JPH0218038A - Inner packaging composite panel base raw material and panel - Google Patents

Abstract

PURPOSE:To not require the spray of water or the like, or the process of adhesive agent applying or the like, and enable the press work to be carried out in an appropriate open time by providing a glass paper admixed with organic fibres or not admixed with them in use of hot melt film adhesive agent on one side or both sides of a polyurethane foam sheet capable of thermoforming. CONSTITUTION:A polyurethane foam sheet 1 has layers of hot melt film adhesive agent 2 on its both sides, and provided further with layers of glass paper 3 thereon. The glass paper used herein is of type in which glass fibres are formed with a web by means of a paper machine, and it is adhered and fixed by a synthetic resin. And, the glass paper can be used of both types in which organic fibres are admixed or not admixed therewith. In particular, the glass paper admixed with organic fibres is excellent in extending by heating with the preferable result that it may not be broken during the molding period, and its R-sags never happen in a form of deep drawing.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention is applicable to interior materials, particularly molded ceilings, doors) interior composite panel bases for automobiles and other homes such as IJs, pillars, trunk trims, etc. Regarding raw materials and panels.

(Prior Art) Examples of known technologies for composite panels using polyurethane foam include the following.

MU Komei No. 63-7577 A flexible polyurethane foam is impregnated with an isocyanate compound, and water containing or not containing an amine is sprayed onto it to form glass fibers, plastic films, non-woven fabrics,
A method for manufacturing composite panels in which skins, etc. are laminated and heated and formed using a press mold.

(2) G B 2028714B (cold-open brazing method)
Apply adhesive to a polyurethane foam sheet and/or a reinforcing sheet such as glass fiber, and bond them together, 170
- A method for producing a reinforced panel of polyurethane foam, which involves heating the lower end to 220"C and then immediately molding it with a press mold.

Since method (1) above uses flexible polyurethane foam, a step of impregnating it with an incyanate compound and then curing it is necessary to ensure strength.

Since incyanate compounds react with moisture in the air and begin to harden, they must be thermoformed immediately after impregnation, which has poor storage stability and cannot be stocked, and requires a series of continuous equipment from impregnation to press molding. It has the disadvantage of requiring large capital investment. Furthermore, the process is cumbersome, including the step of spraying water containing or not containing amine.

On the other hand, the method (2) above involves the step of applying an adhesive such as polyurethane nylast mark ib, and immediately after removing the heated composite of polyurethane 7 ohm sea 1 and reinforcing sheet from the heat source, i.e. 3-10 ohms The process is complicated, including the process of putting it into a press mold within seconds, or the press process must be performed in a short open time.

(Problems to be Solved by the Invention) The object of the present invention is to provide an interior composite panel that does not include processes such as spraying water or applying adhesive, and can be press-processed in a moderate open time, and an original base material therefor. Our goal is to provide the following.

Another object of the present invention is to provide an interior composite panel with excellent sound absorbing properties and air permeability.

A further object of the present invention is to provide an interior composite panel with excellent rigidity.

A further object of the present invention is to provide an interior composite panel in which the surface material can be omitted.

(Means for Solving the Problems) The present invention is a base material material for press molding after preheating, using a hot melt film adhesive on one or both sides of a thermoformable polyurethane foam sheet. The present invention relates to an original interior composite panel base material and an interior composite panel obtained therefrom, characterized in that it is provided with glass paper mixed with or without organic fibers.

The above-mentioned base material of the present invention is a thermoformable polyurethane foam sheet with a hot melt film adhesive placed on one or both sides, and a lath paper mixed with or without organic fibers placed on top of the adhesive. This is a flat interior composite panel base material obtained by hot pressing. The base material of the present invention also includes the base material disclosed in Utility Model Application No. 1982-2211 filed by the same applicant as the present application.

The present invention will be explained below with reference to the drawings. FIG. 1 shows an embodiment of the base material of the present invention, which has a layer of hot melt film adhesive 2 on both sides of a polyurethane foam sheet 1, and further has a layer of glass paper 3 thereon.

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
Closed cell ratio at 0 kg/J is 0 to 80%, preferably 0 to 80%
Semi-rigid or rigid polyurethane foam with a high proportion of open cells of 10% is preferably used. Specific examples of such polyurethane foam include the above-mentioned G B
2028714 B or ModernP 1as
ticS International+G
(3) Polyurethane foams described in 17° 1976 and the like can be mentioned. Also, the thickness of the polyurethane foam sheet is 5-15III! 1 is preferable, and 8 to 10 mm is more preferable.

As the hot melt film adhesive, for example, hot melt films of olefin copolymers such as ethylene copolymers and propylene copolymers, ethylene vinyl acetate copolymers (EVA), and mixtures thereof can be used. This hot melt film is preferably cut with minute slits as shown in FIG. 2, and FIG. 3 shows an enlarged view of its surface.

When this is heat-processed, the slits are expanded into a network shape as shown in FIG. 4, and the air permeability and sound absorption properties of the base material itself can be improved. The basis weight of hot melt film is 30-1
00g/m2 is preferable, and 30-50. /112 is more preferable.

As the glass paper 3, a web of glass fibers formed by a paper machine and adhesively fixed with a synthetic resin can be used. At this time, if some pulp is mixed into the glass fibers, web formation becomes easier and the cost becomes lower. Examples of synthetic resins for fixing the web include melamine 1 (fat, urea resin, epoxy resin, polyvinyl chloride (PVC), polyvinyl alcohol (PVA),
P V Ac), vinyl butyral, acrylic acid ester copolymer, butadiene copolymer, etc. are used. In the present invention, as the glass paper,
Both glass paper mixed with n or not mixed with n can be used. In particular, glass paper mixed with organic m fiber has good elongation when heated, does not tear during molding, and does not cause R sag in deep drawing shapes. preferable.

The 01 dimension weight of the glass paper is preferably 10 to 100 g/m2, more preferably 30 to 50 g/m2.

Glass paper does not need to be covered with a surface material such as a non-woven fabric as is the case with ordinary glass A-fiber reinforcement materials, and has the functions of both a reinforcement material and a surface material, and the surface material can be omitted.

In addition, the glass paper can be impregnated with 0 (fat), and in that case, the rigidity of the interior composite panel can be improved.The amount of resin impregnated is 20 to 150 g/dry weight.
112 is preferable, and 50 to 100 g/2 spears is more preferable.

In the present invention, if more rigidity is required, fjS
As shown in Fig. S, a layer of reticulated cloth 4 made of glass fiber or organic fiber may be provided between the polyurethane foam and the hot melt film. Examples of the net-like cloth include cloths in which glass fibers or organic fibers (polyester, vinylon, aramid, etc.) are assembled vertically, horizontally, or diagonally and fixed with an adhesive (acrylic resin, EVA, etc.).
For example, glass scrim cloth (Asahi fiberglass),
Known fabrics such as Nitsumugi fabric and Ojiku fabric (Nittobo) can be used. The weight of the mesh cloth is 10-100g/l
112 is preferable, and 30 to 50 g/1112 is more preferable.

In the present invention, for example, a non-woven fabric (print), a fiber material, a via material, etc. are used as the surface layer, which can also be provided with a surface layer, on the base material. Laminates of similar synthetic resin foams are also used. These synthetic resin foams need to be substantially open-celled in order to ensure the breathability and sound absorption properties of the interior material.

The interior composite panel base material raw material of the present invention is obtained by, for example, stacking the above-mentioned layers other than the facing layer and adhesively laminating them using a hot press, a hot roll, or the like. The laminate is preferably 18
It is heated at 0 to 190°C for 15 to 35 seconds to obtain the desired base material. When forming a surface layer, it is obtained by placing a surface layer material on one of the glass paper layers with a hot melt adhesive layer, synthetic rubber adhesive layer, etc., and then performing cold press molding. Cold pressing is performed by preheating the component on which the above-mentioned facing material is placed and then press-molding it.

Preheating is preferably carried out using an infrared heater to
00℃ for about 25-35 seconds, and the surface temperature is about 160℃.
The temperature is 200°C, preferably about 180 to 190°C. The heated composite was then removed from the heater and placed into a press mold within 15-20 seconds of opening.
Pressing is performed for several tens of seconds at a temperature of 0° C. or lower, preferably for 30 to 60 seconds at a temperature of 30 to 60° C. (cold pressing). After molding, the panel is removed from the press mold.

(Effects of the invention) The present invention aims to reduce weight by using polyurethane foam with a high expansion ratio, and the polyurethane is also made of hard or semi-hard urethane with thermoplastic properties, improving moldability and providing greater freedom in design. It's also big. In addition, by using glass paper as a reinforcing material, the single glass fibers do not stick to the skin, causing no discomfort.Furthermore, when bonding polyurethane and reinforcing materials, hot melt film with micro slits can be used. Hard with a high proportion of open cells,
By using a semi-rigid polyurethane foam sheet, the breathability and sound absorption properties of the interior material itself can be improved.

Further, it is preferable to use a glass paper mixed with organic fibers because this glass paper has good elongation when heated, does not break during molding, and does not cause R sag in a deep drawing shape.

Furthermore, by using glass paper, it is possible to omit the surface material, and when the glass paver is impregnated with resin, the rigidity of the interior composite panel can be improved, and it is also possible to use polyurethane foam and hot melt film. Rigidity can also be increased by providing a layer of reticulated fabric in between.

(Example) A detailed explanation will be given below using examples.

Example 1 Thermoformable rigid polyurethane foam (density 45 kg/
n3. Slice the cell size 1,8+am), thickness On+e, width 130(hm, length 1700IllIl)
I made a board of l. On both sides of this, glass paper with a basis weight of 50g/mackerel 2 with epoxy resin as a binder, and a basis weight of 5
Approximately 1 for 0g/n2 slit hot melt film
They were bonded together using a heat press at 80°C to create a plate-shaped base material. A nylon tricot laminated with a soft polyurethane foam having a thickness of 2+aTn and having a hot melt layer on the back side is placed on this original base material as a facing material, and this
tn m @40 vertically by far infrared heater
The surface temperature was heated to 180°C by heating at 0°C for about 25 seconds, and then press-molded into an automotive molding ceiling press mold using an ascending mold temperature EO'C to produce an excellent quality automotive molded ceiling with a thickness of about 71 cm. I got it.

Example 2 Thermoformable rigid polyurethane foam sheet (density 3
0 kg/m", thickness 81). A slit hot melt film of polypropylene copolymer (fabric weight 50 g/m2) was placed on both sides of the film, and 50% polypropylene fibers and 450% plus fibers were mixed on top of this. Glass paper with acrylic resin as binder (date 50g/
1o2). This aggregate was heated on a hot plate at 180°C for 3
Press heat is applied for 0 seconds to bond the components to obtain a plate-shaped base material.

A printed nonwoven fabric laminated with a hot melt film is laminated onto this base material as a covering material. Heat for 30 seconds between far infrared heaters with a surface temperature of 350°C to bring the surface temperature of the component to 180 to 190°C. Thereafter, within 15 seconds, the heated component was placed between the upper and lower press molds at a mold temperature of 60° C., and press-molded to an average plate thickness of 71 for 30 seconds. Thereafter, the press mold was opened to obtain a molded composite roof panel.

Example 3 A reticulated lath cross (fabric weight 30 g/m2) was placed on both sides of the same polyurethane foam sheet as in Example 2, and a slitted hot melt film of polypropylene copolymer (fabric weight 50 g/m2) was placed on top of it, and It was then impregnated with vinyl acetate-based emulsion of glass vapor (basis weight 50 g/1112) made of acrylic resin mixed with 50% polypropylene fiber and 50% glass fiber, and then dried (dried resin adhesion amount 50 g/2 pieces). Stack things. This aggregate is press-heated for 30 seconds on a hot plate at 180° C. to adhere the components and obtain a plate-shaped base material.

Using this base material, a composite roof panel was obtained in the same manner as in Example 2.

Example 4 Thermoformable rigid polyurethane foam sheet (density 4
5 kg/m', thickness 8 mm). A hot melt film of polypropylene copolymer having a basis weight of 50 g/m2 is placed on both sides, and lath paper having a basis weight of 50 g/m2 and having an epoxy resin as a binder is placed on both sides. This aggregate is press-heated for 30 seconds with a hot plate at 180'C to adhere the components and obtain a plate-shaped base material.

Using this base material, a composite roof panel was obtained in the same manner as in Example 2.

Example 5 Thermoformable rigid polyurethane foam sheet (density 4
0kg/u3, thickness 8a+Ts) is prepared. A hot melt film of polypropylene copolymer with a basis weight of 50 g/m2 is placed on both sides, and a hot melt film of a polypropylene copolymer with a basis weight of 50 g/l112
A glass paper with an acrylic resin binder made of a mixture of 50% polyester fiber and 50% glass fiber is placed on the paper. This aggregate is press-heated for 30 seconds on a hot plate at 180° C. to adhere the components and obtain a plate-shaped base material.

Using this base material, a composite roof panel was obtained in the same manner as in Example 2.

[Brief explanation of the drawing]

Figure tjrJ1 shows the product of the raw interior composite panel base material of the present invention/
A cross-sectional view showing an example of Hliη structure, Fig. 2 shows a hot melt film with slits, Fig. 3 shows an enlarged view of its surface, and Fig. 4 shows a hot melt film with slits expanded into a network by thermal processing. The schematic diagram shown in FIG. 5 is a cross-sectional view showing another example of the original interior composite panel base material of the present invention. 1... Polyurethane foam sheet that can be aged, 2
... Hot melt film adhesive, 3... Glass paper, 4... Reticulated cloth. (Above) Applicant Toyo Rubber Industries Co., Ltd. Agent Patent Attorney 1) Iwao Mura Figure 1 Figure 5 Figure 2 Figure 3 Figure 4

Claims (5)

[Claims] (1) After preheating, using a hot melt film adhesive on one or both sides of a thermoformable polyurethane foam sheet, which is the base material for press molding,
An interior composite panel base material material comprising glass paper mixed with or without organic fibers. (2) The raw interior composite panel base material according to claim 1, wherein the hot melt film has slits that are opened by heating. (3) The raw interior composite panel base material according to claim 1 or 2, wherein the glass paper is impregnated with a resin. (4) The raw interior composite panel base material according to any one of claims 1 to 3, wherein one or both sides of the polyurethane foam sheet are reinforced with a mesh cloth of glass fiber or organic fiber. (5) An interior composite panel obtained by placing a facing material on the original panel base material according to any one of claims 1 to 4 and cold pressing the material.