JP2559276B2 - Core material for automobile interior - Google Patents

Description

TECHNICAL FIELD The present invention relates to a core material for an automobile interior, which is lightweight and has excellent mechanical strength.

[Conventional technology]

Conventionally, hardboards, resin felt boards, synthetic resin plates, or synthetic resin foams reinforced with glass fibers have been used as core materials for automobile interiors.

[Problems of conventional technology]

In recent years, with the increase in size of automobile interior parts, high rigidity and light weight have become essential conditions. However, when trying to increase the rigidity with hardboards, resin felt boards, synthetic resin boards, etc., which have been conventionally used,
It is necessary to increase the plate thickness or attach a metal reinforcing component, which leads to an increase in weight, which does not meet the requirement for weight reduction described above. The automobile interior core material described in JP-A-59-78847 is a plate-shaped thermosetting resin foam in which glass fiber sheets are embedded in layers.
It has the highest rigidity and lightest weight among the core materials for automobile interiors that have been known so far, but in reality, higher rigidity and lighter weight are being demanded. It was a situation that could not be fully dealt with.

[Means for solving problems]

The present invention is intended to solve the above-mentioned problems, and it is required to polymerize a glass fiber mat impregnated with a foamable thermosetting resin on both surfaces of a plate-shaped honeycomb body having a predetermined thickness and heat and pressurize the same. It is formed by foam molding.

[Action]

The thermosetting resin foam that has been foamed by heating enters the interior space of the honeycomb body and is solidified to strongly bond the glass fiber mat to both sides of the honeycomb body.

The thermosetting resin foam permeates the glass fiber mat to prevent the glass fibers from falling off and to finish the surface smooth, and to eliminate the peculiar and unpleasant feel of the glass fibers.

Since the honeycomb body is strong against the stress in the thickness direction, and the glass fiber mat is strong against the stress in the direction orthogonal to it,
Both materials complement each other's weak points and become stronger against stress in all directions.

The honeycomb body has many hollow portions and is extremely lightweight. Therefore, even if the plate thickness is increased, the weight does not increase so much, and an extremely lightweight core material can be manufactured.

〔Example〕

Next, the manufacturing method of the core material for automobile interior of the present invention will be described with reference to FIG.

In the figure, reference numeral 1 denotes a glass fiber mat which is formed into a sheet by appropriately cutting a chopped strand obtained by cutting the glass fiber into a length of 50 to 100 mm with a binder. As the glass fiber mat used here, in addition to the one obtained by solidifying the chopped strands as described above, the one obtained by solidifying the glass fiber with a binder without cutting (Continuous mat) or the glass fiber non-woven fabric, Glass fiber paper or glass fiber woven cloth may be used. However, this glass fiber mat 1 is unwound from a roll and sent on a conveyor 2 to form a foamable phenolic resin compound spraying device 3
Pass vertically underneath. The spraying device 3 is composed of a hopper 4, a vibration plate 5, a conveyor 6, and a brush roll 7, and by the vibration plate 5 attached to the lower part of the hopper 4,
A certain amount of foamable phenolic resin compound is supplied to the conveyor 6. The compound sent by the conveyor 6 is evenly distributed on the glass fiber mat by the brush roll 7. The amount of the adhered compound can be adjusted by the frequency of the vibrating plate 5, the speed of the conveyor 6 and the feeding speed of the glass fiber mat. The glass fiber mat 1 on which the compound is sprinkled is introduced into a heating oven 8 controlled at a temperature above the melting temperature (flow point) of the expandable phenol resin and below the curing start temperature to ensure that the compound adheres and drops. Prevent. Further, a pair of pressure rollers 9 and 9 are provided at the outlet of the oven 8 to sandwich the glass fiber mat 1 from above and below to cool and solidify the melted compound and to further ensure the adhesion. Then, the cutter 10 is used to cut this into an appropriate size.

On the other hand, as shown in FIG. 2, the plate-shaped honeycomb body 12 having a constant thickness is formed by adjoining adjacent paper pieces at regular intervals.
It is a known paper honeycomb body in which hexagonal through holes are formed when stretched.

The glass fiber mat 1 produced as described above is polymerized on both sides of the honeycomb body 12, and is heated and pressed by the pressing device 13 to be molded as shown in FIG. At this time, the honeycomb body 12
As shown in FIG. 2, it is expanded so that hexagonal through holes are present, and is placed between the superposing press dies 14, 14 so that the compound adhering surface of the glass fiber mat 1 is in contact with both surfaces.

The press dies 14, 14 are concavo-convex molds heated to a temperature of 150 to 250 ° C., which is sufficient to cure the expandable phenol resin. As the press dies 14 and 14 are closed, the glass fiber mat 1 and the honeycomb body 12 are slightly shifted and are fitted into the curved surface and the uneven shape of the die to be formed into a desired shape. Further, at this time, since the glass fiber mat 1 and the honeycomb body 12 are not yet adhered to each other, they can be easily deviated, and due to this misalignment, relatively deep drawing can be formed reasonably and uniformly. Not only that, but the stress due to molding hardly remains and a product with stable shape can be obtained. The foamable phenol resin compound starts to foam at the same time when the press molds 14 and 14 are closed and heat is applied, and it is cured when heating is continued. In this foamed state, the mold shape of the outer edge of the product is formed with a weir 15 as shown in FIG. 6 to prevent leakage of the foamed resin, and when the resin is cured by a chemical reaction from a slight gap. Make sure that the gas that is generated is released. In this way, the resin expands while expanding and enters the gap of the glass fiber,
Further, it penetrates into the space of the honeycomb body 12 to bond the honeycomb body 12 and the glass fiber mat 1 together. At this time, the foam 11 that has penetrated into the space portion of the honeycomb body 12 does not penetrate enough to completely fill the space due to the pressure of the air trapped therein, leaving a slight air layer and stopping the penetration. . With this air layer, it is possible to obtain a high sound absorbing property and heat insulating property which are not found in other core materials.

As shown in FIG. 9, the core material 16 for automobile interior made in this way is made of a skin material 17 such as vinyl chloride, cloth, or non-woven fabric.
It is used as an interior material by adhering it with an adhesive material or a hot melt film.

3 to 5 describe the variation of the honeycomb body 12, and FIG. 3 is a modification of FIG.
Staggered rectangular through-holes, Fig. 4 is a continuous sheet of curving paper strips, and Fig. 5 is a corrugated cardboard sheet with alternating flat and corrugated sheets. Is. Regarding the material of these honeycomb bodies, aluminum box,
Since it is made of a wide variety of materials such as paper and synthetic resin, it can be selected and used to meet the required strength and various other conditions when making core materials for automobile interiors.

〔The invention's effect〕

Thus, the core material for automobile interiors of the present invention is a glass fiber mat formed by polymerizing a glass resin mat impregnated with a foamable thermosetting resin on both sides of the honeycomb body and subjecting it to foaming by heating and pressing. By strongly adhering to and integrating with the honeycomb body, it is possible to provide a core material having high rigidity and being extremely lightweight.

BRIEF DESCRIPTION OF THE DRAWINGS The drawings show an embodiment of the present invention. FIG. 1 is a vertical cross-sectional view of a core material for automobile interiors, and FIGS. 2 to 5 are perspective views of honeycomb bodies. FIG. 6 is a partial vertical sectional view of a press die, FIG. 7 is a manufacturing process diagram of a glass fiber mat, FIG. 8 is a front view of a press machine, and FIG. 9 is a partial sectional perspective view of an automobile interior material. 1 ... glass fiber mat, 11 ... foam, 12 ... honeycomb.

Claims (3)

(57) [Claims] 1. An automobile interior in which a glass fiber mat impregnated with a foamable thermosetting resin is polymerized on both sides of a plate-shaped honeycomb body having a predetermined thickness, and this is heat-pressed to foam-mold into a desired shape. Core material. 2. The core material for an automobile interior according to claim 1, wherein the expandable thermosetting resin is a phenol resin. 3. The honeycomb body is made of paper.
The core material for an automobile interior as described in.