JPS63209925A - Manufacture of laminated interior finish plate for vehicle - Google Patents

Abstract

PURPOSE:To manufacture a lightweight and rigid laminated interior finish plate for vehicular trim by a method wherein a polystyrene-based foamed sheet is treated under specified pressurizing treatment and, after that, laminated to a decorative material layer. CONSTITUTION:A polystyrene-based foamed sheet 1 is rapidly heated in a heating furnace so as to raise the surface of the sheet 1 up to 150 deg.C. The sheet expands. Next, the sheet 1, both the surfaces of which are brought into molten state by heating, is pinched with compression rollers 14 and 15 so as to reduce the thickness of the sheet to 0.5-0.9 times as thick as the original thickness of the sheet. In succession, the resultant sheet is also pinched and cooled with cooling rolls 16 and 17 so as to produce a skinned foamed sheet 4, the skin part of the foamed layer of which is in non-foamed state 2, and at the central part of which a foamed layer 3 is left. A laminated interior finish plate 8 for vehicle is obtained by gluing a decorative material layer 7 to said sheet 4.

Description

DETAILED DESCRIPTION OF THE INVENTION (1) The present invention relates to a method for manufacturing a lightweight and highly rigid laminated interior panel used for vehicle interiors such as vehicle ceilings.

Takeshi Fumitake 1 Conventional vehicle ceilings have a foaming ratio of 5 as shown in Figure 4.
A base material 32 with a thin non-foamed polystyrene sheet 31 of the same material affixed to both sides of a double polystyrene foam sheet 30 is formed into the shape of a ceiling, and a decorative material 33 is further affixed to one side of the base material 32, which is then attached to a vehicle. It was getting worse.

481'-n'! However, since the conventional base material 32 is made by pasting thin non-foamed polystyrene sheets 31 on both sides of a polystyrene foam sheet 30, the pasting work is complicated.
Furthermore, due to the large difference in rigidity between foamed and non-foamed sheets, it is difficult to stack them, form them into the shape of a ceiling, attach decorative materials, trim the outer periphery, and transport them. When the decorative material 33 is attached to a vehicle or while the vehicle is in operation, peeling may occur at the interface between these materials.In particular, if the decorative material 33 peels off after being pasted, there is no way to correct it, and the defective waste including the decorative material 33 may be removed. I had to refuse.

2) 1. The method for manufacturing a laminated interior panel for vehicles of the present invention involves rolling a polystyrene foam sheet, in which at least both surface layer portions are in a softened and molten state, between compression rolls to reduce the original thickness of the foam sheet to zero.
．． A foamed sheet with an outer skin layer is formed on both sides of the sheet by compressing the sheet to a pressure of 5 to 0.9 times, followed by cooling, and then one side of the foamed sheet with an outer skin is produced. Since the laminated interior panel for vehicles is characterized in that a decorative material layer is attached to the interior of the vehicle, the problems of the prior art can be solved.

According to the method of manufacturing a laminated interior panel for vehicles of the present invention, by heating and pressing a polystyrene foam sheet, substantially non-foaming outer skin layer portions are formed on both sides of the sheet in the central portion of the sheet. Since it is integrally formed with the foam layer portion remaining, a lightweight and highly rigid sandwich structure can be obtained without the need to attach a non-foamed polystyrene sheet as in the past.

In addition, the foaming ratio at the interface between the foam layer and the outer skin layer of a polystyrene-based foam sheet with an outer skin changes continuously. The cortical layer does not separate from the outside of the foamed part.

Furthermore, after forming the outer skin layer on the polystyrene foam sheet, the decorative material layer can be attached subsequently, which simplifies the process of manufacturing the laminated interior board.

Light-1-1 The method for manufacturing a laminated interior panel for vehicles according to the present invention will be explained in detail with reference to the drawings.

FIG. 1 is a side view schematically showing an apparatus for manufacturing a laminated interior panel for vehicles.

Using a general-purpose polystyrene resin as the polystyrene resin, pre-foaming polystyrene resin beads in which the resin absorbs foaming gas, and extruding the pre-foamed beads into a sheet shape using an extruder has an expansion ratio of 10 times. A polystyrene foam sheet 1 with a thickness of 5.2 mm is continuously sent forward at a constant speed while being sandwiched between delivery rolls 11 and 12, and the surface of the sheet 1 is 150 mm from both sides of the sheet 1 in a heating furnace 13. The sheet is rapidly heated to 0.degree. C., during which time the sheet expands to a thickness of 6.2 mm. The sheet 1, whose both surfaces have become molten due to heating, is compressed between the circumferential surfaces of compression rolls 14 and 15, and its thickness is reduced to 3.
．． It will be 8mm. The sea) 1 is a plurality of sets of cooling rolls 1
6. In the cooling device 18 consisting of 17, the cooling roll 1
6.17 and cooled by cold air while suppressing re-expansion, and the outer skin layer portion 2 in a substantially non-foamed state is formed on both sides of the foam layer portion 3 as shown in FIG. This results in a foam sheet 4 with an integrally formed outer skin.

This skinned foam sheet 4 has a thickness a, emm, an apparent specific gravity of 0.18, and a longitudinal bending modulus of 65,000.
kg/l/. On the other hand, the base material 32 is made by pasting the non-foamed polystyrene sheets 31 of 0.2 mm on both sides of the conventional 5 times foamed polystyrene foam sheet 30 of 3.2 mm in thickness, and has an apparent thickness of 3.6 mm. had a specific gravity of 0.20, but its flexural modulus was only 60,000 kg/m'. From this, it was found that the skinned foam sheet 4 of the present invention is lightweight and has high rigidity.

Next, between the pinch rolls 19 and 20, the foam sheet 4 with outer skin is
A decorative material layer 7 made of a soft vinyl chloride resin sheet that has been treated with an adhesive in advance is adhered to one side of the sheet, and then cut to a certain length by a cutting device consisting of a fixed blade 22 and a movable blade 21. .

In this way, the polystyrene outer layer is formed into a foam sheet 4.
A laminated vehicle interior panel 8 having a decorative material layer 7 adhered to one side thereof is obtained, which is then molded into a predetermined shape and then attached to a vehicle.

Polystyrene resins used in this invention include styrene homopolymers, copolymers with other monomers such as butadiene, acrylonitrile, maleic anhydride, and A
Examples include BS resin.

The polystyrene foam sheet 1 is produced by adding a decomposable chemical blowing agent to the above polystyrene resin or impregnating it with a volatile liquid, pre-foaming it, and extruding it from a flat die or circular die of an extruder. Ru. The foamed sheet containing desiccated styrene used in the present invention has an expansion ratio of 5 to 20 times, a thickness of 2 to 30 mm, and is generally provided in the form of a roll having a length of 10 to 50 m.

The heating furnace 13 rapidly heats and melts both surface layer portions of the polystyrene foaming sheet 1, and the thickness of the melted portion is 3 to 10 times the thickness of the outer skin layer portion 2 to be obtained. Use as a guide. At this time, the heating temperature and heating time in the heating furnace 13 are adjusted in consideration of the thickness and expansion ratio of the polystyrene foam sheet 1. Generally, the heating temperature is 120 to 200°C on the surface of the sheet 1, and the heating time rW1, that is, the time for passing through the furnace is 10 seconds to 2 minutes.

Compression roll 14. ．． 15 is adjusted to a temperature 30 to 80" lower than the surface temperature of the sheet which normally passes through it,
The sheet l whose surface layer portion is melted in the heating furnace 13 is compressed between the peripheral surfaces of its rolls to destroy the foam cells in the surface layer portion and form a molten film.

The gap between the compressed a-rules 14 and 15 is suitably 0.8 to 0.9 times the thickness of the foamed sheet 4 with the outer skin. At this time, it is preferable to determine this gap by calculating on the assumption that the molten surface layer portion is compressed and its expansion ratio becomes 1 to 2. Generally, the gap is preferably in the range of 0.5 to 0.9 times the thickness of the polystyrene foam sheet l before heating.

If the thickness is less than 0.5 times, the thickness of the outer skin layer portion 2 increases and the specific gravity becomes high, making it difficult to obtain a lightweight sandwich structure, and if it exceeds 0.9 times, the thickness of the outer skin layer portion 2 increases. It becomes thinner and the effect of improving rigidity due to the sandwich structure is less.

The polystyrene foam sheet 1 with a molten film formed on its surface after passing between the compression rolls 14 and 15 increases its thickness due to expansion from the inside.
．． 17, the molten film is quickly solidified to form a strong outer skin layer part 2 by direct cooling from the roll circumferential surface and indirect cooling by cold air while being compressed, and also cools the molten film to the inside. By cooling and fixing the foam cells, the expansion of the foam layer portion 3 is suppressed, and the foam sheet 4 with outer skin is formed.
is completed.

Note that the peripheral speed of the compression rolls 14 and 15 is the same as that of the delivery roll 1.
It is 1.05 to 1.3 times the peripheral surface velocity of 1.1 and 12. 1
．． If it exceeds 3 times, the cells of the foamed sheet 4 with outer skin will be highly oriented in the direction of take-up, making it easy to break in that direction. This orientation can be reduced by further annealing at about 70'C.

The foamed sheet 4 with the outer skin manufactured in this way is then bonded to the decorative material N7 between the pinch rolls 19 and 20 to complete the laminated interior panel 8 for a vehicle. This laminated interior panel for vehicles 8 is automatically cut to a predetermined size by a movable blade 21 and a fixed blade 22, and after being formed into the shape of the part to be used by thermoforming, press molding, or other methods, it is attached to the vehicle. It will be done.

The decorative material layer 7 is made of a synthetic resin sheet, as shown in FIG.
In addition to the case where the facing material 5 is a single layer such as a woven fabric or a non-woven fabric, it may be a composite layer with a cushion layer 6 such as highly foamed polyethylene, polypropylene, polyurethane foam, etc.
After an adhesive layer is previously provided on the back side of the sheet, it is bonded to the foam sheet 4 with an outer skin.

In the above example, the outer skin layer was formed by heating and melting the surface layer of the pre-formed polystyrene foam sheet 1, but the polystyrene foam sheet, which was in a softened and molten state after being extruded, was immediately compressed. Roll 14, 15
A similar foamed sheet 4 with an outer skin can be obtained by forming the outer skin layer portion 2 while cooling the surface layer. However, in this case, it is important to remove the distortion by annealing after cooling.

Miscellaneous-11 Since the method for manufacturing a laminated interior panel for a vehicle according to the present invention is configured as described above, it has the following effects.

By heating and pressing the polystyrene foam sheet,
Since the substantially non-foamed outer skin layer portions are formed integrally on both sides with the foamed layer remaining in the center, there is no need to attach a non-foamed polystyrene sheet as in the past. Therefore, it is possible to easily produce a so-called sandwich structure that is lightweight and highly rigid, which is particularly desired as a laminated interior panel for vehicles.

In addition, the foaming ratio of the interface between the foam layer and the outer skin layer of a polystyrene-based foam sheet with an outer skin changes continuously. Since the skin layer does not peel off from the foam layer, it can withstand long-term vibrations and actual operating conditions as a laminated interior panel for vehicles.

After forming the outer skin layer on the rough polystyrene foam sheet, the decorative material layer can be attached subsequently, which simplifies the process of manufacturing laminated interior panels for vehicles and is economically advantageous. .

[Brief explanation of the drawing]

FIG. 1 is a side view schematically showing an apparatus for manufacturing a laminated interior panel for vehicles according to the present invention, FIG. 2 is a sectional view of a foam sheet with an outer skin according to the present invention, and FIG. 3 is a laminated vehicle interior panel according to the present invention. FIG. 4 is a sectional view of a conventional laminated interior board. l... Polystyrene foam sheet 2... Outer skin layer portion 4... Foam sheet with outer skin 7... Decorative material layer 8... Laminated interior board for vehicle 14.15... Compression roll

Claims (1)

[Claims] A polystyrene foam sheet in which at least both surface layer portions are in a softened and molten state is compressed between compression rolls to a thickness of 0.5 to 0.9 times the original thickness of the foam sheet, and then cooled. A laminated interior panel for a vehicle is produced by manufacturing a foam sheet with an outer skin layer on both sides of the sheet, and then pasting a decorative material layer on one side of the foam sheet with an outer skin. Production method.