JPH0667575B2 - Interior material manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention mainly relates to a method for manufacturing an interior material such as a ceiling material, a door trim and a rear parcel of an automobile.

[Conventional technology]

Conventionally, as a method for producing an interior material of this type, a polyvalent isocyanate compound is impregnated in a porous body, and the polyvalent isocyanate is polymerized and reticulated by spraying steam or water to the porous body. A method for forming a body into a predetermined shape is provided (for example, Japanese Patent Laid-Open No. 58-5346).
issue).

[Problems to be Solved by the Invention]

However, in the above-mentioned conventional method, the curing reaction of the polyvalent isocyanate compound is started from the point of time when water vapor or water is sprayed on the porous body impregnated with the polyvalent isocyanate compound. There has been a problem that the quality of the polyvalent isocyanate compound varies greatly depending on the time from the contact with water until the molding, and the quality is not constant.

[Means for solving problems]

The present invention, as a means for solving the above conventional problems,
Production of an interior material in which a block polyvalent isocyanate compound that regenerates at a temperature of 160 ° C. or less is impregnated into a porous body, and the porous body is molded into a predetermined shape at a temperature equal to or higher than the regeneration temperature of the block polyvalent isocyanate compound It provides a method.

Examples of the porous material used in the present invention include a soft polyurethane foam sheet, a foam sheet having open cells of a soft plastic such as a soft polyvinyl chloride foam sheet, a non-woven fabric, and a fiber entangled sheet such as felt. It is illustrated.

As the polyvalent isocyanate compound used in the present invention,
2,4 or 2,6-toluene diisocyanate, hexamethylene diisocyanate, polyvalent isocyanate monomer such as 4,4′-diphenylmethane diisocyanate, or ethylene glycol or glycerin of the monomer Examples thereof include adducts with polyhydric alcohols, or prepolymers having two or more free isocyanate groups at the ends obtained by reacting the monomers with polyalkylene glycols such as polyethylene glycol and polypropylene glycol. Block the polyisocyanate compound. Examples of the blocking agent include malonic acid diethyl ester, acetoacetic acid ester, acetylacetone, hydrocyanic acid, and sodium acid sulfite. The polyvalent isocyanate compound blocked with such a blocking agent is regenerated by heating at a temperature of 160 ° C. or lower. The regeneration temperature of the polyvalent isocyanate compound is 130 to 140 ° C when the blocking agent is malonic acid diethyl ester,
In the case of acetoacetic acid ester, the temperature is 140 ° C, in the case of acetylacetone, 150 ° C, in the case of hydrocyanic acid, 120 ° C, and in the case of sodium acid sulfite, the temperature is 40 to 50 ° C.

The above examples do not limit the present invention.

In order to impregnate the porous material with the block polyvalent isocyanate compound, the block polyvalent isocyanate compound may be in the form of a liquid, or toluene, xylene, ethyl acetate, n-butyl acetate, or acetone. , Dissolved in an organic solvent such as methyl ethyl ketone, methylene dichloride, trichlorethylene, etc.
Alternatively, the block polyvalent isocyanate compound is emulsified in water using a surfactant to form an emulsion.

If desired, the solution or emulsion of the block polyvalent isocyanate compound may be water and / or a compound and / or a synthetic resin having a functional group having an active hydrogen such as a hydroxyl group, a carboxy group or an amino group and capable of reacting with an isocyanate. May be mixed. Examples of the above compound include methanol, ethanol, isopropanol, n-butanol,
Alcohols such as ethylene glycol, propylene glycol, glycerin, organic acids such as formic acid, acetic acid, butyric acid, oxalic acid, citric acid, malonic acid, triethylamine, triethanolamine, diisopropylamine, acetamide,
There are organic amines such as propionamide and acid amides, and the synthetic resin is an acrylic resin having the above functional group, a styrene resin, a vinyl acetate resin, a urea resin,
There are melamine resin, phenol resin, epoxy resin and the like.

Further, the polyvalent isocyanate compound includes cobalt naphthenate, benzyltrimethylammonium hydroxide, stannous chloride, tri-n-butyltin acetate, n-butyltin trichloride, trimethyltin hydroxide, dimethyltin dichloride, dimethyltin. A catalyst such as dilaurate may be added.

The solution or emulsion is sprayed on the porous body, or the porous body is immersed in the solution. After impregnating the above-mentioned block polyvalent isocyanate compound into the above-mentioned porous body, if desired, the impregnation amount is adjusted with a roll squeeze or the like, and then it is carried out at room temperature or heated and dried. The above block polyvalent isocyanate compound is usually added to the above porous body in an amount of 50 to 150% by weight.
Impregnated to a degree.

The porous body impregnated with the block polyvalent isocyanate compound is then heat-molded into a predetermined shape by press molding or the like. The press molding is performed at a temperature above the regeneration temperature of the block polyvalent isocyanate compound, usually 130 to 160 ° C.
It is carried out at a moderate temperature.

A compound and / or a synthetic resin having a functional group capable of reacting with water and / or an isocyanate in a porous material impregnated with the block polyvalent isocyanate compound prior to the molding, or the water, a compound containing a functional group, and synthesis. A solution or emulsion in which the above catalyst is added to the resin may be added by means such as spraying or dipping.

Although the interior material is molded by the method of the present invention as described above, in the present invention, the porous body may be colored in a predetermined manner. Further, before or during molding, or after molding, synthetic resin-impregnated paper or a porous reinforcing layer may be polymerized on both surfaces or one surface of the porous body. The synthetic resin-impregnated paper is paper impregnated with acrylic resin, styrene resin, vinyl acetate resin, vinyl chloride resin, epoxy resin, urethane resin, urea resin, melamine resin, phenol resin, etc., and the porous reinforcing layer Is a coarse non-woven or knitted fabric with a basis weight of about 60 to 200 g / m ² , metal, glass fiber string, organic fiber string,
Examples include a net knitted with a paper string or the like, paper, a non-woven fabric, a porous layer obtained by punching a metal conducting plate, or the like. The above examples do not limit the present invention. The synthetic resin-impregnated paper or the porous reinforcing layer is polymerized into the above-mentioned porous body, and further, a knitting layer of synthetic fibers such as polyester fiber, acrylic fiber, acetate fiber, etc. is the same as the synthetic resin used for the synthetic resin-impregnated paper. A synthetic resin-impregnated knit layer impregnated with another synthetic resin may be polymerized.

The synthetic resin-impregnated paper and the porous reinforcing layer are adhered to the porous body by an adhesive or a heat-sensitive adhesive sheet, but the block impregnated in the porous body without using such an adhesive. It is also possible to use polyvalent isocyanate as an adhesive. Further, the synthetic resin-impregnated knitted layer can also be bonded to the synthetic resin-impregnated paper or the porous reinforcing layer using an adhesive agent or the synthetic resin impregnated in the knitted layer can be used as an adhesive agent, and in particular, the porous reinforcing layer can be used. In the case of a layer, the knitted layer can be directly bonded to the porous body through the porosity of the porous reinforcing layer.

[Action]

When the block polyvalent isocyanate impregnated porous body is heat-molded at a temperature equal to or higher than the regeneration temperature, the bond between the isocyanate group and the blocking agent is dissociated by heating to regenerate the free isocyanate group as described above, and the polyvalent isocyanate is regenerated. When the nato compound is polymerized and networked through the isocyanate group, the polyvalent isocyanate is cured and the porous body is maintained in a predetermined molded shape.

〔The invention's effect〕

Therefore, in the present invention, since the isocyanate group of the block polyvalent isocyanate compound is regenerated and cured during molding, variations in the curing state of the polyvalent isocyanate compound are eliminated, and a product of uniform quality can be obtained.

Further, in the present invention, if the porous body is colored, the porous body itself has a covering property, and it is not necessary to attach a covering material.

Further, when the synthetic resin-impregnated paper is polymerized into a porous body in the present invention, the porous body is reinforced and the molding shape stability and heat resistance are improved.

Further, in the present invention, when the porous reinforcement layer is polymerized into a porous body, the porous body is similarly reinforced, but in the case of the porous reinforcement layer, the stretchability is good and the conformability to the molded shape is large, No cracks or the like are generated even by drawing.

〔Example〕

Embodiment 1 FIGS. 1 and 2 show an embodiment of the apparatus used in the present invention. (1) is a polyether type soft polyurethane foam sheet (density 0.017 g / cm ³ , thickness 5 mm), and the sheet (1) is guided by a guide roll (2) and introduced into a dipping tank (3). The dipping tank (3) was filled with a 40% by weight trichloroethylene solution (9) of 4,4′-diphenylmethane diisocyanate (MDI) blocked with malonic acid diethyl ester, and the dipping tank (3) The sheet (1) in the solution is compressed rolls (4),
The block MDI solution (9) is impregnated twice with (5) and then the block MDI solution (9) is discharged from the dipping tank (3) and the blocked MDI impregnation amount is about 100 g / Adjusted to m ² . The block MDI-impregnated sheet (1) A is then sent to a ventilation dryer (7) at 70 ° C., dried for 5 minutes, and then cut into an appropriate size by a cutter (8).

Shredded the block MDI impregnated sheet (1) A basis weight 70 g / m ² in the upper mold, as subsequently shown in FIG. 2 (10) A and the lower mold (10) heated press mold composed of a B (10) 50g ethylene-vinyl acetate copolymer 50wt% emulsion containing 1wt% stannous chloride in coarse polyester nonwoven fabric
The undried reinforcing tank (1) B impregnated at a ratio of / m ² is polymerized and molded into a predetermined shape under molding conditions of 150 ° C. and 3 kg / cm ² .

In the above-mentioned molding, the block MDI impregnated in the sheet (1) A regenerates an isocyanate group by heating, and is rapidly cured by water and stannous chloride contained in the ethylene-vinyl acetate copolymer emulsion. To do.

In this way, it is possible to obtain an interior material having good molding shape stability, light weight, and excellent soundproofing.

Example 2 Toluene diisocyanate (TDI) 3 blocked with acetylacetone instead of the block MDI of Example 1
The soft polyurethane foam sheet used in Example 1 was impregnated with a trichlorethylene solution containing 0% by weight and a 3: 1 copolymer of methylmethacrylate: dimethylaminoethylmethacrylate 10% by weight in the same manner as in Example 1 to block. create a TDI impregnated sheet, the block TDI impregnated melamine resin solution on both sides of the sheet (50 wt%) and 60 g / m polymerized 160 ° C. the glass fiber nonwoven fabric impregnated (basis weight 80 g / m ²⁾ at a ratio of ² Was molded into a predetermined shape under molding conditions of 3 kg / cm ² .

In the above molding, the block impregnated into the sheet
TDI regenerates the isocyanate group by heating and reacts with the amino group of the copolymer to rapidly cure.

In this way, an interior material similar to that of Example 1 is obtained.

[Brief description of drawings]

1 and 2 show one embodiment of the present invention. FIG. 1 is a process drawing of MDI impregnation and ethylene glycol spraying, and FIG. 2 is a molding process drawing. In the figure, (1) …… Polyether type soft polyurethane foam sheet (9) …… Blocked MDI solution (10) …… Heating and pressing mold

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Claims (4)

[Claims] 1. A porous body is impregnated with a block polyvalent isocyanate compound that is regenerated at a temperature of 160 ° C. or lower, and the porous body is heated to a predetermined shape at a temperature not lower than the regeneration temperature of the block polyvalent isocyanate compound. A method for manufacturing an interior material, which comprises molding. 2. The method for producing an interior material according to claim 1, wherein a synthetic resin-impregnated paper is polymerized on the porous body to form a predetermined shape. 3. The method for producing an interior material according to claim 1, wherein a porous reinforcing layer is polymerized on the porous body to be molded into a predetermined shape. 4. The method for producing an interior material according to claim 1, 2 or 3, wherein the porous body is colored in a predetermined manner.