JPH02225027A - Manufacture of molded ceiling - Google Patents
Manufacture of molded ceilingInfo
- Publication number
- JPH02225027A JPH02225027A JP1045980A JP4598089A JPH02225027A JP H02225027 A JPH02225027 A JP H02225027A JP 1045980 A JP1045980 A JP 1045980A JP 4598089 A JP4598089 A JP 4598089A JP H02225027 A JPH02225027 A JP H02225027A
- Authority
- JP
- Japan
- Prior art keywords
- laminate
- thermosetting resin
- ceiling
- ceiling base
- press molding
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 13
- 239000000463 material Substances 0.000 claims abstract description 39
- 239000000835 fiber Substances 0.000 claims abstract description 35
- 239000006260 foam Substances 0.000 claims abstract description 28
- 229920005989 resin Polymers 0.000 claims abstract description 25
- 239000011347 resin Substances 0.000 claims abstract description 25
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 23
- 238000000465 moulding Methods 0.000 claims abstract description 11
- 229920003002 synthetic resin Polymers 0.000 claims abstract description 8
- 239000000057 synthetic resin Substances 0.000 claims abstract description 8
- 239000003365 glass fiber Substances 0.000 claims abstract description 7
- 238000001035 drying Methods 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 15
- 238000003475 lamination Methods 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 5
- 239000012779 reinforcing material Substances 0.000 abstract description 7
- 238000010030 laminating Methods 0.000 abstract description 4
- 230000006835 compression Effects 0.000 abstract description 3
- 238000007906 compression Methods 0.000 abstract description 3
- 229920000877 Melamine resin Polymers 0.000 abstract description 2
- 239000004640 Melamine resin Substances 0.000 abstract description 2
- 239000002904 solvent Substances 0.000 abstract description 2
- 239000004744 fabric Substances 0.000 abstract 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 abstract 1
- 238000003466 welding Methods 0.000 abstract 1
- 239000004745 nonwoven fabric Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 238000005304 joining Methods 0.000 description 3
- 230000002542 deteriorative effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000012943 hotmelt Substances 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 206010040844 Skin exfoliation Diseases 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Landscapes
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Laminated Bodies (AREA)
- Molding Of Porous Articles (AREA)
Abstract
Description
【発明の詳細な説明】
〔産業上の利用分野］
本発明は成形天井の製造方法に関し、更に詳細に説明す
ると、天井基材の表面に表皮材が接合された所望形状の
成形天井を形成する成形天井の製造方法に関する。[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing a molded ceiling. More specifically, the present invention relates to a method for manufacturing a molded ceiling. More specifically, a molded ceiling having a desired shape is formed by bonding a skin material to the surface of a ceiling base material. Relating to a method of manufacturing a molded ceiling.
従来より、軟質ポリウレタンフォーム等の軟質発泡体層
に剛性を付与させるために不織布等の補強材を接合させ
て形成された成形天井等が存在する。BACKGROUND ART Conventionally, molded ceilings and the like have been formed by bonding reinforcing materials such as nonwoven fabrics to impart rigidity to a soft foam layer such as flexible polyurethane foam.
軟質発泡体層１に不織布２を接合させる手段としては、
第５図に示す如く、接着剤３を軟質発泡体層１または不
織布２に塗布し、または第６図に示す如く、ホントメル
トフィルム等の熱融着性フィルム４を用いるもの等が存
在する。As a means for joining the nonwoven fabric 2 to the soft foam layer 1,
As shown in FIG. 5, an adhesive 3 is applied to a soft foam layer 1 or a nonwoven fabric 2, or as shown in FIG. 6, a heat-fusible film 4 such as a true melt film is used.
そして軟質発泡体層１に適度の剛性を付与させるために
熱硬化性樹脂を含浸させて成形天井を形成している（特
公昭５８−５２４９５号）。In order to impart appropriate rigidity to the soft foam layer 1, a molded ceiling is formed by impregnating it with a thermosetting resin (Japanese Patent Publication No. 58-52495).
然し乍ら、従来の如く、軟質発泡体層１と不織布２等の
補強材とを接着剤３または熱融着性フィルム４を用いて
接合させる場合には、これらの積層作業及びセット作業
が煩雑で作業能率を向上させることができない欠点を有
し、また接着剤３の塗布が作業環境を悪化させたり、ま
たは熱融着性フィルム４が高価でコストアンプの原因と
なる等の欠点を有していた。However, when the soft foam layer 1 and the reinforcing material such as the nonwoven fabric 2 are bonded using the adhesive 3 or the heat-fusible film 4 as in the past, the lamination work and setting work are complicated and laborious. It has the drawback that efficiency cannot be improved, and the application of the adhesive 3 worsens the working environment, and the heat-fusible film 4 is expensive and causes cost increase. .
本発明の目的は軟質発泡体層と補強材の接合作業を簡易
迅速に行え、作業環境を悪化させる虞れがなく、また高
価な熱融着性フィルムを用いることがなく経済性に優れ
、更に軟質発泡体層と補強材としての繊維層との接合力
が強固で剥離する虞れがなく、強度が強く、外観の優れ
た成形天井を得ることのできる成形天井の製造方法を提
供するものである。The purpose of the present invention is to enable the joining work of a soft foam layer and a reinforcing material to be performed simply and quickly, without the risk of deteriorating the working environment, without using an expensive heat-fusible film, and with excellent economic efficiency. To provide a method for manufacturing a molded ceiling in which the bonding force between a soft foam layer and a fiber layer as a reinforcing material is strong, there is no risk of peeling, and a molded ceiling with strong strength and excellent appearance can be obtained. be.
本発明は上述せる課題に鑑みてなされたもので、天井基
材の表面に表皮材が接合された所望形状の成形天井を形
成する成形天井の製造方法において、軟質発泡体層の表
面にガラス繊維及びまたは合成樹脂繊維からなる繊維層
をフレームラミネートにより融着させて積層品を形成し
、次いで軟質発泡体層と繊維層との積層品を熱硬化性樹
脂溶液中に浸漬し、所定量の熱硬化性樹脂溶液を積層品
に含浸させ、次いで積層品を加熱乾燥させて天井基材を
形成し、該天井基材を加熱プレス成形することを特徴と
する。The present invention has been made in view of the above-mentioned problems, and includes a method for manufacturing a molded ceiling in which a skin material is bonded to the surface of a ceiling base material to form a molded ceiling in a desired shape. A laminate is formed by fusing fiber layers made of and/or synthetic resin fibers by frame lamination, and then the laminate of the soft foam layer and the fiber layer is immersed in a thermosetting resin solution and heated to a predetermined amount. The method is characterized in that a laminate is impregnated with a curable resin solution, then the laminate is heated and dried to form a ceiling base material, and the ceiling base material is hot press-molded.
本発明に依れば、軟質発泡体層の表面にガラス繊維及び
または合成樹脂繊維からなる繊維層をフレームラミネー
トにより融着させて積層品を形成したので、接合力が強
く、剥離強度を向上させることができ、次いで積層品を
熱硬化性樹脂溶液中に浸漬しているので軟質発泡体層と
繊維層とに一度に熱硬化性樹脂溶液を含浸させることが
でき、次いで積層品を加熱乾燥させてセミキュア状態と
した天井基材を形成し、該天井基材に表皮材を積層させ
または積層しないで加熱プレス成形し、表皮材を積層し
なかった場合には別途表皮材を接合させることにより成
形天井を得ることができるものである。According to the present invention, a laminate is formed by fusing a fiber layer made of glass fiber and/or synthetic resin fiber to the surface of a soft foam layer by frame lamination, so that the bonding force is strong and the peel strength is improved. Then, since the laminate is immersed in the thermosetting resin solution, the soft foam layer and the fiber layer can be impregnated with the thermosetting resin solution at the same time, and then the laminate is heated and dried. A ceiling base material in a semi-cured state is formed, and then a skin material is laminated to the ceiling base material or hot press molded without laminating it, and if a skin material is not laminated, a skin material is separately bonded and molded. The ceiling is something you can get.
以下本発明に係る成形天井の製造方法を図面を参照して
詳述する。The method for manufacturing a molded ceiling according to the present invention will be described in detail below with reference to the drawings.
第り図乃至第３図には本発明に係る成形天井の製造方法
の一実施例の概略が夫々示されており、第４図には本発
明方法により製造された成形天井の一例が示されている
。3 to 3 each show an outline of an embodiment of the method for manufacturing a molded ceiling according to the present invention, and FIG. 4 shows an example of a molded ceiling manufactured by the method of the present invention. ing.
第１図に示す如く、スラブウレタン等からなる連続気泡
を有する軟質発泡体層１１の表面に補強材としてのガラ
ス繊維または、合成樹脂繊維からなる繊維層１３を積層
する。この繊維層１３はガラス繊維のみ、または合成樹
脂繊維のみから形成されたもの、またはこれらガラス繊
維と合成樹脂繊維とを混合して形成されもの、更にはガ
ラス繊維層と合成樹脂繊維層とを積層して形成したもの
を用いることができる。As shown in FIG. 1, a fiber layer 13 made of glass fiber or synthetic resin fiber as a reinforcing material is laminated on the surface of a soft foam layer 11 having open cells made of slab urethane or the like. This fiber layer 13 may be formed only from glass fibers or synthetic resin fibers, may be formed by mixing these glass fibers and synthetic resin fibers, or may be formed by laminating a glass fiber layer and a synthetic resin fiber layer. It is possible to use the one formed by
軟質発泡体層１１と繊維層１３とは、軟質発泡体層１１
の表面を加熱溶融させて繊維層１３を融着させるフレー
ムラミネートにより融着されている。軟質発泡体層１１
と繊維層１３とをフレームラミネートして形成した積層
品１５はローラ１５ａに巻き取られる。尚第１図中、Ｉ
ｌａは軟質発泡体層１１０ローラ、１３ａは繊維層１３
のローラ、１４はバーナー等の加熱手段である。また本
実施例では軟質発泡体層１１の表裏両面に繊維層１３を
融着させた場合が示されているが、軟質発泡体層１１の
一面にのみ繊維層１３を融着するものであってもよく、
また軟質発泡体層１１の表裏面に繊維層１３を融着した
場合には軟質発泡体層１１を中間よりスライスして２枚
取りとすることもできる。The soft foam layer 11 and the fiber layer 13 are
The fiber layer 13 is fused by flame lamination, which heats and melts the surface of the fiber layer 13 to fuse the fiber layer 13. Soft foam layer 11
A laminate 15 formed by frame laminating the fiber layer 13 and the fiber layer 13 is wound around a roller 15a. In Figure 1, I
la is the soft foam layer 110 roller, 13a is the fiber layer 13
The roller 14 is a heating means such as a burner. Further, in this embodiment, a case is shown in which the fiber layer 13 is fused to both the front and back sides of the soft foam layer 11, but the fiber layer 13 is fused only to one side of the soft foam layer 11. Good too,
Further, when the fiber layer 13 is fused to the front and back surfaces of the soft foam layer 11, the soft foam layer 11 can be sliced from the middle to form two layers.
次に、第２図に示す如く、軟質発泡体層１１と繊維Ｎ１
３との融着品である積層品１５をメラミン樹脂、ウレタ
ン樹脂、尿素樹脂、熱硬化性アクリル樹脂等からなる熱
硬化性樹脂１７の溶液中に浸漬し、一対の送りローラ１
８，１９間で一次的に積層品１５に含浸した熱硬化性樹
脂１７溶液を絞り、次いで圧縮ローラ２１，２２間で二
次的に積層品１５に含浸した所定量以上の余分な熱硬化
性樹脂１７ｉ液を絞り取る。Next, as shown in FIG. 2, the soft foam layer 11 and the fiber N1
A laminated product 15, which is a fused product with 3, is immersed in a solution of a thermosetting resin 17 made of melamine resin, urethane resin, urea resin, thermosetting acrylic resin, etc.
The thermosetting resin 17 solution impregnated into the laminate 15 is firstly squeezed out between compression rollers 21 and 22, and then the excess thermosetting resin of a predetermined amount or more is secondarily impregnated into the laminate 15 between compression rollers 21 and 22. Squeeze out the resin 17i liquid.
次いで、加熱乾燥室で積層品１５に含浸した熱硬化性樹
脂１７熔液中の溶剤及び水分を１５０ ’Ｃ〜１６０°
Ｃの温度条件下で５分間乾燥させて蒸発させ、熱硬化性
樹脂１フをセミキュア状態とじた天井基材２４を形成す
る。Next, the solvent and moisture in the thermosetting resin 17 melt impregnated into the laminate 15 are heated to 150'C to 160°C in a heating drying room.
The resin is dried and evaporated for 5 minutes at a temperature of C to form a ceiling base material 24 in which the thermosetting resin 1 is semi-cured.
次いで第３図に示す如く、所定の大きさにカットされた
積層品１５からなる天井基材２４に表皮材２８を積層し
、この天井基材２４と表皮材２８とを加熱プレス成形機
２５の上型２６及び下型２７間で加熱プレス成形し、所
望形状の成形天井３１に成形する。この加熱プレス成形
により、軟質発泡体層１１及び繊維層１３に含浸した熱
硬化性樹脂１７が硬化し、軟質発泡体層１１に繊維層１
３が強固に融着された成形天井３１が得られる（第４図
参照）。Next, as shown in FIG. 3, a skin material 28 is laminated on a ceiling base material 24 made of a laminate 15 cut to a predetermined size, and this ceiling base material 24 and skin material 28 are placed in a hot press molding machine 25. Heat press molding is performed between an upper mold 26 and a lower mold 27 to form a molded ceiling 31 of a desired shape. By this hot press molding, the thermosetting resin 17 impregnated into the soft foam layer 11 and the fiber layer 13 is cured, and the fiber layer 1
A molded ceiling 31 in which 3 is firmly fused is obtained (see FIG. 4).
尚前記積層品Ｉ５からなる天井基材２４と表皮材２８と
の接合は表皮材２８に予めホットメルトシートを接着さ
せたものを用い、または天井基材２４と表皮材２８との
間にホットメルトシートを積層させて加熱プレス成形す
ることにより一体的に接合される。尚天井基材２４のみ
を加熱プレス成形し、表皮材２８を後工程で加熱プレス
成形された天井基材２４に接合させることもできる。Note that the ceiling base material 24 made of the laminate I5 and the skin material 28 are bonded by using a hot melt sheet adhered to the skin material 28 in advance, or by using a hot melt sheet bonded between the ceiling base material 24 and the skin material 28. The sheets are laminated and integrally joined by hot press molding. It is also possible to heat press mold only the ceiling base material 24 and join the skin material 28 to the heat press molded ceiling base material 24 in a subsequent process.
［発明の効果］
以上が本発明に係る成形天井の製造方法の一実施例の方
法であ葛が、斯る方法に依れば、軟質発泡体層の表面に
ガラス繊維及びまたは合成樹脂繊維からなる繊維層をフ
レームラミネートにより融着させて積層品を形成したの
で、接合力が強く、剥離強度を向上させることができ、
軟質発泡体層と繊維層との積層品を熱硬化性樹脂溶液中
に浸漬しているので軟質発泡体層と繊維層とに一度に熱
硬化性樹脂溶液を含浸させることができ、次いで積層品
を加熱乾燥させてセミキュア状態とした天井基材を形成
し、該天井基材を加熱プレス成形することにより所望形
状の天井基材が得られこの際表皮材と一体に加熱プレス
成形し、または後工程で表皮材を接合させて成形天井が
得られるので、成形作業を簡易迅速に行え、また作業環
境を悪化させる虞れがなく、また天井基材を加熱プレス
成形した場合に皺の発生が少なく外観の優れた成形天井
を形成することができ、軽量で剛性に優れ、且つ経済性
に優れた成形天井を得ることのできる成形天井の製造方
法を得ることができる。[Effects of the Invention] The above is an embodiment of the method for manufacturing a molded ceiling according to the present invention. The fiber layers are fused using frame lamination to form a laminated product, so the bonding force is strong and the peel strength can be improved.
Since the laminated product of the soft foam layer and the fiber layer is immersed in the thermosetting resin solution, the soft foam layer and the fiber layer can be impregnated with the thermosetting resin solution at the same time, and then the laminated product is soaked in the thermosetting resin solution. A ceiling base material in a semi-cured state is formed by heating and drying, and a ceiling base material having a desired shape is obtained by heat press molding the ceiling base material. Since the molded ceiling is obtained by joining the skin materials in the process, the molding work can be done easily and quickly, there is no risk of deteriorating the working environment, and there are fewer wrinkles when the ceiling base material is hot press molded. It is possible to obtain a method for manufacturing a molded ceiling, which can form a molded ceiling with an excellent appearance, is lightweight, has excellent rigidity, and is economical.
第１図乃至第３図は本発明に係る成形天井の製造方法の
一実施例の概略を夫々示すもので、第１図は軟質発泡体
層と繊維層との融着状態を示す工程図、第２図は積層品
を熱硬化性樹脂溶液中に浸漬している状態の断面説明図
、第３図は加熱プレス状態の断面説明図、第４図は成形
天井を加熱プレス成形した状態の断面説明図、第５図及
び第６図は従来の軟質発泡体層と補強材との接合状態を
夫々示す断面説明図である。
図中、１１・・・軟質発泡体層、１３・・・繊維層、１
４・・・加熱手段、１５・・・積層品、１７・・・熱硬
化性樹脂、２４・・・天井基材、２５・・・加熱プレス
成形機、２６・・・上型、２７・・・下型、２８・・・
表皮材、３１・・・成形天井。
第１図
第２図
第３図1 to 3 each schematically show an embodiment of the method for manufacturing a molded ceiling according to the present invention, and FIG. 1 is a process diagram showing the state of fusion of the soft foam layer and the fiber layer; Figure 2 is an explanatory cross-sectional view of the laminated product immersed in a thermosetting resin solution, Figure 3 is an explanatory cross-sectional view of the heat-pressed state, and Figure 4 is a cross-sectional view of the molded ceiling heated and press-molded. The explanatory drawings, FIG. 5, and FIG. 6 are cross-sectional explanatory views showing the bonding state of the conventional soft foam layer and the reinforcing material, respectively. In the figure, 11... soft foam layer, 13... fiber layer, 1
4... Heating means, 15... Laminated product, 17... Thermosetting resin, 24... Ceiling base material, 25... Hot press molding machine, 26... Upper mold, 27...・Lower mold, 28...
Skin material, 31... Molded ceiling. Figure 1 Figure 2 Figure 3
Claims (1)
成形天井を形成する成形天井の製造方法において、軟質
発泡体層の表面にガラス繊維及びまたは合成樹脂繊維か
らなる繊維層をフレームラミネートにより融着させて積
層品を形成し、次いで軟質発泡体層と繊維層との積層品
を熱硬化性樹脂溶液中に浸漬し、所定量の熱硬化性樹脂
溶液を積層品に含浸させ、次いで積層品を加熱乾燥させ
て天井基材を形成し、該天井基材を加熱プレス成形する
ことを特徴とする成形天井の製造方法。(1) In a molded ceiling manufacturing method that forms a molded ceiling of a desired shape in which a skin material is bonded to the surface of a ceiling base material, a fiber layer made of glass fiber and/or synthetic resin fiber is attached to the surface of a soft foam layer as a frame. fusing by lamination to form a laminate, and then immersing the laminate of the flexible foam layer and the fiber layer in a thermosetting resin solution to impregnate the laminate with a predetermined amount of the thermosetting resin solution; A method for manufacturing a molded ceiling, comprising: then heating and drying the laminate to form a ceiling base material, and hot press molding the ceiling base material.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1045980A JPH02225027A (en) | 1989-02-27 | 1989-02-27 | Manufacture of molded ceiling |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1045980A JPH02225027A (en) | 1989-02-27 | 1989-02-27 | Manufacture of molded ceiling |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH02225027A true JPH02225027A (en) | 1990-09-07 |
Family
ID=12734336
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1045980A Pending JPH02225027A (en) | 1989-02-27 | 1989-02-27 | Manufacture of molded ceiling |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH02225027A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2022517620A (en) * | 2019-01-16 | 2022-03-09 | オートニアム マネジメント アクチエンゲゼルシャフト | Sandwich panel for passenger cars that can carry loads |
-
1989
- 1989-02-27 JP JP1045980A patent/JPH02225027A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2022517620A (en) * | 2019-01-16 | 2022-03-09 | オートニアム マネジメント アクチエンゲゼルシャフト | Sandwich panel for passenger cars that can carry loads |
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