JP2835756B2 - Manufacturing method of interior material base material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for producing a base material for an automotive interior material such as a molded ceiling, a door trim, a trunk trim, a pillar garnish, or other interior materials such as vehicles and furniture. About.

(Prior Art) As a method of manufacturing an interior material base material using a polyurethane foam, for example, there is the following method.

(1) Japanese Patent Publication No. Sho 63-7577 A flexible polyurethane foam is impregnated with an isocyanate compound, sprayed with water containing or not containing an amine, laminated with glass fibers, plastic films, non-woven fabrics, and skins, and heated with a press mold. A method of manufacturing a composite panel to be formed.

(2) GB2028714B (cold press method) An adhesive is applied to a polyurethane foam sheet and / or a reinforcing sheet such as glass fiber, and the two are bonded together.
A method for producing a polyurethane foam reinforced panel which is preheated to 170 to 220 ° C. and then immediately molded by a press mold.

In the method (1), the isocyanate compound impregnated in the flexible polyurethane foam reacts with moisture in the air to start curing, so that it is necessary to carry out thermoforming immediately after the impregnation, and the storage is poor and stock cannot be obtained. Therefore, it is necessary to make a series of continuous equipment from impregnation to press molding, and the equipment investment is large. Further, the process is complicated, including a process of spraying water containing or not containing an amine.

On the other hand, the above method (2) includes a step of immediately taking out the heated composite of the polyurethane foam sheet and the reinforcing sheet from the heat source, that is, putting the same into a press mold within 3 to 10 seconds. Alternatively, the pressing process must be performed in a short open time. In addition, a rigid polyurethane foam having thermoplasticity is usually used as the urethane foam sheet, and this is softened by heating, but cannot be coped with where the change in shape is large, and the foam is broken.

Furthermore, the resin used for bonding in either of the above (1) and (2) does not cure so hard as to harden the glass fiber, so that the surface becomes sticky as it is, so a surface material (non-woven fabric) is always required, and weight and price are required. Is not preferred in terms of

(Problems to be Solved by the Invention) The object of the present invention does not include a step of spraying water or the like, and since the pot life of the resin to be impregnated is long, the steps from impregnation to pressing need not be continuous, and Another object of the present invention is to provide a method of manufacturing an interior material base material capable of performing press working without preheating a base material raw material.

Another object of the present invention is to provide a method of manufacturing an interior material base material which is excellent in weight, price and physical properties, and has no surface thorniness, and can omit a surface material.

(Means for Solving the Problems) In the present invention, a flexible or semi-rigid polyurethane foam sheet is formed by laminating, on both sides, a bundle of glass filaments that have been cut into fixed lengths and uniformly dispersed in a random direction. After the entire laminate is impregnated with a urethane-modified unsaturated polyester resin, the resin is thickened under mild conditions and aged until the surface is no longer tacky, and then cured and integrated by hot press molding. And a method for manufacturing an interior material base material.

As shown in FIG. 1, the base material for the interior material of the present invention is a urethane-modified polyurethane material reinforced with a core material layer 4 in which a urethane-modified unsaturated polyester resin 3 is impregnated into a soft or semi-rigid polyurethane foam sheet 1 and a glass fiber 2. It consists of a reinforcing face material 5 of an unsaturated polyester resin 3.

As the flexible or semi-rigid polyurethane foam of the present invention, those well known in the art can be used, for example, a density of 10 to 50 kg / m ³ , preferably 10 to ³⁰ kg / m ³ .
closed cell content is 0-30% m ^3, preferably polyurethane foam 0% high celled semi rigid or soft is preferably used. The thickness of the polyurethane foam sheet is preferably 3 to 15 mm, more preferably 4 to 10 mm.

The urethane-modified unsaturated polyester resin used in the present invention is a polyester polyol having an unsaturated group, a urethane catalyst, and a crosslinking material of an unsaturated group (usually a styrene monomer).
(Polyether polyol or the like may be added to this) and an isocyanate component obtained by mixing an isocyanate and a peroxide.

In practicing the present invention, on both sides of a polyurethane foam sheet, strands obtained by bundling dozens to hundreds of single fibers of glass fiber with a sizing agent, or a set of several strands (roving) are fixed. Length (25 ~
Dispersion in the random direction while cutting into 60mm)
To 150 g / m ² preferably those obtained by 100 g / m ² or less) is, total 200 to 600 g / m ^2, preferably a urethane-modified unsaturated polyester resin was impregnated about 300 to 400 g / m ^2, gentle resin It is thickened under the conditions and then hot pressed. At this time, the reaction that takes place is such that the polyol and the isocyanate are urethane-bonded under the influence of the urethane catalyst to extend the chain length. Thereafter, under the influence of the peroxide catalyst, the unsaturated group in the molecule and a crosslinking material such as a styrene monomer undergo radical polymerization under heating to form a highly crosslinked cured resin. All of the raw materials have low molecular weights and are easy to handle because of low initial viscosity. Unless the temperature of the liquid resin rises, only the urethane reaction proceeds, and no crosslinking reaction of unsaturated bonds occurs. Since the urethane reaction can be adjusted with a catalyst, thickening can be delayed for a long time. Even when the urethane reaction progresses and gradually increases in viscosity and loses tackiness (aged state), it is diluted with styrene monomer and remains in a soft state. When heated, it temporarily melts and then hardens. It can be thermoformed even after a long time. The cured resin has improved properties such as impact resistance and strength, has less shrinkage during molding, and has heat resistance not found in polyurethane, as compared to ordinary unsaturated polyester resins.

Processability of this urethane-modified unsaturated polyester resin,
Utilizing the characteristics of physical properties, low initial viscosity allows good impregnation into urethane foam and glass fiber, and sufficient impregnation even with a small amount of resin enables weight reduction. This eliminates the need for a continuous process, and furthermore, the resin is highly cured, so that the glass fibers can be completely solidified, and no surface material is required, which makes it possible to reduce the weight and cost. Further, by using a soft / semi-rigid urethane foam as the core material, it is possible to manufacture an integrated interior material base material by hot press molding a laminated product without preheating.

An example of a method for manufacturing the interior material base material of the present invention will be described with reference to FIG.

A urethane-modified unsaturated polyester resin 3 is uniformly and continuously applied on a release film 6 such as a polyethylene film or a polypropylene film by a doctor blade 7 or the like, and the glass fiber 2 is cut into a predetermined length on the coating. The urethane foam sheet 1 is placed on the dispersed and laminated product. Next, the glass fiber 2 'is cut again to a predetermined length and dispersed and laminated thereon. A release film 6 ′ coated with a resin 3 ′ is coated on the inside from above by a doctor blade 7 ′ in the same manner as described above, and compressed by a roll 8 or the like.
Prepreg 9 obtained by uniformly impregnating resin throughout the laminate
May be cut at the time of use after winding, or cut in accordance with the product shape immediately after impregnation. At this time, resin 3,3 '
As a method of uniformly applying, it may be applied on the release films 6, 6 'by spraying. Alternatively, the resin 3, 3 'may be applied in a necessary amount to only the release film 6 or 6' on one side to impregnate the entire laminate. In addition to the method of simultaneously impregnating urethane foam and glass fiber as in the present method, the resin may be separately impregnated with urethane foam and glass fiber to increase the viscosity, and then laminated before molding.

The prepreg 9 is sealed with a cellophane film 10 or the like,
Prevent volatilization of styrene monomer and increase viscosity for one day or more under mild conditions of 20-40 ° C.

Release film 6 from prepreg 9 with thickened resin
Remove 6 '.

The laminated product is inserted into a hot press mold 11 at 130 to 160 ° C, preferably 140 to 150 ° C, for 0.5 to 3 minutes, preferably 0.5 to 2 minutes.
Hot press molding for minutes.

Remove the molded interior material base material by removing the mold.

The skin may be adhered after molding or may be adhered simultaneously during molding. This is adjusted according to the type of skin.

(Effect of the Invention) Since it is composed of a reinforcing layer composed of a resin having high strength and glass fiber and a core material of a polyurethane foam having a low specific gravity, it is relatively lightweight and has high rigidity.

Due to the combination of high heat resistant resin and glass fiber, it has heat resistance and extremely high dimensional stability.

Because it is a resin with excellent moisture resistance, it has high moisture and heat resistance.

Since a soft or semi-rigid urethane foam is used, the moldability is good and the degree of design freedom is high.

Since the resin is highly cured, the glass fibers can be completely hardened and the surface material can be omitted.

Hereinafter, the present invention will be described with reference to examples.

Example 1 On a polyethylene film, a urethane-modified unsaturated polyester resin obtained by mixing a polyol component and an isocyanate component was uniformly applied with a doctor blade so as to have an application amount of 200 g / m ^2, and the polyethylene film was continuously kept constant. Move at speed. The glass fiber cut at 30 mm intervals is continuously supplied by inserting a roving of glass long fiber between the roll of urethane rubber and the roll attached with a knife blade at 30 mm intervals on it and rotating them, 100 g / m ² glass fibers are uniformly dispersed and laminated in random directions. Next, a flexible polyurethane foam sheet with a thickness of 5 mm and a specific gravity of 0.02 is continuously placed on it,
Next, a glass fiber cut into 30 mm in the same manner as above is uniformly dispersed and laminated at 100 g / m ² . Further, a resin is further formed on the polyethylene film as described above.
It is applied uniformly at 200 g / m ² , laminated continuously from above with the resin surface inside, compressed by a press roll of a constant pressure, and wound up in a roll. The wound roll was sealed with a cellophane film and left at 23 ° C. for 7 days. Remove the cellophane film before molding and cut the prepreg, which has lost adhesiveness, according to the product length, and also remove the polyethylene film on the front and back sides. Press molding to 3 mm in general thickness
A molded ceiling substrate of g / m ² was obtained.

[Brief description of the drawings]

FIG. 1 shows a cross-sectional view of the substrate obtained by the present invention. FIG. 2 shows an example of the manufacturing method of the present invention. 1 ... Soft or semi-rigid polyurethane foam sheet 2,2 '... Glass fiber 3,3' ... Urethane-modified unsaturated polyester resin 4 ... Core layer 5 ... Reinforcement panel 6,6 ' Release film 7,7 'Doctor blade 8 Roll 9 Pre-preg 10 Cellophane film 11 Hot press mold

──────────────────────────────────────────────────の Continuing from the front page (72) Inventor Narito Mimura 3rd Ikuyama, Utsugoe, Miyoshi-cho, Nishikamo-gun, Aichi Prefecture Inspector, Toyo Rubber Industries Co., Ltd. 63-176114 (JP, A) JP-B 63-7577 (JP, B2) British publication 2028714 (GB, B) (58) Fields investigated (Int. Cl. ⁶ , DB name) B32B 1/00- 35/00 B60R 13/02 B29B 11/00-11/16

Claims (1)

(57) [Claims] Claims 1. A soft or semi-rigid polyurethane foam sheet, on both sides of which a bundle of glass long fibers cut into a given length and uniformly dispersed in a random direction is laminated.
After the entire laminate is impregnated with a urethane-modified unsaturated polyester resin, the resin is thickened under mild conditions and aged until the surface is no longer tacky, and then cured and integrated by hot press molding. A method for producing an interior material base material, comprising: