JPH0562062B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to interior materials for automobiles. More specifically, the present invention relates to interior materials for automobiles, particularly those used for automobile ceiling materials, rear passenger compartments, and the like.

[Prior Art] Conventionally, automobile interior materials such as automobile ceiling materials and rear passenger compartments have been made by bonding a skin material such as a soft-textured woven fabric or non-woven fabric to a base material.

In such automobile interior materials, a film made of a thermoplastic resin such as polyamide is usually provided on one surface of a base material such as plastic foam, resin felt, or cardboard, and a skin material is further provided on the upper surface. Those that are glued together and integrated are used.

However, the above-mentioned automobile interior materials require a film between the skin material and the base material, so it is difficult to accurately laminate and integrate them, and the manufacturing process is extremely difficult. In addition to being complicated, the film has the disadvantage that it stretches at both edges and becomes wavy.

Therefore, a skin material lined with a web made of heat-melting fibers (Jikkosho 57−
13314) and a base material have been proposed.

[Problems to be Solved by the Invention] The above-mentioned automobile interior materials can be suitably used as flat plates that do not require forming using a press or the like. When applied to large-scale molding of automobile interior materials, the thickness of the automobile interior material is large, and the base material and the skin material are superficially fixed by linear or net-shaped adhesive parts, so it is difficult to bend the automobile interior material. A misalignment occurs between the base material and the skin material at the
Further, since the strength of the bonded portion is weak, the restoring force of such an automobile interior material after molding causes the base material and the skin material to separate, resulting in a problem that lifting occurs at the bent portion.

Therefore, in view of the problems of the prior art as described above, the present inventors aimed to develop an automobile interior material that does not cause lifting even when deep drawing is performed as described above and can be easily manufactured. As a result of extensive research, we have found that it is possible to easily manufacture a skin material with dots of thermoplastic resin adhered to one surface by overlapping the surface to which the thermoplastic resin is adhered and the base material and then integrating them. The inventors have discovered that a completely new interior material can be obtained that is both flexible and does not cause lifting even when deep drawing is performed, and has completed the present invention.

[Means for Solving the Problems] That is, the present invention involves superimposing the thermoplastic resin-adhered surface of a skin material on which the thermoplastic resin is adhered in dots on one surface with a base material, and then molding them into one piece. Related to automotive interior materials.

[Operations and Examples] In the automobile interior material of the present invention, the skin material and the base material are bonded to each other by thermoplastic resin arranged in dots on the skin material, so it is possible to perform, for example, deep drawing. Even if this happens, the strain during molding is absorbed between the thermoplastic resin arranged in a dot shape, so no lifting occurs in the deep drawn area, and furthermore, the distortion during molding is absorbed by the thermoplastic resin arranged in a dot shape. Since the skin material and the base material are firmly bonded by the plastic resin, there is no separation between the base material and the skin material.

The interior material for an automobile of the present invention is obtained by superimposing the thermoplastic resin-adhered surface of a skin material on which the thermoplastic resin is adhered in the form of dots on one surface with a base material, and then integrally molding them.

Examples of skin materials used in the present invention include polyester fibers, polyethylene fibers, polypropylene fibers, polyvinyl chloride fibers, polyvinylidene chloride fibers, polyamide fibers, ethylene-vinyl acetate copolymer fibers, rayon fibers, acetate fibers, etc. Examples include semi-synthetic fibers, non-woven fabrics made of natural fibers such as cotton and wool, tricot fabrics, raised tricot plain woven fabrics, and knitted woven fabrics made of velour-like fabrics.

Examples of the method for making the nonwoven fabric into a nonwoven fabric include the conventional fiber adhesion method (fiber bonding method), print bond method, needle punch method,
Although the hydroentanglement method can be adopted, the needle punch method is preferable from the viewpoint of the thickness, strength, moldability, etc. of the nonwoven fabric.Furthermore, among the needle punch nonwoven fabrics obtained by the needle punch method, one side of the nonwoven fabric is made of synthetic resin. Those impregnated with emulsion and subjected to backing treatment are particularly suitable for use. When using this needle-punched nonwoven fabric to make use of the soft texture of the nonwoven fabric as a surface material when providing thermoplastic resin dots as detailed below, the thermoplastic resin dots are placed on the impregnated surface of the synthetic resin emulsion. It is preferable that the

In addition, as the thickness of the skin material used in the present invention as described above increases, its formability decreases when forming such as deep drawing.
Also, if the thickness is too small, when the thermoplastic resin dots are attached to the skin material, the thermoplastic resin will be applied to the surface of the skin material opposite to the thermoplastic resin, that is, the surface that is normally the surface of the interior material. The resin will ooze out and the texture and appearance of the interior material will deteriorate.
Its thickness is 0.5~4.0mm, especially 1.0~2.5mm
It is preferable that

The thermoplastic resin used in the present invention is provided in the form of dots on one surface of the skin material. Here, the term "dot shape" refers to a state in which the thermoplastic resins are arranged in dots on the skin material, with respective thermoplastic resins spaced apart from each other. The thermoplastic resin may have any shape as long as it is dotted, that is, it may be circular, triangular, quadrangular, polygonal, etc., and is not limited to these shapes. In addition, there is no particular limit to the area of the adhesion surface of the thermoplastic resin on the skin material, but if the area is too small, the adhesive strength with the base material will decrease, causing peeling between the skin material and the base material. Therefore, it is preferable that the amount is 0.5 mm ² or ^more , particularly 1 to 25 mm ² per 1 cm 2 of the skin material. In addition, if the amount of thermoplastic resin adhered to the surface material is less than 10 g/m ² , the adhesive force will be insufficient, and the base material and the skin material will easily separate, and if the amount is less than 10 g/m ²
If it exceeds 10 to 50 g/m ² , preferably 20 to 40 g/m ² , the texture of the skin material becomes partially hard and the thermoplastic resin content increases, increasing the cost. Further, the number of thermoplastic resins adhered to the skin material in the form of dots may be 1 to 200 per cm ² of the skin material, particularly preferably 4 to 200.
There are 100 pieces. The number of such thermoplastic resins is 1
If the number is less than 1, peeling will easily occur between the skin material and the base material, and if it exceeds 200, it will be difficult to absorb the distortion caused by molding, so the moldability will decrease, and if the number is less than 1, it will be difficult to absorb the distortion caused by molding. Similarly, peeling is likely to occur between the skin material and the base material. In addition, if 1/4 to 2/3 of the volume of each dot-shaped thermoplastic resin attached to the skin material is embedded in the skin material, its anchoring effect will cause This is preferable because it improves the peel strength with the material. As mentioned above, the thermoplastic resin has a melting point of 100 to 180℃,
Preferably, a resin having a temperature of 100 to 130°C is used, and specific examples of such thermoplastic resins include polyester resins, polyamide resins, ethylene-vinyl acetate resins, and the like. The method of attaching thermoplastic resin to the skin material is to dissolve the thermoplastic resin in advance in a solvent or make a highly concentrated emulsion into a paste form, apply it in dots using a screen, etc., and dry it. There are various methods such as a method of fixing the resin by doping and a method of depositing powdered resin in dots using a gravure roll or the like and fixing by heating, but any of these methods can be employed in the present invention.

Next, the surface of the skin material to which the thermoplastic resin is adhered in dots is superimposed on the base material, and the two are integrally molded to obtain an automobile interior material.

As the base material, resin felt, plastic foam, wood stock, etc. are used. Here, udstok refers to resin such as polypropylene with 30 to 60% wood chips added. The thickness of these base materials varies depending on the type of base material, but as the thickness increases, the formation of the material decreases when forming processing such as deep drawing is performed.
It is preferably 30 mm or less, especially 10 to 20 mm.

The adhesion between the skin material and the base material is achieved by overlapping the thermoplastic resin-attached surface of the skin material and the base material, and then applying the thermoplastic resin adhered to the skin material from the upper surface of the skin material by, for example, hot pressing. This is done by melting the resin. When bonding is performed using the above-mentioned hot press, the press pressure is 5 to 60
It is preferably about Kg/cm ² .

The interior materials obtained in this way can be used as they are or after being cut into a predetermined shape or subjected to processing such as deep drawing, to be used as ceiling materials, rear car cage materials, door materials, etc.
Used as trunk material and other automotive interior materials.

Next, the automotive interior material of the present invention will be explained in more detail based on Examples, but the present invention is not limited to these Examples.

Example 1 After forming a web made of polyester fiber (fineness: 3 denier, fiber length: 64 mm), a needle punch nonwoven fabric (fabric weight: 200 g) was formed using the needle punch method (needle density: 150 pieces/cm ² , needle depth: 10 mm). / ^m2 ,
Thickness: 3.0mm).

A binder of ethylene-vinyl chloride emulsion (containing 60% vinyl chloride) was foamed on one surface of the obtained nonwoven fabric to achieve a solid content of 30 g/m ² by impregnation.
After impregnation, it was dried and subjected to backing treatment.

Next, a polyamide copolymer with a melting point of 110℃ was applied to the binder-impregnated surface at a rate of 25 g/m ² with a diameter of 1 mm.
Holes of mm diameter were deposited so as to be arranged in dots through a screen provided at the intersections of the lattice pattern.

Approximately 1/2 of the volume of the resin arranged in the dot shape is embedded in the nonwoven fabric, and 1/2 of the volume of the resin arranged in the dot shape is
Thirty resin dots were placed per cm ² .

Lay resin felt as a base material on the surface of the nonwoven fabric to which the polyamide copolymer is attached, place it on a deep drawing mold (female mold) having a predetermined shape (the shape of the ceiling of a car), and insert the male mold from above. By heating (125°C) and pressurizing (600Kg/cm ² ), the material was integrally molded to obtain an automobile ceiling material. The resulting ceiling material had no floating areas between the nonwoven fabric and the resin felt, and its shape was faithful to the mold.

Example 2 The nonwoven fabric obtained in Example 1 was subjected to backing treatment in the same manner as in Example 1, and then a polyamide copolymer with a melting point of 110°C was applied to the binder-impregnated surface in an amount of 50 g/m ² . A ceiling material was obtained in the same manner as in Example 1, except that holes with a diameter of 0.6 mm were attached in dots using a screen provided at the intersections of the grid pattern.

Approximately 2/3 of the volume of the resin arranged in the dot shape was embedded in the nonwoven fabric, and 100 resin dots were provided per 1 cm ² of the nonwoven fabric.

This ceiling material had no looseness between the nonwoven fabric and the resin felt, and was faithful to the mold.
However, compared to Example 1, the peel strength of the adhesive surface was stronger, and the surface texture was slightly harder.

Example 3 The nonwoven fabric obtained in Example 1 was subjected to backing treatment in the same manner as in Example 1, and then a polyamide copolymer with a melting point of 110°C was applied to the binder-impregnated surface in an amount of 10 g/m ² A ceiling material was obtained in the same manner as in Example 1, except that holes with a diameter of 1.2 mm were attached in dots using a screen provided at the intersections of the grid pattern.

In addition, about 1/4 of the volume of the resin arranged in the dot shape is embedded in the nonwoven fabric, and there is no floating between the nonwoven fabric and the resin felt.
It was faithful to the mold. However, compared to Example 1, the peel strength of the adhesive surface was slightly weaker, and the surface texture was softer.

Comparative Example 1 The nonwoven fabric obtained in Example 1 was subjected to backing treatment in the same manner as in Example 1, and then 25 g/sheet of filaments made of a polyamide copolymer with a melting point of 110°C was stacked on the binder-impregnated surface. A ceiling material was obtained in the same manner as in Example 1 except that m ² was attached.

The resulting ceiling material showed some lifting in the deep-drawn area, and peeling occurred between the nonwoven fabric and the resin felt.

[Effects of the Invention] In the automobile interior material of the present invention, the skin material and the base material are bonded together by the thermoplastic resin arranged in dots on the skin material, so that distortion during molding does not occur in the dots. The skin material is absorbed between the thermoplastic resins arranged in a shape, and the skin material and the base material are firmly bonded through each thermoplastic resin. Therefore, even when deep drawing is performed, the skin material It is extremely useful because no peeling occurs between the material and the base material, and so-called floating does not occur at all.

Claims (1)

[Scope of Claims] 1. An interior material for an automobile, which is formed by laminating the thermoplastic resin-adhered surface of a skin material having dots of thermoplastic resin adhered to a base material on one surface, and then integrally molding the two. 2. The interior material for an automobile according to claim 1, wherein the amount of the thermoplastic resin adhered is 10 to 50 g/m ² . 3. Claim 1, in which the number of thermoplastic resin particles of the skin material attached in dots is 1 to 200 pieces per cm ²
Automotive interior materials described in Section 1. 4. The interior material for an automobile according to claim 1, wherein the thermoplastic resin of the skin material adhered in the form of dots is embedded in the skin material by 1/4 to 2/3 of its volume.