JPH0143627B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for integrally molding a laminated interior material for automobiles having inserts, and in particular to a method for forming a cured base material, cushion material, and surface material used in automobile door trims, quarter trims, etc. The present invention relates to a method of integrally molding a laminated interior material having a three-layer structure and having inserts, in which the three layers are integrally molded into a desired shape and inserts are attached at the same time.

For automobile door trims, quarter trims, etc.
Laminated interior materials of various shapes, planar or three-dimensional, are used, which have an approximately three-layer structure of a hardened base material, a cushion material, and a surface material, and have inserts. In this case, the cured base material itself has a certain hardness and functions to support the laminated interior material for automobiles in the desired shape, and the inserts are used to form the laminated interior material after molding. It functions when attaching a material to an automobile body, when attaching other accessory parts to a laminated interior material after molding, when reinforcing the laminated interior material itself after molding, etc.

Conventionally, when molding this type of laminated interior material, generally a hardened base material such as wood board molded into the desired shape is separately prepared in advance, and a soft material impregnated with vinyl chloride resin as a cushion material is used as the cushion material. A molding method is used in which polyurethane foam is layered with cloth, leather, etc. as a surface material, molded in this state using a high-frequency welder, and then metal or plastic parts are attached as inserts.

However, such conventional molding methods require a large number of steps, are complicated and troublesome, and are also difficult to mold a cured base material having a certain hardness into a particularly complex three-dimensional shape. Furthermore, since the inserts are attached after molding, there are constraints from the shape, making the attachment work troublesome and the attachment strength insufficient.

Therefore, while using a material that has shape adaptability during molding and has a certain hardness after molding as a precursor material of the cured base material, such a material and the cushion material and the surface A molding method is required that allows inserts to be attached at the same time as the material is integrally molded.

The present invention eliminates the drawbacks of the conventional methods described above and provides a method for integrally molding a laminated interior material for automobiles having inserts, which meets such demands.
The purpose is to use a base material containing a carrier impregnated with a liquid softening polyurethane resin, position the inserts, the base material, cushion material, and surface material in the mold, and attach them at the same time as integral molding. This improves molding efficiency and shape adaptability,
It also aims to improve the installation work and installation strength of inserts.

Therefore, the present invention provides a method for integrally molding a laminated material having inserts, in which a cushion material is interposed between a cured base material and a surface material, and the inserts and the inserts are formed in a mold having a desired shape. a base material containing a carrier impregnated with a liquid curable polyurethane resin in contact with a cushion material, and a cushion material in contact with the base material; and a cushion material in contact with the cushion material. At this time, an adhesive is applied between the cushion material and the surface material, and a catalyst is applied to the base material.The inserts are then integrally molded by heat compression and hardened at the same time. It consists of being attached to a base material. In order for the cured base material after molding to better perform its functions, when the base material is impregnated with a liquid curable polyurethane resin and consists of a carrier and a reinforcing material, the liquid curable polyurethane resin is used for reinforcement. This includes cases where the liquid curable polyurethane resin is a polyurethane prepolymer.

Hereinafter, the configuration of the present invention will be explained in detail based on the drawings.

Laminated automotive upholstery materials with inserts may be planar as shown in Figure 1, which is a cross-sectional view, or three-dimensional, as shown in Figure 2, a partially omitted cross-sectional view. There are various shapes such as objects. In the example of the drawing, cushion materials 3 and 13 are interposed between the hardened base materials 1 and 11 and the surface materials 2 and 12, and inserts 4 and 4 are provided at the ends of the hardened base materials 1 and 11.
14 and 24 are attached.

In the conventional method, a material having essentially a certain degree of hardness, such as a wood board, is prepared in advance by being molded into a desired shape, and cushion materials 3 and 13 are applied to the material.
This method involves integrally molding the surface materials 2 and 12 and then attaching the inserts 4, 14, 24 by a chemical method such as adhesion or a mechanical method using a fastener, so there are various drawbacks as described above. .

In contrast, the present invention, as shown in FIG. 3, which is a schematic process diagram, is a method in which the base material, cushion material, and surface material are integrally molded and inserts are attached at the same time.

First, a base material that is a precursor material of a hardened base material after molding is prepared. Such substrates are obtained by impregnating essentially lightweight carriers such as flexible polyurethane foam, coarse felt, glass mat, palm lock or paper with a liquid curable polyurethane resin having foaming properties.

As the liquid curable polyurethane resin, a composition for general polyurethane foam, such as a polyol with a molecular weight of 500 to 5000 and a functional group number of 2 to 8,
Isocyanates such as tolylene diisocyanate and polymethylene polyphenyl polyisocyanate,
It consists of a crosslinking agent and the like, and these can be foamed and hardened by adding a catalyst and, if necessary, water as a foaming agent. A polyurethane prepolymer, which is formed by reacting the polyol and the isocyanate in advance, is more preferable because it is easy to handle and cures quickly.

After curing by thermal compression, the base material thus obtained functions as a laminated interior material for automobiles to support cushioning materials and surface materials. A reinforcing material such as gold cloth, nonwoven fabric, wire mesh, or paper is superimposed on a carrier, or a reinforcing material made of inorganic powder such as glass chips or shirasu balloons is mixed into the liquid curable polyurethane resin as described above. It is better to use one that has been impregnated.

On the other hand, like the base material, a flat cushion material, a surface material, and inserts processed into appropriate shapes are prepared. As the cushion material, various similar synthetic resin foams are used, including soft polyurethane foam, and as the surface material,
Cloth, leather, etc. can be used. As the inserts, for example, metals or plastics are used, which are provided with holes or grooves in order to obtain higher mounting strength.

Next, the inserts, base material, cushion material, and surface material are positioned in a mold having a desired shape. At this time, an adhesive such as a well-known prepolymer for flexible polyurethane foam is applied to one contact surface between the cushion material and the surface material, and a catalyst, e.g. Apply an aqueous solution of a water-soluble tertiary amine catalyst. Such catalysts include various catalysts such as triethylenediamine, triethylamine, and diethylaminoethanol.

Finally, the mold is closed with a cushion material interposed between the base material that contacts the inserts and the surface material, and the base material is cured by heat compression, and at the same time, these materials, including the inserts, are integrally molded. . The conditions during this time vary depending on the type of materials used and the desired characteristics of the laminated interior material for automobiles.
In general, molding conditions using thermal compression are sufficient; for example, thermal compression is performed at 50 to 100° C. for about 5 to 15 minutes.

FIG. 4 is a sectional view showing such a molded state of the laminated material illustrated in FIG. 1, and FIG. 5 is a sectional view similarly showing another example of the molded state.
is cured by thermal compression in the molds 5 and 15, and becomes the cured base material 1. In the case of Figure 5, inserts 4, 1
4 is positioned so as to be sandwiched between the base material 1a and the other base materials 1b and 11b, but this is to more firmly attach the inserts 4 and 14.

As explained above, the present invention uses a carrier impregnated with a liquid curable polyurethane resin as a base material when molding a laminated automotive interior material having inserts, By positioning the inserts, the base material, the cushion material and the surface material in the mold and attaching them at the same time as integral molding, molding efficiency and shape adaptability are improved,
In addition, there is an effect that the installation work and installation strength of inserts can be improved.

Example The following materials were prepared in advance.

Inserts... Rectangular plate-shaped steel metal carrier with appropriate holes drilled in it... Coarse felt cushion material with a thickness of 6 mm... Soft polyurethane foam surface material with a thickness of 6 mm... Liquid nylon cloth Curable polyurethane resin A polyurethane prepolymer adhesive obtained by reacting a polyol with a molecular weight of 2000 with an excess amount of polymethylene polyphenyl polyisocyanate and containing 18% free isocyanate... A general pre-printer for flexible polyurethane foam. Polymer catalyst: an aqueous solution of triethylenediamine Next, inserts, carriers impregnated with liquid curable polyurethane resin with catalyst coated on both sides, and cushion materials with adhesive coated on the surface that will contact the surface material. The surface coated with the catalyst and the surface material were sequentially positioned in a mold having a desired shape.

Finally, the mold was closed and hot pressed at 90°C for 5 minutes.

The other conditions were general molding conditions using hot compression, thus obtaining a laminated interior material for automobiles having inserts. The molded article was a one-piece molded article with inserts attached at the same time as desired.

[Brief explanation of drawings]

1 and 2 are cross-sectional views illustrating a laminated interior material for automobiles having inserts, FIG. 3 is a schematic process diagram of the present invention, and FIGS. 4 and 5 are illustrative molding states of the present invention. FIG. 1, 11... Cured base material, 2, 12... Surface material,
3, 13... cushion material, 4, 14, 24...
Inserts, 5, 15... Molding mold, 1a, 1
b, 11b...Base material.

Claims (1)

[Scope of Claims] 1. A method for integrally molding a laminated material having inserts in which a cushion material is interposed between a cured base material and a surface material, wherein the inserts and the inserts are formed in a mold having a desired shape. A base material comprising an essentially lightweight carrier impregnated with a liquid curable polyurethane resin having foaming properties when in contact with the base material, and a synthetic resin foam while in contact with the base material. positioning the cushion material and the surface agent in contact with the cushion material, respectively,
At this time, an adhesive is applied between the cushion material and the surface material, and a catalyst is applied to the base material, and then the inserts are attached to the hardened base material at the same time as integral molding by heat compression. A method for integrally molding a laminated interior material for automobiles having inserts. 2. A method for integrally molding a laminated interior material for an automobile having inserts according to claim 1, wherein the base material is a carrier impregnated with a liquid curable polyurethane resin and a reinforcing material. 3. Claim 1 or 2, in which the liquid curable polyurethane resin contains a reinforcing agent.
A method for integrally molding a laminated interior material for automobiles having the inserts described in 2.