JPS638040A - Manufacturing method of ceiling formed with glass fiber - Google Patents

Abstract

PURPOSE:To prevent an offensive smell from being given by heating both a glass fiber mat employing thermoplastic resin as binder and a skin material, on which hot melt adhesive is temporarily laminated so as to be integrally formed by press thereafter. CONSTITUTION:A glass fiber mat 1 as a core material is made by entangling polyproplane fibers as binder by means of needle punching. On the other hand, a skin member 6 is made by laminating knitted fabrics 7 and polyurethane foam 8 whereby hot melt adhesive 9 is laminated on the surface of said polyurethane foam 8 temporarily. Then a glass fiber mat 1 and the skin material 6 are heated for melting the adhesive 9, after then, the mat 1 and the skin material 6 are bonded simultaneously in forming integrally. This constitution can prevent an offensive smell due to the heating of binder from being given.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method of manufacturing a molded glass fiber ceiling for use in a vehicle.

[Prior art]

Traditionally, glass fiber ceilings for automobiles and other vehicles have been made by hot press molding a glass fiber mat with phenolic resin as a binder to create a core material, and then forming it with knit fabric/polyurethane foam, PvC/polyurethane foam, etc. It was manufactured by bonding the skin material together by press molding using a hot melt adhesive.

[Problem that the invention seeks to solve]

However, in the conventional manufacturing method for glass fiber molded ceilings, a glass fiber mat using phenolic resin as a binder is hot press-molded at high temperatures, which poses a problem in that unreacted formaldehyde generates an odor. Further, there was a problem in that it was impossible to adhesively mold the skin material at the same time as the core material molding because the core material molding temperature was as high as 200''C, exceeding the limit temperature of the skin material.

An object of the present invention is to provide a method for manufacturing a glass fiber molded ceiling, which allows a glass fiber mat and a skin material to be integrally molded at the same time without deteriorating the working environment.

[Means for solving problems]

The present invention involves heating a glass fiber mat formed using a fibrous or powdery thermoplastic resin as a binder and a skin material formed from a polyurethane foam laminated on one side with a hot melt adhesive. Glass fiber molded ceilings are manufactured by integral press molding using hot melt adhesive.

[Effect]

According to this method, after heating the glass fiber mat and the skin material to melt the hot melt adhesive,
The mat and skin material can be adhesively molded together at the same time using a mold. Furthermore, since a thermoplastic resin is used as the binder for the glass fiber mat, no odor is emitted even when heated.

〔Example〕

1 to 4 are longitudinal sectional views showing an embodiment of the method for manufacturing a glass fiber molded ceiling according to the present invention. As shown in Fig. 2, the glass fiber mat 1 serving as the core material is a glass fiber mat 2k with a basis weight of about 800 g/rrl'.
It is made by needle patching and intertwining polypropylene fibers 3 with a basis weight of about 300 g/m. Then, as shown in FIG. 3, this glass fiber mat 1 is held by a clamp 4 and heated by a far-infrared heater 5 at a temperature of about 200° C. for about 30 seconds. On the other hand, the skin material 6 is made by laminating a knit fabric 7 and a polyurethane foam 8, as shown in FIG. . Then, the skin material 6 is heated to the activation temperature of the hot melt adhesive 9, approximately 115° C., in the same manner as the heating method of the glass fiber mat 1 shown in FIG. Next, as shown in FIG. 1, the heated glass fiber mat 1 and the skin material 6 are overlapped and simultaneously molded into one piece using the upper mold 1o and lower mold 11 of a press mold for about 30 seconds at a mold temperature of 50°C. , the fiberglass molded ceiling is completed. That is, by heating the glass fiber mat 1 and the skin material 6 temporarily laminated with hot melt adhesive in advance, they can be integrally molded into one mold at the same time via the melted hot melt adhesive. .

In this example, the case where fibrous polypropylene was used as the binder of the glass fiber mat 1 was explained.
This binder may be in powder form, and the material may be another thermoplastic resin such as polyethylene. Furthermore, the hot melt adhesive is not limited to nylon adhesives, and other hot melt adhesives such as polyester adhesives may be used. Needless to say, in these cases, heating conditions are selected that suit each case.

Furthermore, the heating means is not limited to the far-infrared heater, and may be other heating means.

〔Effect of the invention〕

According to the present invention, a thermoplastic resin is used as a binder for the glass fiber mat, and a hot melt adhesive is heated in advance together with the temporarily laminated skin material, and the glass fiber mat and the skin material are bonded to each other through the melted hot melt adhesive. Since the materials are bonded and molded together by press processing,
It is possible to prevent the generation of odor due to heating of the binder, and the working environment will not be deteriorated. In addition, the conventional type 2
The ceiling, which was previously manufactured by multiple processes, can be press-molded at the same time using one mold, streamlining the process.

[Brief explanation of the drawing]

Fig. 1 is a longitudinal cross-sectional view showing a press working method according to an embodiment of the manufacturing method of a glass fiber molded ceiling according to the present invention, Fig. 2 is a longitudinal cross-sectional view showing a glass fiber mat, and Fig. 3 is a heating method. FIG. 4 is a vertical cross-sectional view showing the skin material. 1...Glass fiber mat, 3...Polypropylene fiber, 6...Skin material, 8...Polyurethane foam,
9...Hot melt adhesive.

Claims (3)

[Claims] (1) After heating a glass fiber mat made of a fibrous or powdered thermoplastic resin as a binder and a skin material made of polyurethane foam laminated on one side with a hot melt adhesive, A method for manufacturing a glass fiber molded ceiling, characterized by integral press molding using a melt adhesive. (2) The method for manufacturing a glass fiber molded ceiling according to claim 1, wherein the thermoplastic resin is polypropylene. (3) The method for manufacturing a glass fiber molded ceiling according to claim 1, wherein the thermoplastic resin is polyethylene.