JPH0621708Y2 - Interior composite panel base material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial field of application) The present invention relates to an interior composite material, particularly an interior composite panel base material for automobiles such as molded ceilings, door trims, pillar garnishes, trunk trims, and other furniture.

(Prior Art) Known techniques of a composite panel using a polyurethane foam include, for example, the following.

(1) Japanese Examined Patent Publication No. 63-7577 Soft polyurethane foam is impregnated with an isocyanate compound and sprayed with water containing or not containing an amine to obtain glass fiber, plastic film, non-woven fabric,
A method for producing a composite panal in which skins and the like are laminated and heat-molded by a press mold.

(2) GB2028714B (cold press method) An adhesive is applied to a polyurethane foam sheet and / or a reinforcing sheet such as glass fiber, and the both are adhered to each other.
A method of manufacturing a reinforced panel of polyurethane foam, which is preheated to 20 ° C and then immediately molded in a press mold.

Since the method (1) uses a flexible polyurethane foam, it requires a step of curing after impregnation with an isocyanate compound in order to secure strength. Since the isocyanate compound reacts with the moisture in the air and begins to cure, it is necessary to perform thermoforming immediately after impregnation, it is not stockable and it is impossible to stock it, and it is necessary to make a series of continuous equipment from impregnation to press molding. Investment has a big drawback. Further, the process is complicated since it includes a process of spraying water containing or not containing an amine.

On the other hand, the above method (2) includes the step of taking out the heated composite of the polyurethane foam sheet and the reinforcing sheet from the heat source immediately, that is, putting it in the press mold within 3 to 10 seconds, and the pressing step with a short open time. It must be made.

Furthermore, both of the above methods use a fiber material (glass fiber) to reinforce the urethane foam, but in order to obtain a reinforcing effect with this, the thickness of the fiber is made considerably thicker and a large amount of weight (about (100 g / m ² or more) is required, the weight of the component and the weight of the price are high, and the surface of the component becomes thorny, so plastic film and surface material (nonwoven fabric) are always required. Moreover, it is not preferable in terms of weight and price.

(Problems to be solved by the invention) The object of the present invention is not to include a spraying process of water and the like, and is different from the cold pressing method in which the raw material substrate is preheated and pressed. An object is to provide an interior composite panel base material.

Another object of the present invention is to provide an interior composite panel base material having excellent sound absorption and air permeability.

Another object of the present invention is to provide an interior composite panel base material having excellent rigidity.

A further object of the present invention is to provide an interior composite panel base material which is excellent in weight, price and physical properties and has no splinter on the surface.

(Means for Solving the Problems) The present invention has a layer of hot melt film adhesive on one or both sides of a thermoformable polyurethane foam sheet, on which a thermosetting resin is impregnated and cured. The present invention relates to an interior composite panel base material having a layer of

The base material of the present invention is a thermoformable polyurethane foam sheet, on one or both sides of which a hot melt film adhesive is placed, on which a thermosetting resin is applied, and then a surf aging mat is laminated thereon. Then, the thermosetting resin is obtained by impregnating the surface-curing resin with a thermosetting resin and curing the thermosetting resin. or,
Another example of the substrate of the present invention is a thermomelt resin coating layer on a hot melt film adhesive layer, and a surfing mat and a non-woven fabric laminated on top of the hot melt film adhesive layer. It can also be obtained by impregnating a thermosetting resin up to the surf aging mat and the non-woven fabric layer and curing.

The present invention will be described below with reference to the drawings. FIG. 1 shows one embodiment, which has a layer of a hot melt film adhesive 2 on both sides of a polyurethane foam sheet 1 and a layer of a surf aging mat 3 impregnated with a thermosetting resin thereon.

FIG. 2 shows another embodiment of the present invention, in which a non-woven fabric layer 4 is further formed on the layer of the surf escaping mat 3 impregnated with the thermosetting resin.
With layers.

The well-known thermoformable polyurethane foam is used as the polyurethane foam of the present invention.
For example the density 20~kg / m ^3, preferably 0 to 80 percent closed cell ratio of 30-40 kg / m ^3, preferably 0 to 10% of the proportion of open cells is high semirigid or rigid polyurethane foam is suitably used. Specific examples of such a polyurethane foam include, for example, GB2028714B or Modern Plas.
Examples thereof include polyurethane foams described in tics International, 6 (3) 17,1976 and the like. Moreover, the thickness of the polyurethane foam sheet is preferably 5 to 15 mm, and 8 to
10 mm is more preferable.

As the hot melt film adhesive, for example, an olefin copolymer such as an ethylene copolymer or a propylene copolymer, an ethylene vinyl acetate copolymer (EVA), or a hot melt film such as a mixture thereof can be used. This hot melt film is preferably cut with fine slits as shown in FIG. 3, and FIG. 4 shows an enlarged view of the surface thereof. When this is heat-processed, the slits spread like a mesh as shown in FIG. 5, and the air permeability and sound absorption of the base material itself can be improved. Basis weight of the host bracts melt film is preferably 30 to 100 g / m ^2, preferred more is 30 to 50 g / m ²
Good

Examples of the thermosetting resin include phenol-based and melamine-based resins, and these are simple substances or acrylic resins,
It is used as a mixture with emulsion resins such as vinyl acetate. The coating amount is preferably 20 to 200 g / m ^{2 and} more preferably 50 to 150 g / m ^{2 in} dry weight.

Next, the surface of the thermosetting resin is dried before the surface of the thermosetting resin is laminated, and if necessary, a nonwoven fabric is laminated thereon. The thermosetting resin or a mixture of the thermosetting resin and the emulsion resin may be applied to a surf escaping mat in advance by coating or impregnation. In that case, it is preferable that the adhesion amount is the same as the above-mentioned application amount. Examples of the surf aging mats include, for example, surf ace mats, overlay mats or Glaslon surf aging mats, and the basis weight is 30
-150 g / m < ² > is preferable and 50-100 g / m < ² > is more preferable. Here, the surf escutting mat is a single matting glass fiber that is laminated in a non-directional manner on a flat surface and formed into a thin mat with a special binder. It is mainly used on the surface of FRP molded products. By forming a resin cut layer on the surface portion, smoothness and gloss are obtained, and corrosion resistance, water resistance, and light resistance are improved. The basis weight of non-woven fabric is
10 to 100 g / m ² is preferable, and 30 to 50 g / m ² is more preferable.

In the present invention, a surface covering layer may be provided on the surface of the above-mentioned surfacing mat or non-woven fabric. As the covering layer, for example, a non-woven fabric (print) or a fiber knitted fabric is used, and a soft polyurethane foam is used for this. Other representative synthetic resin foam laminates are also used. These synthetic resin foams need to be substantially open-celled bodies in order to ensure air permeability and sound absorption of the interior material.

The interior composite panel substrate of the present invention can be obtained, for example, by stacking the above-mentioned layers other than the facing layer, press-molding with a hot press mold, and simultaneously laminating and stacking the layers. The mold temperature at this time is 130 to 160 ° C., preferably 140 to 150 ° C., and the pressing time is preferably about 1 to 5 minutes and more preferably 1 to 3 minutes until the thermosetting resin is cured. At this time, a thermosetting resin is impregnated into the surf mat and the non-woven fabric to cure. Next, the press is released to obtain the target substrate. In the case of forming a cover layer, a cover material having a hot melt layer is placed on one surface of a surfing mat or a non-woven fabric, placed in a press die and pressed at a temperature of 120 to 160 ° C. for 10 to 60 seconds. After molding, remove the panel from the press mold.

(Effect of the invention) The present invention aims to reduce the weight by using a polyurethane foam having a high expansion ratio, and the polyurethane is also made of rigid or semi-rigid urethane having thermoplastic properties to improve the moldability, and the degree of freedom in design. Is also big. Furthermore, when laminating polyurethane and reinforcing materials, it is possible to improve the air permeability and sound absorption of the interior material by using a hot-melt film containing micro slits and a rigid or semi-rigid polyurethane foam sheet with a high proportion of open cells. Can be improved.

In addition, an interior composite panel that is excellent in weight, price, and physical properties, and has no splinter on the surface by using a surfing mat, which is the lightest of the glass fibers, and impregnating it with a thermosetting resin and thermosetting A substrate can be obtained.

(Examples) Hereinafter, examples will be described in detail.

Example 1 Thermoformable rigid polyurethane foam sheet (density 30
Prepare kg / m ³ and thickness 8 mm). On both sides, slit olefin-based hot melt film (Basis weight 40 g /
m ² ) put. 60g / on top of the hot melt film
Add 30 m ² of surf aging matt to phenol resin powder.
Part, a mixture of 100 parts of acrylic emulsion (nonvolatile content 40%) and dried (dry resin adhesion amount 100 g / m ² ) are stacked. Further, a non-woven fabric (weight per unit area of 30 g / m ² ) is placed on both sides. This assembly is placed between the upper and lower molds of a roof panel molding die (mold temperature 150 ° C.) set in a press and press-molded for 2 minutes. Next, the press is opened and the molded roof panel base material is taken out.

Next, using the press and mold used above, the mold temperature is set to 120 ° C., and the panel base material taken out above is set again in the mold. A covering material sheet made of vinyl chloride leather, soft urethane foam and olefin-based hot melt is placed on the panel base material and pressed for about 20 seconds. The press was released to obtain a composite roof panel.

Example 2 Thermoformable rigid polyurethane foam sheet (density 30
Prepare kg / m ³ and thickness 8 mm). An olefin-based hot melt film (basis weight: 40 g / m ² ) is placed on both sides. Further, a dry weight of a melamine resin adhesive was applied to the overlay mat (basis weight of 60 g / m ² ) on the hot melt film.
Stack the impregnated materials to give 0 g / m ² . A roof panel molding die (mold temperature 15
It is placed between the upper and lower molds (0 ° C.) and press-molded for 3 minutes.
Next, the press is opened and the molded roof panel base material is taken out.

Next, using the press and mold used above, the mold temperature is set to 120 ° C., and the panel base material taken out above is set again in the mold. A sheet of covering material made of polyester tricot, soft polyurethane foam and polyamide-based hot melt is placed on the panel base material and pressed for about 20 seconds. The press was released to obtain a composite roof panel.

Example 3 Thermoformable rigid polyurethane foam sheet (density 30
Prepare kg / m ³ and thickness 8 mm). On both sides, slit olefin-based hot melt film (Basis weight 40 g /
m ² ) put. 60g / on top of the hot melt film
A m ² surfing mat is impregnated with a water-soluble phenol resin solution (nonvolatile content 60%) at about 200 g / m ² and then dried (dry resin amount 120 g / m ² ), and the obtained reinforcing material is overlaid. A polyester non-woven fabric of 30 g / m ² is overlaid on the reinforcing material. This assembly is placed between the upper and lower molds of a roof panel molding die (mold temperature 140 ° C.) set in a press and press-molded for 2 minutes. Next, the press is opened and the molded roof panel base material is taken out.

Next, using the press and mold used above, set the mold temperature to 60 ° C, and dry the chloroprene-based synthetic rubber adhesive on the surface of the panel base material and the back surface of the polyester-based printed non-woven fabric taken out above in a dry weight of 30 g. Spray-apply at a rate of / m ² and dry at room temperature for 2-3 minutes. Then, the panel base material is set on the prepared press die, the above-mentioned cover material sheet is placed thereon, and pressed for about 1 minute. The press was released to obtain a composite roof panel.

[Brief description of drawings]

FIG. 1 is a sectional view showing an example of a laminated structure of an interior composite panel base material of the present invention, FIG. 2 is a sectional view showing another example of an interior composite panel base material of the present invention, and FIG. 3 is a slit. FIG. 4 is an enlarged view of the surface of the hot melt film, and FIG. 5 is a schematic view showing the hot melt film in which the slits are spread in a mesh shape by heat processing. 1 ... Thermoformable polyurethane foam sheet, 2 ...
... hot melt film adhesive, 3 ... thermosetting resin impregnated surf aging mat, 4 ... nonwoven fabric.

Claims (4)

[Scope of utility model registration request] 1. An interior composite panel having a layer of a hot melt film adhesive on one or both sides of a thermoformable polyurethane foam sheet, and a layer of a surfing mat impregnated and cured with a thermosetting resin thereon. Base material. 2. A thermoformable polyurethane foam sheet having a layer of a hot melt film adhesive on one or both sides, and a surface layer of a thermosetting resin impregnated and cured surfing mat and a nonwoven fabric, respectively. Interior composite panel base material. 3. The interior composite panel substrate according to claim 1 or 2, wherein the hot melt film has a slit which is opened by heating. 4. The interior composite panel substrate according to claim 1, wherein a mixture of a thermosetting resin and an emulsion resin is used.