JPS63126981A - Production of automotive interior material - Google Patents

Abstract

PURPOSE:To obtain the titled interior material having excellent heat resistance, by sticking base material of the interior material and a surfacing material together with an adhesive mainly containing a mixture of emulsion type adhesive and epoxy resin. CONSTITUTION:A base material such as resin board, high density foam urethane, etc., and a surfacing material (e.g. polyvinylchloride leather, laminate obtained by lining a nonwoven to a leather, etc.) are stuck together with an adhesive prepared by adding a curing agent such as an aliphatic polyamine, isocyanate (for said emulsion resin), etc., to a mixture of an emulsion type adhesive, e.g. natural rubber, synthetic rubber latex or (meth)arylic acid ester based elusion and epoxy resin to provide the aimed automotive interior material having extremely excellent heat resistance. The epoxy resin includes a condensate obtained by reaction of epichlorohydrin with bisphenols, etc.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a method for manufacturing automobile interior materials used for ceiling materials, door trims, rear boards, rear trays, trunk wall materials, seat sheets, floor materials, etc. .

[Background of the invention]

This type of interior material is resin board, high-density foamed urethane,
Cardboard, polystyrene foam panels.

It is manufactured by laminating a covering material such as polyvinyl chloride leather, a laminate of polyvinyl chloride leather and polyurethane foam sheet, nonwoven fabric, or textile knitted fabric to a base material such as hardboard or plastic panel.

[Conventional technology]

Conventionally, heat-sensitive adhesives and two-component curing solvent-based adhesives have been mainly used to bond base materials and facing materials together in the production of interior materials.

[Problem that the invention seeks to solve]

However, when heat-sensitive adhesives are used, there are problems with heat resistance, when two-component curing solvent-based adhesives are used, the boat life is short when a curing agent is mixed with the adhesive, and when organic solvents are used, the boat life is short. There are also concerns about toxicity and flammability due to the use of

[Failure to solve the problem]

The present invention solves the above-mentioned conventional problems by bonding a base material and a facing material using an adhesive mainly composed of a mixture of an emulsion type adhesive and an epoxy resin.

Examples of emulsion adhesives used in the present invention include natural rubber, styrene-butadiene rubber, and styrene-butadiene rubber.
Latex of natural or synthetic rubber such as butadiene blow copolymer, styrene-isoprene blow copolymer, acrylonitrile-butadiene rubber, imprene rubber, chloroprene rubber, butyl rubber, kerriisobutylene rubber, polybutene rubber, kraft rubber, acrylic acid ester resins, methacrylate ester resins, vinyl acetate resins, vinyl propionate resins, vinyl acetate resins
Ethylene copolymer resin, vinyl acetate-maleic acid copolymer resin, styrene resin.

These are synthetic resin emulsions such as vinyl chloride resins, vinyl chloride-ethylene copolymer resins, vinyl chloride-vinyl acetate copolymer resins, vinylidene chloride resins, and polyvinyl ether resins. The synthetic rubber latex and synthetic resin emulsion have carboxyl groups, hydroxyl groups,
Methylol group.

It is desirable to have a functional group capable of reacting with an epoxy group such as an amino group or an acid amide group. Two or more kinds of the above synthetic rubber latex and synthetic resin emulsion may be mixed.

Furthermore, the adhesive of the present invention includes tackifiers such as rosin, petroleum resin, coumaron resin, rosin derivative, terpene resin, phenol resin, alkylphenol thread resin, etc. , methyl ethyl ketone, methyl imbutyl ketone, cellosolve acetate, n-butyl cellosolve, ethylene glycol, diethylene glycol, propylene glycol,
Organic solvents or wetting agents such as chrycerin, polyethylene glycol, polypropylene glycol, fillers such as clay, talc, bentonite, calcium carbonate, etc. may be added.

The epoxy resin used in the present invention refers to all synthetic resins having epoxy groups, and such epoxy resins include condensates obtained by reacting epichlorohydrin with bisphenols and/or polyhydric alcohols, glycidyl methacrylate, and glycidyl acrylate. Examples include copolymers obtained by copolymerizing epoxy group-containing vinyl monomers such as , glycidyl allyl ether, and the like. The epoxy resin is provided in the form of an organic solvent mH1 or an emulsion such as badrol, quidylol, ethyl acetate, n-butyl acetate, methyl ethyl ketone, methyl imbutyl ketone, cellosolve acetate, ethyl cellosolve, n-butyl cellosolve.

Although the mixing ratio of the emulsion type adhesive and the epoxy resin may be arbitrary, it is generally desirable that the weight ratio of the adhesive and the epoxy resin is about 98:2 to 65:35 in terms of solid content. If the ratio of epoxy resin is below the above range, the heat-resistant adhesive strength will decrease, and if it exceeds the above range twice, the life of the boat will be shortened.

In addition to the above components, the adhesive of the present invention includes aliphatic polyamine,
Hexamethylene diamine carbamate.

Epoxy resin hardeners such as ammonium benzoate and acid anhydrides, hardeners for emulsion adhesives such as diisocyanates and melamine resins, polyvinyl alcohol, methyl cellulose, carboxymethyl cellulose, hydroxymethyl cellulose, IS>.

Modified starch, pigments, dyes, antiaging agents, antioxidants, etc. may be added. The amount of the epoxy resin curing agent is usually 10 to 40% by weight based on the solid content of the epoxy resin.

As the base material of the present invention, resin boards, high-density urethane foam, cardboard, polystyrene foam panels, hardboards, polypropylene, polyvinyl chloride, plastic panels such as acrylonitrile-butadiene-styrene copolymers, etc. are used. The facing material of the present invention is a leather made of polyvinyl chloride, polyamide, polyurethane, etc., or the leather is coated with a glue material such as a nonwoven fabric, a fiber knitted fabric, a polyethylene foam, a polyvinyl tetrachloride foam, a polyurethane foam, etc. Laminated materials, non-woven fabrics, fiber knitted fabrics, etc., are used.

The base material of the present invention is formed into a predetermined shape in advance, if desired, and then the adhesive of the present invention is applied to the surface of the base material and/or the back surface of the facing material, and if desired, after pre-drying, the base material and the facing material are are pasted together. For bonding the base material and the facing material, methods such as holstering, doweling, cold pressing, vacuum forming, etc. are applied. If desired, molding may be performed at the same time as bonding the base material and the facing material, or may be performed after bonding the base material and the facing material.

[For production]

When an epoxy resin or its curing agent is mixed with an emulsion-type adhesive, the synthetic resin or rubber constituting the emulsion-type adhesive, or the epoxy resin and curing agent are contained in micelles of surfactant. No mutual molecular contact occurs between the two. The boat life, or pot life, of the mixture is therefore increased. After adhesion, moisture evaporates and the adhesive forms a film. In the film, 1 is a nuclear synthetic resin or rubber, and the epoxy resin or curing agent is brought into molecular contact and cured.

〔Effect of the invention〕

Therefore, in the present invention, since the adhesive is of the emul resin type, there is no need to worry about toxicity or flammability, and the work process is streamlined because the pot life is long, and furthermore, after curing, an adhesive with extremely good heat resistance can be obtained. Ceiling materials used in automobile interior materials, door) IJ.

It is very useful as an adhesive for manufacturing rear boards, rear trays, seats, trunk trim, wall materials, floor materials, etc.

Example 1 90 parts by weight (hereinafter simply referred to as parts) of a 50% by weight (hereinafter simply referred to as %) emulsion consisting of a copolymer of vinyl acetate and ethyl diacrylate: acrylonitrile in a weight ratio of 60:80:10. , 10 parts of a 50% epoxy emulsion consisting of a condensate of epichlorohydrin and bispheno-A/A were mixed, and 1 part of a polyamine was added as a curing agent.
．． Prepare Adhesive A by mixing 5 parts. Adhesive A was applied to the resin board used as the base material for the door trim at 80g/W.
1 (Dry), and after drying for 5 minutes at 80'CX, apply a laminated covering material made of polyvinyl chloride leather lined with non-woven fabric.
It was laminated by vacuum forming for 0 minutes. Table 1 also shows the results of changes in the viscosity and adhesive strength of Adhesive A depending on the elapsed time after addition of the curing agent.

Table 1 △ shows broken wood of polyvinyl chloride leather, normal condition: strength floor 2I after being left at room temperature for 24 hours after lamination
T1 heat: After lamination and left at room temperature for 24 hours, 80'CX8
Strength after standing for hours Wood 8 Water resistance: After lamination, left at room temperature for 24 hours, strength after immersion in water at 20'C for 24 hours Example 2: 45% in 80 parts of a 50% emulsion consisting of vinyl acetate-ethylene copolymer Adhesive B is prepared by mixing 20 parts of the 50% terpene resin emulsion and 20 parts of the 50% epoxy emulsion according to Example 1, and further mixing 4 parts of polyamide as a curing agent.

The adhesive B was applied to both sides of the heart board used as the base material of the rear board and the needle punch carbate used as the facing material at a coating amount of K 80 g/m, and then heated at 80°C.
Dry for 5 minutes at 1.0 kg/ax at 2.90°C x 0.
It was laminated by hot pressing for 5 minutes. The adhesive strength of this product was measured in the same manner as in Example 1, and the results are shown in Table 2.

Second surface water, aging resistance: 80'C after lamination and left at room temperature for 24 hours
Strength after heat aging for 20 days Example 3 80 parts of a 50% polychloroprene emulsion, 15 parts of a 50% epoxy emulsion of a cocondensate of epichlorohydrin and bisphenol/l/Al/ethrene glycol and 0.5% carboxymethyA / Add 8 parts of cellulose, 0001 parts of blue dye, and further add 3.5 parts of polyamide as a hardening agent and mix to prepare adhesive C. Polystyrene foam using adhesive C as a base material for ceiling adhesive. to 1
Apply with a coating amount of 20 g/d (Dry) and heat at 70°C
After drying for 5 minutes, the laminated surface material of non-woven fabric and foamed polyethylene was layered and bonded together by cold pressing at a pressure of 0.6 kg/1yn2. 50°cX9
Even in the 8%RHX500hr humidity test, there was no peeling or blistering.
No other abnormalities were observed.

Example 4 60% styrene-butadiene rubber latte 0 parts to 5 parts
10 parts of a 0% phenolic resin emulsion and 30 parts of a 50% emulsion of acrylic/l/copolymer containing 20% of glycidyl methacrylate were mixed, and 0.9 part of maleic anhydride was further mixed to form an adhesive. adjust. Using the adhesive as a base material, a molded high-density foamed urethane foam to be used for a seat sheet was coated with a coating amount of 120 g/y, and then the edges were layered, dried at 80° C. for 5 minutes, and bonded.

Table 3 shows the adhesive strength test results of this product.

Table 8 Example 5゜50% of vinyl acetate-ethylene copolymerization used in Example 2
The emulsion was mixed with 50% epoxy emulsion at various mixing ratios as shown in Table 4, and 100 g was applied to the resin board as the base material.
/m (Dry), dried at 80°C for 0 minutes, and covered with a foamed polyvinyl chloride sheet for 0.7 tc.
Table 5 shows the adhesion strength of the samples laminated by q/al', so°CXI, and the viscosity change after addition of the curing agent.

In addition, as a curing agent, polyamide is used in a ratio of 1 part to epoxy resin.
Added 5%.

Table 4: True 1 Lie: Adhesive strength after being left at room temperature for 24 hours after lamination *6 Heat resistance: 3 at 80°C after being left at room temperature for 24 hours after lamination
Adhesive strength after being left for a while *7 Heat aging resistance: 80°C after being left at room temperature for 24 hours after lamination
Adhesive strength after being left for 20 days at room temperature, water resistance: Adhesive strength after being left at room temperature for 24 hours after lamination, and then immersed in water at 20°C for 24 hours As shown in Examples 1 to 5, the manufacturing method of the present invention The adhesive used is an emulsion and has a high risk of fire.
It has a long pot life, good workability, and is found to have excellent adhesive properties as an interior material for automobiles, especially in heat resistance and water resistance. In addition, from Example 5, samples without epoxy resin (heat resistance 9) are inferior in water resistance, and when the epoxy resin content is less than 2%, the adhesion is poor, and when the epoxy resin content is 35% or more, the pot life is shortened. You can see that it will be shorter.

Claims (1)

[Claims] A method for producing an automobile interior material, which comprises laminating a base material and a facing material using an adhesive mainly consisting of a mixture of an emulsion type adhesive and an epoxy resin.