JP2860051B2 - Chip molding and molding method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a chip molded product used as an insulator material for, for example, automotive interior materials, and a method of molding the chip molded product.

[0002]

2. Description of the Related Art As shown in FIG. 8, a chip molded product (15) is composed of an outer die (22) and an inner die (23). A pulverized material such as plastic is filled with a molding material (24) mixed with a binder, and the molding material (24) is pressed between an outer mold (22) and an inner mold (23) as shown in FIG. When the binder is thermosetting, the binder is heated, and when the binder is moisture-curable, the binder is cured by contacting with water vapor and cured. Such a chip molding (25)
Conventionally, it has been proposed to attach a non-woven fabric or a plastic film to the chip molded product (25) in order to reinforce the surface of the chip (25).

[0003]

However, the above-mentioned conventional nonwoven fabric and plastic film have almost no formability and rigidity, and it is impossible to hold the surface of a chip molded product. Also, the nonwoven fabric and the plastic film can hardly be expected to have sound insulation.

[0004]

Means for Solving the Problems According to the present invention, as a means for solving the above-mentioned conventional problems, a ground material containing a ground fiber material is formed into a predetermined shape, and the surface of a molded body which is bound with a binder, (6) A chip molded article (5) provided with a protective sheet made of a plastic foam impregnated with a thermosetting synthetic resin is provided, and the chip molded article (5) is further provided with an outer mold (2).
Thermosetting on the mold surface of the chip mold (1) consisting of
Consists of plastic foam impregnated with conductive synthetic resin
It is allowed to be present for protection sheet (6), outer mold (2) a binder filled with a mixture of the pulverized product containing the fibers pulverized product into, between the outer mold and (2) an inner type and (3) An object of the present invention is to provide a molding method in which the pulverized material is bound with a binder and molded.

The pulverized material used in the present invention includes a pulverized fiber. Examples of the pulverized fiber include organic fibers such as polypropylene fiber, polyester fiber, acrylic fiber, polyamide fiber, acetate fiber and cotton fiber. Crushed material, pulp, wood chips, wood wool, plywood crushed material, paper crushed material,
There is a pulverized wood fiber such as a pulverized hard board. A pulverized plastic, a pulverized plastic film, a pulverized plastic foam, and the like may be mixed with the pulverized fiber. However, the pulverized product of the present invention preferably contains 30% by weight or more, more preferably 40% by weight or more, and still more preferably 50% by weight or more of a fiber pulverized product. The crushed fiber is usually made to have a diameter of about 4 to 30 mm. These pulverized materials are obtained, for example, from scraps of fiber products such as automobile interior materials and sheets. That is, since the ceiling material of an automobile is made of a resin board, a corrugated cardboard, a base material made of a synthetic resin-impregnated polyurethane foam, a polystyrene foam, and the like, and a skin material such as a nonwoven fabric, the base material is made of resin board from the scrap of the ceiling material In the case of crushed fiber, in the case of corrugated cardboard, crushed paper and fiber, and in the case of polyurethane foam or polystyrene foam, crushed plastic foam and fiber are obtained. Since it is composed of a vinyl sheet, a crushed fiber and a crushed polyvinyl chloride sheet are obtained from the scrap of the dashboard, and the carpet for the car floor consists of a carpet body and a polyethylene film lined with the carpet body. From the scrap of the carpet for the car floor, ground fiber and polyethylene Pulverized material is obtained, and the door trim is composed of a base material such as a hard board or a resin board and a skin material such as a non-woven fabric. When a fiber crushed product or a resin board is used as a base material, a fiber crushed product is obtained, and the sheet is composed of a pad made of polyurethane foam and a skin material such as a fiber knitted fabric. A crushed body and a crushed fiber are obtained. In addition, the ceiling material and the skin material of the door trim may be lined with a wading material such as polyethylene foam, polypropylene foam, or polyurethane foam, and in this case, in addition to the above, pulverized plastic foam may also be used. can get. In the present invention, in addition to scraps of the above-mentioned automobile interior materials and sheets, pulverized materials obtained from scraps of packaging materials, scraps of clothing, scraps of building materials, and the like can be used.

In the present invention, the binder used for binding the pulverized material containing fibers includes, for example, polyethylene, polypropylene, ethylene-propylene copolymer,
Ethylene-vinyl acetate copolymer, polyvinyl chloride, polyester, polystyrene, polyamide, fluororesin, thermoplastic acrylic resin, thermoplastic synthetic resin binder such as thermoplastic urethane resin, urethane resin, melamine resin,
Thermosetting synthetic resin binder such as thermosetting acrylic resin, urea resin, phenol resin, epoxy resin, thermosetting polyester, urethane resin prepolymer, epoxy resin prepolymer, melamine resin initial condensate, urea resin initial condensation Products, precondensates of phenolic resins, diallyl phthalate prepolymers, acrylic oligomers, prepolymers such as polyvalent isocyanates, methacrylic ester monomers, diallyl phthalate monomers, oligomers and monomers. The binder is used as an organic solvent solution, emulsion, latex, powder or the like, and is usually added to the pulverized product of the present invention in an amount of about 3 to 40% by weight.

As the protective sheet used in the present invention, polyethylene, polypropylene, polyvinyl chloride,
Urethane resin, melamine resin, thermosetting acrylic resin, urea resin, phenol resin, epoxy resin, thermosetting polyester resin, urethane resin prepolymer,
Epoxy resin prepolymer, melamine resin precondensate,
Thermosetting synthetic resin such as urea resin precondensate, phenol resin precondensate, polyvalent isocyanate, diallyl phthalate monomer, diallyl phthalate prepolymer, prepolymer, oligomer, monomer, etc., or thermosetting synthetic resin precursor Is a sheet impregnated with. The thickness of the protective sheet is usually 3 to 5 mm, and the specific gravity is 0.01 to 0.
08, and the impregnation amount of the thermosetting synthetic resin is usually 3 to 40.
% By weight. The protective sheet is present on the die surface of the chip mold including the outer mold and the inner mold at the time of molding the chip molded article, and is adhered to the chip molded article simultaneously with the molding of the chip molded article. The adhesion between the protective sheet and the chip molded product is performed by using a thermosetting synthetic resin impregnated in the protective sheet, a binder for the chip molded product, or an adhesive separately from the binder.

[0008]

According to the present invention, since the protective sheet (6) is adhered to the surface of the chip molded product (5), the pulverized material peels off from the surface of the molded product (5). (6) is prevented. On the other hand, since the protective sheet (6) is made of a plastic foam, it has excellent low-frequency sound absorbing properties, and the chip molded article (5) contains a crushed fiber, so that it has excellent high-frequency sound absorbing properties. The protective sheet (6) is impregnated with a thermosetting synthetic resin, whereby the protective sheet (6) has excellent moldability and rigidity after molding, that is, excellent shape retention, and the surface of the molded article (5) is strengthened to maintain its shape. I do. Conventionally, the surface shape of the molded article (5) could not be formed into a finer shape than the size of the pulverized material. However, if the protective sheet (6) is used, the protective sheet
By changing the thickness of the plastic foam of (6), it is possible to mold even such a fine shape.

[0009]

1 to 4 show a first embodiment of the present invention. In the figure, an outer die (1) of a chip forming die (1) comprising an outer die (2) and an inner die (3), and having a bead-shaped die surface (2A) at the bottom of the outer die (2). As shown in FIG. 1, a protective sheet (6) is inserted in the lower part of FIG. 2 and a molding material (4) is filled thereon, and a protective sheet (6) is further placed on the molding material (4). Is placed and pressed from above with an inner mold (3) as shown in FIG. 2 to produce a molded product (5) having a predetermined shape as shown in FIG.

As the molding material (4), 30% by weight of a carpet for car floor coverings, that is, a crushed material (mixed crushed material of fiber and polyethylene film) of a scrap of a carpet in which a polyethylene sheet is lined with a carpet body. A mixture of a urethane prepolymer as a binder is used, and a polyurethane foam impregnated with 6% by weight of a urethane prepolymer is used as the protective sheet (6). Then, at the time of molding, water vapor is sprayed on the molding material (4), and the molding material (4) and the urethane prepolymer of the protective sheet (6) are polymerized by moisture and are three-dimensionally cured. In this way, a molded product (5) having a bead shape (5A) on the bottom is obtained, and the molded product (5) and the protective sheet (6) are obtained.
Is adhered by the urethane prepolymer cured product,
The surface of the molded article (5) is reinforced by the urethane prepolymer cured product.

The molded article (5) is adhered to the back of a carpet (8) for a car floor by way of a polyethylene sheet (7) as an insulator material, for example, as shown in FIG.

FIGS. 5 to 7 show a second embodiment of the present invention. In the figure, the chip mold (11) is the outer mold (12) and the inner mold (13)
A mold surface (12A) having a fine convex shape is provided at the bottom of the outer mold (12). Outer die (12) of the molding die (11)
As shown in FIG. 5, a protective sheet (16) is inserted into the inside, and a molding material (14) is filled thereon.
A protective sheet (16) is placed on (14), and is pressed from above by an inner mold (13) as shown in FIG. 6 to form a molded product (15) having a predetermined shape as shown in FIG. Manufactured.

As the molding material (14), a melamine resin precondensate in a proportion of 25% by weight is added to a pulverized scrap of automobile ceiling material (mixed pulverized fiber and polyurethane foam sheet and polyvinyl chloride leather). A mixture obtained as a binder is used, and as the protective sheet (16), a polyvinyl chloride foam impregnated with 10% by weight of a melamine resin precondensate is used. When molding, the molding material (1
4) is heated to 150 ° C., and the melamine resin precondensate in the molding material (14) is polymerized and three-dimensionally hardened. In this way, a molded product (15) having a fine groove (15A) on the upper surface is obtained. The width of the groove (15A) is the same as the molding material (14).
Although it is smaller than the diameter of the pulverized material, since the concave groove (15A) is formed on the surface of the protective sheet (16), it is not related to the diameter of the pulverized material.

[0014]

Thus, in the present invention, the sound insulation of the molded chip is excellent over a wide range of frequencies, and the surface of the molded article can be given a fine shape.

[Brief description of the drawings]

 1 to 4 show a first embodiment of the present invention.

FIG. 1 is an explanatory view before molding.

FIG. 2 is an explanatory view at the time of molding.

FIG. 3 is a sectional view of a molded product.

FIG. 4 is an explanatory view of a use state. FIGS. 5 to 7 show a second embodiment of the present invention.

FIG. 5 is an explanatory view before molding.

FIG. 6 is an explanatory view at the time of molding.

FIG. 7 is a perspective view of a molded product.

FIG. 8 is a conventional explanatory view before molding.

FIG. 9 is an explanatory view at the time of conventional molding.

[Explanation of symbols]

 1,11 Mold 2,12 Outer mold 3,13 Inner mold 4,14 Molding material 5,15 Molded product 6,16 Protection sheet

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ identification symbol FI B29K 105: 26 501: 10 B29L 9:00 31:58 (58) Fields investigated (Int.Cl. ⁶ , DB name) B29C 43 / 00-43/58 B29C 44/00-44/60, 67/20 B32B 1/00-35/00 B29D 1/00-31/02

Claims (3)

(57) [Claims] 1. A protective sheet made of a plastic foam impregnated with a thermosetting synthetic resin is coated on the surface of a molded product obtained by molding a crushed product containing a crushed fiber product into a predetermined shape and binding with a binder. Chip molded product characterized by wearing 2. A plastic foam in which a thermosetting synthetic resin is impregnated on a mold surface of a chip mold comprising an outer mold and an inner mold.
The protection sheet allowed to exist consisting of a binder and filler are mixed into the pulverized product containing the fibers pulverized product into the outer mold, sintered at a binder as well as forming the pulverized material between the outer mold and the inner mold Chip forming method characterized by wearing 3. The chip molded product according to claim 1, wherein the binder is a thermosetting synthetic resin.