JPH0333507B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for producing a core material for automobile interiors that is lightweight and has excellent mechanical strength.

[Prior art and its problems] Core materials for automobile interiors used for the inner walls of automobiles, etc. must be lightweight, have a certain strength and elasticity, be water resistant, and be manufactured at low cost. Conventionally, hard boards, resin felt boards, synthetic resin boards, and others have been used. In addition, in order to further reduce the weight, it has been considered to use synthetic resin foam, but this foam has the disadvantage that it is brittle and has the so-called stiffness of the material and is easily damaged by external force.

Note that Japanese Patent Publication No. 48-4632 discloses a method for producing a laminate in which a sheet-like base material such as glass fiber or synthetic fiber is interposed in a layered manner within a synthetic resin foam. The manufacturing method shown is
A resin solution such as a phenol resin, an unsaturated polyester resin, or a polyurethane resin is used, and the resin solution is applied to a sheet-like base material by, for example, coating with a knife coater or laminating with an extrusion molding machine. Ta. However, when applying with a knife coater, it is difficult to uniformly apply a small amount of resin, and the sheet-like base material is subject to considerable elasticity. There is a problem that it may break and cannot be applied properly. Furthermore, the method using an extrusion molding machine may similarly cause the sheet-like base material to be easily torn. In short, when applying a highly viscous resin solution, it is difficult to apply it thinly and uniformly to a coarse sheet with weak cohesiveness, such as a glass fiber sheet.

[Means for Solving the Problems] The present invention has been made in view of the above, and includes scattering a powdered foamed phenol resin compound onto a glass fiber sheet that moves horizontally at a constant speed. After the foamed phenol resin compound is adhered to the glass fiber sheet by letting it fall naturally, the glass fiber sheets are stacked in multiple layers and this is controlled to be above the melting temperature of the foamed phenol resin compound and below the curing start temperature. This layered glass fiber sheet is passed through a dry hot air oven, cut into appropriate dimensions, and then placed in a concave-convex mold heated to a temperature sufficient to harden the foamed phenol resin compound, and hot-pressed into the desired shape. This method of manufacturing a core material for an automobile interior is characterized by infiltrating a foam of a foamed phenol resin compound between the fibers of a glass fiber sheet and integrating the foam.

The term "glass fiber sheet" as used herein is a general term for sheet-like glass fibers such as glass fiber nonwoven fabric, glass fiber surf mat, glass fiber paper, and glass fiber woven fabric.

[Example] The core material for automobile interiors and the manufacturing method thereof according to the present invention will be described below.

An example of the manufacturing equipment is shown in Fig. 1, in which 1 is a blower, 2 is a raw material hopper provided in the middle of a duct 3 on the blowing side, 3a, 3b, and 3c are ventilation tunnels to which the ducts are branched, and 4 The ventilation circulation ducts 5a, 5b, and 5c are glass fiber surf mats having a basis weight of about 10 to 200 g/m ² , 6 is a guide roller, and 7 is a drying hot air oven. The foamed phenol resin compound 2' is supplied from the raw material hopper 2 into the duct 3, and the ventilation tunnels 3a, 3b, 3c are
The foamed phenolic resin compound is scattered on the foamed phenolic resin compound. The glass fiber surf ace mats 5a, 5b, 5c unwound from the roll are placed in the ventilation tunnel 3.
The foamed phenol resin compound is moved horizontally at a constant speed so as to traverse the interiors of the surface mats 5a, 3b, and 3c, and the foamed phenol resin compound is allowed to adhere (screening adhesion) to the surfaces of the surf ace mats 5a, 5b, and 5c by gravity. At this time, Surf Ace Mats 5a, 5
The amount of the compound deposited can be adjusted by controlling the roughness of the holes b and 5c, the particle size of the compound, the wind pressure, and the air volume. Surf Ace Mats 5a, 5 with the compound attached in this way
In b and 5c, after passing through a guide roller and stacking three layers, in order to prevent the compound from falling, the compound is passed through a drying hot air oven 7 which is controlled to be above the melting temperature (flow point) of the compound and below the curing start temperature. be sure to fuse.
The thus obtained phenolic resin-coated glass fiber surf mat 8 is cut into appropriate dimensions and then hot-press molded using a press apparatus as shown in FIG. This press mold is a concave-convex mold heated to a temperature of 150 to 250°C, which is sufficient to harden the phenolic resin.
As shown in the cross-sectional view of the mold, a weir 9 is formed on the mold surface at the outer edge of the product to prevent leakage of the resin during hot pressing and to allow gas to be vented from a slight gap between the weirs. FIG. 4 is a sectional view of a core material for an automobile interior formed in this manner, in which glass fiber sheets 5a, 5b, and 5c are integrated and embedded in three layers in a thermosetting resin foam. Further, in this case, the foam penetrates into the spaces between the fibers of the glass fiber sheet and is firmly integrated. And since the glass fiber sheet is not exposed on the surface, there is no prickly feel that is typical of glass fiber. This core material for automobile interior is further coated with vinyl chloride, cloth, etc.
is pasted using adhesive or hot melt film and finished as an interior material as shown in Figure 5.

The core material for automobile interior manufactured in this manner has a particularly significant improvement in tensile strength by embedding the glass fiber sheet in a layered manner between thermosetting resin foams. In addition, it is extremely lightweight, has appropriate elasticity, and has excellent water resistance, meeting various conditions necessary for use as a core material for automobile interiors.

[Effects of the Invention] As described above, the method for producing a core material for automobile interior according to the present invention spreads the powdered foamed phenol resin compound onto the glass fiber sheet by gravity, so no tension is applied to the glass fiber sheet. Can be applied uniformly. Therefore, by controlling the amount of spraying, it is possible to manufacture core materials for automobile interiors with a multilayer structure that has a thickness depending on the intended use. Then, after spraying the foamed phenol resin compound and passing the glass fiber sheet stacked in multiple layers through a dry hot air oven, the foamed phenol resin compound was fused to the glass fiber sheet to prevent it from falling.
This is cut into appropriate dimensions and molded into the desired shape by infiltrating the foam between the fibers using hot pressure molding using a concave-convex mold, making it suitable for mass production, excellent in mechanical strength, and lightweight for automobile interiors. It has the beneficial effect that the material is easy to manufacture.

[Brief explanation of drawings]

FIG. 1 is a longitudinal cross-sectional view showing an example of an apparatus for manufacturing a core material for automobile interior according to the present invention, FIG. 2 is a schematic diagram of a press apparatus, and FIG. 3 is a cross-sectional view of a part of the uneven mold. FIG. 4 is a sectional view of a core material for an automobile interior according to the present invention, and FIG. 5 is a partially broken perspective view of the automobile interior material. 2... Raw material hopper, 2'... Foamed phenol resin compound, 5a, 5b, 5c... Glass fiber sheet (glass fiber surf mat),
7...Dry hot air oven.

Claims (1)

[Claims] 1. After adhering the foamed phenol resin compound to the glass fiber sheet by scattering the powdered foamed phenol resin compound onto a glass fiber sheet that moves horizontally at a constant speed and allowing the foamed phenol resin compound to fall naturally, A plurality of layers of glass fiber sheets were stacked and passed through a drying hot air oven controlled at a temperature above the melting temperature of the foamed phenolic resin compound and below the curing start temperature, and then this layered glass fiber sheet was cut into appropriate dimensions. Then, the foamed phenol resin compound is clamped onto a concave-convex mold heated to a temperature sufficient to harden it, and then hot-press molded into the desired shape, and the foamed phenol resin compound is infiltrated between the fibers of the glass fiber sheet to integrate it. A method for producing a core material for automobile interiors, characterized by: