JPH0314613B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Object of the Invention] (Industrial Field of Application) The present invention relates to a method for manufacturing a roof lining.

(Prior Art) Automobiles equipped with glass windows in the ceiling have come into use. In such an automobile interior ceiling panel (referred to as a roof lining), an opening having a size substantially equal to that of the window is formed at a location corresponding to the window.

Conventional roof linings have been suspended ceilings made of thin metal wires such as steel wires attached to interior materials such as leather, but these have had the following problems.

They have low heat insulation and sound absorption properties, and require a considerable thickness of space to be attached to the vehicle body, requiring a corresponding increase in vehicle height.

By using glass fiber pine molded into a predetermined shape (called a pine molded body),
Attempts have also been made to reduce the thickness of the roof lining and the space required for installation.

However, since the roof lining has a fairly large opening, the strength near the opening is low, and if you try to attach it to the vehicle body by supporting one end of the roof lining made of molded pine by hand, The roof lining tends to break near the opening.

If the bulk specific gravity of the pine molded body is increased, the strength will be increased, but the weight will be increased.

If the strength is increased by increasing the thickness of the pine molded body, the space required for installation cannot be reduced.

In order to increase the mechanical strength of the pine molded body, a method of reinforcing the pine molded body by bonding reinforcing members such as FRP or metal plates has been proposed (see Japanese Utility Model Publication No. 14493/1983). , has the following problems.

(1) The pine molded body and the reinforcing member are likely to separate.

(2) The weight per unit area becomes large.

(3) If the pine molded body is in the form of a flat plate,
A reinforcing member and an inorganic fiber mat containing an uncured binder may be superimposed, and the binder may be cured by applying pressure and heat to form a mat molded body, which can also be integrally bonded to the reinforcing member. (Hereinafter, this method will be referred to as the integral molding method.) However, if the plate-shaped body has a curved shape, it is difficult to manufacture a reinforced plate-shaped body by the integral molding method, and the pine molded body and the reinforcing member are separated. This not only complicates the manufacturing process, but also makes it difficult to perfectly match the shapes of the two, creating gaps between the pine molded body and the reinforcing member, which may cause peeling or This can easily cause a decrease in strength.

(Problems to be Solved by the Invention) The present invention aims to solve the above-mentioned problems that the prior art had.

[Structure of the Invention] (Means for Solving the Problems) The present invention has been made to solve the above-mentioned problems, and includes a method for manufacturing a roof lining having apertures, in which the roof lining is impregnated with a phenolic resin solution. The dried fabric containing the B-stage phenolic resin is then mixed with uncured glass fiber mat containing moisture and the A-stage phenolic resin binder.
The phenol resin is overlapped at least near the part where the openings are to be formed, and the phenol resin is cured by applying pressure and heating to form a molded body in which the pine and the cloth-like material are integrally bonded, and a part of this molded body is The present invention provides a method for manufacturing a roof lining, characterized in that an opening is formed by cutting and removing the roof lining.

Next, the present invention will be explained in more detail.

In the present invention, the uncured glass mat containing water and an A-stage phenolic resin binder is obtained by adding an aqueous solution of a binder containing an A-stage phenolic resin to short glass fibers obtained by a centrifugal method, a flame method, etc. A mat obtained by spraying a binder (abbreviated as "binder") and depositing it on a perforated conveyor whose lower surface is kept under reduced pressure can be suitably used.

Although the thickness of the inorganic fibers varies depending on manufacturing conditions, it is desirable to use inorganic fibers with a thickness of 3 to 15 μm.

As the phenolic resin binder, an aqueous solution of a water-soluble initial product (Rail) rich in oxymethyl groups obtained by addition condensation of phenol and formaldehyde or its derivatives is suitable, and it is suitable for industrial production of glass fiber mat. A phenolic binder used in can be suitably used.

The binder solid content and water content contained in the glass fiber mat are suitably 8 to 30 wt% and 3 to 10 wt%, respectively.

The weight per unit area of the glass fiber mat is determined depending on the size of the roof lining, etc., but when using the method of the present invention, the roof lining has sufficient bending strength even when using mat of ^about 400gr/m2. can be obtained.

As cloth-like materials, natural organic fibers such as cotton and linen,
Synthetic organic fibers such as polyester, woven fabrics, non-woven fabrics, linter paper, kraft paper, etc. made of fibers such as glass fibers can be suitably used. In particular, cotton woven fabric, kraft paper, etc. are preferred.

As the phenolic resin solution, a lower alcohol solution of resol is suitable.

A cloth-like material is impregnated with a predetermined amount of a phenolic resin solution and then dried. It is appropriate that the degree of drying be at least dry to the touch or higher, preferably to such an extent that the resin loses its plasticity at room temperature.

If the degree of drying is insufficient, workability is poor, it takes a long time to harden the fabric, and industrial integral molding becomes difficult.

Industrially, a dried cloth can be efficiently obtained by passing a cloth impregnated with a predetermined amount of a phenolic resin solution through a drying oven maintained at a predetermined temperature.

During drying, the crosslinking reaction of the phenolic resin progresses, resulting in a state of resitol (B stage).

The fabric weight (weight per unit area) of the fabric, the weight of the resin that should be impregnated into the fabric, the degree of reinforcement required (strength required for roof lining)
Although it is determined according to ^the
20~75gr/ ^m2 especially 75~85gr/ ^m2 , 50~70gr/
It is appropriate to set it as m ² .

According to the present invention, it is possible to obtain a roof lining with sufficient strength at about 500 gr/m ² .

The above-mentioned uncured glass fiber mat containing moisture and an A-stage phenolic resin binder (hereinafter referred to as the "main mat") and a cloth-like material containing a B-stage phenolic resin impregnated with a phenolic resin (hereinafter referred to as a dry cloth-like material) ) are placed one on top of the other, pressed between a pair of molds, and heated.

The dry cloth-like materials are stacked so that the vicinity of the portion of the main mat 1 where the opening 2 is to be formed is covered with the dry cloth-like material 3.

In the embodiment shown in FIG. 1, a dry cloth material 3 is layered to cover the portion of the mat 1 where the opening 2 is to be formed, as indicated by the dotted line, and its entire circumference (the entire vicinity). The removal operation cuts away the part reinforced with the cloth-like material.

In the embodiment shown in FIG. 2, a dry cloth is used to cover a part of the mat 1 where the aperture 2 is to be formed and a part of the vicinity of the part where the aperture is to be formed. 3 are stacked one on top of the other, and a part of the cloth-reinforced part and an unreinforced part adjacent to this part are cut out to form an opening.

Although it is possible to reinforce the entire surface of the roof lining by layering the dry cloth over the entire mat, by forming an opening, it is possible to reinforce only the area near the opening where the strength is particularly low. It is desirable to reduce the weight of the roof lining, and even if such partial reinforcement is performed, there will be no hindrance to the operation of integral molding, and there will be no peeling etc. in the obtained roof lining. It was found that there was no such thing.

The B-stage phenolic resin contained in the cloth-like material dried by heating is once softened and then hardened. For this reason, the cloth-like material can undergo sufficient plastic deformation before hardening, and therefore conforms well to the mold.
It is also possible to produce deeply curved roof linings.

Simultaneously with the curing due to the crosslinking reaction of the B-stage phenolic resin contained in the dried fabric, the curing due to the crosslinking reaction of the A-stage phenolic resin contained in the mat also proceeds. The resin contained in the dried fabric is B stage (resitor), the resin contained in the mat is A stage (resol), and the mat contains a considerable amount of water. It was discovered that even though matte has a larger weight per unit area and is thicker, both can be cured simultaneously in a short time, and the two are firmly bonded together without peeling. .

When two objects containing uncured thermosetting resin are heated while being pressed together to harden the resin and join the two objects together, the thermosetting resins contained in the two objects are similar, It is common sense to preferably use those of the same stage.

Contrary to such common sense, the reason why the above effects can be obtained by using resins of different stages in the present invention is as follows.

Uncured pine contains A-stage phenolic resin and water. Moisture is also generated by the condensation of the A-stage phenolic resin when heated, so when uncured mat is heated, a large amount of water vapor is generated, and this water vapor sufficiently softens the cloth-like material containing the B-stage phenolic resin. It becomes easier to deform and mold conformability is improved.

While the fibers that make up the mat containing uncured A-stage phenolic resin can move freely, the fibers that make up the mat that are bonded with B-stage phenolic resin are bound together by this resin and are restrained. I can't move freely because of it. Therefore, the former is easier to deform than the latter, has better conformability to the mold, and can be deep drawn.

Since A-stage phenolic resin is more fluid than B-stage phenolic resin,
The phenolic resin contained in the uncured mat sufficiently penetrates into minute recesses on the surface of the cloth-like material, and the two adhere well.

Further, the curing speed of the B-stage phenolic resin contained in the cloth-like material is slowed down by the action of the water vapor, and the curing of both is completed almost simultaneously, so that the two are firmly bonded.

When a cloth-like material containing an A-stage phenolic resin is used, the cloth-like material becomes sticky and has poor workability, and the resin tends to adhere to the mold.

In addition, if the mat is heated in advance and the A-stage phenolic resin contained in the mat is changed to the B-stage, mold conformability will be reduced, and the adhesion between the mat and the cloth material will be insufficient, and both may peel off or A gap is likely to occur between the two.

Heating temperature is 190-250℃, preferably 200-220℃
It is appropriate that the heating time is 40~
It is about 120 seconds.

The density of the roof lining obtained is determined by the weight per unit area of this mat and the distance between the upper and lower molds. It is appropriate that the density is usually 100 to 400 Kg/m ³ .

After molding, a blade is used to cut and remove a portion of the portion reinforced with the cloth-like material or a portion adjacent to the portion reinforced with the cloth-like material to form an opening.

When the method of the present invention is used, even when a large opening of about 40 cm x 80 cm is formed, a roof lining with sufficient strength, light weight, and small thickness can be obtained.

(Function) The B-stage phenolic resin contained in the dried fabric is softened by heating, and the dried fabric can be plastically deformed under the action of moisture generated from the mat, and it conforms well to the mold, making it easier to dry. As a result of the simultaneous curing of the B-stage phenolic resin contained in the fabric and the A-stage phenolic resin contained in the mat, both are firmly integrated and a sufficient reinforcing effect can be obtained without peeling.

Example 1 Short glass fibers with an average diameter of 7μ obtained by centrifugation were sprayed with a binder containing A-stage phenolic resin, and collected on a perforated conveyor whose lower part was kept under reduced pressure to produce 400gr/m. ^2. An uncured glass fiber mat with a thickness of 15 mm and a solid content of 18 wt% resin and 5 wt% water was obtained.

Number of threads made of #40 cotton thread, 68 warp threads, weft thread
60 plain-woven cotton cloths (80gr/ ^m2 ) are impregnated with an alcoholic solution of A-stage phenolic resin, heated and dried, and B-stage phenolic resin is applied.
A dry fabric containing 70 gr/m ² was obtained.

A 100cm x 150cm mat and a 50cm x 100cm dry cloth were placed on top of each other as shown in Figure 1.
Heated for 90 seconds in a pair of molds kept at 220℃ to create a curved shape with a thickness of 3 mm and bulk density.
A molded body of 130Kg/m ³ was obtained. A part of this molded body was cut and removed using a blade mold, and the length was 40 cm as shown in Figure 1.
An opening of 80 cm was formed and a roof lining was obtained.

The mat and the cloth-like material are integrally bonded without peeling, and when one end of the obtained roof lining is held in the hand and supported horizontally, the degree of bending is slight, and neither bending nor peeling occurs. Ta. This roof lining was lightweight, weighing 627gr, and had good heat insulation and sound absorption properties.

Example 2 In place of the uncured glass fiber mat of Example 1,
600gr/m ² , resin content 13wt%, 20mm thick pine is used instead of cotton cloth, 0.1mm thick, 75gr/m ²
was obtained using kraft paper. Example 1 Two sheets of 50 cm x 5 cm dry cloth with a phenolic resin content of 40 gr/m ² were used as shown in Figure 2.
obtained similar results.

(Effects) A roof lining that is lightweight, has excellent heat insulation and sound absorption properties, and has sufficient strength can be obtained.

[Brief explanation of drawings]

1 and 2 are plan views for explaining the method of manufacturing a roof lining according to the present invention. In the figure, 1 indicates a glass fiber mat, 2 indicates an opening, and 3 indicates a cloth-like material.

Claims (1)

[Scope of Claims] 1. In a method for producing a roof lining having openings, a cloth containing a B-stage phenolic resin that has been impregnated with a phenolic resin solution and then dried is soaked with water and an A-stage phenolic resin binder. A molded body in which the mat and the cloth-like material are integrally bonded by stacking the uncured glass fiber mat containing at least the vicinity of the part where the openings are to be formed and applying pressure and heat to harden the phenolic resin. None, a roof lining manufacturing method characterized by cutting and removing a part of this molded body to form an opening. 2 Glass fiber mat has a solid content of 8 to 30wt
% of a phenolic resin. 2. The method for producing a roof lining according to claim 1, wherein the roof lining contains % of a phenolic resin. 3. The method for manufacturing a roof lining according to claim 2, wherein the fabric contains 20 to 75 gr of phenome resin per m ² as a solid content.