a polyvalent isocyanate, a methacrylic ester monomer or a diallyl phthalate monomer, an oligomer or a monomer, or a synthetic resin precursor. Breathable thermoplastic foams such as foams, semi-rigid polyurethane foams having an open-cell structure and breathability, polystyrene foams, polypropylene foams, the above synthetic resins and synthetic resin precursors alone or in combination of two or more. The mixture is fiber sheet or the like binding the fibers as a binder, polyester fiber As the fibers, polyethylene fibers, polypropylene fibers,
Polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, acetate fiber, vinylon, rayon, cupra, pulp, cotton, wool, coconut fiber, bamboo fiber, hemp fiber, etc. synthetic or natural fiber, Inorganic fiber such as glass fiber, rock wool, ceramic fiber, carbon fiber, carpet, non-woven fabric, felt, fiber knitted fabric, recycled fiber obtained by crushing and disintegrating waste materials such as paper, etc. A mixture of more than one species is used.

The thermoplastic fiber layer used in the present invention means
For example, polyethylene, polypropylene, polyacrylonitrile, polyvinyl chloride, polyvinylidene chloride, thermoplastic polyamide, thermoplastic polyester, a single or a mixture of two or more fibers of a thermoplastic resin such as thermoplastic polyurethane, a knitted fabric, It is desirable that the melting point of the thermoplastic fiber be equal to or lower than the molding temperature of the base material. The basis weight of the thermoplastic fiber layer is usually 50 to 200 g / m ² .

In the interior base material of the present invention, the thermoplastic fiber layer may be sandwiched on both sides, one side or the middle of the base material. During molding, hot air is passed through the interior base material to soften the thermoplastic resin when the base material itself is thermoplastic or when the base material contains a thermoplastic resin as a binder, When a thermosetting resin is contained as a binder, the thermosetting resin is hardened and formed into a predetermined shape by press molding, vacuum molding or the like. At this time, the thermoplastic fiber layer is heated and melted by the hot air, and the fibers are welded and fluidized by the molding pressure to form a non-air permeable layer. By setting the molding temperature of the base material, that is, the softening temperature when the binder is thermoplastic and the melting temperature of the thermoplastic fiber layer lower than the curing temperature when the binder is a thermosetting resin, the thermoplastic fiber layer is set. Smooth the melt flow of. The forming may be cold forming by heating or hot forming for hot forming. At the time of molding, a skin material may be overlaid and pressure-bonded to the base material simultaneously with molding. At this time, an adhesive or a hot melt adhesive is used for adhesion, but since the thermoplastic fiber layer is molten, it is also possible to adhere the skin material directly or through a substrate.

[0008]

[Operation] Breathable substrate (2) and thermoplastic fiber layer for molding
When hot air is blown through the polymer (1) with (3) to heat it, the base material (2) itself or the binder contained in the base material (2) will be softened if it is thermoplastic and thermosetting. In the case of resin, it cures. At the same time, the thermoplastic fiber layer (3) is melted and the fibers are welded to each other by the molding pressure to flow to form the non-venting layer (16), but it has air permeability until the non-venting layer (16) is formed. From which hot air can pass through the substrate (2),
(2) is heated sufficiently uniformly.

[0009]

1 to 4 show a first embodiment of the present invention.
The polymer (1) shown in Fig. 1 is a thermoplastic fiber layer sandwiched between a base material (2,2) prepared by mixing 30% by weight of a cavoc cotton with a phenol resin as a binder and the base material (2,2). It consists of a certain polyethylene fiber non-woven fabric (3). The polymer (1) is shown in FIG.
It is set together with the skin material (12) made of polyester non-woven fabric in the press mold (4) shown in (1) and molded by the mold (4), and the mold surface of the upper mold (5) of the mold (4) ( 7) is provided with a hot air outlet (8), the mold surface (9) of the lower mold (6) is provided with a hot air suction port (10), and hot air of 200 ° C is blown upward from the air passage port (11). It is introduced into the mold (5) and blown out from the air outlet (8), and the hot air passes through the polymer (1) to heat the base material (2, 2) and the polyethylene fiber non-woven fabric (3) and discharge it. It is discharged from the outlet (13) and returned to the transmission port (11) by the circulation path (14),
During this time, it is heated by the heater (15). The hot pressing conditions are a pressure of 2.5 kg / cm ² and a pressing time of 1 minute. As shown in FIG. 3 by the hot press, the substrate
The interior base material (17) in which the phenolic resin in (2,2) has hardened and the polyethylene fiber nonwoven fabric (3) has melted, and the fibers have been welded and flowed by the molding pressure to form the non-venting layer (16) And the skin material (12) is formed of the polyethylene fiber non-woven fabric.
The melt of (3) is the base material of the skin material (12) side due to the molding pressure.
(2) is adhered by seeping through. In this way, the molded ceiling material (18) for an automobile as shown in FIG. 4 is manufactured. Since the non-ventilated layer (16) is present in the molded ceiling material (18), the circulation of air does not occur. Be blocked. However, the non-breathable layer (1
Since the polymer (1) has air permeability until the formation of 6), hot air passes therethrough and the phenol resin in the substrate (2) is uniformly and completely cured during molding.

5 to 7 show a second embodiment of the present invention. The polymer (21) shown in FIG. 5 is a semi-rigid polyurethane foam substrate (22), a melamine resin-impregnated glass paper (24) backed by the substrate (22), and the surface of the substrate (22). The polypropylene fiber cloth (2 that is the thermoplastic fiber layer attached to the
3) and a polypropylene fiber cloth for the polymer (21).
The polypropylene fiber cloth (23) is melted, the semi-rigid polyurethane foam substrate (22) is softened, and the melamine resin in the glass paper (24) is blown from the (23) side with hot air. Begins to cure. In this state, as shown in FIG. 6, the polymer (21) was used as a skin material (2
Along with 5), the cold press die (26) is set between the upper die (27) and the lower die (28) and cold pressed at 3 kg / cm ² for 30 seconds. As shown in FIG. 7, the press molding causes the melt of the polypropylene fiber cloth (23) to flow to form the interior base material (30) which has become the non-permeable layer (29). However, the polymer (21) has air permeability by heating with hot air before molding, the base material (22) is sufficiently softened by heating, and the melamine resin in the glass paper (24) is also sufficiently heated. Therefore, the base material (22) is smoothly molded even if there is a deep-drawn portion, and the melamine resin in the glass paper (24) is completely cured during molding. Thus the first
An interior material similar to that in the example is manufactured.

In addition to the above examples, the skin material may be laminated before molding the base material, or may be laminated after molding the base material.

[0012]

EFFECTS OF THE INVENTION In the present invention, even if the base material is heated before or during molding, it has air permeability until the non-air permeable layer is formed, so that hot air can pass therethrough and the base material can be heated. Efficiently and uniformly, as a result, the softening of the base material or the softening or hardening of the binder in the base material is smoothly performed, and a non-breathable interior material is easily manufactured.

[Brief description of the drawings]

 1 to 4 show a first embodiment of the present invention.

FIG. 1 Partial cross-sectional view of polymer

FIG. 2 is an explanatory diagram of a molding process.

FIG. 3 is a partial sectional view of an interior base material after molding.

FIG. 4 is a perspective view of a molded ceiling material. FIGS.
It shows an embodiment.

FIG. 5 is a partial sectional view.

FIG. 6 is an explanatory diagram of a molding process

FIG. 7 is a partial cross-sectional view of the interior base material after molding.

[Explanation of symbols]

 1,21 Polymer 2,22 Base material 3,23 Thermoplastic fiber layer 16,29 Non-venting layer 17,30 Interior base material

Claims (2)

[Claims] 1. An interior base material comprising a polymer of an air permeable base material and a non-air permeable layer formed by heating and melting a thermoplastic fiber layer. 2. A thermoplastic fiber layer is laminated on one or both sides of a breathable base material, and hot air is blown through the base material to heat the base material, and the thermoplastic fiber layer is melted to form a non-permeable layer. Forming and forming into a predetermined shape, a method for manufacturing an interior base material