JPS6342036B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention primarily relates to interior materials for automobiles.

Conventionally, this type of interior material has been made of a composite material in which a thermosetting felt, in which fibers are bound together with a phenolic resin, and a facing material are laminated together. In the case of conventional composite materials using such thermosetting felt as a base material, it is necessary to first manufacture the thermosetting felt, mold it, and then laminate the facing material.
This is because phenolic resin has a high curing temperature, so a high temperature of about 180°C is required to mold thermosetting felt, and a surface material made of non-heat resistant polyvinyl chloride sheet or fiber knitted fabric is laminated at the same time. It cannot be molded.

The object of the present invention is to use felt, that is, thermoplastic felt, as a base material using a thermoplastic synthetic resin having a low molding temperature as a binder, and to simultaneously squeeze or mold a facing material and a base material. .

The process of the present invention consists of the following five steps.

Step 1 of manufacturing fleece by mixing and entangling fibers and a binder mainly composed of thermoplastic synthetic resin.Heating the fleece to soften and melt the binder in the fleece to bind the fibers. Step 2 of making thermoplastic felt Step 3 of polymerizing a facing material on the thermoplastic felt via a heat-sensitive adhesive layer using the residual heat from Step 2 of the thermoplastic felt Thermoplastic felt and facing Step 4 of cooling only the surface of the polymerized product from the facing material side; Step 5 of squeezing and/or shaping the polymerized product using a forming die and/or a squeezing die. The present invention will be explained below in the order of steps.

In step 1, fibers and a binder mainly composed of thermoplastic synthetic resin are mixed and entangled to produce a fleece.

The fibers used in the present invention include natural fibers such as cotton, silk, and wool, rayon, Kyupra, acetate,
Chemical fibers such as nylon, vinylon, acrylic, polyester, etc., or knitted fabrics made of the above fibers,
Common fibers such as recycled fibers made by loosening non-woven fabrics and the like are used.

Examples of thermoplastic synthetic resins used in the present invention include styrene resin, methacrylic resin, acrylic resin, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, and acrylonitrile-butadiene-styrene resin. Two or more of the above thermoplastic synthetic resins may be mixed, and thermosetting synthetic resins such as phenol resin, melamine resin, urea resin, and epoxy resin may also be mixed.

Step 1 will be described with reference to an embodiment shown in FIG. 1. First, while the fibers 1 are transported by the belt conveyor 2, a predetermined amount of the binder 4 is supplied by the supply device 3, and then the fibers 1 are conveyed by the belt conveyor 2. The fibers 1 and the binder 4 are uniformly mixed by the machine 5, and the mixture 1B is then entangled with each other by the entanglement machine 6 to form a fleece 1C.
becomes.

In step 2, the fleece 1C produced in step 1 is pressed between a pair of pressing conveyors 9A set in a heating furnace 9 transferred by belt conveyors 7 and 8, as shown in FIG. It is then molded into a pine-like shape. At this time, the softened and melted thermoplastic synthetic resin binds the fibers 1, thus obtaining the thermoplastic felt 1D. The temperature of the heating furnace 9 is usually set at 160 to 220°C.

In step 3, the thermoplastic felt 1D obtained in step 2 is coated with a polyvinyl chloride sheet, a textile knitted fabric, a fiber non-woven fabric, a laminate of a polyvinyl chloride sheet and a polyurethane foam sheet, etc., and the facing material 11 is polyethylene, A material lined with a heat-sensitive adhesive film such as polypropylene or polyamide is polymerized using a pressure roll 12 or the like to obtain a polymer 1E.
At this time, the remaining heat of the thermoplastic felt 1D from step 2 is utilized to adhere the facing material 11 to the thermoplastic felt 1D with a heat-sensitive adhesive film.

In step 4, only the surface portion of the polymer 1E is cooled from the facing material 11 side using a cold air blower 13 or a cooling drum, etc., so that the facing material 11 is cooled to some extent and solidified, and the heat-sensitive adhesive film is solidified to form the facing material. 11 is fixed to thermoplastic felt 1D. In this state, the thermoplastic felt 1D retains the residual heat from step 2 and is ready for molding.

In step 5, the facing material 1 is pressed by the pressing die 14.
1. Squeezing and forming the surface. As mentioned above, since the thermoplastic felt 1D retains the residual heat in step 2, the drawing or shaping in step 5 is possible without the need for particular heating.

Through the above steps, a molded product with a drawn surface is obtained, and this is cut into a predetermined size using a cutter 15 to obtain an interior material 1F.

In this embodiment, the pressing die 14 serves as both a forming die and a squeezing die at the same time, but it goes without saying that the forming die and the squeezing die may be separated, or only one of them may be used. It is.

During drawing or forming in step 5, step 4
Since the facing material is appropriately cooled and solidified, it is possible to precisely perform predetermined drawing and forming, and it is possible to completely prevent drawing and shape deformation after forming, and the mold release property is also good. Moreover, since the heat-sensitive adhesive film is also solidified, it is possible to completely prevent the layer peeling between the thermoplastic felt 1D and the facing material 11 during squeezing or molding.

In the present invention, as described above, after heating the fleece and binding it with a binder to make felt, the remaining heat is used to polymerize and bond the facing material through the heat-sensitive adhesive layer, so the fleece is heated. is not directly applied to the surface material, and can be used even with surface materials that have poor heat resistance.
Furthermore, since a thermoplastic synthetic resin is used as a binder, molding is possible even at low temperatures, and even polymers of facing materials and felt, which have poor heat resistance, can be squeezed and molded at the same time. In addition, since only the surface is cooled from the facing material side prior to molding, the facing material is appropriately cooled and solidified, allowing for precise drawing and molding, and improved mold release properties. At the same time, the heat-sensitive adhesive layer also solidifies. Therefore, the interlayer adhesion strength between the facing material and the felt is improved, and no delamination occurs even when forming or squeezing.Furthermore, even with the cooling mentioned above, the felt remains moldable without being cooled, and there is no problem with squeezing or forming. No hindrance.
In addition, in the present invention, step 2 of making fleece into felt
Thermal energy efficiency is extremely high because the remaining heat is used to polymerize, bond, tie, and even form the covering material.

[Brief explanation of drawings]

The drawings show process diagrams of one embodiment of the present invention, and FIG. 1 shows steps 1 to 2, and FIG. 2 shows steps 3 to 5. In the figure, 1...fiber, 4...binder, 5...mixer, 6...entangler, 1C...fleece, 9...heating furnace, 1D...thermoplastic felt, 11... Surface material, 1E...Polymer, 13...Cold air blowing device, 1
4...Press type, 1F...Interior material.

Claims (1)

[Claims] 1. Step of manufacturing a fleece by mixing and entangling fibers and a binder mainly composed of thermoplastic synthetic resin. 1. Heating the fleece to soften and melt the binder in the fleece. Step 2 of at least binding the fibers to form a thermoplastic felt.Using the residual heat of the thermoplastic felt in step 2, a facing material is polymerized and bonded to the thermoplastic felt via a heat-sensitive adhesive layer. Step 3: Cooling only the surface portion of the polymer of thermoplastic felt and facing material from the facing material side; Step 4: Squeezing and/or forming the composite material with a drawing die and/or forming die; Step 5: A method for manufacturing an interior material comprising steps 1, 2, 3, 4, and 5.