Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Composite having voids in a component
Patent
1993-12-22
1995-12-12
Clark, W. Robinson
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Composite having voids in a component
4283186, 4283188, 264 50, 264 51, B32B 518, B32B 520
Patent
active
054748410
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to a polypropylene resin cellular molded article having a skin, and a production method therefor. More particularly, it relates to a polypropylene resin cellular molded article having an outer skin suitable for use, for example, as an automobile interior trim material or the like, and a production method therefor.
BACKGROUND OF THE INVENTION
Resin cellular molded articles having a skin are used, for example, as materials for automobile interiors or the like. More specifically, examples of automobile interior trim material uses are door material, instrument panel, sun visor, ceiling material, door trim, rear package, knee bolster, air bag door, head rest, arm rest, various pillars, quarter trim, front side trim, front seat back, crash pad, console box, console head, luggage floor cover, partition board, center console, console box cover, and so forth.
Previously, articles such as are formed by pressure molding, in a heat-softened state in a mold, of laminates made by sequentially superimposing an imitation leather sheet such as polyvinyl chloride, a foam sheet such as polypropylene foam and a core material such as ABS resin and binding these together into one unit with adhesive, are known as automobile interior trim materials (Japanese Unexamined Patent Publication (Tokkyo Kokai) No. 54-158471). However, said automobile interior trim material having a foam sheet feels hard to the touch when pressed, and further disadvantages are that the cushioning property is inferior and there is no feeling of depth.
As a means to solve the disadvantages of said automobile interior trim material, a united laminate made by the sequential stacking of an artificial leather sheet made of polyvinyl chloride, a foam sheet such as polypropylene foam, a layer of expanded polyurethane and a core material such as ABS resin is known. As a result of having the intermediate layer of expanded polyurethane, said laminate has both an undoubtedly soft touch given to it when pressed, and an improved cushioning property compared to said automobile interior trim material. However, it is heavier compared to this automobile interior trim material, and moreover, at high temperature a foul odor is emitted due to the polyvinyl chloride, and a further disadvantage is that a harmful gas is produced during burning.
Furthermore, in recent years in the automobile industry, in order to improve the automobile fuel consumption, there has been a great demand for the lightening of automobile constructing parts, and in line with this, still further lightening is being sought. Furthermore, from the viewpoint of the reclamation of resources, the development of an easily recyclable automobile interior trim material is long-awaited. Accordingly, in consideration of said prior art, the present inventors carried out accumulated extensive studies in order to develop an automobile interior trim material which is able to simultaneously satisfy the following numerous demands: (1) a soft and supple feel is given when pressed, (2) the cushioning property is superior, (3) there is a feeling of depth, (4) a foul odor is not produced at high temperature, (5) the amount of noxious gas produced during burning is small, (6) lightening can be promoted, and (7) recycling is easy.
Conversely, a cellular molded article of a polypropylene resin on which is provided a skin material, such as an automobile interior trim material, is produced by a method in which a cellular molded article is fabricated in advance, adhesive, for example, is applied to this and then the skin material is stuck on. However, a disadvantage is that when using this method, since three steps are needed consisting of the fabrication of a molded foam, the application of adhesive and the sticking of the skin material to the molded foam, the manufacturing process is troublesome and the production efficiency is poor.
As a method for solving the disadvantages in the above-mentioned process, a method for manufacturing a unified cellular molded article is known (Japa
REFERENCES:
patent: 5196151 (1993-03-01), Sakaida et al.
Ibata Izumi
Matsuki Kiyoshi
Clark W. Robinson
Kanegafuchi Kagaku Kogyo & Kabushiki Kaisha
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