JPS6329551Y2 - - Google Patents

Description

[Detailed Description of the Invention] The present invention relates to an interior material used as a molded ceiling material for automobiles, for example.

Corrugated cardboard has recently been used as a base material for this type of interior material because of its light weight. However, as is well known in FIG. 4, corrugated cardboard is made up of a corrugated core paper 1A with a cover 1B attached to either both sides or one side, and when formed into a predetermined shape, the core is attached to the curved surface, etc. The wavy shape of the paper may appear as wrinkles, and since the paper material has poor elasticity, cracks may occur in the deep-drawn portion.
As an interior material, a material in which a facing material is attached to the surface of the above-mentioned base material is used. Conventionally, for example, as shown in FIG.
Since the soft polyurethane foam sheet 3A is an almost completely elastic material, it will follow the irregularities such as wrinkles and cracks on the base material, and will eliminate the wrinkles and cracks on the surface of the interior material. There was a drawback that unevenness appeared due to cracks, etc. In order to improve the above drawbacks, it has been proposed to interpose a wrinkle removing material such as felt between the facing material and the base material. Felt is not a completely elastic material, so it absorbs wrinkles and cracks in the base material and prevents unevenness from appearing on the surface of the interior material. However, it is not possible to completely absorb wrinkles and cracks in the base material, and it is not possible to completely prevent the appearance of unevenness on the surface of the interior material. Also, from a mechanical processing point of view, the weight of felt is
It is possible to reduce the weight to 200 to 250 g or less, which increases the weight of the final interior material.

The purpose of this invention is to improve the above-mentioned drawbacks, completely absorb wrinkles and cracks in the base material, and completely prevent the appearance of unevenness on the surface of the interior material. The main idea is to use a synthetic resin foam sheet.

To explain the present invention with reference to an embodiment shown in the drawings, a sun visor storage recess 10A and the like are formed in a molded ceiling material 10 of an automobile shown in FIG.
The molded ceiling material 10 is made of cardboard 1 as shown in FIG.
is used as a base material, a soft synthetic resin foam sheet 2 impregnated with a synthetic resin is attached to the surface of the base material 1,
Further, a covering material 3 is attached to the surface of the soft synthetic resin foam sheet 2.

Corrugated cardboard 1 is one in which a cover 1B is pasted on both sides of a corrugated core paper 1A, as shown in Figure 2, or a cover 1B is pasted on one side of a core paper 1A, as shown in Figure 6. Or, as shown in FIG. 7, there is a honeycomb structure 1A between the covers 1B. The cardboard 1 includes phenol resin, resorcinol resin, melamine resin, urea resin, urethane resin, epoxy resin, polyamide resin, alkyd resin, acrylic resin, methacrylic resin, styrene resin, vinyl acetate resin, ethylene-
Synthesis of vinyl acetate copolymer, acrylonitrile-butadiene-styrene copolymer, styrene-butadiene rubber, acrylonitrile-butadiene rubber, ethylene-propylene rubber, ethylene-propylene terpolymer, polyethylene, polypropylene, polyvinyl chloride, fluororesin, etc. Impregnated with resin or rubber alone or a mixture of two or more, or coated with the above synthetic resin or rubber on core paper 1A or cover 1B.
It may be applied to one or both sides of the. By reinforcing cardboard with such synthetic resin or rubber, the shape retention of the cardboard, especially at high temperatures and high humidity, is improved.

The moldable synthetic resin foam sheet 2 is a soft synthetic resin foam sheet impregnated with a synthetic resin, such as a flexible polyurethane foam sheet, a styrene-butadiene rubber foam sheet, or an acrylonitrile-butadiene rubber foam sheet. As described above, the soft synthetic resin foam sheet is a completely elastic body as it is, and it follows the wrinkles of the base material and develops unevenness on the surface as it is. Therefore, the sheet 2 base, which is a completely elastic body, is coated with polymerizable materials such as urethane prepolymer, diallylphthalate monomer, unsaturated polyester, ethylene glycol dimethacrylate, urea resin, melamine resin, phenol resin, resorcinol resin, epoxy resin, urethane resin, etc. Thermosetting synthetic resins such as resins, thermoplastic polyurethane, polymethacrylate, polyacrylate, polystyrene,
Polyvinyl chloride, polyvinyl acetate, styrene-butadiene copolymer, acrylonitrile-butadiene copolymer, acrylonitrile-butadiene-styrene copolymer, polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-
A synthetic resin such as a thermoplastic synthetic resin such as a vinyl acetate copolymer or an ethylene ionomer is impregnated in an organic solvent solution, an emulsion, or a melt, and the synthetic resin is incorporated into the substrate by means such as polymerization, drying, and cooling. Fix it. In this way, a sheet 2 that can be molded with varying thickness is obtained. The synthetic resin foam sheet 2 is adhered to the surface of the cardboard base material 1 by means such as an adhesive, thermal welding, or by the synthetic resin itself impregnated into the sheet 2. The sheet 2 can also be colored to serve as a covering material 3 if desired. Molding is generally carried out on a polymer of substrate 1 and sheet 2, or on a polymer of substrate 1, sheet 2 and facing material 3. Molding is generally performed by heating or cold pressing. In the case of press molding, the sheet 2 can be formed with varying thickness, so the upper surface is regulated by the mold surface of the press mold, but the lower surface is deformed and the third
As shown in the figure, it conforms to the irregularities such as wrinkles generated on the base material 1 during molding, and thus the surface of the sheet 2 is prevented from exhibiting irregularities such as wrinkles on the base material 1. The synthetic resin impregnated into the sheet 2 is polymerized, hardened, heated, softened, cooled, etc. in the above-mentioned molding process, and maintains the above-mentioned shape.

As the covering material 3, common materials such as fiber knitted fabrics, non-woven fabrics, plastic sheets, and laminated materials of plastic sheets and plastic foams are used.

After forming the base material 1, the sheet 2, or a polymer of the sheet 2 and the facing material 3, may be pressure bonded. In this case, a compression mold is generally used, and the upper surface of the sheet 2 is constrained by the mold surface of the compression mold, while the lower surface is deformed to conform to the surface shape of the base material 1.

An example of manufacturing the interior material of the present invention will be shown below.

Example: Soft polyurethane foam sheet (3m/m thickness)
was impregnated with a 40% by weight triol solution of urethane prepolymer, and the impregnation amount was adjusted to 25 g/m ² as urethane prepolymer using a squeezing machine. The above-mentioned impregnated sheet 2 was placed on the surface of the corrugated cardboard base material 1 impregnated with 30% by weight of phenolic resin and weighed 220% in an undried state.
Heat-press molding is performed at ~230°C, 2-3 kg, and 20-30 seconds. Next, by utilizing the preheating of the hot press molding, a facing material 3 made of a nonwoven fabric backed with a polyamide nonwoven fabric as an adhesive is pressed onto the surface of the sheet 2.

Since the present invention has the above-mentioned structure, the lower surface of the synthetic resin foam sheet deforms and conforms to the surface shape of the corrugated cardboard base material, which has wrinkles or cracks, thereby creating irregularities on the surface of the sheet or covering material. This completely prevents this.

[Brief explanation of the drawing]

The drawings relate to one embodiment of the present invention,
Fig. 1 is a perspective view, Fig. 2 is a side sectional view, Fig. 3 is a side sectional view showing the wrinkle absorption mechanism, Fig. 4 is a side sectional view showing a state in which unevenness has appeared on the surface, Fig. 5, and FIG. 6 is a side view of various types of cardboard. In the figure, 1... Base material (cardboard), 2... Synthetic resin foam sheet, 3... Covering material.

Claims (1)

[Scope of utility model registration request] An interior material characterized by pasting a soft synthetic resin foam sheet impregnated with synthetic resin on the surface of a cardboard base material.