JPH02258238A - Manufacture of composite base material for trim - Google Patents

Abstract

PURPOSE:To obtain a favorable rigidity by being impregnated the inside of a glass wool mat uniformly with foaming phenolic resin powder, by a method wherein foaming phenolic resin powder is spread over a surface material, on the surface of which the glass wool mat is superposed and the foaming phenolic resin powder is spread further over the surface of the glass wool mat for lamination. CONSTITUTION:Foaming phenolic resin powder 5 is spread over a surface material 4. A glass wool mat 2 is laminated to a spread surface of the foaming phenolic resin powder 5. Successively, the foaming phenolic resin powder 5 is spread over the top of the glass wool mat 2. The laminated body is set up to a hot press mold 8 constituted of a top and bottom forces 6, 7 for pressurization. The foaming phenolic resin powder 5 is foamed within the hot press mold 8, foamed phenolic layers 3 are formed on both sides of the glass wool mat 2 and the glass wool mat 2 is molded into a desired form by curing a binder of thermosetting resin in the glass wool mat 2. After cooling, the same is taken out of the mold and a composite base material 1 for trim is obtained.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a method for producing an interior composite base material used as an interior material, particularly as a ceiling material or door trim of a vehicle such as an automobile. The present invention relates to a method for manufacturing a composite base material for interior use on which a foamed phenol layer is formed.

[Conventional technology]

Conventionally, glass wool mats have been used as composite base materials for automobile interiors because they have excellent sound absorption and heat resistance, are lightweight, and can be formed by deep drawing. There is. Although this glass wool mat has the above-mentioned characteristics, it has the disadvantage that the glass wool mat is brittle and easily breaks during transportation or handling.

In order to solve this problem, it may be possible to improve the rigidity of the base material by impregnating the glass wool mat with foamed phenol resin powder to form a foamed phenol layer in the glass wool mat.

In that case, the method of impregnating the glass wool mat with foamed phenolic resin powder is to spray the foamed phenolic resin powder on one side of the glass wool mat with a spreader, or to spread the foamed phenolic resin powder on one side of the glass wool mat. Furthermore, a glass wool mat is polymerized and foamed phenolic resin powder is applied to that surface.
You can sandwich it between two glass wool mats.

[Problem to be solved by the invention]

However, the method of scattering foamed phenolic resin powder on one side of the glass wool mat is difficult to uniformly impregnate the inside of the glass wool mat with the foamed phenolic resin powder. The drawback is that you cannot get the handling you want.

In addition, the structure in which foamed phenolic resin powder is sandwiched between two glass wool mats increases the weight of the base material itself, as the minimum basis weight of one glass wool mat is 400 to 500 g/rrf. It was decided to use a pulley to increase costs. Moreover, the minimum basis weight of glass wool mat is 400-500g/ry.
f, it is also difficult to tear one glass wool mat into two for use.

An object of the present invention is to overcome the above-mentioned problems and provide a method for producing a composite base material for interior use in which the inside of a glass wool mat is uniformly impregnated with foamed phenolic resin powder and good rigidity is obtained.

[Means to solve the problem]

The means of the present invention to solve the problem is to spray foamed phenolic resin powder on the surface material and laminate a glass wool mat impregnated with a binder of thermosetting resin such as phenolic resin on the surface of the foamed phenolic resin powder. Next, after spraying foamed phenolic resin powder on the glass wool mat and laminating the surface material, each layer is molded and integrated by heat pressing, and the foamed phenolic resin powder is foamed to cover both sides of the glass wool mat. A composite base material for interior use was manufactured by forming a foamed phenol layer.

[For production]

Sprinkle foamed phenolic resin powder on the surface material and polymerize the glass wool mat on this surface.Next, spray foamed phenolic resin powder on the surface of the glass wool mat and laminate the surface material, so both sides of the glass wool mat are foamed. Phenolic resin howder is present.

For this reason, the foamed phenolic resin powder present on both sides of the glass wool mat foams during hot press molding, forming foamed phenol layers on both sides of the glass wool mat, and the thermosetting resin impregnated in the glass wool mat. It also hardens and fixes its shape. Therefore, the glass wool mat has a sandwiched structure with a foamed phenol layer, which provides sufficient rigidity.

Furthermore, since the surface material is laminated on both sides of the foamed phenolic resin powder, it has excellent mold releasability.

〔Example〕

An embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a sectional view of an interior composite base material 1 manufactured by the manufacturing method of the present invention. This interior composite base material 1 has a structure in which a foamed phenol layer 3 is formed on both sides of a glass wool mat 2, and a surface material 4 is laminated on each surface of the foamed phenol layer 3.

According to the manufacturing method of the present invention, as shown in the process diagram in FIG. The fabric weight of the surface material 4, which can be made of polyamide), raised knit, woven fabric, glass paper, etc., is preferably from 15 to 120 g/nf. If the basis weight is small, avatars are likely to occur on the surface material 4 when the pressing pressure of the mold is increased, and if the basis weight is too large, it may wrinkle or tear because it is difficult to stretch. The amount of spraying depends on the thickness of the foamed phenol layer 3, but an appropriate amount is 100 to 200 g/po.The foamed phenolic resin powder 5 used in the present invention is a novolac type or a resol type. In the case of the novolak type, a tri-blend of novolac with a curing agent of an aldehyde compound such as paraformaldehyde or hexamethylenetetramine and a blowing agent such as dinitrosopentamethylenetetramine or P-toluenesulfonamide is used. In the case of the type, the glass wool mat 2 is laminated on the sprayed surface of the zero-foaming phenol resin powder 5, which is made by tri-blending the foaming agent with the resol. The glass wool mat 2 can be made of glass wool containing an uncured thermosetting binder such as phenol resin, melamine resin, urea resin, epoxy resin, or unsaturated polyester resin.

Glass wool mat 2 has a basis weight of 400-500g/
rrf is used. The content of the binder varies depending on the type of binder, but when phenolic resin is used, it is preferably in the range of 7 to 12% by weight. Spread 5. The amount of spraying is the same as the amount sprayed onto the surface material 4. Furthermore, the surface material 4 is laminated on this upper surface.

This laminate was set in a hot press mold 8 consisting of an upper mold 6 and a lower mold 7 and pressurized. The foamed phenolic resin powder 5 is foamed in the heat press mold 8 to form foamed phenol layers 3 on both sides of the glass wool mat 2, and the thermosetting resin binder in the glass wool mat 2 is hardened to form the desired shape. is formed into. After cooling, it was taken out from the mold to obtain a composite base material 1 for interior use. The temperature of the heat press mold is 16
The temperature range is preferably from 0 to 250°C, and can be set freely within this range. The pressing time depends on the weight of the glass wool mat 2 and the content of the binder, but the
It was around 1 minute. The thickness of the interior composite base material l at this time is 4
There were ~7 temples.

In addition, if necessary, one side of the surface material 4 may be provided with a cushion layer such as polyurethane foam, polyethylene foam, polypropylene foam, polyvinyl chloride foam, nonwoven fabric, felt, or two or more layers of these. It is also possible to laminate a facing material in which breathable facing materials such as woven fabric, nonwoven fabric, knit, tricot, moquette, etc. are laminated by a known method such as frame lamination.

After the interior composite base material 1 is molded, this facing material is bonded using another mold.

〔Effect of the invention〕

Since the present invention has the above configuration, it has the following effects.

(1) Since the foamed phenolic resin powder is sprayed on the surface material, and then the glass wool mat is laminated and the foamed phenolic resin powder is spread, the foamed phenolic resin powder is sprayed on both sides of the glass wool mat. is obtained.

Therefore, a state in which both surfaces of the glass wool mat are uniformly impregnated with the foamed phenolic resin powder can be obtained, and a composite base material for interior use having uniform rigidity can be manufactured.

(2) A composite base material for interior use in which foamed phenol layers are formed on both sides of a glass wool mat can be manufactured in a series of steps, so productivity is significantly improved.

[Brief explanation of drawings]

FIG. 1 is a sectional view of a composite base material for interior use manufactured according to the present invention, and FIG. 2 is a schematic process diagram of the manufacturing method of the present invention. l... Composite base material for interior design, 2... Glass wool mat, 3... Foamed phenol layer, 4... Surface material, 5...
Foamed phenolic resin powder 6...upper mold, 7...lower mold, 8...hot press mold.

Claims (1)

[Claims] Sprinkle foamed phenolic resin powder on the surface material, laminate a glass wool mat impregnated with a binder of thermosetting resin such as phenolic resin on the surface of the foamed phenolic resin powder, and then apply foamed phenolic resin powder to the glass wool mat. After spraying and laminating the surface material,
A method for producing a composite base material for interior use, which comprises integrally molding each layer by heat pressing and foaming the foamed phenolic resin powder to form foamed phenol layers on both sides of the glass wool mat.