JP3145594B2 - Automotive interior surface materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface material for a vehicle interior such as a door trim, a ceiling trim, and a seat cover for a vehicle interior.

[0002]

2. Description of the Related Art As this kind of surface material for automobile interior, as shown in Japanese Utility Model Laid-Open No. 1-103400, a fabric surface such as a knitted fabric or a woven fabric is formed on the surface of a polyurethane foam excellent in volume and cushioning properties. Laminated skin materials have been used in many cases.However, in this type of laminated skin material, polyurethane foam has insufficient strength. As a result, there is a problem that the cost is increased, and the polyurethane foam has a problem in terms of disposal pollution or recycling.

In order to solve such a problem, recently, a surface material for an automobile interior in which a fiber web is used as a wadding material instead of a polyurethane foam and a skin material is integrally bonded to the wadding material has been proposed in Japanese Utility Model Laid-Open Publication No. 5-159999 and Japanese Unexamined Patent Publication No. 4-33
No. 2590 and the like, however, the one in which a skin material is bonded and integrated to a fiber web is necessary for automobiles because the surface of the fiber web is fuzzed when the skin material is bonded with a small amount of adhesive. There is a problem that the adhesive strength is not obtained, and that when a large amount of adhesive is used, the "feel" is impaired by this adhesive.
When a fibrous web having a large thickness is used, there is also a problem that "set" occurs and the cushioning property is impaired.

[0004]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems and uses a polyurethane foam which has problems in terms of waste pollution or recycling and also has a problem in strength. It uses a fiber-based wading material without having a sufficient adhesive strength with the skin material required for automobiles, as well as ensuring an excellent texture. It has been completed for the purpose of providing a surface material for automobile interiors that can ensure excellent cushioning properties without sagging even when a web is used and that is extremely inexpensive to produce. .

[0005]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, a surface material for an automobile interior according to the present invention is provided in such a manner that fiber filaments are entangled and integrated so that a filament bundle is erected between the front and back surfaces by needle sticking. It is characterized in that a skin material is bonded and integrated with the top side of the small ridge as a point-like adhesive portion on the front side of the wadding material which is formed and the tip of the filament bundle projects as countless small ridges from the surface. Is what you do.

[0006]

When used as a surface material for a vehicle interior such as a door trim or a ceiling trim of a vehicle interior or a seat cover, the appearance of the vehicle interior material is the same as that of a conventional vehicle interior material. Although it is the same as the surface material, the fiber wadding material used in place of the polyurethane foam as the depressing material is entangled and integrated so that the filament bundle stands upright between the front and back surfaces by needle sticking It has a volume feeling comparable to that using polyurethane foam as the base layer, and also causes sagging when a thick wadding material is used. It will exhibit excellent cushioning properties without. In addition, the bonding of the skin material to the wadding material is not surface bonding to a non-woven structure having a lot of fluff, but is point bonding to a small ridge at the tip of the filament bundle protruding to the front side of the wadding material. In addition to being bonded and integrated with adhesive strength, the point-bonding at the countless point-like bonded parts impairs the elasticity and texture of the skin material regardless of the type of skin material used. There is no.

[0007]

Next, an automobile seat cover using the present invention will be described in detail as an embodiment. In the figure, 1 is a fiber-based wading material in which fiber filaments obtained by mixing low-melting fiber filaments and high-melting fiber filaments in a web form are entangled and integrated by needle sticking, and 2 is bonded and integrated to the surface thereof. The wadding material 1 is a fibrous web having a thickness of about 1 to 20 mm and a basis weight of 50 to 1000 g / m ² . In the examples, the wading material 1 is a mixture of a low-melting fiber filament and a high-melting fiber filament. However, the wadding material 1 may be composed of only ordinary fiber filaments or a fiber filament obtained by arbitrarily combining them. Needless to say, it can be selected as appropriate.

In the present invention, the wadding material 1 is entangled and integrated so that the filament bundle 3 stands upright between the front and back surfaces by a needle sticking process. It is configured to protrude from the surface as innumerable loop-shaped small ridges 4, and the top of the small ridges 4 is bonded as a point-like adhesive portion 5 to the skin material 1. Here, the filament bundle 3 is erected between the front and back surfaces of the wading material 1 to sufficiently reinforce the wadding material 1 so that sagging can be accurately prevented and excellent cushioning properties can be secured. In addition, the point-like bonding portion 5 functions to ensure excellent bonding strength and excellent texture. In addition, as shown in FIG. 2, when performing the needle sticking process from the back side using a needle needle having a so-called fork needle having a wide arc-shaped tip, a needle-shaped needle needle is used. Since the filament bundle 3 and the point-like bonding portion 5 are larger than those described above, more excellent effects can be obtained, which is preferable.

Further, as in the embodiment, a high-density nonwoven fabric surface layer 6 may be laminated on the surface side of the wadding material 1. In this case, the strength of the wadding material 1 is further improved and the filament bundle 3 is formed. Is more entangled, and is preferred. Such a high-density nonwoven fabric surface layer 6 is made of a polypropylene fiber, polyester fiber, polyamide fiber, or the like having good wear resistance, which is commercially available as spunbond, and has a thickness of 0.3 to 2 mm and a basis weight of 5.
Generally, a nonwoven fabric sheet of about 200 g / m ² is used, but the material is not limited to such a material as long as the material can have the above-described configuration by needle sticking.

On the other hand, the skin material 2 bonded and integrated to the surface of the fibrous laminated wadding material 1 has no problem in terms of disposal and pollution as well as fabric skin materials such as knitted fabrics, woven fabrics and nonwoven fabrics, and is necessary as a skin material. Any type can be used as long as it has a certain degree of wear resistance. In the case where the high-density nonwoven fabric surface layer 6 is laminated as a reinforcing sheet, a low-weight fabric skin material having a mass of about 230 to 360 g / m ^2, which is conventionally rarely used alone for strength reasons. Since the required strength can be obtained in the vertical, horizontal, and bias directions even if the material is used, it is possible to use such a low-weight fabric skin material in consideration of cost.

The type of adhesive used for bonding the laminated wadding material 1 and the skin material 2 is water-soluble or hot-melt type, as long as they bond the two with sufficient adhesive strength. Although not limited, it is preferable to use a water-soluble adhesive such as an emulsion of an acryl-vinyl acetate copolymer in consideration of problems in working environment. Then, by using this adhesive, the laminated wadding material 1 and the skin material 2 are bonded and integrated at an innumerable point-like bonding portion 5, and the amount used is not emulsion bonding. The content may be 50% to 80% and 20 to 70% for the hot melt type, and a sufficient adhesive strength can be obtained.

[0012] Like the conventional surface material for automobile interiors, the thus constructed one is cut into an arbitrary size by a known means and then sewn to form a seat cover, which is used as a pad material. When coated, the appearance is the same as that of a conventional car interior surface material, but the fiber-based wadding material 1 used in place of polyurethane foam as a pressure-reducing material is exposed by needle sticking. It is entangled and integrated so that the filament bundle 3 stands up between the back surfaces, and exhibits a volume feeling comparable to that using a polyurethane foam as a base layer. Even when the wadding material 1 having a certain texture is used, excellent cushioning properties can be exhibited without sagging.

Further, the bonding of the skin material 2 to the wadding material 1 is not surface bonding to a non-woven fabric structure having a lot of fluff, but to the point of a small ridge 4 at the tip end of the filament bundle 3 protruding to the front side of the wadding material 1. Since they are bonded, they are bonded and integrated with a sufficient bonding strength, and the point bonding at the countless point-like bonding portions 5 makes it possible for any type of skin material to expand and contract. The characteristics and texture are not impaired by the adhesion, and the skin material 2 is integrated with the wading material 1 while maintaining a certain degree of freedom. Even if the material is used, the elastic properties and texture of the skin material 2 are not impaired by adhesion. Further, using a fibrous wadding material 1 in which countless small ridges 4 from which a part of fiber filaments are drawn out are formed, the wadding material 1 and the skin material 2 are bonded to the tops of the small ridges 4 in a point-like manner. Since the portion 5 is bonded and integrated, even if a force in the direction of peeling is applied to the skin material 2, the fiber filament itself following the small ridge 4 will be pulled up together with the skin material 2, making it difficult for the fiber filament to be peeled. There is an advantage that a sufficient adhesive strength can be obtained in combination with the flexibility due to the expansion and contraction of a part of the fiber filaments constituting the ridges 4 and the degree of freedom of expansion and contraction of the skin material 2 can be greatly increased.

[0014]

As apparent from the above description, the present invention uses a fiber-based wadding material without using a polyurethane foam which has problems in terms of disposal pollution or recycling and also has a problem in strength. In addition to having sufficient adhesive strength with the skin material required for automobiles, it can ensure an excellent texture and also causes sagging even when a thick fiber web is used. The present invention has various advantages that can not be seen in a conventional automobile interior surface material which can ensure excellent cushioning properties and has a very low production cost. When the surface layer of the high-density nonwoven fabric is laminated on the fiber filament layer on the surface of the wadding material as described above, the high-density non-woven fabric does not need to be supplemented with the skin material to supplement the strength of the wadding material. Since it can be reinforced with the cloth structure surface layer, the type of the skin material can be diversified. Further, as described in claim 3, the filament bundle is formed by the needle sticking process from the back side with the fork needle, and the small protuberance has a loop shape. What is done is that the filament bundle is supple and the function as a reinforcing pillar is more excellent, and the adhesion to the loop-shaped top part has sufficient adhesive strength because the adhesive force of the adhesive becomes large. It becomes a preferable thing. Therefore, the present invention has an extremely large contribution to industrial development as a surface material for automobile interiors which has eliminated the conventional problems.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of the present invention.

FIG. 2 is a partially cutaway plan view showing an embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Wadding material 2 Skin material 3 Filament bundle 4 Small ridge 5 Point bonding part 6 High density nonwoven fabric surface layer

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B60R 13/00-13/04

Claims (3)

(57) [Claims] 1. A fiber filament is entangled and integrated by needle sticking so that a filament bundle (3) stands upright between the front and back surfaces, and the tip of the filament bundle (3) is innumerably small protruding from the surface. (4) A vehicle interior characterized in that a skin material (2) is bonded and integrated on the front side of a wadding material (1) projecting as (4) with a point-like bonding portion (5) at the top of the small ridge (4). For surface materials. 2. A surface material for an automobile interior according to claim 1, wherein a surface layer (6) of a high-density nonwoven fabric is laminated on the fiber filament layer on the surface of the wadding material (1). The filament bundle (3) is formed by needle sticking from the back side with a fork needle to form a small protrusion (4).
The surface material for an automobile interior according to claim 1 or 2, wherein the member has a loop shape.