JPH08323903A - Interior material for automobile and manufacturing method thereof - Google Patents

Abstract

(57) [Summary] [Purpose] It has both high sound absorption and insulation properties and rigidity, and has good tactile sensation.
To provide an automobile interior material having an excellent aesthetic appearance in an economically advantageous manner by a simplified process. [1] An automobile interior material comprising a sound absorbing and non-woven fabric made of thermoplastic synthetic fiber short fibers as a whole, wherein constituent fibers including at least one surface thereof are colored to form a non-woven fabric design layer, The design layer may be integrally laminated with the non-woven fabric base material layer for enhancing shape retention.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to an automobile interior material, especially
It has excellent functions in terms of sound absorption / insulation characteristics, touch, aesthetics, and other appearance qualities, and is suitable for parts that require high rigidity to maintain its shape, such as door trims, headlining, trunk trims, and dash insulators. The present invention relates to an automobile interior material to be applied.

[0002]

2. Description of the Related Art In recent years, as automobiles have become more sophisticated and have higher performance, there has been a demand for quietness in the passenger compartment and improved tactile and aesthetic appeal of interior materials. However, since conventional automobile interior materials generally place importance on being inexpensive, additional functions such as sound absorption / sound insulation, tactile sensation, and aesthetics are disregarded, and these excellent additional functions are combined. I didn't do much. That is, conventionally, a skin, for example, a non-woven fabric, is simply attached to a base material such as a highly rigid panel for retaining the shape.
The mainstream of interior materials for automobiles has been a structure in which sound absorbing and insulating materials such as elastomer and woven fabric are attached. Typical examples of these base material parts are wooden boards, felt using a thermosetting binder such as phenol resin for recycled fibers, or inorganic fibers such as glass fibers impregnated with a thermoplastic resin for hot pressing or cold pressing. A panel manufactured by using so-called FRTP pressed, or a foamed material having a sandwich structure, and the like can be given. However, of course, although those made of these base materials exert a shape-retaining effect, the sound absorbing and insulating performance is inevitably deteriorated, and further, the surface texture, the tactile sensation, and the like have not only the above-mentioned additional functions, but also the constitution. However, there is also a problem that the process becomes complicated and the number of processes increases. As described above, in the conventional automobile interior materials, it is difficult to maintain the shape of the fiber assembly having good sound absorption / insulation performance due to insufficient rigidity, and if the rigidity is increased to maintain the shape, the sound absorption / insulation performance is significantly reduced. While always encountering the trade-off, there were the following drawbacks.

First, there is no recyclability.
This is because the base material has a multi-layer structure in which the material for each layer is different, and also the material for the base material is different from that for the skin portion.

Secondly, the phenolic resin conventionally used for increasing the rigidity in felts, wood boards, etc. gives off an unpleasant odor. The unpleasant odor when used as an interior material for automobiles is considered to be a serious problem in practical use, and a substitute material is naturally required.

Thirdly, the conventional material has a high possibility of generating an abnormal noise which interferes with the rigid panel of the vehicle body when assembled in the vehicle. In order to solve this, it was necessary to devise a flexible non-woven fabric or urethane foam sandwiched between the base material of the interior material and the panel surface, or the interference surface with other parts, so extra man-hours and parts were required, making it economical. I was at a disadvantage.

Fourthly, since a base material is used as a base material, it is difficult to secure air permeability, and sufficient sound absorbing performance cannot be imparted.

In order to eliminate these drawbacks, the present inventors have prepared a fiber assembly containing different kinds of synthetic fiber staples having specified fineness and softening point temperature, and having specified average apparent density and bending elastic gradient. An automobile interior material including the above is proposed as Japanese Patent Application No. 6-245269. When this fiber assembly is used as a base material, many additional functions can be obtained, but in order to finally obtain an interior material product with an aesthetic appearance, a skin prepared separately from this base material is again used, for example. It has been found that there is a problem in that the heat-sealing film or the like must be used for the attachment, and a process therefor is required.

[0008]

SUMMARY OF THE INVENTION The present invention has been made by paying attention to such conventional problems, and has both high sound absorbing and insulating properties and rigidity, a good tactile sensation, an excellent aesthetic appearance, and the like. It is an object of the present invention to provide an automobile interior material having the additional quality function of 1. and having a simpler structure, in an economically advantageous manner by a more simplified process.

[0009]

Means for Solving the Problems The inventors of the present invention have completed the present invention by analyzing the function of a fiber assembly, especially a non-woven fabric, and the performance by blending, and found a method of enhancing its rigidity and additional function. I arrived. In other words, in order to solve the above-mentioned problems, the composition of the fiber and the type of the fiber to be compounded are made to be more rigid than the conventional ones, and the additional function can be compatible. Furthermore, by specifying the mixing ratio of the high softening point fiber and the low softening point fiber and the low softening point fiber type to be mixed in the fiber assembly, high rigidity and at least one surface is dyed, or by dyeing It has a colored design layer, and the design layer has a function as a skin of an interior material, and has a high additional function by integrating a shape-retaining base material layer with the function as needed. Succeeded in providing interior materials for automobiles.

That is, in the automobile interior material according to the present invention, as shown in FIG. 1, the constituent fibers including at least one surface are colored to form the non-woven fabric design layer 2, and the design layer 2 is integrated with the non-woven fabric layer 2. Laminated non-woven fabric base layer 1 for enhancing shape retention
And a sound absorbing / insulating nonwoven fabric made of thermoplastic synthetic fiber short fibers as a whole.

The weight ratio of the design layer 2 and the base material layer 1 is preferably 3:97 to 100: 0. When the weight ratio of the design layer is less than 3% by weight, the colored design layer on the surface becomes very thin and has a low density. Therefore, when the base material layer is uncolored, it is transparent to the surface. It looks and worsens aesthetics. Further, regarding the coloring portion of the design layer covering the entire base material layer and having a composition ratio of 100% by weight, no problem occurs in terms of aesthetics and rigidity.

The short fibers constituting the design layer 2 preferably have an average fineness of 0.2 to 15 denier. If the average fineness is less than 0.2 denier, it is difficult to obtain a good quality non-woven fabric due to a decrease in productivity due to a decrease in spinning speed or difficulty in forming a web when forming a non-woven fabric. Also, 15
If it exceeds denier, it is difficult to obtain smoothness due to fuzz on the surface, and it is difficult to expect good surface quality in terms of surface texture roughness and the like.

The average fineness of the short fibers constituting the base material layer 1 is preferably in the range of 1.5-40 denier. If the average fineness is less than 1.5 denier, the rigidity of the fiber itself is small, and it becomes difficult to obtain sufficient rigidity as a base material. On the other hand, if it exceeds 40 denier, the total number of fibers per unit volume in the non-woven fabric decreases, the number of adhesion points with the binder fibers described below decreases, and it becomes impossible to obtain sufficient rigidity. Moreover, since the ratio of the surface area / cross-sectional area becomes small due to the increase in the fiber diameter, it becomes difficult to efficiently absorb the sound energy.

With such a constitution, the nonwoven fabric of the present invention having excellent sound absorbing and sound insulating properties as a whole is preferably molded into an average thickness of 1 to 50 mm. If the average thickness is less than 1 mm, it is undeniable that the bending rigidity is reduced due to insufficient thickness, and
Even if the rigidity can be secured, the desired air flow rate cannot be obtained, and it becomes difficult to impart the desired sound absorbing / insulating performance to the interior material. Further, there is a possibility that the texture and aesthetics of the surface may be impaired due to the working pressure during molding. When it exceeds 50 mm, it is difficult to obtain the rigidity of the base material itself, and the shape retention performance is deteriorated.

The average apparent density of the nonwoven fabric in the [0015] present invention is preferably from 0.01 to 1.0 g / cm ^3, in the less than 0.01 g / cm ^3, since small number of fibers per unit volume, nonwoven As a result, it is difficult to obtain sufficient rigidity, and desired ventilation resistance cannot be obtained, and it is difficult to obtain sufficient sound absorbing / insulating performance. Average apparent density is 1.
In the state of higher than 0 g / cm ³ , the nonwoven fabric is too hard to be substantially the same as the conventional panel and board, and it is difficult to expect an additional function.

The fibers used include polyamide, copolyamide, polyester, copolyester,
Polyacrylonitrile, copolymer polyacrylonitrile,
Fibers obtained by single, mixed or composite spinning of thermoplastic polymers such as polyolefin, polyvinyl chloride, polyvinylidene chloride and polyclar are mentioned. Among the fiber types, considering that they have a high crystal melting point (Tm) and are relatively inexpensive, polyester fibers, especially polyethylene terephthalate fibers that are easily available, have relatively high melting points, tensile strengths, and skeletal fibers. It is preferable because it effectively performs the supporting function as. Furthermore, the side-by-side type or core-sheath type conjugate fiber in which homopolyester and copolyester are eccentrically compounded along the fiber axis develops crimping by heat treatment to increase the degree of entanglement of the nonwoven fabric and improve moldability. It is preferable because it increases.

The short fibers of the thermoplastic synthetic fibers constituting the nonwoven fabric of the interior material for automobiles of the present invention are preferably composed of at least two kinds of short fibers including a heat-fusible fiber. That is, this non-woven fabric is a high softening point rigid fiber staple, that is, a low softening point synthetic fiber staple having 5 to 80% by weight of matrix fiber (fiber A) and a softening point lower than that of fiber A by at least 20 ° C., that is, a binder fiber. (Fiber B) 95-
It is preferable that the main constituent fiber is 20% by weight, at least a part of the intersection of the constituent fiber B and the constituent fiber that is in contact with the fiber B is fused, and the retention rate of the bending elastic gradient at 90 ° C. is at least 30%. .

When the amount of the fiber A, that is, the matrix fiber is less than 5% by weight, the ratio of the low softening point fiber to the whole becomes too large, and it becomes difficult to obtain sufficient rigidity at high temperature. On the other hand, if it exceeds 80% by weight, the ratio of binder fibers is small and the number of adhesion points between fibers is small, so that it is difficult to obtain sufficient rigidity, cohesiveness and moldability.

When the amount of the fiber B, that is, the binder fiber is less than 20% by weight, sufficient adhesion points cannot be obtained as in the above case, and there is a possibility that the rigidity is lowered, the moldability and the cohesiveness are deteriorated. On the other hand, if it exceeds 95% by weight, almost all of the fibers are made of low softening point fibers, so that it becomes difficult to secure sufficient rigidity at high temperature.

As the binder of the non-woven fabric, the melting point of the sheath component is 20 to 120 ° C. lower than the melting point of the core component, which is 20 to 120 ° C. lower than the polyester conjugate fiber having a core-sheath structure or the high softening point fiber. Short fibers (fiber B) of low melting point polyester single component fibers having a softening point are preferred. The reason for this is to make the mixing of the binder and the matrix fibers uniform and to maintain the shape of such nonwoven fabric more firmly. When a powdered resin is used as the binder, the binder easily hardens locally, and when a solution-type resin is used, when the fineness of the main constituent fibers is low, the fiber diameter is evenly adhered to the fiber surface. May increase. When the melting point difference is less than 20 ° C,
Since the melting point of the matrix fiber A is too close, not only the binder but also the whole nonwoven fabric may be softened or melted in the molding step of melting and bonding the binder. If the melting point difference is more than 120 ° C., the melting start temperature is low, and it becomes difficult to secure sufficient rigidity at high temperatures. Therefore,
The melting point of the low softening point fiber is preferably 150 to 200 ° C.

In order to secure sufficient rigidity at the above-mentioned high temperature, the central portion (core portion) of the low softening point fiber is polyethylene terephthalate homopolymer, while the peripheral portion (sheath portion) has a melting point of 200 ° C. A crystalline low melting point modified polyester conjugate fiber having a heat of fusion of at least 6 cal / g and preferably at least 8 cal / g,
Alternatively, it is preferably a single component fiber composed of crystalline low melting point modified polyester. A normal low melting point polyester is amorphous and does not have heat of fusion, but a crystalline low melting point modified polyester suitable for the present invention is 8 cal / g.
It has the above heat of fusion, and the core-sheath type conjugate fiber also has the heat of fusion of 6 cal / g or more. Further, the low melting point component crystallized after molding is more thermally stable than the amorphous low melting point component, and has a heat resistance of 90% or more in bending elastic gradient retention rate at 90 ° C. . It is most preferable to use a spun-deposited polymer as a constituent component of these conjugate fibers or monocomponent fibers.

The non-woven fabric for automobile interior materials of the present invention comprises, as described above, at least two kinds of short fibers containing matrix fiber (fiber A) and binder fiber (fiber B),
By making it moldable, shape retention is increased and the shape is stable, surface smoothness, fluff prevention, aesthetics are improved, and a shape with irregularities is added to the surface intentionally. It becomes possible to do.

Regarding the cross-sectional shape of the constituent fibers, a regular circular shape or a deformed shape such as a flat shape, a Y shape, a hollow shape, or the like,
There is no particular limitation. Also, as the matrix fiber, a latent crimpable fiber such as a side-by-side type or a core-sheath type conjugated latent crimpable fiber can be appropriately used.

The automobile interior material of the present invention comprises a short fiber web made of thermoplastic synthetic fibers colored by sizing or dyeing as a design layer, preferably by sizing, and the above-mentioned one prepared separately from the short fiber web. It can be produced by laminating a short fiber web for a base layer made of the same kind of colored or non-colored thermoplastic synthetic fiber, and integrating both by needle punching and / or heat bonding. Further, after the above integration, the obtained nonwoven fabric is further heat-molded to have an average thickness of 1 to 50 mm and 0.01 to 1.0 g / c as a whole.
A sound absorbing / insulating non-woven fabric having an average apparent density of m ³ is preferably used.

In this case, if the fiber type, composition, and color of the constituent fibers of the design layer and the base material layer are the same, the two layers are indistinguishable and are integrated layers, so it is said that the interior material is 100% of the design layer. As long as it has such a single structure and functions as a design layer and has an additional function such as sound absorption and sound insulation as a whole, it is useful as the interior material for automobiles of the present invention.

In a preferred specific example of the above-mentioned manufacturing method, a plurality of cross layers are continuously used, and colored short fiber webs for design layers are supplied from at least one cross layer including the outermost layer web supply. Then, the whole is integrated by needle punching, and heat set if necessary. This method enables mass production in a continuous process.

As described above, according to the method of the present invention, an automobile interior material having excellent additional functions such as sound absorption / insulation, tactile sensation and aesthetics, and also having original functions such as shape maintenance. It can be provided industrially easily and economically with a simplified process.

[0028]

EXAMPLES The effects and examples of the present invention will be shown below. The method for measuring each characteristic value in Examples, Comparative Examples and Conventional Example was as follows. (Sound absorption measurement) JIS for automobile interior material samples
The sound absorption coefficient was measured based on A1405 "method of measuring vertical incidence sound absorption coefficient of building material by in-pipe method", and the sound absorption property was judged. Sample size φ100mm, measurement range 125-1
600 Hz. (Abrasion test) JIS for automotive interior material samples
The wear performance was measured and the wear performance was judged based on K7204 "Plastic Wear Test Method by Wear Wheel". Load 250 gf, test number of 100 times.

Example 1 50% by weight of 2 denier × 51 mm polyethylene terephthalate (hereinafter referred to as PET) fiber dyed in gray
And 3 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) 50% by weight by needle-punching a nonwoven fabric having an area density of 30 g / m ² . The design layer was obtained. Furthermore, 13 denier x 51 mm PET fiber 5
A fiber aggregate composed of 0% by weight and 50% by weight of 2 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) was made into a nonwoven fabric by a roller card machine, and a cross wrapper At the same time, the above-mentioned undyed non-woven fabric design layer prepared at the same time is put into the base material layer by laminating at 180 ° C.
By heat-treating, a temporary molded body having an area density of 1.0 kg / m ² and a thickness of 30 mm was obtained. The temporary molded body obtained as described above was further heated at a temperature of 210 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 20 mm.

Example 2 50% by weight of 15 denier × 51 mm PET fiber sown on gray and 50% by weight of 15 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) Area density of 100 g / m ² by needle punching a fiber assembly composed of
A non-woven fabric design layer was obtained. Furthermore, 15 denier x 51 mm
50% by weight of PET fiber and 2 denier x 51 mm conjugate fiber (core component: PET, sheath component: melting point 170
When a fiber assembly composed of 50% by weight of copolyester at 50 ° C. is made into a non-woven fabric with a roller card machine and laminated with a cross wrapper to form a base material layer, the above-mentioned original-dyed non-woven fabric design layer is prepared separately. It is charged at the same time, compressed to a specified thickness, and then heat treated at 180 ° C to give an areal density of 1.0.
A temporary molded body having a thickness of 25 mm and a weight of 25 kg / m ² was obtained. The temporary molded body obtained above is further heated at a temperature of 210 ° C.,
Press molding was carried out with a cold press to obtain a molded product having a thickness of 20 mm.

EXAMPLE 3 0.2 Denier x 51 mm PET Stained on Gray
Area density by needle-punching a fiber assembly composed of 70% by weight of fiber and 30% by weight of 1.5 denier x 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 130 ° C) 50 g / m
^Two non-woven design layers were obtained. Furthermore, 13 denier X 51m
m PET fiber 50% by weight and 3 denier x 51 mm conjugate fiber (core component: PET, sheath component: melting point 17)
When the fiber assembly composed of 50% by weight of 0 ° C. copolyester) is made into a non-woven fabric by a roller card machine and laminated by a cross-wrapper to form a base material layer, the above-mentioned spun-dyed non-woven fabric design layer is produced separately. Are simultaneously charged, compressed to a specified thickness, and then heat-treated at 180 ° C. to give an areal density of 1.
A temporary molded body of 0 kg / m ² and a thickness of 30 mm was obtained. The temporary molded body obtained as described above was further heated at a temperature of 210 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 20 mm.

Example 4 50% by weight of 15 denier × 51 mm PET fiber and 15 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) 50% by weight dyed on gray % Of the fiber aggregate made into a non-woven fabric with a roller card machine, laminated with a cross wrapper, compressed to a specified thickness, and then heat-treated at 180 ° C. to obtain an areal density of 1.0 kg / m ² and a thickness of 30.
A temporary molded body of mm was obtained. The temporary molded body obtained as described above was further heated at a temperature of 210 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 20 mm.

Example 5 50% by weight of 6 denier x 51 mm PET fiber and 6 denier x 51 mm conjugate fiber sown in gray (core component: sown PET, sheath component: smelting point 170 ° C. copolymerization Polyester) 50% by weight of a fiber assembly is needle-punched to obtain an areal density of 250 g /
A m ² non-woven design layer was obtained. In addition, 40 denier x 51
mm PET fiber 40% by weight and 3 denier x 51 mm conjugate fiber (core component: PET, sheath component: melting point 1
When the fiber assembly composed of 60% by weight of 70 ° C. copolyester) is made into a non-woven fabric by a roller card machine and laminated by a cross wrapper to form a base material layer, the above-mentioned original deposition non-woven fabric design layer is produced separately. Was simultaneously charged, compressed to a specified thickness, and then heat-treated at 180 ° C. to obtain a temporary molded body having an area density of 0.5 kg / m ² and a thickness of 50 mm. The temporary molded body obtained as described above is further heated at a temperature of 210 ° C. and pressure-molded by a cold press to have a thickness of 50 mm.
A molded body of was obtained.

Example 6 70% by weight of 2 denier × 51 mm PET fiber sown on gray and 2 denier × 51 mm conjugate fiber (core component: original PET, sheath component: raw material copolymerization of melting point 170 ° C.) Polyester) 30% by weight of fiber aggregate is needle-punched to obtain an areal density of 100 g /
A m ² non-woven design layer was obtained. In addition, 1.5 denier × 5
50% by weight of 1 mm PET fiber and 1.5 denier x 51
mm fiber conjugate consisting of 50% by weight of conjugate fiber (core component: original PET, sheath component: original polyester copolyester having a melting point of 170 ° C.) is made into a non-woven fabric by a roller card machine and laminated by a cross wrapper. When the above-mentioned undyed non-woven fabric design layer is separately added and compressed to a specified thickness when heat-treated as a base material layer, heat treatment is performed at 180 ° C. to obtain an areal density of 1.0 kg / m ² and a thickness of 30 mm. A temporary molded body of was obtained. The temporary molded body obtained by the above is further 21
It was heated at a temperature of 0 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 1 mm.

Example 7 50% by weight of 2 denier × 51 mm PET fiber sown on gray and 3 denier × 51 mm conjugate fiber (core component: original PET, sheath component: raw material copolymerization of melting point 170 ° C.) Polyester) 50% by weight of fiber aggregate is needle-punched to give an areal density of 100 g /
A m ² non-woven design layer was obtained. In addition, 13 denier × 51
mm PET fiber 50% by weight and 2 denier x 51 mm conjugate fiber (core component: PET, sheath component: melting point 1
When the fiber assembly composed of 50% by weight of 70 ° C. copolyester) is made into a non-woven fabric by a roller card machine and laminated with a cross-wrapper to form a base material layer, the above-mentioned spun-dyed non-woven fabric design layer is produced separately. Were simultaneously charged and compressed to a specified thickness, and then heat-treated at 180 ° C. to obtain a temporary molded body having an area density of 1.0 kg / m ² and a thickness of 30 mm. The temporary molded body obtained as described above is further heated at a temperature of 210 ° C. and pressure-molded by a cold press to have a thickness of 20 mm.
A molded body of was obtained.

Example 8 50% by weight of 2 denier × 51 mm PET fiber and 3 denier × 51 mm conjugated fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) 50% by weight dyed on gray By needle-punching a fiber assembly composed of 100% by weight, a nonwoven fabric design layer having an areal density of 100 g / m ² was obtained. Furthermore, 13 denier x 51 mm P
A fiber aggregate composed of 50% by weight of ET fiber and 50% by weight of 2 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) was made into a non-woven fabric by a roller card machine, When laminating with a cross-wrapper to form a base material layer, the above-mentioned undyed non-woven fabric design layer prepared separately is added at the same time, the design layer and the base material layer are joined by needle punching, and then compressed to a specified thickness. By further heat treatment at 180 ℃, areal density 1.0kg /
A temporary molded body having m ² and a thickness of 30 mm was obtained. The temporary molded body obtained as described above was further heated at a temperature of 210 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 20 mm.

Comparative Example 1 50% by weight of 2 denier × 51 mm PET fiber sown on gray and 3 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) 50% by weight By needle-punching a fiber assembly composed of 10% by weight, a nonwoven fabric design layer having an areal density of 10 g / m ² was obtained. Furthermore, 13 denier x 51 mm PE
A fiber assembly composed of 50% by weight of T fiber and 50% by weight of 2 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) was made into a non-woven fabric by a roller card machine, When laminated as a base material layer with a cross wrapper, the above-mentioned undyed non-woven fabric design layer produced separately is simultaneously charged, and after being compressed to a specified thickness,
By heat treatment at 180 ℃, areal density 1.0kg /
A temporary molded body having m ² and a thickness of 30 mm was obtained. The temporary molded body obtained as described above was further heated at a temperature of 210 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 20 mm.

Comparative Example 2 50% by weight of 20 denier × 51 mm PET fiber sown on gray and 50% by weight of 20 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) 50% by weight Area density of 100 g / m ² by needle punching a fiber assembly composed of
A non-woven fabric design layer was obtained. Furthermore, 15 denier x 51 mm
50% by weight of PET fiber and 2 denier x 51 mm conjugate fiber (core component: PET, sheath component: melting point 170
When a fiber assembly composed of 50% by weight of copolyester at 50 ° C. is made into a non-woven fabric with a roller card machine and laminated with a cross wrapper to form a base material layer, the above-mentioned original-dyed non-woven fabric design layer is prepared separately. It is charged at the same time, compressed to a specified thickness, and then heat treated at 180 ° C to give an areal density of 1.0.
A temporary molded body having a thickness of 30 mm and a kg / m ² was obtained. The temporary molded body obtained above is further heated at a temperature of 210 ° C.,
Press molding was carried out with a cold press to obtain a molded product having a thickness of 20 mm.

Comparative Example 3 50% by weight of 2 denier × 51 mm PET fiber sown on gray and 50% by weight of 3 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) By needle-punching a fiber assembly composed of 100% by weight, a nonwoven fabric design layer having an areal density of 100 g / m ² was obtained. Furthermore, P of 60 denier x 51 mm
Conjugate fiber of 50 wt% ET fiber and 25 denier x 51 mm (core component: PET, sheath component: melting point 170 ° C)
When a fibrous aggregate composed of 50% by weight of the copolyester) is made into a non-woven fabric by a roller card machine and laminated with a cross-wrapper to form a base material layer, the above-mentioned original-deposited non-woven fabric design layer is simultaneously produced. After charging and compressing to a specified thickness, heat treatment at 180 ° C gives an areal density of 1.0k.
A temporary molded body having a g / m ² and a thickness of 30 mm was obtained. The temporary molded body obtained as described above was further heated at a temperature of 210 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 20 mm. However, the above-mentioned non-woven fabric does not have a desired rigidity, and it is difficult to maintain its shape when used as an interior material for automobiles.

Comparative Example 4 50% by weight of 2 denier × 51 mm PET fiber sown on gray and 3 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) 50% by weight By needle-punching the fiber assembly composed of 10% by weight, a non-woven fabric design layer having an areal density of 50 g / m ² was obtained. Furthermore, 13 denier x 51 mm PE
A fiber assembly composed of 50% by weight of T fiber and 50% by weight of 2 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) was made into a non-woven fabric by a roller card machine, When laminated as a base material layer with a cross wrapper, the above-mentioned undyed non-woven fabric design layer produced separately is simultaneously charged, and after being compressed to a specified thickness,
A surface density of 0.5 kg /
A temporary molded body with m ² and a thickness of 80 mm was obtained. The temporary molded body obtained as described above was further heated at a temperature of 210 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 60 mm.

Comparative Example 5 50% by weight of 2 denier × 51 mm PET fiber and 3 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) 50% by weight, which were sown on gray By needle-punching a fiber assembly composed of 100% by weight, a nonwoven fabric design layer having an areal density of 100 g / m ² was obtained. Furthermore, 13 denier x 51 mm P
A fiber aggregate composed of 50% by weight of ET fiber and 50% by weight of 2 denier × 51 mm conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) was made into a non-woven fabric by a roller card machine, When laminating with a cross-wrapper to form a base material layer, the above-mentioned undyed nonwoven fabric design layer prepared separately is charged at the same time, compressed to a specified thickness, and then heat-treated at 180 ° C. to obtain an areal density of 2.6 k.
A temporary molded body having a g / m ² and a thickness of 30 mm was obtained. The temporary molded body obtained as described above was further heated at a temperature of 210 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 0.5 mm.

Comparative Example 6 50% by weight of 2 denier × 51 mm PET fiber and 3 denier × 51 mm of conjugate fiber (core component: PET, sheath component: copolyester having a melting point of 170 ° C.) 50% by weight dyed on gray By needle-punching a fiber assembly composed of 100% by weight, a nonwoven fabric design layer having an areal density of 100 g / m ² was obtained. Furthermore, 1 denier x 51 mm PE
50% by weight T fiber and 1.5 denier x 51 mm conjugate fiber (core component: PET, sheath component: melting point 170 ° C)
When a fibrous aggregate composed of 50% by weight of the copolyester) is made into a non-woven fabric by a roller card machine and laminated with a cross-wrapper to form a base material layer, the above-mentioned original-deposited non-woven fabric design layer is simultaneously produced. After charging and compressing to a specified thickness, heat treatment at 180 ° C gives an areal density of 1.0k.
A temporary molded body having a g / m ² and a thickness of 30 mm was obtained. The temporary molded body obtained as described above was further heated at a temperature of 210 ° C. and pressure-molded by a cold press to obtain a molded body having a thickness of 20 mm. However, the above-mentioned non-woven fabric does not have a desired rigidity, and it is difficult to maintain its shape when used as an interior material for automobiles.

Conventional Example 1 Felt impregnated with a phenol resin having an apparent density of 0.3 g / cm ³ was used as a base material layer, a needle punched nonwoven fabric was used as a skin design layer, and a hot melt film having a thickness of 75 μm was used as an adhesive agent between the design layer and the base material layer. To make a laminated structure using
Heat press molded at 0 ° C and 50 kg / cm ² , thickness 5
mm automobile interior material was obtained.

Conventional Example 2 A phenol resin-impregnated felt having an apparent density of 0.3 g / cm ³ was used as a base material layer, a tricot skin was used as a skin design layer, and a hot melt film having a thickness of 75 μm was used as an adhesive between the design layer and the base material layer. To make a laminated structure using 140
Heat press molding at 50 ℃ / 50 kg / cm ² , thickness 5m
m of automobile interior material was obtained.

Conventional Example 3 A laminated structure containing a polyphenylene oxide foam having an apparent density of 0.1 g / cm ³ was used as a base material layer B, a needle punched nonwoven fabric skin was used as a design layer, and an adhesive agent for the design layer and the base material layer. A hot melt film having a thickness of 50 μm was used to form a laminated structure, which was heated at 160 ° C. and 50 kg / cm ²
Was press-molded to obtain an automobile interior material having a thickness of 6 mm.

Test Examples The above Examples 1 to 8, Comparative Examples 1 to 6 and Conventional Examples 1 to 3
According to the above method, for the automobile interior material obtained in
The normal incident sound absorption coefficient was measured to determine the sound absorption property.
Furthermore, sensory evaluation was performed on the appearance and touch after molding, and abrasion resistance was measured by an abrasion test. The obtained results are shown in Table 1 together with the sample contents.

[0047]

[Table 1]

[Brief description of drawings]

FIG. 1 is a vertical sectional view showing an example of the structure of an automobile interior material according to the present invention.

[Explanation of symbols]

 1 base material layer 2 design layer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Internal reference number FI Technical indication location E04B 1/86 E04B 1/86 D (72) Inventor Keiki Nagayama 2 Takaracho, Kanagawa-ku, Yokohama-shi, Kanagawa Nissan Motor Co., Ltd. (72) Inventor Hitoshi Ito 2 Takaracho, Kanagawa-ku, Yokohama-shi, Kanagawa Nissan Motor Co., Ltd.

Claims (19)

[Claims] 1. A non-woven fabric base material layer for enhancing shape retention, which is formed integrally with the design layer while forming a non-woven fabric design layer by coloring constituent fibers including at least one surface, An automobile interior material comprising a sound absorbing / insulating non-woven fabric made of thermoplastic synthetic fiber short fibers as a whole. 2. The weight ratio of the design layer to the base material layer is 3:97.
The interior material for automobiles according to claim 1, which is ˜100: 0. 3. The average fineness of the short fibers constituting the design layer is 0.2 to 15 denier, and the average fineness of the short fibers constituting the base material layer is 1.5 to 40 denier. Or interior materials for automobiles of 2. 4. The sound absorbing and non-woven fabric as a whole has an average thickness of 1 to 50 mm and 0.01 to 1.0 g / after molding.
The automobile interior material according to claim 1, 2 or 3 having an average apparent density of cm ³ . 5. The automobile interior material according to any one of claims 1 to 4, wherein the short fibers constituting the design layer are dyed or colored by dyeing before spinning. 6. The automobile interior material according to claim 1, wherein the thermoplastic synthetic fiber is a polyester fiber. 7. A low softening point polyester staple in which the short fibers of the thermoplastic synthetic fiber have a high softening point polyester staple (fiber A) of 5 to 80% by weight and a softening point lower than that of the fiber A by at least 20 ° C. (Fiber B) 20
.About.95% by weight, mainly at least two kinds of short fibers, at least a part of the intersections of the fibers B and the constituent fibers in contact therewith are fused, and the sound absorbing and insulating non-woven fabric is 0.01 to The automobile interior material according to any one of claims 1 to 6, which has an average apparent density of 1.0 g / cm ³ and has a retention rate of a bending elastic gradient at 90 ° C of at least 30%. 8. The fiber A is formed of polyethylene terephthalate having a high softening point, and the fiber B is formed of a modified polyester having a softening point lower than that of the fiber A by 20 to 120 ° C. at least in the outer peripheral portion thereof. Interior materials for automobiles. 9. The high softening point polyethylene terephthalate, on which the fibers B are deposited, is used as a core component,
9. The interior material for automobiles according to claim 8, which is a core-sheath type conjugate fiber containing a modified polyester which has been soft-deposited and has a softening point lower than 0 to 120 ° C. as a sheath component. 10. The fiber B is 20 to 12 more than the fiber A.
The automobile interior material according to claim 8, which is a single-component fiber formed of a modified polyester having a softening point lower by 0 ° C. 11. A crystalline low melting point polyester having a melting point of 200 ° C. or lower and a heat of fusion of at least 6 cal / g.
Interior materials for automobiles. 12. The modified polyester is 150 to 20.
The interior material for automobiles according to claim 11, which has a melting point of 0 ° C. 13. A staple fiber web for a base layer, which is made of a colored thermoplastic synthetic fiber and is used for a design layer, and a colored or non-colored thermoplastic synthetic fiber of the same kind as the above prepared separately. A method for manufacturing an interior material for an automobile, characterized by stacking and, and joining and integrating both by needle punching and / or heat bonding. 14. The interior material for an automobile according to claim 13, wherein a plurality of cross layers are continuously used, and the colored short fiber web for design layer is supplied from at least one cross layer including one for supplying the outermost web. Production method. 15. The method for manufacturing an automobile interior material according to claim 13, wherein the weight ratio of the design layer short fiber web to the base layer short fiber web is 3:97 to 100: 0. 16. The average fineness of the staple fibers for design layer is 0.
It is 2-15 denier, and the average fineness of the said short fiber for base material layers is 1.5-40 denier, The manufacturing method of the automotive interior material of any one of Claims 13-15. 17. After the integration, it is further molded to have an average thickness of 1 to 50 mm and 0.01 to 1.0 g / cm as a whole.
^A sound absorbing / insulating non-woven fabric having an average apparent density of ³ is used, and the method for producing an automobile interior material according to any one of claims 13 to 16, wherein: 18. The automobile interior material of the automobile interior material according to any one of claims 13 to 17, wherein the thermoplastic synthetic fiber short fibers are composed of at least two kinds of short fibers including a heat-fusible fiber. Manufacturing method. 19. The method for producing an automobile interior material according to claim 13, wherein the thermoplastic synthetic fiber is a polyethylene terephthalate fiber.