JPS58126140A - Board for molding - Google Patents

Abstract

PURPOSE:To obtain a board for molding which is excellent in moldability, light and suitable for the interior material of an automobile, etc., and provides a molded article of excellent strength, dimensional stability etc., by blending a light weight fine powder and a thermosetting or thermoplastic resin to a fiber material and completing the board. CONSTITUTION:A mixture consisting of (A) 20-75wt% of a natural fiber (e.g.; wooden pulp, used paper), a synthetic fiber (e.g.; polyester, rock wool), an inorganic fiber (e.g.; glass fiber) or a mixture of these, (B) 20-50wt% of a fine powder (e.g.; kieselguhr, perlite) having 0.02-0.3g/cm<3> weight per unit volume and contg. >=50wt% fraction having <=50mum particle size, and (C) 5-30wt% of a thermosetting or thermoplastic resin (e.g.; epoxy resin, phenolic resin) is mixed in water. A desired board for molding of a density 0.3-0.45g/cm<3> is made from an obtained slurry by a wetting method.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is directed to a molding board for producing molded products used as interior materials for vehicles such as automobiles.

It is most important that the molding board used for the interior material of the axle shaft has good moldability, S, and light weight. Besides, m
Dimensional stability after shaping, water resistance, heat resistance, etc. are required.

Traditionally used interior materials for axles include cardboard, boards containing thermoplastic paulownia resin, fiber mats recycled from recycled cloth, glass fiber mats, and styrofoam. Molding is carried out by adding a phenolic resin or the like to the base material, or by placing a skin material backed with an adhesive such as hot melt chick on the base material and hot pressing.

However, it is difficult to obtain molding boards made from these materials with sufficient aging formability and lightness, and when board (board or corrugated board) is used as a base material, it is difficult to obtain dimensional stability against temperature and moisture KK. In the case of dense mats recycled from recovered fabrics, the low melting point fibers mixed therein often melt and stick to the thermoforming mold, causing trouble in the process.

In addition, when polystyrene foam is used as a base material, its quality has advantages and disadvantages depending on the properties of the base material, such as lack of heat resistance. I haven't been able to find anything that satisfies me.

The present inventors have attempted to improve these drawbacks (as a result of extensive research, we have found that by adding a certain type of lightweight fine powder to natural fibers, synthetic fibers, inorganic fibers, or mixtures thereof as main materials), The present inventors have discovered that it is possible to obtain a molding board that is extremely lightweight and has good moldability, and has come up with the present invention.

In other words, the present invention uses natural fibers, synthetic fibers, inorganic fibers, or a mixture of these vI2 with respect to the dry weight of the molding board.
C1-75 weight and unit volume weight 0.02-0.3
L-, consisting of fine powder 20~sO precious powder in which particles with a particle size of 50 μ or less have a charge of ◆ or more, and a thermosetting or thermoplastic resin 5~30 weight, and Wj good is 0.3~0 .45
F, - relates to a molding board.

Hui used in this invention! 1ilI powder wood has a unit volume weight of 0.02-0.3 f/am and particles with a particle size of 50μ or less weighing more than 50% by weight, and among them, diatomaceous earth, perlite, etc. Good result, bad result
.

Since these fine powders have a porous structure with voids within the particles, if the number of particles with a particle size of 50μ or less weighs less than 50*, G'! When fine powder is dispersed in water, the water does not penetrate sufficiently into the particles (the powder floats up and uniform dispersion cannot be obtained.Generally, when the potential volume weight is 0.0
Fine powder with a particle size of less than 2 t/cdK has a coarse particle size, and the particle size distribution of particles with a particle size of 50μ or less does not reach 50% by weight. Further, if the unit volume weight exceeds 0.3 f/at, a sufficient effect of lowering the bore density cannot be obtained. The fine powder is added in an amount of 20 to 50 times the dry weight of the molding board. If it is less than 201tSK, a sufficient effect of lowering the density of the board will not be obtained, and wrinkles and cracks will occur during molding. If the weight exceeds 50% by weight, the ratio of fibers decreases, making it difficult to make paper by a wet process, and the strength of the resulting molded product decreases significantly.

Examples of natural fibers, synthetic fibers, and inorganic fibers used in the present invention include wood valves, waste paper, cotton linters,
Fiber length 5~10s+aF) L/E! Examples include, but are not limited to, fiberglass, polyester rock wool, asbestos, and fiberglass. These fibers are added in an amount of 20 to 75% by weight based on the dry weight of the molding board.

Examples of thermosetting resins and thermosetting resins used in the present invention include urea resins, melamine resins, phenolic resins,
Examples include epoxy resin, polyamide resin, styrene-butadiene latex, styrene-acrylic copolymer emulsion, and olein-based fibrous material. The mixing ratio of these resins is 5 to 30% by solid weight.

5. If the weight is less than 5, the water resistance of the molded product is not sufficient. In addition, when the weight exceeds 30% by weight, water resistance and thermoformability are not improved even though the mixing ratio is increased.

The density of the molding board of the present invention is 0.3 to 0.45V, -
Deabe) 4. A molding board with a density within this range has good paper-making properties in the previous process (V), and also has good moldability when thermoformed, and the molded product when thermoformed is lightweight, yet has good strength and dimensions. Stability etc. are also good. If the Wfi of the molding board is less than 0.3t/edK, the papermaking properties will be affected (not to mention, the strength of the molded product will be reduced. Also, if it exceeds 0.451-, the % characteristic of light weight will become even worse). Formability during thermoforming deteriorates.

The molding board of the present invention is made by pressing as follows. First, fibers, fine powder, and resin are mixed in water at a predetermined ratio to form a slurry. At this time, the fibers and powder are fixed using a synthetic polymer flocculant or aluminum sulfate, and then paper is made using a wet method. When a thermosetting resin is used as the W resin, the drying temperature in the paper machine must be lower than the curing temperature of the resin, and the drying must be completed with the resin in a semi-cured state.

Since the density of the thus obtained molding board of the present invention can be easily lowered to 0.45 f/cd or less, molded products using this molding board are extremely lightweight. Furthermore, because of the Kff shape, the fibers tend to slip uniformly when squeezed with a mold, and since there is a large escape gap for local concentration of fibers, the drawing process can be performed without cracking at the KM drawing part. It is possible. Therefore, the biggest feature of the molding board of the present invention is that it can be used as a light meal and has good moldability.
be.

Also, on boards with dense fibers, the fibers expand and contract due to changes in temperature and humidity! - Although ζ is easily transmitted, the low-density board C according to the present invention is absorbed by the expansion and contraction of the fibers or the voids, so the 4-method change rate is small.

Furthermore, the obtained molded product has a low density and a large thickness per unit weight, and therefore has sufficient bending strength.

The present invention will be explained in more detail with reference to Examples below. Example 1 55 parts by weight of N[P, unit volume weight 0.15F shoulder, and 855 parts by weight of particles with sedimentation particle size distribution of 50 tones or less per 2ite 30 Part by weight, fibrous polyethylene (Mikata Zeravac Co., Ltd. 1
! 8WPW-400) 15 parts by weight were mixed in water to fix a slurry with a concentration of 0.5%.
．． After adding 2 parts by weight, paper was made using a cylinder paper machine, and the paper was laminated on a main roll with a basis weight of 1000 t/dK.
*WA and dry with a heat press at a temperature of 140°C, pressure 0.2
A molding board was made by drying under V- conditions. This board was heated flat at a temperature of 150℃ and a pressure of 5kt'aj.
Heat pressing was performed for 1 minute at 1 year old, and the characteristic values shown in Table 1 were measured before and after the heat pressing.

Separately, a plate-shaped mold (A is 1
001111φ, B is 120mmφ, C is 15s) and thermoformed at a temperature of 150°C and a pressure of 5V for 1 minute, and after cooling, wrinkles and cracks occur in the drawn part of the component. The condition was observed and the moldability was evaluated as mold aging formability.

The results are shown in Table 1.

Example 2 Example IKg NUKP 55 parts by weight K instead NUK
P 45 vehicle degree part, thickness 1.5 denier, length 7.5-
The test was carried out in the same manner as in Example 1 except that the amount of polyester fiber was 10 parts by weight. The results are shown in Table 1.

Example 3 Example 1 Busy 8 Keru NuKP55 Judobu, Barai) 30
The test was carried out in the same manner as in Example 1 except that 65 parts by weight of NLJKP and 20 parts by weight of NLJKP were used instead of 11 parts by weight.The results are shown in Table 1.

Comparative Example 1 Exactly the same as Example 1 except that K [JKP 55 parts by weight, A test was conducted. The results are shown in Table 1.Comparative Example 2 A test was conducted in exactly the same manner as in Example 1 using a commercially available board for vehicle interiors containing a thermoplastic resin as a molding board. The results are shown in Table 1.

T: Vertical direction X: Lateral direction A minus sign indicates contraction.

Note 1) A test piece of 100×100 sha was immersed in water at room temperature, taken out after 24 hours, and the dimensions in the vertical and horizontal directions were immediately measured to calculate the dimensional change rate.

Note 2) The test piece measured in Note 1 was dried at 20°C and 65°C RH for 48 hours, and the dimensions were measured again to calculate the dimensional change rate.

Note 3) A 100 x 100 mm test piece was immersed in water at room temperature, taken out after 24 hours, the water adhering to the surface was quickly wiped off, and the weight was immediately measured to calculate the water absorption rate.

Note 4) 100X10011II corner test piece at 85℃
The sample was dried in a hot air circulating dryer for 2 hours, and the dimensions were measured immediately after taking it out to calculate the dimensional change rate.

Note 5) A single layer test piece of 100×100 was heated at 40°C and 90°C.
It is clear from the above results that the molding board of the present invention has good moldability in terms of quantity and formability. it is obvious. Also, the rate of dimensional change after molding is extremely small. Therefore, it is suitable as an interior material for vehicles.

[Brief explanation of the drawing]

Figure 1 shows a cross-sectional view of the mold used for the aging formability test of the present invention. l・・・・・・・・・Male mold, 2・・・・・・
-...-Female mold, A, B...-... Molding part diameter, C-...
・・・・・・・・・Depth of molded part, Figure 1 Procedures Correction Cao (voluntary) March 9, 1980 Commissioner of the Patent Office Mr. Kazuo Wakasugi 1, Indication of the case 1982 Patent Application No. 209956 No. 2, Name of the invention molding board 3, Relationship with the case of the person making the amendment Patent applicant postal code 104 Column 5 of ``Detailed description of the invention'' of the specification, 1st answer to the amendment.''

Claims (1)

[Claims] Natural fibers, synthetic fibers - 1 per dry weight of molding board
Inorganic fibers or mixtures thereof 20-75% by weight, unit volume weight 0.02-0.3f/at and particle size 50μ
Mold IIjAIIk powder with the following particles weighing 50 to 50 weight or more, and thermosetting or thermoexpandable 11115
~30% weight, density 0.3~0.4S
A molding board that is F/j.