Laminate, manufacturing method thereof, and foam

Abstract

To improve peeling strength by enhancing adhesiveness between a base material and an inorganic fiber layer laminated and adhered to the base material.SOLUTION: There is provided a laminate 10 which has a base material 11 and inorganic fiber layers 21, 25 laminated and adhered to the base material 11, wherein the base material 11 is a foam formed from a foam raw material in which a hydrophilicity imparting agent is blended. The base material 11 and inorganic fiber layers 21, 25 are adhered with an adhesive. An example of the hydrophilicity imparting agent is a polyethersiloxane, an example of the foam constituting the base material 11 is a polyurethane foam and an example of the inorganic fiber layers 21 and 25 is a glass fiber layer.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a laminate in which a substrate and an inorganic fiber layer are laminated and bonded, a method for producing the same, and a foam. [Background technology]

[0002] Conventionally, laminates in which an inorganic fiber layer is laminated and bonded to a substrate have been used in various products. For example, a ceiling interior material for a vehicle is a ceiling material in which a backing material and a surface material are laminated and bonded to a laminate in which an inorganic fiber layer is laminated and bonded to a substrate (Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-46545 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the laminate is required to have improved adhesion between the substrate and the inorganic fiber layer and improved peel strength. The present invention has been made in view of the above-mentioned points, and an object of the present invention is to provide a laminate in which the adhesion between the substrate and the inorganic fiber layer is enhanced and the peel strength is improved, a method for producing the same, and a foam suitable as the substrate of the laminate. [Means for solving the problem]

[0005] A first aspect of the present invention is a laminate having a substrate and an inorganic fiber layer laminated and bonded to the substrate, wherein the substrate is a foam formed from a foam raw material containing a hydrophilicity-imparting agent, and the substrate and the inorganic fiber layer are bonded together with an adhesive.

[0006] A second aspect of the invention is characterized in that, in the first aspect of the invention, the hydrophilicity-imparting agent is polyether siloxane.

[0007] A third aspect of the invention is characterized in that, in the first or second aspect of the invention, the foam is a polyurethane foam, and the inorganic fiber layer is a glass fiber layer.

[0008] A fourth aspect of the invention is a method for producing a laminate having a substrate and an inorganic fiber layer laminated and bonded to the substrate, wherein the substrate is a foam formed from a foam raw material containing a hydrophilicity-imparting agent, the inorganic fiber layer is impregnated with or coated with an adhesive, the inorganic fiber layer impregnated with or coated with the adhesive is laminated on the substrate to form a pre-molded laminate, and the pre-molded laminate is heat-pressed to cure the adhesive.

[0009] A fifth aspect of the invention is characterized in that, in the fourth aspect of the invention, the hydrophilicity-imparting agent is polyether siloxane.

[0010] A sixth aspect of the invention is characterized in that, in the fourth or fifth aspect of the invention, the foam is a polyurethane foam, and the inorganic fiber layer is a glass fiber layer.

[0011] A seventh aspect of the invention is a foam formed from a foam raw material containing a hydrophilicity-imparting agent. [Effects of the Invention]

[0012] According to the present invention, a laminate having improved adhesion between the substrate and the inorganic fiber layer and improved peel strength can be obtained. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a cross-sectional view of a laminate according to one embodiment of the present invention. [Figure 2] FIG. 2 is a cross-sectional view showing the configuration of a pre-formed laminate before lamination. [Figure 3] FIG. 3 is a cross-sectional view showing the state during hot pressing. [Figure 4] 1 is a table showing the compositions and physical properties of examples and comparative examples. DETAILED DESCRIPTION OF THE INVENTION

[0014] The laminate 10 shown in FIG. 1 is used as a ceiling material for vehicle interiors, and has inorganic fiber layers 21 and 25, a back surface material 31, and a surface material 35 laminated and bonded to both sides of a base material 11.

[0015] The substrate 11 is a foam formed from a foam raw material containing a hydrophilicity-imparting agent.

[0016] The hydrophilicity-imparting agent is not particularly limited as long as it is a component that can impart hydrophilicity to a foam. A non-reactive hydrophilicity-imparting agent is preferred. An example of a non-reactive hydrophilicity-imparting agent is a non-reactive silicone. The non-reactive silicone may be any silicone that does not have a reactive group, and may be a modified non-reactive silicone such as a polyether-modified, aralkyl-modified, or long-chain alkyl-modified silicone. The non-reactive silicone used as a hydrophilicity-imparting agent has a viscosity at 20°C (JIS K 7117-2:1999 / ISO 3219:1993) of 200 mPa·s or less, preferably 100 mPa·s or less, more preferably 50 mPa·s or less, particularly preferably 25 mPa·s or less, and most preferably 5 to 25 mPa·s. For example, polyether siloxane (viscosity at 20°C: 10 to 200 mPa·s) may be mentioned. As will be described later, the silicone foam stabilizer contained in polyurethane foam raw materials generally has a viscosity at 20°C (JIS K 7117-2:1999 / ISO 3219:1993) of 300 to 850 mPa s, and the non-reactive silicone used as a hydrophilicity-imparting agent has a lower viscosity than the silicone foam stabilizer.

[0017] By imparting hydrophilicity to the foam constituting the substrate 11, the adhesiveness between the substrate 11 and the inorganic fiber layers 21 and 25 can be increased, and the peel strength can be improved.

[0018] Examples of foams include polyurethane foam, polyethylene foam, polypropylene foam, vinyl chloride foam, polystyrene foam, etc. In particular, polyurethane foam is preferred from the viewpoints of heat insulation, sound absorption, and impact absorption. The polyurethane foam may be either a semi-rigid polyurethane foam or a flexible polyurethane foam. The polyurethane foam can be shaped by hot pressing at about 70 to 220°C, and is suitable as the substrate 11 of the laminate 10 used in a ceiling material as an interior material for a vehicle. Hereinafter, a case where the foam constituting the base material 11 is polyurethane foam will be described.

[0019] The polyurethane foam is formed from polyurethane foam raw materials. The polyurethane foam raw material containing the hydrophilicity-imparting agent contains a polyol, a catalyst, a blowing agent, other auxiliaries, and a polyisocyanate, and further contains the hydrophilicity-imparting agent.

[0020] Polyol is a general term for compounds that have two or more hydroxyl groups in one molecule, and is produced by addition polymerization of alcohols (polyhydric alcohols) with two or more functional groups, or by using these as initiators with ethylene oxide or propylene oxide. As the polyol, polyols for polyurethane foams can be used, such as polyether polyols, polyester polyols, polyether ester polyols, etc., and one or more of these may be used.

[0021] Examples of polyether polyols include polyether polyols obtained by adding alkylene oxides such as ethylene oxide (EO) and propylene oxide (PO) to polyhydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, and sucrose.

[0022] Examples of polyester polyols include polyester polyols obtained by polycondensation of an aliphatic carboxylic acid such as malonic acid, succinic acid, or adipic acid, or an aromatic carboxylic acid such as phthalic acid, and an aliphatic glycol such as ethylene glycol, diethylene glycol, or propylene glycol. Examples of polyetherester polyols include those obtained by reacting polyether polyol with a polybasic acid to form a polyester, and those having both polyether and polyester segments in one molecule.

[0023] As for the polyol, it is preferable to use one or more polyols having a hydroxyl value (OHV) of 10 to 700 mgKOH / g, a functionality of 2 to 4, and a molecular weight of 200 to 10,000 (more preferably 200 to 7,000).

[0024] The catalyst may be any known catalyst for polyurethane foam, such as amine catalysts such as triethylamine, triethylenediamine, diethanolamine, dimethylaminomorpholine, N-ethylmorpholine, and tetramethylguanidine, tin catalysts such as stannous octoate and dibutyltin dilaurate, and metal catalysts (also called organometallic catalysts) such as phenylmercury propionate and lead octenate.

[0025] The foaming agent is preferably water, and the amount of the foaming agent (water) is preferably 3 to 9 parts by weight based on 100 parts by weight of the polyol.

[0026] Other auxiliary agents include a crosslinking agent, a foam stabilizer, a flame retardant, and the like. Examples of the crosslinking agent include ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1-4 butanediol, and 1,6-hexanediol.

[0027] The foam stabilizer may be any known foam stabilizer for polyurethane foam. Examples include silicone-based foam stabilizers, fluorine-based foam stabilizers, and known surfactants. Silicone-based foam stabilizers with a viscosity at 20°C (JIS K 7117-2:1999 / ISO 3219:1993) of 300 to 850 mPa·s or higher are commonly used.

[0028] Examples of the flame retardant include halogenated polymers such as polyvinyl chloride, chloroprene rubber, and chlorinated polyethylene; organic flame retardants such as phosphate esters, halogenated phosphate ester compounds, melamine resins, and urea resins; and inorganic flame retardants such as antimony oxide and aluminum hydroxide.

[0029] The polyisocyanate may be an aliphatic or aromatic polyisocyanate having two or more isocyanate groups, a mixture thereof, or a modified polyisocyanate obtained by modifying the same. Examples of aliphatic polyisocyanates include hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethane diisocyanate. Examples of aromatic polyisocyanates include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xylylene diisocyanate, and polymeric MDI (crude MDI). Other prepolymers may also be used.

[0030] The isocyanate index (INDEX) is preferably 75 to 140. The isocyanate index is calculated by [(isocyanate equivalent in polyurethane foam raw material / active hydrogen equivalent in polyurethane foam raw material)×100].

[0031] The amount of the hydrophilicity-imparting agent in the polyurethane foam raw material is 0.1 to 15 parts by weight, preferably 1.0 to 12 parts by weight, and more preferably 3.0 to 12 parts by weight, per 100 parts by weight of the polyol.

[0032] The polyurethane foam can be produced by stirring and mixing polyurethane foam raw materials to cause foaming. The density of polyurethane foam (JIS K7222:2005 / ISO 845:1988) is 15 to 50 kg / m 3 is preferable, and 20 to 40 kg / m 3 More preferably, it is 20 to 35 kg / m 3 is preferred.

[0033] The inorganic fiber layers 21, 25 are intended to increase the rigidity of the laminate 10, and examples of such layers include carbon fiber, glass fiber, rock wool, and metal fiber. Glass fiber is particularly preferable because it is inexpensive and has high rigidity. When the inorganic fiber layers 21, 25 are glass fiber layers, a layer formed by depositing chopped glass fiber (cut glass roving), or a glass fiber mat, glass fiber cloth, or the like can be used.

[0034] The back surface material 31 is a member that protects the back surface of the laminate 10 and improves the slipperiness of the back surface when working on the laminate 10, and is made of a nonwoven fabric, a plastic sheet, or the like as appropriate. The surface material 35 is a component intended to improve the decorativeness of the laminate 10, and may be made of nonwoven fabric such as polyester nonwoven fabric, woven fabric (knitted surface fabric), fabric such as polyester fiber, or plastic sheet such as TPO (polyolefin thermoplastic elastomer) or PVC (polyvinyl chloride), as appropriate.

[0035] The base material 11, the inorganic fiber layers 21, 25, the back surface material 31, and the front surface material 35 are bonded together by an adhesive (binder) impregnated into or applied to the inorganic fiber layers 21, 25. As the adhesive, a liquid polyisocyanate is suitable, as it is inexpensive and provides good adhesion to the foam substrate.

[0036] The liquid polyisocyanate used as an adhesive is a moisture-curing type, that is, it undergoes reactive curing by reacting with water (or moisture in the air) in the presence of heat and a catalyst, and functions as an adhesive upon curing.

[0037] Examples of liquid polyisocyanates include aromatic TDI (toluene diisocyanate), polymeric MDI (4,4'-diphenylmethane diisocyanate), NDI (1,5-naphthalene diisocyanate), TODI (tolidine diisocyanate), PPDI (paraphenylene diisocyanate), XDI (xylylene diisocyanate), TMXDI (tetramethylxylene diisocyanate), and modified products thereof. Preferably, polymeric MDI, modified TDI and modified MDI that have been variously modified, such as urethane-modified, allophanate-modified, biuret-modified, or carboimide / uretonimine-modified, or mixtures thereof are suitable.

[0038] The manufacturing of the laminate 10 will be described with reference to Fig. 2. A substrate 11 made of a foam formed from a foam raw material containing a hydrophilicity-imparting agent, inorganic fiber layers 21 and 25, a back surface material 31, and a front surface material 35 are prepared. The thickness of the substrate 11 is determined appropriately depending on the intended use of the laminate 10, and is, for example, 3 to 10 mm. The basis weight of the inorganic fiber layers 21, 25 is determined depending on the application of the laminate 10 and the material of the inorganic fiber layers 21, 25, etc., but when the inorganic fiber layers 21, 25 are made of glass fiber, it is, for example, 60 to 150 kg / m 2 Some examples include:

[0039] Adhesives 27 and 29 are impregnated into or applied to the inorganic fiber layers 21 and 25, and reaction accelerators 13 and 15 for the adhesives 27 and 29 are applied to the substrate 11 as needed. The inorganic fiber layers 21 and 25 are then laminated on both sides of the substrate 11 to form a pre-molded laminate 10A shown in FIG. 3. The adhesives 27 and 29 may be impregnated into or applied to both the inorganic fiber layers 21 and 25 and the substrate 11 .

[0040] The inorganic fiber layers 21, 25 can be impregnated with the adhesives 27, 29 by, for example, immersing the inorganic fiber layers 21, 25 in an adhesive tank containing the liquid adhesives 27, 29, or by spraying the adhesives 27, 29 onto the inorganic fiber layers 21, 25. The adhesives 27, 29 can be applied to the surfaces of the inorganic fiber layers 21, 25 using a brush or spray, or by using an application device such as a roll coater. The amount of the adhesives 27, 29 to be impregnated or applied varies depending on the thickness and basis weight of the inorganic fiber layer 21, but is, for example, 10 to 40 g / m 2 Some examples include:

[0041] The reaction accelerators 13 and 15 come into contact with the adhesives 27 and 29 to accelerate the reaction of the adhesives. When the adhesives 27 and 29 are liquid polyisocyanates, an aqueous solution of an amine catalyst is used. The reaction accelerators 13 and 15 are applied to both sides of the substrate 11 by spraying or the like. The application amount of the reaction accelerators 13 and 15 is determined appropriately, for example, 20 to 70 g / m 2 Some examples include:

[0042] The pre-molded laminate 10A is hot-pressed with press dies 41 and 45, and the substrate 11, inorganic fiber layers 21 and 25, back surface material 31, and front surface material 35 are bonded and integrated with adhesives 27 and 29 to form the laminate 10. During the hot-pressing, the pre-molded laminate 10A is compressed, causing the adhesives 27 and 29 to seep out to the lamination surfaces (interfaces) between the inorganic fiber layers 21 and 25 and the substrate 13, and the lamination surfaces (interfaces) between the inorganic fiber layers 21 and 25, the back surface material 31, and the front surface material 35, and react and harden to bond them together.

[0043] The hot pressing method may be either a cold pressing method or a hot pressing method. The cold press method is a method in which the pre-molded laminate 10 is heated to a predetermined temperature and then pressed with a press mold at room temperature. The hot pressing method is a method in which the pre-molded laminate 10 at room temperature is pressed with a press mold heated to a predetermined temperature. The heating temperature is a temperature that allows the adhesive to react and harden, and is, for example, 70 to 220°C.

[0044] The shape of the mold surfaces of the press molds 41 and 45 is not limited to a flat surface, but is preferably a shape according to the use of the laminate 10, such as an uneven shape or a curved shape.

[0045] Alternatively, the laminate 10 may be produced by continuous molding. For example, the laminate 10 may be continuously formed by continuously supplying the substrate 11 and the inorganic fiber layers 21, 25, applying the reaction accelerators 13, 15 to the substrate 11 during the supplying process, impregnating or applying the adhesives 27, 29 to the inorganic fiber layers 21, 25, laminating the inorganic fiber layers 21, 25 on both sides of the substrate 11, laminating the back surface material 31 and the front surface material 35 on the inorganic fiber layers 21, 25, and then hot-pressing the resulting structure to react and cure the adhesives 27, 29. [Example]

[0046] The polyurethane foam raw materials were prepared using the following raw materials according to the formulations of the examples and comparative examples shown in Figure 4. The polyurethane foam raw materials were mixed and foamed in a 270 mm square box with the top open without a lid, forming a polyurethane foam. The top, bottom, and sides were cut, and the core was trimmed to a size of 250 mm x 250 mm x 8 mm thick to form substrate 11.

[0047] Polyether polyol 1: molecular weight 2000, number of functional groups 2, product number: D2000, manufactured by Mitsui Chemicals, Inc. Polyether polyol 2: molecular weight 400, functionality 3, product number: GP400, manufactured by Sanyo Chemical Industries, Ltd. Resinification catalyst: Amine catalyst, product number: DABCO 33LSI, manufactured by Evonik Japan Co., Ltd. Foaming catalyst: Amine catalyst, product number: DABCO BL-11, manufactured by Evonik Japan Co., Ltd. Crosslinking agent: Glycerin Foam stabilizer: Silicone foam stabilizer, product number: SRX280A (viscosity at 20°C 650 mPa·s), manufactured by Dow Corning Toray Co., Ltd. Foaming agent: Water Hydrophilic agent: Polyether siloxane (viscosity at 20°C: 10-25 mPa·s), product number: HPH2, manufactured by Evonik Japan Co., Ltd. Polyisocyanate: Polymeric MDI, NCO%: 31.5%, viscosity: 55 mPa·s

[0048] The ratio of the hydrophilicity-imparting agent in the polyurethane foam in FIG. 4 is the ratio of the weight of the hydrophilicity-imparting agent to the total weight of the polyurethane foam raw materials including the polyisocyanate.

[0049] A reaction accelerator was sprayed onto both sides of the substrate, and inorganic fiber layers coated with adhesive were laminated onto both sides of the substrate 11. A backing material was then laminated onto one of the inorganic fiber layers, and a surface material was laminated onto the other inorganic fiber layer to form a pre-molded laminate.

[0050] The reaction accelerator was a 4% amine catalyst solution, sprayed onto both sides of the substrate. The amount of coating was 32 g / m on each side. 2 It was. The inorganic fiber layer is glass mat, with a basis weight of 80 g / m 2 The glass was manufactured by Nippon Electric Glass Co., Ltd., product number: GM80-1430. The adhesive used was polymeric MDI, NCO%; 31.5%, viscosity 200 mPa·s, and the amount of adhesive applied was 16 g / m on each of the surfaces of the inorganic fiber layers 21 and 25 facing the substrate 11. 2 It was spray coated with. The backing material is a nonwoven fabric made of polyethylene terephthalate fiber and polypropylene fiber, with a basis weight of 45 g / m 2 The product used was a product manufactured by Kirax, product number: BCP1220-1500. The surface material is a needle-punched nonwoven fabric made of polyethylene terephthalate fiber, with a basis weight of 160 g / m 2 The product used was a Dynic product, product number: 2RG145YR416L.

[0051] The pre-molding laminate was sandwiched between press dies and hot-pressed. The press dies had flat surfaces, and were heated to 110°C and compressed at a pressure of 5 MPa for 30 seconds. During this process, the pre-lamination laminate was reduced from its pre-heat-press thickness of 10.5 mm to 9.5 mm (compression amount: 1 mm).

[0052] Among Comparative Examples 1 to 7, which used polyurethane foam formed from polyurethane foam raw materials that did not contain a hydrophilicity-imparting agent as a base material, in Comparative Example 2, an adhesive was applied to both sides of the inorganic fiber layer and the base material, in Comparative Example 3, a hydrophilicity-imparting agent was post-applied to the polyurethane foam (base material), in Comparative Example 4, 10 wt % of the hydrophilicity-imparting agent was added to the adhesive, and in Comparative Example 5, 10 wt % of the hydrophilicity-imparting agent was added to the reactivity accelerator.

[0053] For each example and comparative example, the density and cell diameter of the polyurethane foam substrate and the peel strength of the laminate were measured. The measurement results are shown in FIG. The density of the substrate was calculated by measuring the weight and exact dimensions of a test sample cut into 100 mm x 50 mm x 10 mm thick from the substrate. The cell diameter was measured at 10 random locations on the surface of the substrate using a microscope at 50x magnification, and the average value was calculated. The peel strength was measured by peeling 80 mm of the inorganic fiber layer and surface material from the substrate using a test sample cut to a planar size of 150 x 25 mm. The substrate side and inorganic fiber layer side (inorganic fiber layer + surface material) were attached to a tensile tester and peeled at a speed of 200 mm / min. The average load was recorded as the peel strength. The tensile tester used was an Autograph AG-IS 1KN manufactured by Shimadzu Corporation. Regarding the peel strength, the peel strength of Comparative Example 1, in which no hydrophilicity-imparting agent was blended into the polyurethane foam raw material, was set to 100%, and the ratio of the peel strength of each Example and Comparative Example to the peel strength of Comparative Example 1 was calculated to obtain the "peel strength change rate."

[0054] Examples 1 to 4 are examples in which the amount of hydrophilicity-imparting agent blended in the polyurethane foam raw material was changed within the range of 1 to 12 parts by weight per 100 parts by weight of polyol (polyether polyol 1+polyether polyol 2). In Examples 1 to 4, the peel strength was 1.16 to 1.42 N, and the change rate of the peel strength relative to Comparative Example 1 was 103 to 126%, which means that the peel strength was greater than that of Comparative Example 1 in which no hydrophilicity-imparting agent was blended into the polyurethane foam raw material.

[0055] Comparative Example 1 is an example formed in the same manner as in Examples 1 to 4 using a polyurethane foam raw material with the same composition as in Examples 1 to 4, except that no hydrophilicity-imparting agent was added to the polyurethane foam raw material. The peel strength of Comparative Example 1 was 1.13 N, which was also low compared to the peel strengths of Examples 1 to 4, 1.16 to 1.42 N, and thus the peel strength was low.

[0056] Comparative Example 2 is an example in which an adhesive was applied to both sides of the inorganic fiber layer and the substrate without blending a hydrophilicity-imparting agent into the polyurethane foam raw material, as in Comparative Example 1. The peel strength of Comparative Example 2 was 1.74 N, and the rate of change in peel strength increased to 154% compared to Comparative Example 1 in which the adhesive was applied only to the inorganic fiber layer.

[0057] In Comparative Example 3, no hydrophilic agent was blended into the polyurethane foam raw material, and a hydrophilic agent was applied to both surfaces of the polyurethane foam (substrate), and then a reaction accelerator was applied to both surfaces of the substrate by spraying. The hydrophilic agent was directly applied by spraying, and the amount applied was 16 g / m on one side of the substrate. 2 32g / m on each side 2 The peel strength of Comparative Example 3 was 0.15 N, and the rate of change in peel strength was reduced to 13% compared to Comparative Example 1, which was a large reduction in peel strength.

[0058] In Comparative Example 4, no hydrophilicity-imparting agent was blended into the polyurethane foam raw material, but 10 wt % of the hydrophilicity-imparting agent was added to the adhesive and then applied. The amount of the hydrophilicity-imparting agent applied was calculated to be 1.6 g / m on each of the inorganic fiber layers 21 and 25 on the substrate 11 side.2 , total 3.2g / m 2 The peel strength of Comparative Example 4 was 0.93 N, and the rate of change in peel strength compared to Comparative Example 1 was reduced to 82%.

[0059] Comparative Example 5 is an example in which no hydrophilicity-imparting agent was blended into the polyurethane foam raw material, but 10 wt % of the hydrophilicity-imparting agent was added to the reaction accelerator and then applied. The amount of the hydrophilicity-imparting agent applied was calculated to be 3.2 g / m on one side of the substrate. 2 , 6.4g / m on both sides 2 The peel strength of Comparative Example 5 was 0.35 N, and the rate of change in peel strength compared to Comparative Example 1 was reduced to 31%.

[0060] In Comparative Example 6, neither a hydrophilic agent nor a silicone-based foam stabilizer was blended into the polyurethane foam raw material. The polyurethane foam had coarse cells. The peel strength of Comparative Example 6 was 0.94 N, a decrease of 83% in the peel strength change rate compared to Comparative Example 1.

[0061] In Comparative Example 7, no hydrophilicity-imparting agent was added to the polyurethane foam raw material, and the amount of silicone foam stabilizer was increased to 4 parts by weight, double the amount of 2 parts by weight used in Examples 1 to 4 and Comparative Examples 1 to 6. The polyurethane foam had very fine cells. The peel strength of Comparative Example 7 was 1.07 N, which was almost the same as that of Comparative Example 6, which contained 0 parts by weight of foam stabilizer, and the change in peel strength compared to Comparative Example 1 was 95%. As shown by the results of Comparative Examples 6 and 7, the silicone-based foam stabilizer is not a substitute for the hydrophilicity-imparting agent, and even if the amount of silicone-based foam stabilizer added is increased, the resulting peel strength is lower than that of Examples 1 to 4, in which the hydrophilicity-imparting agent was added to the polyurethane foam raw material.

[0062] Thus, according to the present invention, a laminate having improved adhesion between the substrate and the inorganic fiber layer and improved peel strength can be obtained. The present invention is not limited to the examples, and can be modified within the scope of the invention. [Explanation of symbols]

[0063] 10 Laminate 11 Base material 21, 25 Inorganic fiber layer 31 Backing material 35 Surface material

Claims

1. A laminate having a substrate and an inorganic fiber layer laminated and bonded to the substrate, the substrate is a polyurethane foam formed from a polyurethane foam raw material blended with a hydrophilicity-imparting agent that is a non-reactive silicone having a viscosity at 20°C of 100 mPa·s or less, A laminate, wherein the substrate and the inorganic fiber layer are bonded together with an adhesive that is a liquid polyisocyanate.

2. 2. The laminate according to claim 1, wherein the hydrophilicity-imparting agent is polyether siloxane.

3. 3. The laminate according to claim 1, wherein the inorganic fiber layer is a glass fiber layer.

4. A method for producing a laminate having a substrate and an inorganic fiber layer laminated and bonded to the substrate, comprising: the substrate is a polyurethane foam formed from a polyurethane foam raw material blended with a hydrophilicity-imparting agent that is a non-reactive silicone having a viscosity at 20°C of 100 mPa·s or less, The inorganic fiber layer is impregnated with or coated with an adhesive that is a liquid polyisocyanate, The inorganic fiber layer impregnated with or coated with the adhesive is laminated on the substrate to form a pre-molded laminate; A method for producing a laminate, comprising: heat-pressing the pre-molded laminate to cure the adhesive.

5. 5. The method for producing a laminate according to claim 4, wherein the hydrophilicity-imparting agent is polyether siloxane.

6. 6. The method for producing a laminate according to claim 4, wherein the inorganic fiber layer is a glass fiber layer.

Images