JP7438838B2 - Automotive interior materials and their manufacturing method - Google Patents

Description

The present invention relates to automobile interior parts, and more particularly to a glass mat used in automobile interior parts such as interior ceilings, sliding sunshades, road floors, etc., and a manufacturing method thereof.

For interior parts used in automobile interior ceilings, sliding sunshades, road floors, etc., lightweight plastic foam (semi-rigid urethane foam, etc.) is used to reduce weight to improve fuel efficiency and improve base material rigidity. ) is sandwiched and reinforced with glass mats on both sides to ensure lightness and rigidity (for example, see Patent Document 1).

For example, as shown in FIG. 7, as an interior product used for an interior ceiling, a backing glass mat 42 is laminated on one side of a semi-rigid urethane foam 41, and a skin side glass mat 43 is laminated on the other side. A backing material 44 is laminated on the backing side glass mat 42, and a skin 46 is laminated on the skin side glass mat 43 with a film 45 interposed therebetween.

As shown in FIG. 8, such an interior item includes a semi-rigid urethane foam 41 coated with a liquid adhesive 47 such as polymeric MDI (diphenylmethane diisocyanate) on both sides, a glass mat 42 on the backing side, and a backing material. 44. Prepare the skin laminated material 48 in which the skin side glass mat 43 and the film 45 are laminated on the skin 46. Overlay them in the order of 44. Then, as shown in FIG. 9, the molds were placed into hot press molds 51 and 52 for molding.

JP2008-207730A

However, in the above-mentioned automobile interior parts, the glass mat and the backing material are bonded together using a liquid adhesive, but the liquid adhesive does not stay close to the surface of the backing material, and the backing material is made of nonwoven fabric, etc. Because of this, it sometimes leaked through the backing material and into the mold. As a result, the liquid adhesive adhered to the molding die, resulting in defective interior products.

Furthermore, although a glass mat is a sheet-like mat formed by layering bundles of fine glass fibers, the bristle glass fiber bundles often break through the film on the skin side. As a result, the liquid adhesive passes through the holes formed in the film, reaches the epidermis, and oozes to the surface of the epidermis, resulting in product defects.

Further, although the glass mat was in the form of a sheet, the surface was not smooth but somewhat uneven. As a result, the irregularities on the surface of the glass mat are directly transferred to the skin, making the surface of the skin uneven, which is an obstacle when it comes to achieving a beautiful design surface.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems and provide an automobile interior material that eliminates the problems caused by seepage of a liquid adhesive.

In order to achieve the above object, the present invention uses a laminated material in which an absorbent sheet is bonded to a glass mat, thereby making it possible to prevent unnecessary seepage of a liquid adhesive.

The automobile interior material according to claim 1 includes a semi-rigid urethane foam, a backing side glass mat laminated on one side of the semi-rigid urethane foam, and a skin layer laminated on the other side of the semi-rigid urethane foam. In an automobile interior product comprising a side glass mat, a backing material laminated to the backing side glass mat, a film laminated to the skin side glass mat, and a skin laminated to the film, the backing material side The glass mat is characterized in that an absorbent sheet pasted in advance is placed on the backing side.

The automobile interior material according to claim 2 includes a semi-rigid urethane foam, a backing side glass mat laminated on one side of the semi-rigid urethane foam, and a skin layer laminated on the other side of the semi-rigid urethane foam. In an automobile interior product comprising a side glass mat, a backing material laminated to the backing side glass mat, a film laminated to the skin side glass mat, and a skin layered to the film, the skin side glass The mat is characterized in that an absorbent sheet pasted in advance is placed on the epidermis side.

The automobile interior material according to claim 3 includes a semi-rigid urethane foam, a backing side glass mat laminated on one side of the semi-rigid urethane foam, and a skin layer laminated on the other side of the semi-rigid urethane foam. In an automobile interior product comprising a side glass mat, a backing material laminated to the backing side glass mat, a film laminated to the skin side glass mat, and a skin laminated to the film, the backing material side The glass mat has a pre-laminated absorbent sheet placed on the backing side, and the skin material-side glass mat has a pre-laminated absorbent sheet placed on the skin side. There is.

The automobile interior material according to claim 4 is characterized in that it is a nonwoven fabric having a basis weight of 12 g/m ² to 80 g/m ² .

In the method for producing an automobile interior material according to claim 5, when producing a glass mat, an absorbent sheet is laminated on the glass mat body immediately after the heating furnace, and then the absorbent sheet is mixed into the glass mat by pressing and cooling. The structure is characterized in that the binder is solidified and integrated.

In the automobile interior material according to claim 1, since the absorbent sheet is interposed between the backing side glass mat and the backing material, the liquid adhesive applied to the plastic foam is absorbed by the absorbent sheet, so that the molding die There is no possibility of molding defects caused by adhesive adhering to the molding die.

In the automobile interior material according to claim 2, since the absorbent sheet is interposed between the skin-side glass mat and the film, it is possible to prevent the glass fibers from piercing the film and making holes, so that the liquid adhesive does not reach the skin. It does not penetrate and can maintain the epidermis in good condition. Furthermore, since the absorbent sheet suppresses the unevenness of the glass mat as a whole, the surface of the glass mat can be kept free of unevenness, and as a result, the surface of the epidermis can also be made smooth.

In the automobile interior material according to claim 3, similarly to the automobile interior parts according to claims 1 and 2, molding defects do not occur, the skin can be maintained in a good condition, and the skin can be maintained in a good condition. The surface can be made smooth.

In the automobile interior material according to claim 4, since a nonwoven fabric is used as the absorbent sheet, the liquid adhesive can be efficiently absorbed, and the basis weight of the nonwoven fabric is 12 g/m ² to 80 g/m ² . , can reliably absorb liquid adhesive, and does not make it thicker than necessary.

In the method for producing an automobile interior material according to claim 5, the absorbent sheet is laminated over the entire glass mat body immediately after the heating furnace during production of the glass mat body, and then pressed and integrated. However, they can be laminated and integrated easily and inexpensively using a simple process.

A schematic diagram showing the layer structure of an automobile interior product according to the present invention Schematic diagram showing the manufacturing process of automobile interior parts according to the present invention Schematic diagram showing the manufacturing process of automobile interior parts according to the present invention A diagram showing an apparatus for manufacturing a glass mat laminated with an absorbent sheet for use in automobile interior parts according to the present invention. A diagram showing the storage state of a glass mat laminated with an absorbent sheet for use in automobile interior parts according to the present invention. A schematic diagram showing the layer structure of an automobile interior product according to the present invention Schematic diagram showing the layer structure of conventional automobile interior parts Schematic diagram showing the manufacturing process of conventional automobile interior parts Schematic diagram showing the manufacturing process of conventional automobile interior parts

The automobile interior product according to the present invention includes a semi-rigid urethane foam, a backing side glass mat laminated on one side of the semi-rigid urethane foam, and a skin-side glass mat laminated on the other side of the semi-rigid urethane foam. In an automobile interior product consisting of a mat, a backing material laminated to the glass mat on the backing side, a film laminated to the glass mat on the skin side, and a skin layered to the film, an absorbent sheet is laminated in advance. This eliminates problems caused by liquid adhesive seeping out by using a glass mat that has been stained.The absorption sheet is placed between the backing glass mat and the backing material, and between the outer glass mat and the film or both.

In other words, the absorbent sheet absorbs excess liquid adhesive and prevents it from passing through the backing material and reaching the molding die, suppresses the glass fibers and prevents holes in the film, and also prevents the unevenness of the glass mat from forming holes. By pressing and smoothing the skin, it prevents unevenness from forming on the epidermis.

The absorbent sheet is not particularly limited as long as it is a material that can absorb liquid, but nonwoven fabrics and paper materials are preferred from the viewpoint of absorbency. As the nonwoven fabric, spunlace, spunbond, thermal bond, etc. can be used. As the paper material, pulp material made by a wet paper-making method or pulp material made by a dry air-laid method can be used.

When a nonwoven fabric is used as the absorbent sheet, the basis weight is preferably 12 g/m ² to 80 g/m ² . When the basis weight is less than 12g/m ² , there is a risk that the absorption of the liquid adhesive may be insufficient, and when the basis weight exceeds 12g/m ² to 80g/m ² , the thickness will increase unnecessarily and the cost will increase. becomes higher.

The basis weight of the glass mat is 20 g/m ² to 600 g/m ² depending on the required rigidity level of the automobile interior parts to be used. It is preferable to use it in a range of 70 g/m ² to 500 g/m ² .

The method for manufacturing the glass mat of the present invention, which is made by laminating an absorbent sheet to the main body layer of the glass mat, has been carefully studied with simplicity and low cost in mind. After mixing a chopped strand glass mat with a polyester binder, it is heated in a heating furnace. It has been discovered that the absorbent sheets can be firmly bonded to the glass mat body by stacking the absorbent sheets at the exit of the heating furnace and pressing them with a cooling roll in a high temperature state where the binder is melted.

[Example 1]
It is an automotive interior material used for things such as sliding sunshades for sunroofs that require high rigidity and load floors placed in luggage compartments.

<Layer structure of automotive interior materials>
As shown in FIG. 1, the automobile interior material 1 according to Example 1 has a backing glass mat 12 laminated on one side of a semi-rigid urethane foam 11, and a skin side glass mat 13 laminated on the other side. A backing material 15 is laminated on the backing glass mat 12 with an absorbent sheet 14 interposed therebetween, and a skin 17 is laminated on the skin side glass mat 13 with a film 16 interposed therebetween. A thermosetting liquid adhesive (polymeric MDI) was used to bond the urethane foam 11 and the glass mats 12 and 13.

<Manufacture of automotive interior materials>
First, as shown in FIG. 2, a semi-rigid urethane foam 11 coated with polymeric MDI 18, 18 on both sides, a glass mat laminate material 21 on the backing side in which an absorbent sheet 14 is laminated in advance to a glass mat 12 on the backing side, and a backing material 15. Prepare the skin-side glass mat 13 and the skin-side laminated material 22 in which the film 16 is laminated on the skin 17. Lay them on top of each other in the order of backing material 15. Then, as shown in FIG. 3, it was put into hot press molds 31 and 32 and molded. That is, the polymeric MDI 18 applied to the semi-rigid urethane foam 11 also wets the glass mat and begins to harden when heated.

<Manufacture of backing side glass mat laminate material>
In order to manufacture the backing side glass mat laminate material 21 in which the absorbent sheet 14 is laminated to the backing side glass mat 12, a glass mat manufacturing apparatus as shown in FIG. 4 is used. That is, the glass roving 33 is cut into countless glass fibers by a cutting machine 34, and then arranged on a conveyor to form a glass web 35, and a polyester binder is sprinkled thereon by a spreading machine 36. After that, the glass web 35 is passed through a thermal oven 37 to melt the polyester binder, and the glass web 35 is impregnated with the molten polyester binder.The web 35 that comes out of the thermal oven 37 is overlaid with the absorbent sheet 14, and then nipped with iron cooling rolls 38. . Then, the polyester binder binds the glass web 35 and at the same time adhesively laminates the absorbent sheet 14 to the glass web 33, completing the backing side glass mat laminate material 21 consisting of the backing side glass mat 12 and the absorbent sheet 14. . Incidentally, such a backing side glass mat laminate material 21 is stored and supplied in the form of a roll, as shown in FIG.

Alternatively, the backing glass mat 12 and the absorbent sheet 14 may be produced separately and then bonded together.

<Liquid adhesive seepage>
After manufacturing the automobile interior material, the surface of the hot press mold 31 was observed, but no phenomena such as adhesion of the liquid adhesive 18 were observed. Further, no trace of the liquid adhesive 18 was found on the surface of the backing material. This is because the excess polymeric MDI 18 passes through the backing side glass mat 12 and reaches the backing material 15, but the absorbent sheet 14 absorbs the liquid adhesive 18 to some extent and it passes through the backing material 15 and oozes out. This prevents the

[Example 2]
This is an automotive interior product used for interior ceilings, etc., where surface design (smoothness, etc.) is important.

<Layer structure of automotive interior materials>
As shown in FIG. 6, the automobile interior material 1 according to Example 2 has a backing glass mat 12 laminated on one side of a semi-rigid urethane foam 11, and a skin side glass mat 13 laminated on the other side. A backing material 15 is laminated on the backing glass mat 12 with an absorbent sheet 14 interposed therebetween, and a film 16 and a skin 17 are sequentially laminated on the outer glass mat 13 with an absorbent sheet 19 interposed therebetween. There is. A thermosetting liquid adhesive (polymeric MDI) was used to bond the semi-rigid urethane foam 11 and the glass mats 12 and 13.

That is, Example 2 is the same as Example 1 except that the absorbent sheet 19 is laminated between the skin-side glass mat 13 and the film 16.

Further, the manufacturing of the automobile interior material is also the same as in Example 1.

<Liquid adhesive seepage>
Similar to Example 1, phenomena such as adhesion of polymeric MDI 18 to the surface of the hot-press molding press mold 31 were not observed, and no traces of polymeric MDI 18 were observed on the surface of the backing material. Furthermore, the glass fibers did not break through the film 16, and the skin 17 was not contaminated with the liquid adhesive 18. This is thought to be because the absorbent sheet 19 suppressed the glass fibers, such as those standing up, toward the surface, and as a result, no holes were generated in the film 16.

<Design (smoothness)>
The surface of the skin 17 had no defects such as irregularities or undulations, and was smooth and rich in design. This is thought to be because by suppressing the skin-side glass mat 13 as a whole with the absorbent sheet 19, the irregularities on the surface of the skin-side glass mat 13 were made uniform, resulting in an extremely smooth surface.

1: Automotive interior material 11: Semi-rigid urethane foam 12: Backing side glass mat 13: Outer skin side glass mat 14: Absorbent sheet 15: Backing material 16: Film 17: Outer skin

Claims (5)

Semi-rigid urethane foam, a glass mat on the back side laminated on one side of the semi-rigid urethane foam, a glass mat on the skin side laminated on the other side of the semi-rigid urethane foam, and glass on the back side In an automobile interior material comprising a backing material laminated to a mat, a film laminated to the glass mat on the skin side, and a skin laminated to the film, the glass mat on the backing material side is laminated in advance . An automobile interior material characterized in that an absorbent sheet that absorbs a liquid adhesive applied to semi-rigid urethane foam is placed on the backing side. Semi-rigid urethane foam, a glass mat on the back side laminated on one side of the semi-rigid urethane foam, a glass mat on the skin side laminated on the other side of the semi-rigid urethane foam, and glass on the back side In an automobile interior material comprising a backing material laminated to a mat, a film laminated to the glass mat on the skin side, and a skin layered on the film, the glass mat on the skin side is laminated in advance to the glass mat on the skin side . An automobile interior material characterized in that an absorbent sheet that absorbs a liquid adhesive applied to a hard urethane foam is arranged on the outer skin side. Semi-rigid urethane foam, a glass mat on the back side laminated on one side of the semi-rigid urethane foam, a glass mat on the skin side laminated on the other side of the semi-rigid urethane foam, and glass on the back side In an automobile interior material comprising a backing material laminated to a mat, a film laminated to the glass mat on the skin side, and a skin laminated to the film, the glass mat on the backing material side is laminated in advance . An absorbent sheet that absorbs the liquid adhesive applied to the semi-rigid urethane foam is arranged on the backing material side, and the glass mat on the surface material side is attached in advance to the liquid adhesive applied to the semi-rigid urethane foam. An automobile interior material characterized in that an absorbent sheet that absorbs water is placed on the outer skin side. The automobile interior material according to claim 1, 2 or 3, wherein the absorbent sheet is a nonwoven fabric having a basis weight of 12 g/m ² to 80 g/m ² . When producing chopped strand glass mats, an absorbent sheet is laminated on the glass mat body immediately after the heating furnace, and then the binder mixed into the glass mat is solidified and integrated by pressing and cooling. 5. The method for manufacturing an automobile interior material according to claim 1, 2, 3 or 4.

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