JPH0970908A - Surface material for car interior upholstery and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a comfortable feeling, an adequate air permeability and a sufficient adhesive strength by enabling a cubic hot melt adhesive which fixes a bundle of fiber filaments, in an upright standing state, on the top of down-like projections to be present, and sticking both wadding and a skin material in one piece in such a state that the adhesive is pervaded into the interfiber space of the skin material. SOLUTION: A cubic hot melt adhesive 4 for fixing a bundle of fiber filaments forming down-like projections 3 standing upright, is applied to the top of the down-like projections 3 existing on the surface of wadding 1. In addition, both wadding 1 and skin material 2 are stuck in one piece in such a state that the cubic hot melt adhesive 4 is pervaded into the interfiber space of the skin material 2. Further, a high density unwoven cloth structural surface layer 5 can be laminated on the front side of the wadding 1. That is, the high density unwoven cloth structural surface layer 5 is stacked on the surface of the wadding 1 and stitched. Thus, the tips of the bundle of fiber filaments projecting from the surface of the wadding 1 can be protruded, as numerous down-like projections, from the surface of the high density unwoven cloth structural surface layer 5.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile interior surface material used for automobile interiors such as door trims, ceilings and seat covers of an automobile, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, as a surface material for an automobile interior of this type, a laminated skin material in which a fabric skin material such as a knitted fabric or a woven fabric is laminated on the surface of polyurethane foam having an excellent volume feeling and cushioning property is often used. However, as the cost increases, polyurethane foam has problems in waste pollution and recycling,
Recently, various surface materials have been proposed in which a fibrous web is used as a wadding material instead of polyurethane foam and a skin material is adhered and integrated with the wadding material (for example, actual kaihei 5-1589).
9 and JP-A-4-332590). Then, such a surface material is manufactured by bonding and integrating the above-mentioned wadding material and skin material with a hot melt adhesive as seen in Japanese Patent Publication No. 6-98728 and Japanese Patent Laid-Open No. 3-87242. Is normal.

However, when the wadding material and the skin material are bonded and integrated by a hot melt adhesive, there is a problem that when the adhesive is applied to the entire surface, the surface rigidity is increased and the texture, breathability and feel are deteriorated. Further, if a film-like adhesive is used to avoid this, there is a problem that the production cost becomes high. On the other hand, when the hot-melt adhesive is applied in dots, the adhesive impregnates the wadding material at the time of coating, increasing the rigidity and the texture and inferior touch,
There is a problem that the amount of the adhesive used increases due to the impregnation, which leads to an increase in cost, and there is also a problem that the adhesive strength between the wadding material and the skin material is not sufficient.

[0004]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems and ensures excellent texture, breathability and feel without impregnating a wadding material with a hot melt adhesive. (EN) A surface material for an automobile interior and a method for manufacturing the same, which can reduce the production cost by using a small amount of an adhesive and can also sufficiently secure the adhesive strength between a wadding material and a skin material. It was completed for that purpose.

[0005]

DISCLOSURE OF THE INVENTION The present invention, which has been made to solve the above-mentioned problems, is intended for an automobile interior in which a wadding material made of fiber filament and having numerous fluff-like protrusions on its surface and a skin material are integrally bonded. In the surface material, a spherical hot-melt adhesive for bundling the fiber filaments constituting the fluff-like projections and fixing them in an upright state is present on the tops of the fluff-like projections, and the spherical hot-melt adhesive is used as a skin material fiber. A first aspect of the invention is a surface material for an automobile interior, which is characterized in that a wadding material and a skin material are bonded and integrated with each other in a state of being inserted between them, and a wadding having fiber filaments and innumerable fluff-like protrusions on the surface. After hot-melt adhesive is applied spirally on the surface of the material, heat treatment is performed to melt the hot-melt adhesive and cause it to aggregate by surface tension. An automobile interior characterized in that innumerable spherical hot-melt adhesives are present on the tops of the fluff-like protrusions, and then a skin material is pasted, and then a wadding material and a skin material are pressure-bonded and integrally bonded. A second aspect of the present invention is a method for manufacturing a surface material for use.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION The type of the wadding material 1 in the present invention is not particularly limited, but in a particularly preferred embodiment, a fiber filament made of polyester fiber or the like is formed between the front and back surfaces by needle stick processing. It is assumed that the filament bundles are entangled and integrated so as to stand upright, and the tip end of the filament bundle is projected as innumerable fluff-like projections 3 from the surface, and the hot-melt adhesive is spirally applied to the surface of the wadding material 1. After that, heat treatment is performed to melt and cut the hot melt adhesive, and the hot melt adhesive is aggregated by surface tension so that the spherical hot melt adhesive 4 is present innumerably at the top of the fluff. Spherical hot melt adhesion in which fiber filaments forming the fluff-like protrusions 3 are bundled on the top of the sheet 3 and fixed in an upright state 4 in the presence of, shall the spherical hot melt adhesive 4 are bonded and integrated the wadding material 1 and the skin 2 are allowed to enter between the skin 2 fibers.

In the present invention, the wadding material 1
A spherical hot-melt adhesive 4 for bundling the fiber filaments constituting the fluff-like projections 3 and fixing them in an upright state is present on the top of the fluff-like projections 3 on the surface of the spherical hot-melt adhesive 4. Since the wadding material 1 and the skin material 2 are bonded and integrated with each other while being inserted between the fibers of the skin material 2, the wadding material 1 can exhibit an excellent texture without being impregnated with the adhesive. It has a merit that the adhesiveness is constant, the air permeability is surely maintained, and the amount of the adhesive used is small. Moreover, since the spherical hot melt adhesive 4 is adhered in a state in which it intervenes between the fibers of the skin material 2, the adhesive strength is strong and the backing effect is also excellent. As the above-mentioned hot melt adhesive, a reactive hot melt adhesive which is easily reduced in viscosity at a low temperature so as to instantly form a molten dot when subjected to a reheating treatment is suitable. For example, as a guideline, the viscosity at the time of application is 10,000 cps. / 120 ℃, reheat viscosity is 50
Use a temperature of about 00 cps / 140 ° C.

In this case, the fiber filament used as the material of the wadding material 1 may be a low-melting point fiber filament, a high-melting point fiber filament, or a fiber filament obtained by mixing them in a web form. Material 1 has a thickness of about 1 to 20
mm, basis weight 50 to 1000 g / m ² . Alternatively, the surface layer 5 of the high-density non-woven fabric may be laminated on the front surface side of the wadding material. In this case, the fiber filaments are entangled and integrated so that a filament bundle is erected between the front and back surfaces by needle stick processing. At this time, if the high-density non-woven fabric surface layer 5 is overlaid on the surface and needle sticking is performed, the tips of the filament bundles protruding from the surface are projected as innumerable fluff-like projections 3 from the surface of the high-density non-woven fabric surface layer 5. Of course, when this is done, the strength of the wadding material 1 is further improved and the entanglement with the filament bundle becomes stronger, which is preferable.
Such a high-density nonwoven fabric structure surface layer 5 has a thickness of 0.3 to 2 mm and is made of polypropylene fiber, polyester fiber, polyamide fiber, or the like, which is called spunbond and which is commercially available and has good wear resistance. ~ 200 g / m ²
Although it is general to use a non-woven sheet of a certain degree, the present invention is not limited to such a material as long as the material can have the above-mentioned constitution by needle stick processing.

On the other hand, as the skin material 2 which is adhesively integrated with the surface of the wadding material 1, there is no problem in terms of waste pollution such as fabric skin material such as knitted fabric, woven fabric, non-woven fabric, etc. Those having abrasion resistance are preferable. When the high-density non-woven fabric surface layer 5 is laminated as a reinforcing sheet, a mass of 230 to 3 which is rarely used alone in the past is used for strength reasons.
Even if you use a low-basis-weight fabric skin material of about 60 g / m ^{2, the} required strength can be obtained in the vertical, horizontal, and bias directions. It will be possible.

Next, a method of manufacturing such a surface material for an automobile interior will be described. As shown in FIG. 2, a hot-melt adhesive which is heated and melted at about 120 ° C. by a spiral spray coating machine 11 is continuously applied in a spiral shape on the surface of the wadding material 1 supplied from a roll type supply machine 10 ( (See FIG. 3). Next, hot air type or far infrared type heater 1
When only the surface of the wadding material 1 is rapidly heat-treated by about 2 to about 140 ° C., as shown in FIG. 4, the continuous hot melt adhesive becomes less viscous and melts and agglomerates due to surface tension. As a result, countless spherical hot melt adhesives 4 are present on the tops of the fluffy protrusions 3. Next, after bonding the skin material 2 supplied from the roll-type feeder 13, the wadding material 1 and the skin material 2 are pressure-bonded by the pressure-bonding machine 14 and bonded and integrated to continuously form the surface material for automobile interior. To produce.

The viscosity of the hot melt adhesive is
Viscosity at the time of application is 3000-40000 cps / 120
Viscosity when heated at ℃ 1000-10,000cps / 14
It is preferable to adjust the temperature in the range of 0 ° C. This is because when the viscosity at the time of coating is less than 3000 cps / 120 ° C, it becomes a mist and loses the stringing property, making continuous coating in a spiral shape difficult.
If the temperature is higher than 120 ° C, the spiral pattern will be disturbed and stable coating will not be possible. Also, if the viscosity when heated is less than 1000 cps / 140 ° C, penetration will occur when sticking to the skin material 2, while 10,000 cps / 140 ° C.
This is because if it is larger, it does not become spherical even if it is heated.

The surface material for automobile interiors produced as described above is cut into an arbitrary size by a known means and sewn into a seat cover like the conventional surface material for automobile interiors of this kind. When this is coated on a pad material, it does not change in appearance from conventional surface materials for automobile interiors of this type and its manufacturing method, but it is a fiber-based material used in place of polyurethane foam as a decubitus material. The wadding material 1 of No. 1 has a spherical hot-melt adhesive 4 present on the tops of the fluff-like projections 3 on the surface thereof, and the spherical hot-melt adhesive 4 is inserted between the fibers of the skin material 2 to form the wadding material. 1 and the skin material 2 are integrally bonded and have excellent adhesive strength, and are comparable to those using polyurethane foam as the base layer. It will be exhibited feeling arm, also becomes possible to exhibit excellent cushioning properties without causing or Moe when using the wadding material 1 with a thickness.

Moreover, since the skin material 2 is adhered to the wadding material 1 not by surface adhesion, but by fluffy projections 3 on the front side of the wadding material 1, they are bonded and integrated with sufficient adhesive strength. In addition, because of the point-to-point adhesion in the innumerable point-like adhesion portions, the expansion and contraction characteristics and the texture of the skin material are not impaired by the adhesion regardless of what kind of skin material is used. Further, the skin material 2 is integrated with the wadding material 1 while maintaining a certain degree of freedom. Therefore, no matter what kind of skin material 2 is used, The elastic properties and texture that it has are not impaired by adhesion. Furthermore, since the bonding between the two is innumerable dot-shaped bonding, sufficient air permeability as a seat cover can be secured. In particular, when the high-density nonwoven fabric structural surface layer 5 is laminated on the surface side of the wadding material 1, the strength of the wadding material 1 is further improved and the entanglement with the filament bundle 3 is further strengthened, which is preferable.

[0014]

As is clear from the above description, the first
The invention of (1) can secure excellent texture, breathability and feel without the hot melt adhesive impregnating the wadding material, and can reduce the production cost because the amount of the adhesive used is small, and The adhesive strength between the wadding material and the skin material can be sufficiently ensured, and there is no problem in terms of waste pollution, recycling, or strength. The second invention is such an automobile. The interior surface material can be easily produced at low cost. Therefore, the present invention, as a surface material for automobile interiors and a method for producing the same that eliminates the conventional problems, has a great contribution to the development of industry.

[Brief description of drawings]

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

FIG. 2 is a front view showing the entire manufacturing equipment of the present invention.

FIG. 3 is an explanatory diagram showing a hot melt adhesive application process.

FIG. 4 is an explanatory view showing an aggregated state of a hot melt adhesive in a heat treatment.

[Explanation of symbols]

 1 wadding material 2 skin material 3 fluffy protrusions 4 hot melt adhesive 5 high density nonwoven structure surface layer

Claims (4)

[Claims] 1. A wadding material (1) and a skin material (2) which are made of fiber filaments and have numerous fluff-like projections (3) on the surface.
In an automobile interior surface material in which and are bonded and integrated, a spherical hot melt adhesive for bundling the fiber filaments forming the fluff-like protrusions (3) on the top of the fluff-like protrusions (3) and fixing them in an upright state ( 4) is present, and the spherical hot melt adhesive (4) is adhered and integrated with the wadding material (1) and the skin material (2) in a state where the spherical hot melt adhesive (4) is inserted between the fibers of the skin material (2). A surface material for automobile interiors characterized by. 2. A high-density nonwoven fabric surface layer (5) is laminated on the surface of a wadding material (1), and fluffy protrusions (3) are erected on the surface of the high-density nonwoven structure surface layer by needle stick processing. The surface material for an automobile interior according to claim 1, which is entangled and integrated. 3. A hot-melt adhesive is spirally applied to the surface of a wadding material made of fiber filaments and having innumerable fluff-like projections, and then heat treatment is carried out to melt and cut the hot-melt adhesive and surface tension. The number of spherical hot melt adhesives is present on the tops of the fluffy protrusions by aggregating with each other, and then the skin material is pasted, and then the wadding material and the skin material are pressure-bonded to be integrated. And a method for producing a surface material for an automobile interior. 4. The production of a surface material for an automobile interior according to claim 4, wherein the viscosity at the time of applying the hot melt adhesive is adjusted to 3000 to 40,000 cps / 120 ° C., and the viscosity at the time of heating is adjusted to 1,000 to 10,000 cps / 140 ° C. Method.