JPH08290502A - Interior materials for automobiles - Google Patents

Abstract

(57) [Summary] [Purpose] Floor carpets and seatbacks that are lightweight and have excellent sound insulation performance, especially sound insulation in the road noise area.
Provided is a vehicle interior material suitable for a lower insulator. [Structure] A non-woven fabric cushioning material layer laminated on a skin sound-insulating layer of a carpet or the like has a low density, and a polyester-based staple fiber constituting the non-woven fabric has a thick denier, and preferably a heat-sealing fiber is mixed to impart shape stability. Interior materials for automobiles.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile interior material, and more particularly to an automobile interior material which is lightweight and has excellent sound insulation.

[0002]

2. Description of the Related Art In recent years, good sound insulation performance and light weight have been demanded for automobile interior materials, particularly floor carpets and seat back lower insulators. Generally, a seat back lower insulator has a structure in which a backing material 3 as a sheet-like sound insulation layer, a cushioning material layer 4, and a floor panel 6 are laminated in this order as shown in FIG. As shown in FIG. 3, a sheet-like sound insulation layer composed of a carpet pile 1, a skin 2, and a backing material 3, a cushioning material layer 4, a mel sheet 5, and a floor panel 6 are laminated in this order.

Felt is often used as a cushioning material for conventional seat back and lower insulators, and felt or urethane foam (Japanese Patent Laid-Open No. 3-176241) is often used as a cushioning material layer for floor carpets. . However, these materials have drawbacks in some respects such as sound insulation, light weight, durability and decorativeness. For this reason, some cushioning materials using synthetic fibers such as polyester have been proposed (JP-A-62-223357,
JP-A-4-272263, JP-A-4-18575
4 publication). These synthetic fiber cushioning materials are generally superior in sound insulation compared to felt and urethane foam. Also,
There is an advantage that the weight of the cushioning material can be reduced by up to 30% compared with felt or urethane foam.

[0004]

However, in the conventional cushioning material made of synthetic fiber, it was difficult to significantly reduce the weight of the cushioning material by 50% or more because the sound insulation performance and the durability were deteriorated. Further, although the synthetic fiber cushioning material has particularly excellent sound insulation in the region of 500 Hz or higher, the sound insulation in the road noise region (200 to 500 Hz), which is important for floor carpets and seat back lower insulators, is further improved. Improvement is required.

Therefore, an object of the present invention is to use a shock absorbing material made of synthetic fiber, which enables a significant weight reduction as compared with felt and urethane foam, and has sound insulation performance, particularly in the road noise region (200 to 500 Hz). An object of the present invention is to provide an interior material for an automobile, which is suitable for floor carpets, seat backs, and lower insulators having excellent sound insulation.

[0006]

Means for Solving the Problems As a result of intensive studies to solve the above problems, the present inventors have used synthetic staple fibers such as polyester staple fibers as a cushioning material and have a large fiber diameter of the main fiber. In addition, the inventors have found that the sound insulation performance can be improved and the weight can be significantly reduced by reducing the density, and have reached the present invention.

The above object of the present invention is to provide an automobile interior material comprising at least a sheet-like sound insulation layer and a cushioning material layer formed on the back surface thereof by a nonwoven fabric composed of synthetic staple fibers, wherein The average apparent density is 0.01 to 0.04 g / cm ³ , preferably 0.02.
To 0.035 g / cm ³ , and 60 to 95% by weight of the synthetic staple fibers are polyester staple fibers having a single yarn fineness in the range of 6 to 50 denier. Achieved by

When the sheet-like sound insulation layer constituting the automobile interior material of the present invention comprises at least a carpet skin and a backing material composed of a thermoplastic resin laminated on the back surface of the carpet skin, An automobile interior material suitable for being laid on a floor panel of an automobile can be obtained.

The synthetic staple fibers constituting the nonwoven fabric are preferably at least two kinds of polyester staple fibers A and B, that is, polyester staple fibers A having a single yarn fineness of 10 to 40 denier and single yarn fineness 1 to.
15 denier polyester staple fiber B, and the content of fiber A and fiber B is 75 to 95, respectively.
It is desirable to be in the range of 5% by weight and 5 to 25% by weight.

Further, the fiber A is a matrix fiber consisting essentially of polyethylene terephthalate, the fiber B has a core-sheath type conjugate structure, and the melting point of the sheath component is at least 20 ° C. lower than the melting point of the fiber A. If the binder fiber is a copolyester, the fiber A
By heating the non-woven fabric at a temperature between the melting point of the fiber B and the melting point of the fiber B sheath component, the intersections of the constituent fibers in contact with the fiber B are fused and shaped into an appropriate shape to stabilize its form.

Furthermore, when the fiber A is a fiber having a side-by-side type conjugate structure in which crimp is latent, the crimp is expressed by heat treatment or the like,
It is preferable because it can increase the entanglement of the non-woven fabric and densify or stabilize the morphology.

The structure of the present invention will be described in detail below together with its operation. The most important point in the present invention is that the main fibers of the synthetic staple fibers constituting the nonwoven fabric cushioning material layer, that is, the fibers occupying 60 to 95% by weight are thick denier fibers having a single yarn fineness in the range of 6 to 50 denier, and The average apparent density of the buffer material layer is in the range of 0.01 to 0.04 g / cm ³ .

One of the general and effective means for improving the sound insulation performance is to reduce the dynamic spring constant of the cushioning material layer. In the case of a porous material such as a cushioning material composed of the fiber material used in the present invention, the dynamic spring constant thereof is, as shown in FIG. 3, a spring (fiber spring in this case) of the base material itself and air. It is the sum of the springs. The factors that determine the fiber spring include fiber diameter, density, and binder fiber amount, and the factors that determine the air spring include the degree of air escape (aeration amount). In the present invention, attention is paid to the air spring, and the dynamic spring constant of the entire cushioning material layer is reduced by reducing the air spring.

The dynamic spring constant of the air spring is closely related to the air flow rate, and the air spring decreases as the air flow rate increases.
Further, the air flow rate is reduced by decreasing the density and increasing the fiber diameter. If only the density is simply reduced, the overall dynamic spring constant is reduced, but durability and formability are reduced, and proper cushioning properties cannot be obtained. Also, if the fiber diameter is simply increased, the durability and air permeability will be improved, but the fiber spring will become too hard, the overall dynamic spring constant will increase and the sound insulation performance will decline, and it will not be possible to obtain an appropriate cushioning property. . Therefore, an appropriate balance between fiber diameter and density is required. By adopting the configuration of the present invention, it is possible to achieve both improved sound insulation performance, particularly in the low frequency region, and a significant reduction in density, and further obtain durability and formability equivalent to those of conventional products.

In the present invention, polyester staple fibers are advantageously used as the synthetic staple fibers constituting the nonwoven fabric from the viewpoints of cost, moldability, durability, stability of performance after processing and the like.

The non-woven fabric used in the present invention comprises at least two types of polyester staple fibers A and B, of which the main matrix fiber, that is, the fiber A occupying 60 to 95% by weight based on the total amount of the non-woven fabric constituent fibers is 6.
It is preferable to have a single yarn fineness in the range of ˜50 denier. Here, if the amount of the fiber A is less than 60% by weight, the amount of thick denier fiber is small, the durability is poor, and the reduction of the air spring due to the increase of the ventilation amount cannot be expected. Further, when the amount of the fiber A exceeds 95% by weight, the thick denier fiber becomes excessive and the cushioning material becomes hard, so that not only suitable cushioning property cannot be obtained, but also it is difficult to mix an appropriate amount of binder fiber for imparting moldability. Become. The more preferable content of the fiber A is in the range of 75 to 95% by weight based on the total amount of fibers constituting the nonwoven fabric.

When the single yarn fineness of the fiber A is less than 6 denier,
The expected effect of thick denier cannot be obtained, and durability and ventilation volume are insufficient. On the other hand, when it exceeds 50 denier, the fiber spring rises and the dynamic spring constant of the entire cushioning material layer increases, so that the sound insulation performance deteriorates. In addition, the number of fibers contained per unit volume is reduced, so that the durability is also reduced. More preferably, the range of 10-40 denier is good.

The fiber A is a matrix fiber made of polyester staple fiber, and in order to achieve a load bearing function (supporting function) as the matrix fiber, and also to secure a difference in melting point from the binder fiber, In order to widen the melting point width of the binder fiber that can be selected, it is preferable that the binder fiber is substantially composed of a homopolymer of polyethylene terephthalate that exhibits high tensile strength and high modulus and has a high melting point. Here, "substantially homopolymer" is understood to mean a homopolymer in which the inclusion of up to about 5% by weight of copolymerization components, blending components, impurities is permitted. Further, more preferably, a side-by-side type conjugate fiber in which a substantially homopolyester and a copolyester are compounded along the fiber axis is used, whereby crimping is caused by heat treatment and the degree of entanglement of the nonwoven fabric is increased. Good moldability and cushioning properties can be obtained.

The fiber B as the binder fiber in the present invention comprises a load-bearing component consisting of substantially homopolyester and a copolyester which is a heat-sealing component bonded along the fiber axis, and the copolyester component is A polyester-based conjugated staple fiber that occupies at least a part of the fiber surface, has a single yarn fineness in the range of 1 to 15 denier, and is 5 to 25% by weight on the basis of the total amount of nonwoven fabric constituent fibers.
Occupy The heat-sealing component is a copolyester having a melting point lower than the melting point of the fiber A by at least 20 ° C., for example, a copolyester obtained by lowering the melting point of polyethylene terephthalate polyester by a comonomer such as isophthalic acid. Preferably there is. Such fiber B
Is heated at a temperature between the melting point of the fiber A and the melting point of the heat-sealing component of the fiber B, whereby the heat-sealing component of the fiber B is melted, the fiber intersections are melted, and shaped into an appropriate shape. It will be possible. That is, the nonwoven fabric according to the present invention is subjected to heat treatment to bond the constituent fiber intersections to give the nonwoven fabric morphological stability,
In cooperation with the support function of the matrix fiber, it becomes possible to absorb the irregular shape attached to the surface of the nonwoven fabric or to intentionally impart the irregularity to the surface stably. Fiber B
A sheath-core type polyester-based conjugate fiber that uses homopolyester as a load-bearing core component and heat-fusible copolyester as a sheath component has a heat-sealing function in the sheath component while maintaining the supporting function of the core component. Can be fulfilled. Further, when the side-by-side type conjugate fiber is used, the non-woven fabric can be prevented from being hardened due to the formation of excessive fusion points by reducing the contact points of the heat fusion components.

When the amount of the fiber B is less than 5% by weight, the effect as the binder fiber is small and the moldability is deteriorated. On the other hand, 2
When it exceeds 5% by weight, the content of the fiber A is relatively reduced accordingly, and the expected effect of thick denier cannot be obtained, resulting in insufficient durability and air permeability. More preferable content is
It is in the range of 10 to 20% by weight based on the total amount of fibers constituting the nonwoven fabric.

When the single yarn fineness of the fiber B is less than 1 denier,
The spinning speed is significantly reduced, the card passing property is poor, and not only the operability is impaired, but also the quality of the nonwoven fabric is deteriorated.
On the other hand, when it exceeds 15 denier, the number of fibers contained per unit volume decreases, so that durability and moldability deteriorate.

The melting point difference between the heat fusion component of the fiber B and the fiber A is 2
If the temperature is less than 0 ° C, the temperature conditions during molding become strict,
Molding may be difficult. If the difference in melting point is too large, it does not pose a problem so the upper limit is not specified.
When the temperature is 50 ° C. or higher, the melting point of the heat-sealing component of the fiber B becomes too low and handling becomes difficult, and stickiness occurs even at near room temperature, making it impossible to smoothly carry out the steps after spinning. Fiber B
The material of the load-bearing component is not particularly limited as long as it is a polyester polymer, but polyethylene terephthalate is preferable for facilitating the function as a binder fiber.

In the present invention, the average apparent density of the nonwoven fabric forming the cushioning material layer is in the range of 0.01 to 0.04 g / cm ³ . If the average apparent density is less than 0.01 g / cm ³ , the carpet tends to lack sufficient durability, cushioning property, and moldability. Also, 0.04 g /
When it exceeds ³ cm ³ , the cushioning material becomes too hard, and it is difficult to obtain an appropriate cushioning property, and it is against the weight reduction which is one of the objects of the present invention. A more preferable range of average apparent density is
It is 0.02-0.035 g / cm ³ .

When a non-woven fabric is used for the cushioning material layer of a floor carpet, pressing and trimming of unnecessary portions are performed in the same manner as felt. At this time, high-density portions often occur near the ends of the cushioning material and the trimmed portions, but the above-mentioned numerical value regulation regarding the density is not naturally applied to these portions.

The cross-sectional shape of the fiber is not particularly limited, such as a regular circular shape or a modified cross-section such as a flat shape, a Y shape, or a hollow shape. In particular, by blending an appropriate amount of hollow fibers, it is possible to adjust the sound absorbing / insulating properties of the nonwoven fabric. Further, by forming the hollow fiber as a side-by-side conjugate fiber, it is possible to contribute to the improvement of the entanglement property and moldability due to the expression of crimps.

[0026]

The present invention will be described in more detail below with reference to examples, but the present invention is not limited thereto.
In the examples, "%" and "parts" are based on weight. Examples 1 to 11 assume floor insulators.

(Embodiment 1) In FIG. 2, a carpet 1
Is a pile surface density of 580 which is commonly used for automobiles such as needle punched carpets and tufted carpets.
A g / m ² carpet was used. The pile is fixed to the backing material 3 by the latex 2. As the backing material 3, a polyethylene thermoplastic resin sheet having an areal density of 600 g / m ² was used. Carpet 1, latex 2
The backing material 3 constitutes a sound insulation layer. This sound insulation layer was obtained by using one in which the above-mentioned three parts were previously integrally bonded. The sound insulation layer, the cushioning material layer 4, and the mel sheet 5 are laminated in this order, and have a thickness of 0.8 mm and an areal density of 6.3 k.
It is heat-sealed to the floor panel 6 of g / m ² . The mel sheet 5 has a thickness of 2.5 mm and an areal density of 4.0 kg / m.
The asphalt sheet No. ² was used, and the buffer material layer 4 was made of polyester non-woven fabric having a thickness of 30 mm and an areal density of 600 g / m ² . The fiber composition of the polyester non-woven fabric is single yarn fineness 6 denier, hollow side-by-side conjugate type polyester fiber 80% with cut length 51 mm, single yarn fineness 2 denier, cut length 51 m
m core-sheath type polyester binder fiber (melting point of the sheath component was 110 ° C.) was 20%.

The non-woven fabric is heated in an oven until the internal temperature reaches 160 ° C., and then 20 mm thick by a pressing machine.
Was molded so that The density of the non-woven fabric at this time is 0.
It was 03 g / cm ³ . The backing material layer 3 and the cushioning material layer 4 were adhered by preliminarily melting the backing material at 130 ° C., placing the molded cushioning material on the backing material, and pressing and cooling to bond them. Generally, a floor panel for an automobile is provided with a bead shape in order to obtain rigidity, and there are irregularities for passing a heater duct, a wire harness, etc., but for the purpose of evaluating sound insulation performance, cushioning property, etc., for convenience, It remained flat. It goes without saying that the polyester non-woven fabric used in this example can be processed along the shape of the floor panel by shaping the mold of the press machine. The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties, and compared with Comparative Examples 1 to 4 described later, but it was confirmed that at least equivalent performance was obtained. .

(Example 2) The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 500 g / m ² was used. The fiber composition of the non-woven fabric made of polyester is as follows: single yarn fineness 10 denier, hollow side-by-side conjugate type polyester fiber 85% with cut length 64 mm, single yarn fineness 2 denier, cut length 51 m
m core-sheath type polyester binder fiber (melting point 110 ° C. of the sheath component) was 15%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to a backing material.
The density of the nonwoven fabric at this time was 0.025 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties, and compared with Comparative Examples 1 to 4 described later, but it was confirmed that at least equivalent performance was obtained. .

Example 3 The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 400 g / m ² was used. The fiber composition of the non-woven fabric made of polyester is as follows: single yarn fineness 13 denier, hollow side-by-side conjugate type polyester fiber 90% with cut length 51 mm, single yarn fineness 2 denier, cut length 51
mm core-sheath type polyester binder fiber (melting point of sheath component: 110 ° C.) was 10%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to a backing material. The density of the nonwoven fabric at this time was 0.02 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning property, and Comparative Examples 1 to 4 described later.
As a result, it was confirmed that the same or higher performance was obtained for all the performances.

Example 4 The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 25 mm and an areal density of 300 g / m ² was used. As the fiber composition of the non-woven fabric made of polyester, a single regular type polyethylene terephthalate fiber 9 having a single yarn fineness of 20 denier and a cut length of 51 mm
0%, single yarn fineness 2 denier, core-sheath type polyester binder fiber with a cut length of 51 mm (melting point of sheath component is 1
10 ° C.) and 10%. 20 mm thick as in Example 1
Then, it was bonded to a backing material. The density of the nonwoven fabric at this time was 0.015 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties, and compared with Comparative Examples 1 to 4 described later, but it was confirmed that at least equivalent performance was obtained. .

Example 5 The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. As the cushioning material layer 4, a polyester non-woven fabric having a thickness of 20 mm and an areal density of 200 g / m ² was used. The fiber composition of the polyester non-woven fabric is a single regular type polyethylene terephthalate fiber 9 with a single yarn fineness of 40 denier and a cut length of 76 mm.
0%, single yarn fineness 4 denier, core-sheath type polyester binder fiber with a cut length of 51 mm (melting point of sheath component 1
10 ° C.) and 10%. 20 mm thick as in Example 1
Then, it was bonded to a backing material. The density of the nonwoven fabric at this time was 0.01 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties, and compared with Comparative Examples 1 to 4 described below.
It was confirmed that the same or higher performance was obtained for all performances.

(Example 6) The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. As the cushioning material layer 4, a polyester non-woven fabric having a thickness of 20 mm and an areal density of 200 g / m ² was used. The fiber composition of the polyester non-woven fabric is a single regular type polyethylene terephthalate fiber 9 with a single yarn fineness of 50 denier and a cut length of 51 mm.
0%, single yarn fineness 4 denier, core-sheath type polyester binder fiber with a cut length of 51 mm (melting point of sheath component 1
10 ° C.) and 10%. 20 mm thick as in Example 1
Then, it was bonded to a backing material. The density of the nonwoven fabric at this time was 0.01 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties, and compared with Comparative Examples 1 to 4 described below.
It was confirmed that the same or higher performance was obtained for all performances.

(Example 7) The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 800 g / m ² was used. The fiber composition of the non-woven fabric made of polyester is as follows: single yarn fineness 6 denier, cut length 51 mm, hollow side-by-side conjugate type polyester fiber 90%, single yarn fineness 2 denier, cut length 51 mm
10% of the core-sheath type polyester binder fiber (melting point of the sheath component is 110 ° C.). It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to a backing material. The density of the nonwoven fabric at this time was 0.04 g / cm ³ .
For the sample obtained by the above method, the sound transmission loss,
The cushioning property was evaluated and compared with Comparative Examples 1 to 4 described later, and it was confirmed that the performance equal to or higher than that of any performance was obtained.

(Example 8) The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. As the cushioning material layer 4, a polyester non-woven fabric having a thickness of 20 mm and an areal density of 200 g / m ² was used. As for the fiber composition of the polyester nonwoven fabric, the single yarn fineness is 13 denier, the hollow side-by-side conjugate type polyester fiber 80% of the cut length 51 mm, the single yarn fineness 2 denier, the cut length 51 m
m core-sheath type polyester binder fiber (melting point of the sheath component was 110 ° C.) was 20%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to a backing material.
The density of the nonwoven fabric at this time was 0.01 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties, and compared with Comparative Examples 1 to 4 described later, but it was confirmed that at least equivalent performance was obtained. .

Example 9 The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 400 g / m ² was used. The fiber composition of the polyester nonwoven fabric is as follows: single yarn fineness 13 denier, hollow side-by-side conjugate type 80% polyester fiber with cut length 51 mm, single yarn fineness 4 denier, cut length 51 m
m core-sheath type polyester binder fiber (melting point of the sheath component was 110 ° C.) was 20%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to a backing material.
The density of the nonwoven fabric at this time was 0.02 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties, and compared with Comparative Examples 1 to 4 described later, but it was confirmed that at least equivalent performance was obtained. .

Example 10 The same carpet 1, latex 2, backing material 3, mel sheet 5, and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 400 g / m ² was used. The fiber composition of the polyester non-woven fabric is as follows: single yarn fineness 13 denier, hollow side-by-side conjugate type 70% polyester fiber with cut length 51 mm, single yarn fineness 15 denier, cut length 51
mm core-sheath type polyester binder fiber (melting point of the sheath component: 110 ° C.) was 30%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to a backing material. The density of the nonwoven fabric at this time was 0.02 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning property, and Comparative Examples 1 to 4 described later.
As a result, it was confirmed that the same or higher performance was obtained for all the performances.

(Example 11) The same carpet, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. As the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 600 g / m ² was used. As the fiber composition of the polyester non-woven fabric, single yarn fineness 13 denier, hollow side-by-side conjugate type polyester fiber 80% with cut length 51 mm, single yarn fineness 15 denier, cut length 51
mm core-sheath type polyester binder fiber (melting point of the sheath component: 110 ° C.) was 20%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to a backing material. The density of the nonwoven fabric at this time was 0.03 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning property, and Comparative Examples 1 to 4 described later.
As a result, it was confirmed that the same or higher performance was obtained for all the performances.

Example 12 In FIG. 1, as the backing material 3, a thermoplastic resin sheet made of EVA polymer having an areal density of 1800 g / m ² was used. The backing material 3 is laminated with the cushioning material layer 4 to have a thickness of 0.8 mm and an areal density of 6.3 kg /
It was laminated and adhered to a floor panel 6 of m ² . For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 20 mm and an areal density of 300 g / m ² was used. As the fiber composition of the polyester non-woven fabric, single yarn fineness 6 denier, hollow side-by-side conjugate type polyester fiber 80% with cut length 51 mm, single yarn fineness 2 denier, cut length 51 m
m core-sheath type polyester binder fiber (melting point of the sheath component was 110 ° C.) was 20%. The non-woven fabric was heated in an oven until the internal temperature reached 160 ° C., and then formed into a thickness of 10 mm by a pressing machine. The density of the nonwoven fabric at this time was 0.03 g / cm ³ . The backing material 3 and the cushioning material layer 4 are adhered to each other by using the backing material 130
It was made into a molten state at 0 ° C. in advance, and the molded cushioning material was placed on it and pressed and cooled to bond it. The sample obtained by the above method was evaluated for sound transmission loss and compared with Comparative Example 9 described later, but it was confirmed that equivalent or higher performance was obtained.

(Embodiment 13) Backing material 3, floor pad
The same material as in Example 12 was used as the channel 6. Cushioning material layer 4
Has a thickness of 15 mm and an areal density of 150 g / m²Polyeste
A non-woven fabric made of le was used. Polyester non-woven fiber distribution
As a result, single yarn fineness 20 denier, cut length 51 mm
Solid regular type polyester fiber 90%, single
A core-sheath type with a yarn fineness of 2 denier and a cut length of 51 mm
Reester-based binder fiber (melting point of sheath component 110 ° C)
It was set to 10%. Molded to a thickness of 10 mm as in Example 12.
Then, the backing material 3 was bonded. Non-woven at this time
The density of the cloth is 0.015g / cm ³Met. With the above method
The sound transmission loss of the obtained sample is evaluated.
In comparison with Comparative Example 9 described later, the same or better performance was obtained.
It was confirmed that it was done.

Comparative Examples 1 to 8 assume floor insulators. Comparative Example 1 Comparative Example 1 shows a case where urethane foam is used for the cushioning material layer. The urethane foam was prepared by the following method. Propylene oxide 1,2,6-as a polyol in an injection foaming mold having a clearance of 20 mm
Hexanetriol: 100 parts, Water: 2 parts, Surfactant: 1 part, Carbon black: 0.5 part To A solution, Tolylene diisocyanate: 100 parts, Silicon oil: 0.5 parts B solution to polyol. It was obtained by foaming by injecting at low pressure so that the isocyanate was 1.25 times equivalent. The urethane foam sheet obtained has a thickness of 20 m.
m, the apparent density was 0.06 g / cm ³ . The buffer material layer 4 and the backing material 3 were adhered by applying a spray type adhesive.

The carpet 1, latex 2, mel sheet 5, and floor panel 6 used were the same as in Example 1. The backing material 3 has an EV with an areal density of 1500 g / m ² .
A thermoplastic resin sheet made of A polymer was used. The samples obtained by the above method were evaluated for sound transmission loss and cushioning property, and compared with Examples 1 to 11 and Comparative Examples 3 to 5.

Comparative Example 2 Comparative Example 2 shows a case where felt (trade name: Feltop, manufactured by Towa Textile Industry Co., Ltd., thickness 20 mm, apparent density 0.06 g / cm ³ ) is used for the buffer material layer. The backing material and the cushioning material layer were adhered by previously melting the backing material at 130 ° C., placing the cushioning material layer on the backing material, and then pressing and cooling to bond them.

The same carpet 1, latex 2, mel sheet 5 and floor panel 6 as in Example 1 were used. The backing material 3 has an EV with an areal density of 1500 g / m ² .
A thermoplastic resin sheet made of A polymer was used. The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties, and compared with Examples 1 to 11 and Comparative Examples 3 and 4.

(Comparative Example 3) The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 1000 g / m ² was used. As the fiber composition of the polyester non-woven fabric, single yarn fineness 2 denier, cut length 51 mm solid side-by-side conjugate type polyester fiber 80%, single yarn fineness 2 denier, cut length 51 m
m core-sheath type polyester binder fiber (melting point of the sheath component was 110 ° C.) was 20%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to the backing material 3. The density of the nonwoven fabric at this time was 0.05 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties and compared with Comparative Examples 1 and 2, and it was confirmed that the same or higher performance was obtained in any performance. .

(Comparative Example 4) The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 1000 g / m ² was used. As for the fiber composition of the polyester non-woven fabric, single yarn fineness 2 denier, cut length 51 mm, solid side-by-side conjugate type polyester fiber 60%, single yarn fineness 6 denier, cut length 51 m
m hollow side-by-side conjugate type polyester fiber 30%, single yarn fineness 2 denier, core-sheath type polyester binder fiber (cut point 51 mm, melting point 110 ° C.) 10%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to the backing material 3. The density of the non-woven fabric at this time is 0.05 g / cm
^{Was 3} . The samples obtained by the above method were evaluated for sound transmission loss and cushioning property, and Comparative Examples 1 to 3
As a result, it was confirmed that the same or higher performance was obtained in any performance.

Comparative Example 5 The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. As the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 600 g / m ² was used. The fiber composition of the polyester non-woven fabric is single yarn fineness 3 denier, cut length 51 mm, solid side-by-side conjugate type polyester fiber 80%, single yarn fineness 2 denier, cut length 51 mm
20% of the core-sheath type polyester binder fiber (melting point of the sheath component is 110 ° C.). It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to the backing material 3.
The density of the nonwoven fabric at this time was 0.03 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning properties, and compared with Examples 1 and 11. It was confirmed that although sound insulation performance was equivalent to that in the high frequency range, it was inferior in the low frequency range, and that durability and moldability also decreased.

Comparative Example 6 The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. As the cushioning material layer 4, a polyester non-woven fabric having a thickness of 20 mm and an areal density of 200 g / m ² was used. The fiber composition of the polyester non-woven fabric is single yarn fineness 70 denier, cut length 51 mm, solid side-by-side conjugate type polyester fiber 90%, single yarn fineness 4 denier, cut length 51 m
m core-sheath type polyester binder fiber (melting point of the sheath component was 110 ° C.) was 10%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to the backing material 3. The density of the nonwoven fabric at this time was 0.01 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning property, and compared with Examples 5 and 6. The sound insulation performance deteriorated in all frequency regions, and the cushioning property was too hard for a floor carpet. It was also confirmed that the durability was slightly reduced.

Comparative Example 7 The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 30 mm and an areal density of 1000 g / m ² was used. As the fiber composition of the polyester non-woven fabric, single yarn fineness 6 denier, hollow side-by-side conjugate type polyester fiber 90% with cut length 51 mm, single yarn fineness 2 denier, cut length 51 m
m core-sheath type polyester binder fiber (melting point of the sheath component was 110 ° C.) was 10%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to the backing material 3. The density of the nonwoven fabric at this time was 0.05 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning property, and compared with Examples 1 and 3. Compared to Example 1, the performances were almost the same, but the sound insulation performance in the low frequency region was slightly reduced, and the weight of the cushioning material was increased by about 1.7 times. Compared with Example 3, the performance was the same except that the sound insulation performance was slightly improved in the high frequency region. However, the weight of the cushioning material increased about 2.5 times.

(Comparative Example 8) The same carpet 1, latex 2, backing material 3, mel sheet 5 and floor panel 6 as in Example 1 were used. For the cushioning material layer 4, a polyester non-woven fabric having a thickness of 20 mm and an areal density of 100 g / m ² was used. As the fiber composition of the polyester non-woven fabric, a single regular type polyethylene terephthalate fiber 90 with a single yarn fineness of 40 denier and a cut length of 76 mm
%, Single yarn fineness 4 denier, cut length 51 mm, core-sheath type polyester binder fiber (melting point of sheath component 11
(0 ° C.) 10%. It was molded to a thickness of 20 mm in the same manner as in Example 1 and adhered to the backing material 3. The density of the nonwoven fabric at this time was 0.005 g / cm ³ . The samples obtained by the above method were evaluated for sound transmission loss and cushioning property, and compared with Examples 5 and 8. It was confirmed that the sound insulation performance, cushioning property, durability, and moldability were all deteriorated.

(Comparative Example 9) Comparative Example 9 assumes a seat back insulator. For the cushioning material layer, felt (trade name: Feltop, manufactured by Towa Textile Industry, thickness 10
mm, apparent density 0.06 g / cm ³ ) was used. For the adhesion between the backing material and the cushioning material layer, the backing material is preliminarily set to 1
A molten state was kept at 30 ° C., a cushioning material layer was placed thereon, and then pressed and cooled to bond them. The same floor panel 6 as in Example 12 was used. As the backing material 3, a thermoplastic resin sheet made of EVA polymer having an areal density of 2500 g / m ² was used. The sound transmission loss of the sample obtained by the above method was evaluated, and
Compared to 3.

Tables 1 and 2 collectively show the structures of the above-mentioned examples and comparative examples.

[Table 1]

[Table 2]

Table 3 collectively shows the comparison results of the characteristic values of the above-mentioned respective examples and comparative examples.

[Table 3]

[0054]

EFFECTS OF THE INVENTION Since the interior material for automobiles of the present invention has the above constitution, it has the following effects. (1) The weight of the cushioning material is 50% while ensuring performance equal to or higher than that when using felt or urethane foam as the cushioning material.
The above can be reduced. (2) Sound insulation performance is improved in the road noise region of 200 to 500 Hz which is important for automobile floor carpets, seat backs and lower insulators. (3) Despite the low density of the cushioning material layer, good moldability and cushioning property can be obtained.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view showing the basic structure of a general vehicle seat back lower insulator.

FIG. 2 is a vertical sectional view showing the basic structure of a general automobile floor carpet.

FIG. 3 is a model diagram of a spring made of fiber material.

[Explanation of symbols]

 1 Carpet skin 2 Latex 3 Backing material 4 Buffer material layer 5 Melsheet 6 Floor panel

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Tomohiro Ito 2 Takara-cho, Kanagawa-ku, Yokohama, Kanagawa Nissan Motor Co., Ltd. (72) In Ren Hitoshi 2 Takara-cho, Kanagawa, Yokohama, Kanagawa Pref. (72) Inventor Hiroshi Sugawara 2 Takaracho, Kanagawa-ku, Yokohama-shi, Kanagawa Nissan Motor Co., Ltd.

Claims (10)

[Claims] 1. An automobile interior material comprising at least a sheet-like sound insulation layer and a cushioning material layer formed on the back surface thereof by a nonwoven fabric composed of synthetic staple fibers,
The average apparent density of the non-woven fabric is 0.01 to 0.04 g /
The range of cm ³ is 60 to 60% of the above synthetic staple fiber.
An interior material for automobiles, characterized in that 95% by weight is a polyester staple fiber having a single yarn fineness in the range of 6 to 50 denier. 2. The automobile interior material according to claim 1, wherein the sheet-shaped sound insulation layer is composed of at least a carpet skin and a backing material made of a thermoplastic resin laminated on the back surface of the carpet skin. 3. The average apparent density of the non-woven fabric is 0.02.
In the range of ~0.035g / cm ³ according to claim 1 or 2
Interior materials for automobiles. 4. The synthetic staple fiber has a single yarn fineness of 10
To 40 denier polyester staple fibers A and single yarn fineness 1 to 15 denier polyester staple fibers B, and at least two polyester staple fibers, each of which has a fiber A content of 75 and a fiber B content of 75.
~ 95% by weight and 5 to 25% by weight range.
The automobile interior material according to any one of 3 above. 5. The fiber A consists essentially of polyethylene terephthalate, and the fiber B consists of a load-bearing polyester component consisting essentially of polyethylene terephthalate and a low melting point that exhibits a melting point that is at least 20 ° C. lower than the melting point of the fiber A. The automobile interior material according to claim 4, wherein the polymerized polyester component and the low melting point component are joined together along the fiber axis so that the low melting point component occupies at least a part of the fiber surface. 6. The automobile interior material according to claim 4, wherein the fiber A has a side-by-side type conjugate structure. 7. The automobile interior material according to claim 4, wherein the fiber A has a hollow side-by-side type conjugate structure. 8. The interior material for an automobile according to claim 4, wherein the fiber B has a core-sheath type conjugate structure. 9. The automobile interior material according to claim 4, wherein the fiber B has a side-by-side type conjugate structure. 10. The automobile interior material according to any one of claims 5 to 9, wherein the intersection of the fiber A and the low melting point component of the fiber B is heat-sealed to stabilize the shape.