MXPA02001171A

MXPA02001171A - Method of producing vehicle interior material having sandwich structure.

Info

Publication number: MXPA02001171A
Application number: MXPA02001171A
Authority: MX
Inventors: Hiroshi Itaba
Original assignee: Bayer Ag
Priority date: 1999-08-04
Filing date: 2000-07-24
Publication date: 2002-07-30
Also published as: HUP0202086A2; HK1047562A1; KR20020016937A; CN1168600C; AU6437000A; HK1047562B; WO2001010637A1; CN1367733A; PL353240A1; CA2391726A1; EP1206348A1; BR0012948A; AU767084B2; JP2001047544A

Abstract

To produce a vehicle interior base material being light and excellent in dimension stability, such as a ceiling material or a door trim material for a vehicle. Used is a method of producing a vehicle interior material having a sandwich structure, comprising the steps of (I) stacking a polyurethane foam, vegetable fibers, a thermosetting adhesive, and optionally a skin for surface decoration and/or a film preventing the exudation of the adhesive, (II) charging the laminate into a mold having a temperature of 80 to 150 °C, and closing the mold to cure the adhesive, and (III) demolding a molded product after the curing of the adhesive, characterized in that the size of the vegetable fibers is adjusted to be a diameter of at most 1.0 mm and a length of 10 mm to 100 mm.

Description

METHOD OF PRODUCTION OF INTERIOR MATERIAL FOR VEHICLE THAT HAS STRUCTURE OF SANDING.

DESCRIPTION OF THE INVENTION The present invention relates to a method of producing interior base material for vehicle that is lightweight and has excellent dimensional stability, such as an interior roofing material or a door upholstery material for a vehicle, and it refers to a laminate that 10 has a sandwich structure, which can be used as an indoor base material for a vehicle. As a technique for producing an interior base material for vehicle having a sandwich structure, a method of producing a sandwich has been proposed. 15 molded product, in which first isocyanate is immersed in a flexible polyurethane foam or rigid polyurethane foam; then water and a urethanization catalyst are added thereto; and then both surfaces are reinforced with fiberglass mats 0 (Japanese Patent Kokoku Publication No. 63-7577 (7577/1988) entitled "Production method of a light and rigid or semi-rigid composite panel"). REP. 135750 iii On the other hand, a method has also been proposed where a polyurethane foam is inserted, which has open cells and can be molded at an ordinary temperature, between two fiberglass mats that are provided with an adhesive in order to shape it thermally (see Japanese Patent Kokai Publication No. 04-211416 (211416/1992) entitled "Method of producing a rigid polyurethane foam having open cells and that can be molded at ordinary temperature, and the use thereof to produce an molded article. ") In all these methods, glass fibers are used as reinforcing material, these glass fibers are considered to have extremely excellent reinforcing effects, although they are expensive and irritate the operator's skin and are also incombustible when discarded. , so that eliminating them is a big problem, there is an example in which a woven fabric is already used as reinforcement material It is made with woven fibers, which in turn are made of hemp fiber with a rough weft of 2 to 3 mm. (Opel: Vectra etc.). However, if a woven fabric is used as reinforcement material, folds are generated in a spinning portion because it is not capable of expanding. fe- .aaaJaat. aA,. ~ ?. im r t¡? -mm &.? a Ja aa.aaa -a - ^ a-J. ., .X-nor to contract freely. In addition, because the adhesive is not easily immersed into the interwoven fibers, curing is insufficient and therefore, the surface is likely to have irregularities or roughness. As a result of intensive studies made with the aim of obtaining a molded product that can be easily recycled and that is light and economical without the use of glass fibers as reinforcement material, it has been discovered that vegetable fibers can be used completely. type of wood fibers, bamboo fibers, cut hemp fibers and cut jute fibers, instead of glass fibers. On the other hand, it has been discovered that it is advantageous, in terms of costs and results, to cut the vegetable fibers to a suitable length and mix them with an adhesive, and then spray them evenly in a polyurethane foam. The present invention provides a method of producing interior material for vehicle having a sandwich structure, which comprises the steps of: ai 4 ^ ß¡U ^? i ti (I) stack: (a) a thermoformable polyurethane foam that has open cells and a density of 20 to 100 Kg / nr, (b) vegetable fibers of 100 g / m: at 300 g / m that are placed on both major surfaces of the polyurethane foam (a), (C) a thermostable adhesive that forms bonds between the polyurethane foam (a) and the vegetable fibers (b) and also forms unions of the vegetable fibers (b) with each other, and optionally (d) a coating for surface decoration and / or a film that prevents the exudation of the adhesive, (II) loading the laminate into a mold having a temperature of 80. at 150 ° C, and then close the mold in order to cure the adhesive; and (III) demolding the molded product once the curing of the adhesive has been carried out, characterized in that the size of the vegetable fibers is adjusted so that it is of a diameter not greater than 1.0 m, and a length of 10 a 100 mm The present invention also provides a laminate comprising: (A) a layer composed of a thermoformable polyurethane foam having open cells and a density of 20 to 100 Kg / m 3; and (B) two layers composed of vegetable fibers of 100 5 g / pr to 300 g / m '1 and a thermoset adhesive, the layer (A) is sandwiched between the two layers (B), where the vegetable fibers have a diameter not greater than 1.0 mm, and a length of 10 mm., to 100 mu :. The laminate is preferred so that the polyurethane foam is a rigid polyurethane foam; the thermoset adhesive comprises an aromatic polusocyanate, water, a catalyst and, optionally, a polyol; and vegetable fibers are those obtd by cutting or milling hemp fibers, jute fibers, henequen fibers, bamboo fibers and wood fibers. The thermoformable polyurethane foam has open cells which can have a density of 20 to 100 Kg / m, for example, 25 to 40 Kg / m, in particular 25 to 35 Kg 20 / 3. Preferably, the shape of the polyurethane It is a rigid polyurethane foam. .. t * 1 ~ t? * mlm ** m * ml. The rigid polyurethane foam is obtained by reacting a polyisocyanate component with a polyol component. The polyol component may comprise a polyol, a catalyst, a foaming agent, and optionally, a flame retardant, a viscosity reducer and a surfactant. The polyurethane foam can be in the form of a film and can have a thickness of 3 to 8 mm. If used as reinforcement material, the vegetable fibers should be evenly distributed on both sides of a layer of polyurethane foam of 100 to 300 g / m, for example, 100 to 200 g / pr. It is required that the size of the vegetable fibers be adjusted to a diameter of no more than 1.0 mm, (for example, 0.2 to 0.8 mm.) And a length of 10 to 100 mm., (For example, 15 to 50 mm. .). If fibers having a diameter exceeding 1.0 mm were used as reinforcement material, irregularities would appear on the surface of the molded product, so that the appearance would deteriorate to a large extent. The diameter used in this document refers to smaller dimensions of the longitudinal and lateral measurements of the cross section of the fiber. These fibers can be cut with a length of 10 to 100 mm., By means of a simple equipment. If the length were smaller than 100 mm, the required reinforcing effects would not be obtained, while if the fibers were too long, they would become entangled with each other, so that they could not be dispersed uniformly over the foam. Therefore, it is required to adjust the length so that it is between 10 and 100 mm., With the purpose that the fibers can be comparatively extended more easily and uniformly on the molded product such as an interior roofing material for vehicle that has a large area, in order to obtain sufficient reinforcement effects that are required. Vegetable fibers can be obtained by cutting and grinding vegetables, mainly those that contain cellulose. The vegetable fibers can be, for example, hemp fibers, jute fibers, henequen fibers, bamboo fibers, wood fibers. The wood fibers are obtained from the trees. The trees can be, for example, cedar, pine, zelkova tree, sun tree, Japanese tree hiba arborvitae, cherry tree, poplar or spruce. ...,4. Aii ,.

The thermoset adhesive forms bonds between the polyurethane foam and the vegetable fibers and also forms bonds of the vegetable fibers together. In the case where the vegetable fibers are bonded together, the adhesive is immersed between the vegetable fibers in order to form a layer made of vegetable fibers and the adhesive. The thermoset adhesive may be an adhesive comprising an aromatic polyisocyanate, water, a catalyst and optionally, a polyol. The aromatic polyisocyanate can be, for example, toluene diisocyanate, diphenylmethane diisocyanate or polymethylene polyphenyl polyisocyanate (polymeric MDI), and is preferably a polymeric isocyanate of the MDI type. The water may be comprised between 10 to 50 parts by weight, for example, 15 to 30 parts by weight, based on 100 parts by weight of the aromatic polyisocyanate. The catalyst may be, for example, an amine of the type of monoamine, diamine, or triamine (for example, bis (dimethylaminoethyl) ether, N, N, N ', N', N "- pentamethyldiethylenetriamine, triethylenediamine, or dimethylethanolamine. ). The catalyst can be comprised from 0.1 to 1.0 parts by weight, for example, from 0.2 to 0.5 parts by weight. i ^ sa? ttaa? ^? S *. weight, based on 100 parts by weight of the aromatic polyisocyanate. The polyol to be used can be, for example, a polyhydric alcohol (for example, ethylene glycol, glycerin, trimethylolpropane, pentaerythritol, sorbitol, sugars, a polyether polyol or a polyester polyol) Examples of polyether polyol include one which is obtained by adding an alkylene oxide (for example, propylene oxide or ethylene oxide) to a polyhydric alcohol and a polyether polyol which is obtained by adding an alkylene oxide (for example, propylene oxide or ethylene oxide) to an aliphatic amine (e.g., monoethylamine, ethylenediamine , N, N-dimethylethylamine or diethylenetriamine The polyether polyol can have a hydroxyl value of 100 to 1000 mgKOH / g, for example 300 to 600 mgKOH / g The amount of polyol can not be more than 10 parts by weight , for example, from 2 to 5 parts by weight based on 100 parts by weight of the polyisocyanate The amount of thermoset adhesive can be from 50 to 300 parts by weight, for example, 70 to 150 parts by weight based on 100 parts by weight of vegetable fibers.

Optionally, a coating for surface decoration and / or a film can be provided which prevents the exudation of the adhesive on the layer made of vegetable fibers and the thermosetting adhesive. The surface decoration coating may be woven or nonwoven fabric of polyolefin, polyester or polyamide, a vinyl skin or the like. The thickness of the surface decoration coating can be, for example, 0.1 to 3 mm. The film that prevents the exudation of the adhesive may be an olefin film or a polyamide film. The thickness of the film that prevents the exudation of the adhesive can be, for example, from 10 to 40 m. The laminate can be produced, for example, by first applying a thermosetting adhesive (eg, if applied with a sprayer) on both surfaces of a polyurethane foam, by spreading or spreading the vegetable fibers next, on both surfaces, if desired. optionally has a coating for decoration of surface and / or a film that prevents the exudation of the adhesive in order to produce a laminate, then the laminate is loaded in a heated mold at a temperature of 80 to 150 C, for example, from 120 to 140"C for the purpose of pressurizing, curing the adhesive and removing the molded product from the mold Alternatively, once the thermosetting adhesive or a component of the thermoset adhesive has been mixed (for example, aromatic polyisocyanate) with vegetable fibers, the mixture can be applied on both surfaces of the polyurethane foam.In the laminate, the thickness of the layer made of polyethylene Polyurethane can be from 4 to 8 mm. , and the thickness of the layer made of vegetable fibers and the thermosetting adhesive can be from 0.2 to 2 mm. The laminate of the present invention can be used as an automotive interior base material, for example, for interior roofing material or an automotive door trim material. From here on, Examples will be shown and the present invention will be specifically explained.

In the following examples, the evaluation of a molded product was carried out as follows. (1) Bending Module The bending module was measured according to JIS K6301 A sample having a length of 150 mm was cut from the molded product. , and a width of 50 mm., and the flexure aodule was measured with a wheelbase of 100 mm. 5 and a test speed of 50 mm. / min. (2) Moldability During molding, the mouldability was judged on the basis of the rigidity of the molded product, by the degree of damage of the coating for surface decoration, and the like. EXAMPLE 1 Polymeric isocyanate spray of the MDI type (Isocyanate SBU-0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.) was applied in an amount of 70 g / nr, on both 15 surfaces of the rigid thermoformable polyurethane foam sheet ( with the following dimensions: 30 cm X 30 cm X 5.5 cm), which has open cells and a weight per unit per area of 200 g / m *. Then, water containing 1% of a urethanization catalyst (Catalyst SBU-H544, manufactured by Sumitomo Bayer Urethane Co., Ltd.) in an amount of 20 g / m 2 was applied by means of spray.

MtWlMWIkmm mWSBmWU i i .1 I í? .ÍtftM * l - », * im? .. . ... ^^ ",,,,. "-a," -., -?, -a. . , .. "> After that, wood fibers (of the type of pulped wood pulp) having a diameter of 0.7 mm and a length of 10 to 50 mm were spread on a basis weight of 150 g / m2. on both surfaces, and a non-woven fabric (polyester with a thickness of 0.1 mm.) was placed approximately 40 g / m2 on both surfaces in order to achieve the lamination, and the laminate was pressurized for 60 seconds in a mold at 130"C for the purpose of manufacturing the molded product having a thickness of 5 mm.The molded product, although it has a density of 0. 15 g / cpr (apparent density) and a weight per unit area of 750 g / m2 to be extremely light, presented a flexural modulus of 3,000 Kg / cm "and had a full capacity as an interior roofing material for automobile Example 2 Was applied by spray, water containing 1% by weight of a urethanization catalyst (Catalyst SBU- H544, manufactured by Sumitomo Bayer Urethane Co., Ltd) in an amount of 20 g / m2 on both surfaces of the rigid thermoformable polyurethane foam sheet (with the following dimensions: 30 cm, X 30 cm, X 5.5 cm) It has open cells and a weight per unit area of 200 g / m2. 50 parts by weight of polymeric isocyanate of the MDI type (Isocyanate SBU-0418, manufactured by Sumitomo Bayer Urethane Co. , Ltd) to 100 parts by weight of bamboo fibers with a diameter of 0.7 mm., And a length of 10 to 50 mm., And the resulting mixture was well stirred. The polymeric isocyanate mixture of the MDI type and the bamboo fibers were spread uniformly, at a basis weight of approximately 200 g / m ", on both surfaces of the polyurethane foam sheet having urethanization catalyst, which contains water On the outer part of the same, approximately 200 g / m2 of coating (polyester with a thickness of 1 mm) was placed for surface decoration in order to produce a laminate, and the laminate was pressurized during 60 seconds in a mold at 130 CC with the purpose of manufacturing a molded product having a thickness of 5 mm.This molded product, although it has a density of base material of 0.14 g / cm3 (apparent density) and a weight per unit of area of base material of 700 g / m "to be extremely light, presented a flexural modulus of 3,000 Kg / cm" and the coating for surface decoration did not have any damage. * ¡^^^^^ & ^^^^^^^^^^ ¿¡^ ^ ^^^ s ^ * .- * «i» *, i, aj ^ Comparative Example 1 Applied by dew , water containing 1% by weight of a urethanization catalyst (Catalyst SBU-H544, manufactured by Sumitomo Bayer Urethane Co., Ltd.) in an amount of 20 g / m2 on both surfaces of a rigid thermoformable polyurethane foam sheet ( with the following dimensions: 30 cm, X 30 cm, X 5.5 cm) which has open cells and a weight per unit area of 200 g / m. "50 parts by weight of polymeric isocyanate of the MDI type (Isocyanate SBU- 0418, manufactured by Sumitomo Bayer Urethane Co., Ltd.) to 100 parts by weight of wood fibers of the pulped wood pulp type with a diameter of approximately 2 mm, and a length of 2 to 15 mm., And the The resulting mixture was well stirred The mixture of polymeric isocyanate of the MDI type and of wood fibers was spread uniformly, at a basis weight of approximately 200 g / m, over both surfaces of the polyurethane foam sheet having urethanization catalyst containing water applied thereon. On the outer part of the same, approximately 200 g / m2 of coating was available (polyester with a thickness of 1 mm) for surface decoration in order to produce a laminate, and the laminate was pressurized for 60 seconds in a mold at 130 ° C for the purpose of manufacturing a molded product having a thickness of 5 mm. This molded product had a base material density of 0.14 g / cmJ (apparent density) and a weight per unit area of base material of 700 g / m. "The rigidity in the demolding time was low, and the molded product was In addition, the flexural modulus was only 1,000 Kg / cm2, so that a molded product could not be obtained that could be used as an automotive interior roofing material The molded product obtained according to the present invention, Despite being extremely light, it presents a high rigidity.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention. ^^ j ^^^^^^^ w¡ ^ ?? j ^^^ * «g * ^^^^ s ^^ * ^^^^^^.

Claims

CLAIMS Having described the invention as above, the content of the following claims is claimed as property: 1. A method of producing an interior material for a vehicle having a sandwich structure, which comprises the steps of: (I) stacking: ( a) a thermoformable polyurethane foam having open cells and a density of 20 to 100 Kg / mJ, (b) vegetable fibers of 100 g / m2 to 300 g / m that are placed on both main surfaces of the polyurethane foam, (C) a thermoset adhesive which forms bonds between the polyurethane foam and the vegetable fibers and which also forms bonds of the vegetable fibers together, and optionally (d) a coating for surface decoration and / or a film that avoid the exudation of the adhesive, (II) load the laminate in a mold having a temperature of 80 to 150 ° C, and close the mold in order to cure the adhesive; Y

Item*. . aJJ-j, ai- »it» Mfaa ». t, ***. l t? ? (III) demolding the molded product once the curing of the adhesive has been carried out, characterized in that the size of the vegetable fibers is adjusted so that it is of a diameter not greater than 1.0 mm, and has a length of 10 to 100 mm
2. The method according to claim 1, characterized in that the polyurethane foam is a rigid polyurethane foam; the thermoset adhesive comprises an aromatic polyisocyanate, water, a catalyst and, optionally, a polyol; and vegetable fibers are those obtained by cutting or milling hemp fibers, jute fibers, henequen fibers, bamboo fibers and wood fibers.