JPS6153257B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a laminated interior material, and particularly to a laminated interior material suitable for use in an automobile interior material.

Among conventional automobile interior materials, suspended ceilings are most commonly used as interior linings for automobile interior ceilings. The structure consists of pasting a pad on the inner surface of the loop panel, passing a lifting wire through a bag sewn to the ceiling lining with appropriate tension, and inserting the bent end of the lifting wire into a hole in the side wall of the body. It is fitted and locked.
In addition, the end of the ceiling lining is the door opening flange,
After being wrapped around the front and rear window surrounding flanges, etc., it is trimmed with a trim piece or weather strip. However, such a configuration has the following drawbacks: (a) It takes a lot of man-hours to install it on the vehicle body, and (b)
It requires skill to install on the car body, (c) the space between the roof panel is large and the interior space becomes narrow, (d) there is no heat insulation or sound absorption, and a separate insulator must be used (e) There is no impact mitigation effect, and (f) there is little freedom in design.

Molded ceilings have recently been used as interior ceiling linings for automobile interiors that overcome the above-mentioned drawbacks. A specific example is a laminate made of glass fiber hardened with a thermosetting resin (e.g. phenolic resin), a cushion material attached to a molded base material, and a facing material attached. It is attached to the ceiling of an automobile interior with screws or the like, and its edges are trimmed with trim beads or weather strips. In this configuration, the base material used is made of glass fiber hardened with thermosetting synthetic resin as described above, so when handling the glass fiber, the glass fibers may stick to the body and cause irritation to the skin. Since glass fiber is expensive, there is an economic limit to the amount of glass fiber that can be used, and the base material must be as thin as possible. There is a drawback that the ceiling has low rigidity and may break during transportation or installation work. If the thickness is increased in order to solve this problem, it will naturally become extremely expensive and uneconomical, and the molded ceiling will become unnecessarily heavy, which will not only hinder the installation work but also increase the weight of the vehicle.

In order to improve the disadvantages caused by the use of glass fiber, instead of glass fiber, coarse hemp or a mixture of natural fibers and synthetic fibers, which are spread out, is used, and an appropriate amount of thermosetting synthetic resin is used. The hardened felt is heated and compressed into a shape that can be bonded to the ceiling of an automobile interior, and a cushion material (for example, polyurethane) and a facing material are bonded in advance to make a sheet-like product, and the cushion material side and the felt are combined. There is molded automobile ceiling material that is crimped together.
In this case, since a mixture of natural fibers and synthetic fibers is used, there is no discomfort such as itching even if the fibers adhere to the skin. However, because it uses a base material made by mixing natural fibers and synthetic fibers with thermosetting synthetic resin and compression molding, it is unnecessarily heavy as a ceiling material, and requires a pressing force of 1 to 3 kg/cm ² and a mold. Temperature 160~
Since the molding is carried out at 200° C. for 1 to 4 minutes, the molding conditions are disadvantageous.

In addition, there is one in which a lath wire mesh is laminated in a sandwich pattern between two cross-linked highly foamed polyethylene sheets, and a facing material is laminated on the outer surface of one of the sheets. In this case, since lath wire mesh is used, hot press molding can be performed at a relatively low temperature, and an improvement in molding efficiency can be expected.However, although a fairly thick lath wire mesh is used, the rigidity is somewhat poor.
In addition, it is too heavy for a molded ceiling, and there is no freedom in design, and the lath wire mesh is exposed at the molded end, which causes problems such as injuring hands and fingers during installation work and reducing efficiency during installation work. ing.

An object of the present invention is to provide a laminated interior material for automobiles that solves the various drawbacks of the prior art described above.

Another object of the present invention is to provide a laminated interior material suitable for various uses such as interior decoration.

The laminated interior material of the present invention is characterized by having a thermoplastic synthetic resin foam layer, a surface layer, and in addition to these two layers, a cushion layer and a reinforcing layer.

As the thermoplastic synthetic resin foam layer constituting the laminated interior material of the present invention, polystyrene, high impact polystyrene, acrylonitrile-styrene copolymer, acrylonitrile-butadiene-styrene copolymer, modified polyphenylene oxide, polychloride Uses foams of vinyl, acrylic-butyl-styrene copolymer, polypropylene, medium-low pressure polyethylene, polystyrene-ionomer resin mixture, acrylic resin, polycarbonate, methyl methacrylate, polyamide resin, high-pressure polyethylene, and mixtures of the above resins. can do.

The thickness and expansion ratio of this foam layer vary depending on the purpose of the interior material, the area where it is used, its dimensions, the space, and the synthetic resin used. Incidentally, when used for ceilings, rear parcel shelves, pillars, etc., molding performance is particularly important, and the foaming ratio can range from low foaming to high foaming, but is generally 3 to 15 times, preferably The foaming ratio is 2 to 12 times, preferably 2 to 10 times, and the thickness is 2 to 10 mm, preferably 3 to 6 mm. Also, when used for doors, dart boards, etc., rigidity is important, and the foaming ratio is 2 to 12 times, preferably 2 to 10 times. Good results can be obtained when the cell size is 2 mm or less, preferably 1 mm or less, and the thickness is 2 to 12 mm, preferably 3 to 10 mm. Therefore, the use of interior materials,
The type of resin used, expansion ratio, thickness, bubble size, heat resistance, flame retardance, etc. may be determined from the design conditions.

As the surface layer, sheets such as soft polyvinyl chloride, polyurethane, polyethylene synthetic paper, polypropylene synthetic paper, polyolefin-polystyrene synthetic paper, etc., or leather, fibrous fabric, knitted fabric, flocked fabric, or nonwoven fabric can be used. This also includes a coating layer applied directly to the foam board.

The cushion layer includes polyolefin resin foam, flexible polyurethane foam, flexible polyvinyl chloride foam, polyester foam, natural fiber,
There are products made of synthetic fibers, glass fibers or mixtures thereof.

As a reinforcing layer, plastics, natural fibers,
Synthetic fibers or mixtures of these materials are made into film sheets, woven fabrics, knitted fabrics, nonwoven fabrics, laminate cloths, etc., and also include those with surface treatments. The plastic used as a reinforcing material is
Polystyrene, high impact polystyrene, acrylonitrile-styrene copolymer, acrylonitrile-butadiene-styrene copolymer, modified polyphenylene oxide, polyvinyl chloride, polyvinylidene chloride, acrylic-butyl-styrene copolymer, high-pressure polyethylene, Medium and low pressure polyethylene, polypropylene, ionomer, polystyrene-ionomer resin mixture, polypropylene
Ionomer resin mixture, polyethylene-ionomer resin mixture, polyamide (6, 66, 12),
Examples include polyester, polyurethane, acrylic resin, vinyl acetate resin, polyether, polycarbonate, methyl methacrylate resin, polyethylene synthetic paper, polypropylene synthetic paper, polyolefin-polystyrene synthetic paper, or mixtures thereof. In addition, natural fibers include seed wool fibers such as cotton and Kapotsk, bast fibers such as jute, hemp, and ramie, leaf vein fibers such as Manila hemp, vegetable fibers such as fruit fibers such as coconut, wool, alpaca, and cashmere. , animal fibers such as animal hair fibers such as mohair, silk fibers such as domestic and wild animal silks, and mineral fibers such as asbestos. Chemical fibers include recycled fibers such as rayon and Kyupra, semi-synthetic fibers such as acetate, polyamide-based, polyvinyl alcohol-based, polyvinylidene chloride-based, polyvinyl chloride-based, polyester-based, polyacrylonitrile-based, polyethylene-based, polypropylene-based, It refers to synthetic fibers such as polyurethane-based and polyfluoroethylene-based fibers, and inorganic fibers such as glass fibers, lock fibers, and gold-silver-based metal fibers.

The laminated interior material of the present invention has a thermoplastic synthetic resin foam layer 1, a cushion layer 3, a reinforcing layer 4, and a facing layer 2, as shown in FIGS. 1 to 3.

When making the laminated interior material of the present invention, heat press,
Lamination is carried out by thermal fusion by vacuum forming, adhesion by hot rolls, adhesion by adhesive, etc.

The laminated interior materials shown in FIGS. 1 to 3 have a thermoplastic synthetic resin foam layer 1, a cushion layer 3, and a reinforcing layer 4 on the surface side of a facing layer 2, with different combination order and number of reinforcing layers 4. Figure 3) The reinforcing layer 4 can be provided with a radiant heat reflecting material. The material for the reinforcing layer with radiant heat reflector includes all of the plastic films or sheets mentioned above, with aluminum vapor-deposited on one side, and aluminum foil on the surface of the reinforcing material. By reflecting the heat radiation emitted from the heat accumulated on the steel plate before being conducted to the foam board, it has the effect of suppressing the rise in temperature inside the vehicle interior and improving comfort. These interior materials, especially the interior materials shown in Figure 2, are (a) capable of being designed to meet all the requirements of automotive interior materials, (b) lightweight, formability, heat insulation, heat retention, sound absorption, It has the effect of having a well-balanced performance in the required conditions of shock absorption, design suitability, rigidity, room space, and economy.

Next, examples of the present invention will be described.

Example 1 Flame retardants, additives, and blowing agents were added to 20 parts of modified polyphenylene oxide (trade name: Modified Noryl 731, manufactured by Engineering Plastics Co., Ltd.) and 80 parts of polystyrene (trade name: Styron 686, manufactured by Asahi Dow Co., Ltd.). A self-extinguishing foam board with an expansion ratio of 5 times, a thickness of 3 mm, a cell size of 1 mm, a width of 1300 mm, and a length of 1700 mm was made by extrusion molding using an extruder. A polyester film with a thickness of 0.03 mm is bonded to this as a reinforcing material with adhesive, and then radiant heating is performed at about 500°C for 20 seconds using heaters on the top and bottom surfaces about 200 mm apart in a vacuum forming machine, so that the reinforcing material is aligned with the panel side. It was molded to look like this. Next, a self-extinguishing soft urethane foam with a thickness of 3 mm and a vinylidene chloride film with a thickness of 0.1 mm as a covering material were adhered with a nitrile adhesive, and then this composite sheet was spread and supported on the molded ceiling base material. ,SBR
A molded ceiling for automobiles with excellent heat resistance, impact resistance, cushioning properties, and flame retardancy is created by heat pressing a 10 mm thick urethane foam using a type of adhesive and applying pressure evenly over the entire mold. I got it.

Example 2 Using the same mixed polymer as in Example 1, a self-extinguishing foam board with a foaming ratio of 7 times, a thickness of 3 mm, a width of 1300 mm, a length of 1700 mm, and a cell size of 0.3 mm was made. A 0.05 mm thick high-impact polystyrene film (product name: Styro Film, manufactured by Asahi Dow) was simultaneously bonded to this board as a reinforcing material from both sides using a hot roll.A composite board was obtained using a vacuum forming machine, with both sides approximately Radiant heating was performed for 20 seconds at a distance of 150 mm from a heater heated to 500°C, and vacuum forming was performed to create a molded automobile ceiling. Next, as the cushion layer and surface layer, we used a 2 mm thick self-extinguishing soft urethane and a 0.3 mm thick soft vinyl chloride sheet glued together using a nitrile adhesive, and then bonded the urethane side with an SBR adhesive. A foam board made from the above mixed polymer was glued together to form the structure shown in Figure 3, and then placed 200 mm away from heaters on the top and bottom surfaces heated to 450°C using a vacuum forming machine, and radiant heated for 30 seconds to form an integral piece. and made molded ceilings for automobiles.

The laminated interior material of the present invention is mainly composed of thermoplastic synthetic resin foam and is constructed by devising additional constituent materials, so it has the following effects.

(a) It is extremely lightweight and can be made extremely thin without sacrificing strength.

(b) The molding cycle is shortened to 1/3 to 1/5 of the conventional time.

(c) Good mold reproducibility, excellent moldability, and a large degree of freedom in design.

(d) Since the walls can be made thinner, the space inside the car can be expanded.

(E) A wide range of physical properties can be obtained by selecting the expansion ratio, thickness, and material, and it can be used for various parts of interior materials.

(f) Since reinforcing materials are also used, the applications and effects such as rigidity and shock absorption properties are expanded.

(g) The combination of aluminum vapor-deposited film and foam as a radiant heat reflective material can suppress the rise in indoor temperature in the summer.

(h) Because it fits well into the panel, is lightweight, and has a good texture, the required man-hours for installing the vehicle body can be reduced and efficiency can be significantly improved.

(li) It can easily meet domestic and international standards for flame retardancy.

[Brief explanation of the drawing]

1 to 3 are cross-sectional views of the laminated interior material of the present invention. 1... Thermoplastic resin foam layer, 2... Surface layer,
3...Cushion layer, 4...Reinforcement layer.

Claims (1)

[Claims] 1. A thermoplastic synthetic resin foam layer, a cushion layer, a reinforcing layer made of a sheet material of plastics, fibers, or a mixture of these materials, and a surface layer. Laminated interior material. 2 A thermoplastic synthetic resin foam layer, a cushion layer, plastics, fibers, or a mixture of these materials are used as sheet materials, a reinforcing layer having a radiant heat reflective material, and a facing layer, and the reflective material is the facing layer. A laminated interior material characterized by being located on the back side of the layer.