JPH0939142A - Backing for interior design - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior design material for a car etc., which has a good appearance and a mold releasing property. SOLUTION: As the backing 11 of an interior design material, a glass mat 13 and a sheet of glass paper 14, which are impregnated with a thermosetting resin, are stuck as reinforcing materials on the surface of a polyurethane foam sheet impregnated with a synthetic resin, and a stretchable gas barrier film 15 is stuck on the glass mat 13 on which a skin material is to be stuck.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a base material for an interior material such as an automobile ceiling material.

[0002]

2. Description of the Related Art A synthetic resin-impregnated polyurethane foam sheet is lightweight and excellent in heat insulation and soundproofing and is desirable as an interior material for automobiles. However, since it lacks in rigidity, a glass paper impregnated with melamine resin should be attached. Are reinforced by. Conventionally, as shown in FIG. 4, an interior base material (1) having a synthetic resin-impregnated polyurethane foam sheet (2) and melamine resin-impregnated glass paper (3, 3) adhered to both sides is provided. Overlay the skin material (4) on 1) and press (5)
The interior material is manufactured by hot press molding between the upper mold (6) and the lower mold (7).

[0003]

In the above-mentioned prior art, since the glass paper (3, 3) has poor extensibility, wrinkles occur in the deep-drawing portion. Also, in order to prevent heat damage to the skin material (4) during molding, the mold surface temperature of the upper mold (6) with which the skin material (4) contacts is set to 140 ° C to 150 ° C, and the mold of the lower mold (7) is set. The surface temperature is set to 180 ℃, but the upper glass paper (3)
The melamine resin impregnated in the resin slowly cures, penetrates the breathable skin material (4) and adheres to the mold surface of the upper mold (6), which causes the mold release property to deteriorate. It was

[0004]

Means for Solving the Problems As a means for solving the above-mentioned conventional problems, the present invention attaches a thermosetting resin-impregnated glass mat (13) to the surface side of a synthetic resin-impregnated polyurethane foam sheet (12). Provided with the thermosetting resin-impregnated glass paper (14) on the back side, and the stretchable non-venting film (15) on the glass mat (13). To do.

The synthetic resin-impregnated polyurethane foam sheet used in the present invention includes, for example, polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, poly Vinyl 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, phenol resin, epoxy resin, synthetic resin such as thermosetting resin such as thermosetting polyester, Alternatively, 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, a polyvalent isocyanate, and a methacrylic ester monomer that produce the thermosetting resin. A flexible polyurethane foam sheet impregnated with a prepolymer such as a diallylphthalate monomer, an oligomer, a synthetic resin precursor such as a monomer, or a mixture of two or more thereof, wherein the synthetic resin and / or the synthetic resin precursor The amount of impregnation is 100 to 150% by weight solids for normal soft quality polyurethane foam sheet, the weight of the synthetic resin-impregnated polyurethane foam sheet is usually 170~220g / m ^2.

A thermosetting resin-impregnated glass mat is attached to the front side of the synthetic resin-impregnated polyurethane foam sheet, and a thermosetting resin-impregnated glass paper is attached to the back side of the synthetic resin-impregnated polyurethane foam sheet. The glass mat is made from a slurry dispersed in water containing a binder, and the glass mat usually has a basis weight of 100 to 150 g /
m ^2, typically having a basis weight 40~80g as the glass paper
/ M ² . The glass mat and glass paper are impregnated with a thermosetting resin such as urethane resin, melamine resin, thermosetting acrylic resin, urea resin, phenol resin, epoxy resin, thermosetting polyester, etc. In order to impregnate the glass paper with a thermosetting resin, the thermosetting resin is applied to both surfaces of the synthetic resin-impregnated polyurethane foam sheet. The coating amount of the thermosetting resin is usually 50 to 100 g / m ² as a solid content. The glass paper is affixed to a synthetic resin impregnated polyurethane foam sheet by a thermosetting resin which is usually impregnated.

An extensible non-ventilating film is attached on the glass paper. As the material of the film, polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, plastic such as polyamide, polyester, polyurethane, acrylic rubber, butyl rubber, silicon rubber, urethane rubber, fluoride rubber, Polysulfide rubber, graft rubber, butadiene rubber, isoprene rubber, chloroprene rubber, polyisobutylene rubber, polybutene rubber, isobutene-isoprene rubber, acrylate-butadiene rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, pyridine-butadiene rubber, Styrene-isoprene rubber, acrylonitrile-chloroprene rubber, styrene-chloroprene rubber, and other synthetic rubbers, styrene-butadiene-styrene copolymers, styrene-isoprene-sulphone Styrene-based thermoplastic elastomers such as ren copolymers, styrene-hydrogenated polyolefin-styrene copolymers, butadiene-styrene block copolymers, block copolymers such as styrene-rubber intermediate block-styrene copolymers, etc. A material with a high elongation rate is used, and the thickness is 12
˜50 μ. It is desirable that the elongation rate is 50% or more. The stretchable non-ventilating film is attached by a thermosetting resin impregnated in the glass mat, a normal adhesive,
It may be adhered with a hot melt sheet or the like.

The interior base material is usually formed by hot pressing. The molding conditions in this case are usually a molding temperature of 140
˜180 ° C., molding pressure 2.0 to 4.0 kgf / cm ² , molding time 50 to 70 seconds. A skin material is attached to the interior base material before molding, simultaneously with molding, or after molding to form an interior material. Polyester fiber as the surface material,
Nonwoven fabrics and knitted fabrics such as polypropylene fibers, polyamide fibers and acrylic fibers, or laminates obtained by laminating the nonwoven fabrics and knitted fabrics with wadding materials such as polyurethane foam, polypropylene foam and polyethylene foam are used.
When a skin material having poor heat resistance such as polypropylene fiber non-woven fabric is attached to the above-mentioned interior base material before molding or at the same time as molding, the mold surface temperature of the press molding material is higher than the mold surface temperature of the opposite side. It is desirable to lower the temperature to prevent thermal deterioration of the skin material. In this case, for example, the mold surface temperature on the skin material side is 140 to 150 ° C., and the mold surface temperature on the opposite side is 170 to 190.
Set to about ℃.

[0009]

[Function] Since the glass mat (13) and the stretchable non-ventilating film (15) of the present invention stretch in accordance with the stretching force at the time of molding,
The interior base material (11) of the present invention can be easily molded, and wrinkles do not occur even in the deep-drawn portion. When the surface material (16) has low heat resistance and the mold surface temperature on the surface material (16) side is set low, the thermosetting resin impregnated in the glass mat (13) is cured. Although it becomes slower, since the stretchable non-permeable film (15) is arranged on the outer side, the thermosetting resin does not penetrate to the surface of the skin material (16) and the releasability is not impaired.

[0010]

1 to 3 show one embodiment of the present invention. In the interior substrate (11) shown in FIG. 1, 4, 4 '
The soft polyurethane foam sheet (12) impregnated with 100% by weight of diphenylmethane diisocyanate has a weight of 17
0 g / m ² , and the polyurethane foam sheet (12) is coated with melamine resin on both sides at a solid content of 80 g / m ^2.
The surface side of the glass mat (13) with a basis weight of 100 g / m ² ,
A glass paper (14) having a basis weight of 60 g / m ² is laid on the back side.

A thickness of 25 is further provided on the surface side of the interior base material (11).
A polyamide film (melting point 215 ° C.) (15) which is a stretchable non-ventilating film of μ is laminated, and a skin material (16) made of polyester fiber is laminated thereon as shown in FIG. It is set between the upper mold (6) and the lower mold (7). The mold surface temperature of the upper mold (6) of the press machine (5) is 150.
° C., mold surface temperature of the lower mold (7) is set to 170 ° C., the polymer is a molding pressure 3.0 kgf / cm ^2, it is hot pressed at a molding time of 60 seconds.

In the above hot press, the glass mat (1
3) and the glass paper (14) are impregnated with the melamine resin applied on both sides of the polyurethane foam sheet (12) and hardened, and the glass mat (13) and the glass paper (14) are the melamine resin. And the polyamide film (15) is adhered by the melamine resin impregnated in the glass mat (13). And the glass mat (13)
The polyamide film (15) and the polyamide film (15) are stretched in accordance with the stretching force by the hot press, no wrinkles are generated even in the deep drawn portions shown in A and B of the ceiling material (17) shown in FIG. 3, and the glass mat ( It is also possible that the melamine resin impregnated in 13) penetrates into the skin material (16) side of the polyamide film (15)
And the skin material (16) is adhered by the heat-softened polyamide film (15). Then, the ceiling material (17) becomes impermeable by the polyamide film (15). The ceiling material (17) is reinforced by the glass mat (13) containing the cured melamine resin and the glass paper (14), and is excellent in heat resistance and shape retention.

[0013]

EFFECTS OF THE INVENTION By using the interior base material of the present invention, an interior material excellent in wrinkle-free appearance and having good mold release property can be obtained, and since the interior material is non-breathable, it is stretched on an automobile, for example. In this case, since the air inside the vehicle does not flow, it is not contaminated by dust contained in the air, cigarette smoke, or the like.

[Brief description of drawings]

 1 to 3 show an embodiment of the present invention.

FIG. 1 is a partial sectional view

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

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

FIG. 4 is an explanatory diagram of a conventional example.

[Explanation of symbols]

 11 Interior base material 12 Polyurethane foam sheet 13 Glass matte 14 Glass paper 15 Stretchable non-breathable film

Claims (3)

[Claims] 1. A thermosetting resin-impregnated glass mat is attached to the front side of a synthetic resin-impregnated polyurethane foam sheet, a thermosetting resin-impregnated glass paper is attached to the back side thereof, and further stretched on the glass mat. Interior base material characterized by sticking a non-permeable air-permeable film 2. The stretchable non-breathable film has a stretch rate of 50%.
The above is the interior base material according to claim 1. 3. The interior base material according to claim 1, wherein the stretchable non-permeable film is a polyamide film having a melting point of 200 ° C. or higher.