JPH02208040A - Production of base material for interior material - Google Patents

Abstract

PURPOSE:To obtain a base material for an interior material excellent from the aspect of a wt., cost and physical properties and having no surface roughness by coating both surfaces of a heat-moldable polyurethane foam sheet with a urethane modified unsaturated polyester resin and laminating a glass fiber mat to both surfaces thereof and subsequently integrating the laminated product by heat press molding. CONSTITUTION:A urethane modified unsaturated polyester resin 3 wherein a polyol component and an isocyanate component are mixed is uniformly applied to both surfaces of polyurethane foam 1 in an amount of 100-300g/m<2>, pref., 150-250g/m<2> per single surface by a roll coater 5 or spraying. When the resin is thickened before use, release sheets such as polyethylene films 6 are applied to both surfaces of said coated foam and the whole is lightly compressed by a roll 7 or a press to impregnate a glass fiber mat with the resin so as to improve physical properties and surface smoothness at the time of the formation of a product. Next, the release sheet and a cellophane film 8 are preliminarily removed before heat press molding.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for manufacturing interior materials, particularly base materials for automotive interior materials such as molded ceilings, door trims, pillar garnishes, trunk trims, and other interior materials for vehicles and furniture. .

(Prior Art) Examples of methods for manufacturing interior material base materials using polyurethane foam include the following.

(1) Japanese Patent Publication No. 63-7577 A flexible polyurethane foam is impregnated with an incyanate compound, and water containing or not containing an amine is sprayed onto the foam to form glass fibers, glass film, non-woven fabrics, etc.
Composite panels made by laminating layers of skin, etc. and heating and forming them using a press mold! ! How to send.

(2) GB 2028714 B (cold pressing method)
Apply adhesive to a polyurethane foam sheet and/or a reinforcing sheet such as glass fiber, stick them together, and
A method for producing a reinforced panel of polyurethane foam, which is preheated to ~220°C and then immediately molded with a press mold.

Since the method (1) above uses a flexible polyurethane foam, a step of impregnating it with an incyanate compound and then curing it is necessary to ensure strength. Because incyanate compounds react with moisture in the air and harden, they must be thermoformed immediately after impregnation, which has poor storage stability and cannot be stocked.Therefore, it is necessary to use a series of continuous equipment from impregnation to press molding. However, the equipment investment is large, and the process is complicated, including the step of spraying water containing or not containing amines.

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

In addition, both (1) and (2) above are used for reinforcement or adhesion (because the fat has no strength and low heat resistance, it is recommended to thicken the glass fiber or use a material with a large basis weight of about 100°/2 or more. ), which increases the weight and price of the component, and the surface of the component becomes sticky, so a surface material (non-woven fabric) is required, which is also preferable in terms of weight and price. do not have.

(Issue 1 to be solved by the invention) The object of the present invention is that it does not include a spraying process using water or the like, and since the pot life of the resin to be impregnated is long, it is necessary to carry out the processes from impregnation to pressing with insects continuously. Another object of the present invention is to provide a method for manufacturing an interior material base material that can be press-formed without preheating the original base material.

Another object of the present invention is to provide a method for manufacturing an interior material base material that is excellent in terms of weight, cost, and physical properties, and has no surface roughness.

(Means for Solving the Problems) The present invention applies urethane-modified unsaturated polyester resin to both sides of a thermoformable polyurethane foam sheet, laminates glass fiber mats on both sides, and then heat-press molds the laminate. The present invention relates to a method for producing an interior material base material characterized by being integrated.

As shown in FIG. 1, the interior material base material of the present invention includes a thermoformable polyurethane foam sheet 1 and a urethane-modified unsaturated polyester resin 3 reinforced with a glass fiber mat 2.
It consists of a reinforcing layer 4.

As the polyurethane foam of the present invention, a conventionally well-known thermoformable polyurethane foam is used,
For example, density 20-50 kg/m', preferably 30-4
Bubble rate at 0 kg/m' is 0 to 80%, preferably 0
Semi-rigid or rigid polyurethane foams with a high proportion of open cells of ~10% are preferably used. Specific examples of such polyurethane foam include the above-mentioned G B
2028714 B or Modern P Ia
sLies International, 6
(3) Polyurethane foams described in 17m1976 and the like can be mentioned. Moreover, the thickness of the polyurethane foam sheet is preferably 3 to 15 m, and 4 to 10 m.
Crane is more preferred.

Examples of glass fiber mats used include chopped strand mats, continuous strand mats, and woven fabrics, but weight reduction and surface treatment (use of non-woven fabrics, etc.)
It is preferable to use a Sur7 Essing Mat with a weight of 30 to 150 g/m.

In the present invention, urethane-modified unsaturated polyester resin is coated on both sides of the 7-ohm urethane sheet. Urethane-modified unsaturated polyester resin is made of a polyol component (to which polyether polyol etc. may be added in some cases), which is a mixture of a polyester polyol having unsaturated groups, a urethane catalyst, and a crosslinking agent (usually styrene monomer) for unsaturated groups; In the zero reaction obtained by mixing an isocyanate component which is a mixture of incyanate and a peroxide, first, the polyol and incyanate bond with urethane under the influence of the urethane catalyst, and the M length is extended. Thereafter, under the influence of a peroxide catalyst, the unsaturated groups in the molecule and a crosslinking agent such as a styrene monomer undergo radical polymerization under heating or light or at room temperature, resulting in a highly crosslinked cured resin.

Since all raw materials are of low molecular weight, their initial viscosity is low and they are difficult to handle.As long as the liquid resin is not heated to high temperatures, only the urethane reaction will proceed and the crosslinking reaction of unsaturated bonds will not occur.The urethane reaction is catalyzed. Because it can be adjusted, thickening can be delayed for a long time.

Even when the urethane reaction progresses and gradually thickens and loses its tackiness, it remains soft because it is diluted with styrene monomer, and when heated, it melts again and then hardens over a long period of time. It can also be thermoformed. It becomes easier to handle when used in a state where it has lost its stickiness. The cured resin has improved physical properties such as impact resistance and strength compared to ordinary unsaturated polyester, and has heat resistance not found in polyurethane.

Taking advantage of the processability and physical properties of this urethane-modified unsaturated polyester resin, it has a low initial viscosity, making it easy to apply to 7-ohm urethane, and the long pot life of the resin allows for long-term storage, making it a continuous process. Furthermore, the excellent physical properties of the resin itself (rigidity, heat resistance, heat and humidity resistance, etc.) make it possible to reduce the weight and cost of glass fibers, and eliminate the need for surface treatment. By combining them, an integrated interior material base material can be manufactured by hot press molding the laminate without preheating.

Furthermore, after applying the resin to the 7-ohm urethane, laminating glass fiber mats on both sides and lightly compressing the whole thing to impregnate the resin even into the glass fibers, the resin was thickened under mild conditions to reduce the stickiness of the surface. It is aged until it disappears, making it easier to handle.
This can also be hot press molded in the same manner as above.

An example of the manufacturing method for the interior material base material of the present invention will be explained with reference to FIG. 2.

■Urethane-modified unsaturated polyester resin 3, which is a mixture of a polyol component and an isocyanate component, is applied to polyurethane foam 1 using a roll coater 5, spraying, etc. to give 100 to 300 g per side, preferably 150 to 250 g.
/m” evenly on both sides.

■Next, place the glass fiber mat 2 on both sides of ■.

■In addition, when using the resin after thickening it, cover both sides of ■ with a release sheet such as polyethylene film 6, and lightly compress the whole thing with rolls 7 or a press to impregnate the resin into the glass fiber mat. The product should have good physical properties and surface smoothness when made into a product. When storing, seal with cellophane film 8 or the like to prevent volatilization of the styrene monomer, and ripen for one day or more under mild conditions at 20 to 40°C.

(2) When performing press molding, in the case (2), insert (2) into a hot press mold 9 at 120 to 160°C, preferably 130 to 150°C, and press mold for 30 seconds to 5 minutes, preferably 30 seconds to 2 minutes. In the case of (2), the mold release sheet and cellophane film are removed in advance and the product is hot press molded in the same manner as (2).

■Remove the mold and take out the molded interior material base material.

The skin may be bonded after molding or may be bonded at the same time as the molding, and this is adjusted depending on the material of the skin.

(Effects of the Invention) Since it is composed of a reinforcing layer made of a combination of high-strength resin and glass fiber and a core material of low specific gravity polyurethane foam, it is relatively lightweight and has high rigidity.

■Good heat resistance due to the combination of heat resistant resin and glass #IL fiber.

■Since it is a resin with excellent water resistance, it has good heat and humidity resistance +11°Φ Since it uses hard or semi-hard urethane with thermoplastic properties, it has good moldability and a high degree of freedom in design.

(Example) The present invention will be explained below with reference to Examples.

Example 1 A thermoformable hard polyurethane foam sheet with a specific gravity of 0.030 and a thickness of 5I was coated with a urethane-modified unsaturated polyester resin prepared by mixing a polyol component and an incyanate component using a roll coater at a coating amount of 200 g/m on one side.
A 0-order 6017m” Sur7 Essing mat coated on both sides so that
It was press-molded to a general thickness of 4 mm using a hot press mold for a molded ceiling at 10°C, and removed from the mold after 1 minute to obtain a base material for a molded ceiling of 670 g/m''.

Example 2 A thermoformable hard polyurethane foam sheet with a specific gravity of 0,030 and a thickness of 51 was coated with a urethane-modified unsaturated polyester resin mixed with a polyol component and an incyanate component using a roll coater at a coating amount of 250 g/m2 on one side.
60g/11+' on the primary coated on both sides so that
Layer the Sur7 Essing Mat on both the top and bottom sides, and then cover both sides with polyethylene film to create a gap of 5.5.
-Al! passed between the rolled rolls. Fifty similar sheets were stacked, the whole was sealed with a cellophane film to prevent styrene monomer from volatilizing, and left at 23° C. for 7 days.

Next, after removing the cellophane film and removing the polyethylene film, the removed laminate was press-molded in a hot press mold for molded ceilings at 140°C to a standard wall thickness of 41 mm.
After a few minutes, the mold was removed to obtain a molded ceiling base material of 770 g/m''.

[Brief explanation of the drawing]

FIG. 1 shows a cross-sectional view of the base material obtained by the present invention. FIG. 2 shows an example of the manufacturing method of the present invention. 1...Thermoformable polyurethane foam, 2...
Glass fiber mat, 3... Urethane modified unsaturated polyester u1M, 4... Reinforcement layer, 5... Roll coater - polyethylene film, 7... Presser roll, 8... Cellophane film, 9...Heatless t
Sculpture. (Above) Applicant Toyo Rubber Industries Co., Ltd. Agent Patent attorney 1) Iwao Mura Proceedings amended July 3, 1989 1. Case description 1999 patent application PIS 29437 Name of invention Interior material base material Manufacturing method diagram 3, relationship with the case of the person making the amendment Patent applicant (314) Toyo Tire & Rubber Industries Co., Ltd. 4, Substitute 1-2-8-6 Sonezaki, Chiku-ku, Osaka-shi, Osaka 530, subject of amendment Section 7 of the "Detailed Description of the Invention" in the specification, contents of amendment (1) Delete "High proportion of open cells" in line 6 of page 5 of the specification. (2) Delete "or light, at room temperature" on page 6, line 12 of the specification.

Claims (2)

[Claims] (1) Interior interior characterized by applying urethane-modified unsaturated polyester resin to both sides of a thermoformable polyurethane foam sheet, laminating glass fiber mats on both sides, and then integrating the laminated products by hot press molding. Manufacturing method of base material. (2) Apply urethane-modified unsaturated polyester resin to both sides of a thermoformable polyurethane foam sheet, laminate glass fiber mats on both sides, and lightly compress the whole to impregnate the glass fibers with the resin. 2. The method for producing an interior material base material according to claim 1, wherein the resin is thickened under mild conditions and aged until surface tackiness disappears, and then the laminate is hot press molded.