JPH0772394B2 - Manufacturing method of skin material for automobile interior - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial application] The present invention relates to a method for producing a skin material for an automobile interior. More specifically, the present invention relates to a method for producing a flocked type skin material for automobile interiors that can be used for the interiors of automobile ceilings and doors.

[Conventional technology and its problems] Conventionally, as a flocked type skin material for automobile interior,
(A) Polyvinyl chloride sheet with flocked surface, (b) After flocking to a nonwoven fabric containing heat-shrinkable fibers,
Those that are shrunk so that the area of the flocked surface is not more than 1/2 (see JP-A-61-179382) are known.

The skin material of (a) has poor deep drawability, and the skin may partially extend to form a non-uniform raised surface.
Further, since the outer skin alone has no cushioning property or sound absorbing property, it has to be combined with other materials such as polyurethane foam, which has a drawback that the manufacturing process is complicated and the cost is high. Further, the skin material (b) has good deep drawability and excellent cushioning property, but the nonwoven fabric usually has a porous structure in which fibers are entangled with each other, and its surface has irregularities. Therefore, the flocked length of the flocked surface is not uniform and only the poor texture is obtained.

[Problems to be solved by the invention]

Therefore, in view of the problems of the prior art, the present inventors have conducted extensive studies to obtain an automobile interior skin material having good deep drawability, excellent cushioning properties, and a uniform flocked surface. The inventors have found a completely new method of manufacturing a skin material that can solve all of these problems, and have completed the present invention.

[Means for solving problems]

That is, the present invention is a method for producing a skin material in which flocking processing is performed on one surface of a needle punch felt, wherein a needle punch felt containing 15 to 40% by weight of heat-fusible fiber is used as the needle punch felt. The surface of the punched felt on which the flocking is applied is subjected to a smoothing treatment, then a water-repellent resin treatment is applied, and then an adhesive is attached to the surface on which the flocking is applied, and then the flocking treatment is applied. The present invention relates to a method of manufacturing a skin material for an automobile interior.

[Operation and Example]

The method for producing a skin material for an automobile interior of the present invention is to use a heat-fusible fiber.
The surface of the needle-punched felt containing 15 to 40% by weight is smoothed by a heat calendar, and the surface is further treated with a water-repellent resin, and then an adhesive is applied, followed by flocking. .

The heat-fusible fibers used in the present invention include, for example, fibers having a melting point of 110 to 230 ° C., undrawn fibers and melting points of 110 to 230 ° C.
Examples thereof include a composite fiber containing a low melting point component. In addition,
Among these fibers, in consideration of the fact that polyester fiber is usually used as the fiber other than the heat-fusible fiber used in the needle punch felt, the melting point is 13
A core-sheath type composite fiber composed of a core component made of a polyester resin at 0 ° C. and a sheath component made of a polyester resin having a melting point of 260 ° C. is desirable. Such a heat-fusible fiber not only gives strength to the skin material by fusing,
It has the function of suppressing the fluff on the surface of the needle punched felt during calendering and improving the smoothness of the surface. In addition, the heat-fusible fiber has weak bonding force when heat is applied during molding, so that the fiber is allowed to move, and when cooled after molding, the bonding force is improved again to provide shape retention. Since it has a function, it is possible to perform molding such as deep drawing.

By the way, in the present invention, the amount of the heat-fusible fiber contained in the needle punched felt is set to 15 to 40% by weight, and when it is less than 15% by weight, a skin material having necessary strength can be obtained. If it exceeds 40% by weight, the texture becomes hard and the cushioning property is deteriorated.

As the fibers other than the heat-fusible fibers, fibers usually used for skin materials can be mentioned. Specific examples of such fibers include synthetic fibers such as polyester fibers, nylon fibers, vinyl chloride fibers, acrylic fibers and polypropylene fibers, and these fibers may be used alone or in combination of two or more kinds. You may. Among these fibers, polyester fiber is less likely to undergo thermal deterioration and color change at high temperatures, and is excellent in heat resistance, weather resistance and antifouling property, and thus can be preferably used. The fineness of these fibers is preferably 6 denier or less in order to obtain a skin material having a uniform smooth surface.

When the basis weight of the needle punch felt is less than 100 g / m ² , the cushioning property is insufficient, and when it exceeds 400 g / m ² , the weight tends to be heavy and the raw material cost tends to be high, and therefore is usually 100. ~ 400g / m ² , especially 150 ~ 350g /
It is preferable to adjust to m ² .

The surface of the needle punched felt on which the flock is applied is smoothed by a thermal calendar. Examples of such a thermal calendar include a flat calendar having a temperature of 120 to 200 ° C. By performing such smoothing treatment, the fluff protruding on the needle punch felt is suppressed, and the surface of the needle punch felt is smoothed.

Next, a water repellent resin is attached to the surface of the needle punched felt that has been subjected to the smoothing treatment in order to prevent an adhesive for flocking from penetrating into the needle punched felt. Examples of such water repellent resins include fluorine-based water repellent resins such as perfluoroalkyl group-containing acrylates and perfluoroalkyl group-containing urethane compounds, and the amount thereof is usually adjusted to 5 to 30 g / m ^2. It When the adhesion amount is less than 5 g / m ² , the water repellent property is reduced and the adhesive agent for flocking penetrates much into the felt, which reduces the adhesion strength of the flocked particles and exceeds 30 g / m ² . And tends to reduce the adhesive strength of the adhesive itself.

Next, an adhesive for flocking is attached to the surface of the needle punch felt on which the water repellent resin is applied. Examples of such adhesives include acrylic resin emulsions and ethylene-vinyl acetate resin emulsions. When the viscosity of such a resin emulsion is less than 10,000 cP, the adhesive strength of the flock may be reduced due to the resin penetrating into the needle punch felt,
If it exceeds 0 cP, the flocked fibers are less likely to stick and the adhesive strength of the flocked tissue tends to decrease.
It is preferably in the range of 0000 cP. The amount of the adhesive for flocking (adhesion amount of resin solids) greatly varies depending on the fineness and the fiber length of the flocked fiber. For example, when flocking nylon short fibers having a fineness of 2 denier and a fiber length of 1.2 mm. ,
If the adhesion amount of the adhesive is less than 40 g / m ² , a short amount of short fibers will not adhere, the flocking density will be low, and only a flocked surface lacking uniformity will be obtained, and if it exceeds 150 g / m ² , since there is a tendency that the adhesive is excessive, 40~150g / m ^2, inter alia 5
It is preferably from 0 to 120 g / m ² .

Fibers are planted on the surface to which the resin for flocking is attached. As a method for such flocking, for example, a commonly used method of electrostatically bristing can be adopted. Examples of fibers used for flocking include rayon fibers,
Examples include nylon fiber and polyester fiber. The fineness of these fibers is 1 to 30 denier because they are not abrasion resistant when they are too thin, and they give a hard touch when they are too thick.If the fiber length is too short, there is no flocking effect, and if they are too long, uniform flocking is difficult. Therefore, it is preferably 0.8 to 5 mm.

Thus, the 30% modulus of the flocked type skin material obtained by the production method of the present invention is preferably 12 kg / 5 cm or less in consideration of the deep drawing formability.

Next, the production method of the interior skin material for automatic company of the present invention will be described in more detail with reference to Examples and Comparative Examples, but the present invention is not limited to these Examples.

Example 1 200 g / m ^{2 of} fiber web composed of 70% by weight of polyester fiber having a fineness of 3 denier and 30% by weight of undrawn polyester fiber
After needle-punching the needle to form a needle-punch felt, the surface is smoothed with a calendar roll at a temperature of 140 ° C, and then water-repellent resin processing is applied to produce a fluorine-based water-repellent resin (manufactured by Dainippon Ink and Chemicals, Inc.) , Dickguard F
−70) 15 g / m ² (solid content) was applied to the needle punch felt surface. Next, 80 g / m ² (solid content attached amount) of an acrylic resin emulsion was applied to this surface, and a nylon pile having a fineness of 2 denier and a fiber length of 1.2 mm was electrostatically flocked to obtain a skin material.

The obtained skin material was examined for tensile strength, tensile elongation, 30% modulus and surface appearance according to the following methods. The results are shown in Table 1.

Next, hot melt material (thickness 30μ
m, a copolyamide film with a melting point of 105 to 125 ° C) was laminated and heat-pressed on a base material (corrugated board) for automobile ceiling materials, and the deep squeezed parts at the corners such as the sun visor and rear parts were also well formed. In addition, the surface also maintained a uniform flocked surface, showing an excellent appearance.

Example 2 In Example 1, instead of the unstretched polyester fiber,
A skin material was obtained in exactly the same manner as in Example 1 except that the core-sheath type polyester composite fiber was used in which the melting point of the core portion was 260 ° C and the melting point of the sheath portion was 130 ° C.

The physical properties of the obtained skin material were examined in the same manner as in Example 1.
The results are shown in Table 1.

Comparative Example 1 Fiber web made of polyester fiber having a fineness of 3 denier
A needle punch felt was formed by needle punching 200 g / m ² , and a water repellent resin treatment was applied in the same manner as in Example 1 to attach 15 g / m ² of the fluorine-based water repellent resin to the surface of the needle punch felt. Next, after applying 80 g / m ² of acrylic emulsion on this surface, fineness of 2 denier and fiber length of 1.2 mm
Electrostatic flocking was performed on the nylon pile to obtain a skin material.

The flocked surface of the obtained skin material was uneven and uneven, and the appearance was poor. The physical properties of the obtained skin material were examined in the same manner as in Example 1. The results are shown in Table 1.

Comparative Example 2 A skin material was obtained in exactly the same manner as in Example 1 except that the water repellent resin process was not performed.

In the obtained skin material, the acrylic emulsion, which is an adhesive agent for flocking, penetrated into the inside, so the adhesion strength of the pile was weak, and it partially slipped off when rubbed hard by hand.

The physical properties of the obtained skin material were examined in the same manner as in Example 1.
The results are shown in Table 1.

Comparative Example 3 The same as Example 1 except that the water repellent resin treatment was not performed and then the acrylic resin emulsion was not applied, but the acrylic resin emulsion was applied and then the water repellent resin treatment was applied. A skin material was obtained in the same manner.

When the hair was transplanted, the nylon pile could not be sufficiently transplanted.

The obtained skin material had a poor surface appearance, and had the drawback that the piled piles could easily fall out if rubbed with hands.

Next, the physical properties of the obtained skin material were examined in the same manner as in Example 1. The results are shown in Table 1.

(Tensile Strength and Tensile Elongation) JIS L 1068
The tensile strength is measured at a tensile speed of 20 cm / min using a tensile tester in accordance with the above, and the strength (kg) and elongation (%) at break are measured, and the average value is obtained. (30% modulus) Five test pieces of 5 cm in height and 20 cm in width are taken, and JIS L 1068 is used.
According to the above, the tensile tester was used to pull at a pulling speed of 20 cm / min, and the stress (kg) was measured when the stretch rate reached 30%.
Calculate the average value.

[Effects of the Invention] The skin material for automobile interior obtained by the production method of the present invention is
It is a high-quality flocked skin material with uniform flocking, can be deep-drawn and has excellent shape retention. In addition, since it has excellent cushioning properties and does not require any combination with other materials such as urethane foam, it has an effect of being lightweight.

Claims (1)

[Claims] 1. A method for producing a skin material in which flocking is applied to one side of a needle punch felt, wherein the needle punch felt is a needle punch felt containing 15 to 40% by weight of a heat-fusible fiber. The surface of the punched felt on which the flocking is applied is subjected to a smoothing treatment, then a water-repellent resin treatment is applied, and then an adhesive is attached to the surface on which the flocking is applied, and then the flocking treatment is applied. Manufacturing method of skin material for automobile interior.